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SERVICE MANUAL Theory of Operation

500 / 420

2006.02
Ver. 1.0
THEORY OF OPERATION TOTAL CONTENTS

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


IMPORTANT NOTICE ................................................................................................S-1
DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION .........................S-1
SAFETY WARNINGS .................................................................................................S-2
SAFETY INFORMATION ...............................................................................................S-12
IMPORTANT NOTICE ..............................................................................................S-12
INDICATION OF WARNING ON THE MACHINE .....................................................S-13
MEASURES TO TAKE IN CASE OF AN ACCIDENT ....................................................S-15
Composition of the service manual ................................................................................. C-1
Notation of the service manual ....................................................................................... C-2

bizhub 500 / 420 Main Body


OUTLINE ........................................................................................................................ 1
COMPOSITION/OPERATION ........................................................................................ 9
* For particulars, see the contents of the main body.

DF-607
OUTLINE ........................................................................................................................ 1
COMPOSITION/OPERATION......................................................................................... 5
* For particulars, see the contents of DF-607.

PC-202
OUTLINE ........................................................................................................................ 1
COMPOSITION/OPERATION......................................................................................... 3
* For particulars, see the contents of PC-202.

PC-402
OUTLINE ........................................................................................................................ 1
COMPOSITION/OPERATION......................................................................................... 3
* For particulars, see the contents of PC-402.

LU-201
OUTLINE ........................................................................................................................ 1
COMPOSITION/OPERATION ........................................................................................ 3
* For particulars, see the contents of LU-201.

i
FS-510/PU-501/OT-601
OUTLINE ........................................................................................................................ 1
COMPOSITION/OPERATION ........................................................................................ 9
* For particulars, see the contents of FS-510/PU-501/OT-601.

FS-511/RU-502
OUTLINE ........................................................................................................................ 1
COMPOSITION/OPERATION........................................................................................ 7
* For particulars, see the contents of FS-511/RU-502.

SD-502
OUTLINE ........................................................................................................................ 1
COMPOSITION/OPERATION ........................................................................................ 3
* For particulars, see the contents of SD-502.

MT-501
OUTLINE ........................................................................................................................ 1
COMPOSITION/OPERATION ........................................................................................ 3
* For particulars, see the contents of MT-501.

JS-502
OUTLINE ........................................................................................................................ 1
COMPOSITION/OPERATION ........................................................................................ 3
* For particulars, see the contents of JS-502.

ii
SAFETY AND IMPORTANT WARNING ITEMS

SAFETY AND IMPORTANT WARNING ITEMS


Read carefully the Safety and Important Warning Items described below to understand
them before doing service work.

IMPORTANT NOTICE
Because of possible hazards to an inexperienced person servicing this product as well as
the risk of damage to the product, Konica Minolta Business Technologies, INC. (hereafter
called the KMBT) strongly recommends that all servicing be performed only by KMBT-
trained service technicians.
Changes may have been made to this product to improve its performance after this Service
Manual was printed. Accordingly, KMBT does not warrant, either explicitly or implicitly, that
the information contained in this Service Manual is complete and accurate.
The user of this Service Manual must assume all risks of personal injury and/or damage to
the product while servicing the product for which this Service Manual is intended.
Therefore, this Service Manual must be carefully read before doing service work both in the
course of technical training and even after that, for performing maintenance and control of
the product properly.
Keep this Service Manual also for future service.

DESCRIPTION ITEMS FOR DANGER,


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

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

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

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


trouble and property damage

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

:Precaution when using the


copier. General Electric hazard High
precaution temperature

:Prohibition when using the


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

:Direction when using the


copier. General Unplug Ground/Earth
instruction

S-1
SAFETY AND IMPORTANT WARNING ITEMS

SAFETY WARNINGS
[1] MODIFICATIONS NOT AUTHORIZED BY KONICA MINOLTA
BUSINESS TECHNOLOGIES, INC.

Konica Minolta brand products are renowned for their high reliability. This reliability is
achieved through high-quality design and a solid service network.
Product design is a highly complicated and delicate process where numerous mechanical,
physical, and electrical aspects have to be taken into consideration, with the aim of arriving
at proper tolerances and safety factors. For this reason, unauthorized modifications involve
a high risk of degradation in performance and safety. Such modifications are therefore
strictly prohibited. The points listed below are not exhaustive, but they illustrate the reason-
ing behind this policy.

Prohibited Actions

DANGER
• Using any cables or power cord not specified by KMBT.

• Using any fuse or thermostat not specified by KMBT.


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

• Disabling fuse functions or bridging fuse terminals with


wire, metal clips, solder or similar object.

• Disabling relay functions (such as wedging paper between


relay contacts)

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


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

• Making any modification to the product unless instructed


by KMBT

• Using parts not specified by KMBT

S-2
SAFETY AND IMPORTANT WARNING ITEMS

[2] POWER PLUG SELECTION


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

Power Cord Set or Power Plug

WARNING
• Use power supply cord set which meets the following
criteria:
AC230V
- provided with a plug having configuration intended for
the connection to wall outlet appropriate for the prod-
uct's rated voltage and current, and
- the plug has pin/terminal(s) for grounding, and
- provided with three-conductor cable having enough cur-
rent capacity, and
AC208V 240V
- the cord set meets regulatory requirements for the area.
Use of inadequate cord set leads to fire or electric shock.
• Attach power plug which meets the following criteria:
- having configuration intended for the connection to wall
outlet appropriate for the product's rated voltage and
current, and
- the plug has pin/terminal(s) for grounding, and
- meets regulatory requirements for the area.
Use of inadequate cord set leads to the product connect-
ing to inadequate power supply (voltage, current capacity,
grounding), and may result in fire or electric shock.

• Conductors in the power cable must be connected to ter-


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

S-3
SAFETY AND IMPORTANT WARNING ITEMS

[3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE


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

1. Power Supply

Connection to Power Supply

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

• Connect power plug directly into wall outlet having same


configuration as the plug.
Use of an adapter leads to the product connecting to kw
inadequate power supply (voltage, current capacity,
grounding), and may result in fire or electric shock.
If proper wall outlet is not available, advice the customer
to contact qualified electrician for the installation.
• Plug the power cord into the dedicated wall outlet with a
capacity greater than the maximum power consumption.
If excessive current flows in the wall outlet, fire may
result.

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


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

• Make sure the power cord is plugged in the wall outlet


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

S-4
SAFETY AND IMPORTANT WARNING ITEMS

Connection to Power Supply

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

Power Plug and Cord

WARNING
• When using the power cord set (inlet type) that came with
this product, make sure the connector is securely inserted
in the inlet of the product.
When securing measure is provided, secure the cord with
the fixture properly.
If the power cord (inlet type) is not connected to the prod-
uct securely, a contact problem may lead to increased
resistance, overheating, and risk of fire.

• Check whether the power cord is not stepped on or


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

• Check whether the power cord is damaged. Check


whether the sheath is damaged.
If the power plug, cord, or sheath is damaged, replace
with a new power cord or cord set (with plug and connec-
tor on each end) specified by KMBT.
Using the damaged power cord may result in fire or elec-
tric shock.

• Do not bundle or tie the power cord.


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

S-5
SAFETY AND IMPORTANT WARNING ITEMS

Power Plug and Cord

WARNING
• Check whether dust is collected around the power plug
and wall outlet.
Using the power plug and wall outlet without removing
dust may result in fire.

• Do not insert the power plug into the wall outlet with a wet
hand.
The risk of electric shock exists.
• When unplugging the power cord, grasp the plug, not the
cable.
The cable may be broken, leading to a risk of fire and
electric shock.

Wiring

WARNING
• Never use multi-plug adapters to plug multiple power cords
in the same outlet.
If used, the risk of fire exists.

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


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

S-6
SAFETY AND IMPORTANT WARNING ITEMS

2. Installation Requirements

Prohibited Installation Places

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

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


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

When not Using the Product for a long time

WARNING
• When the product is not used over an extended period of
time (holidays, etc.), switch it off and unplug the power
cord.
Dust collected around the power plug and outlet may
cause fire.

Ventilation

CAUTION
• The product generates ozone gas during operation, but it
will not be harmful to the human body.
If a bad smell of ozone is present in the following cases,
ventilate the room.
a. When the product is used in a poorly ventilated room
b. When taking a lot of copies
c. When using multiple products at the same time

Fixing

CAUTION
• Be sure to lock the caster stoppers.
In the case of an earthquake and so on, the product may
slide, leading to a injury.

S-7
SAFETY AND IMPORTANT WARNING ITEMS

Inspection before Servicing

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

• Before conducting an inspection, be sure to disconnect


the power plugs from the product and options.
When the power plug is inserted in the wall outlet, some
units are still powered even if the POWER switch is
turned OFF. A risk of electric shock exists.

• The area around the fixing unit is hot.


You may get burnt.

Work Performed with the Product Powered On

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

• Take every care when servicing with the external cover


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

S-8
SAFETY AND IMPORTANT WARNING ITEMS

Safety Checkpoints

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

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


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

• Check wiring for squeezing and any other damage.


Current can leak, leading to a risk of electric shock or
fire.
• Carefully remove all toner remnants and dust from electri-
cal parts and electrode units such as a charging corona
unit.
Current can leak, leading to a risk of product trouble or
fire.

• Check high-voltage cables and sheaths for any damage.


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

• Check electrode units such as a charging corona unit for


deterioration and sign of leakage.
Current can leak, leading to a risk of trouble or fire.
• Before disassembling or adjusting the write unit (P/H unit)
incorporating a laser, make sure that the power cord has
been disconnected.
The laser light can enter your eye, leading to a risk of
loss of eyesight.

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


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

S-9
SAFETY AND IMPORTANT WARNING ITEMS

Safety Checkpoints

WARNING
• When replacing a lithium battery, replace it with a new lith-
ium battery specified in the Parts Guide Manual. Dispose
of the used lithium battery using the method specified by
local authority.
Improper replacement can cause explosion.

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


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

• Check the interlock switch and actuator for loosening and


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

• Make sure the wiring cannot come into contact with sharp
edges, burrs, or other pointed parts.
Current can leak, leading to a risk of electric shock or
fire.
• Make sure that all screws, components, wiring, connec-
tors, etc. that were removed for safety check and mainte-
nance have been reinstalled in the original location. (Pay
special attention to forgotten connectors, pinched cables,
forgotten screws, etc.)
A risk of product trouble, electric shock, and fire exists.

Handling of Consumables

WARNING
• Toner and developer are not harmful substances, but care
must be taken not to breathe excessive amounts or let the
substances come into contact with eyes, etc. It may be
stimulative.
If the substances get in the eye, rinse with plenty of water
immediately. When symptoms are noticeable, consult a
physician.

S-10
SAFETY AND IMPORTANT WARNING ITEMS

Handling of Consumables

WARNING
• Never throw the used cartridge and toner into fire.
You may be burned due to dust explosion.

Handling of Service Materials

CAUTION
• Unplug the power cord from the wall outlet.
Isopropyl alcohol and acetone are highly flammable and
must be handled with care. A risk of fire exists.

• Do not replace the cover or turn the product ON before


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

• Use only a small amount of cleaner at a time and take


care not to spill any liquid. If this happens, immediately
wipe it off.
A risk of fire exists.

• When using any solvent, ventilate the room well.


Breathing large quantities of organic solvents can lead to
discomfort.

S-11
SAFETY INFORMATION

SAFETY INFORMATION
IMPORTANT NOTICE
The Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Admin-
istration implemented regulations for laser products manufactured since August 1, 1976.
Compliance is mandatory for products marketed in the United States.

This copier is certified as a "Class 1" laser product under the U.S.
Department of Health and Human Services (DHHS) Radiation Performance Standard
according to the Radiation Control for Health and Safety Act of 1968. Since radiation emit-
ted inside this copier is completely confined within protective housings and external covers,
the laser beam cannot escape during any phase of normal user operation.

S-12
SAFETY INFORMATION

INDICATION OF WARNING ON THE MACHINE


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

50gap0e001na

S-13
SAFETY INFORMATION

50gap0e002na

CAUTION:
• You may be burned or injured if you touch any area that you are advised by any
caution label to keep yourself away from. Do not remove caution labels. And also,
when the caution label is peeled off or soiled and cannot be seen clearly, replace
it with a new caution label.

S-14
MEASURES TO TAKE IN CASE OF AN ACCIDENT

MEASURES TO TAKE IN CASE OF


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

S-15
MEASURES TO TAKE IN CASE OF AN ACCIDENT

Blank Page

S-16
Composition of the service manual
This service manual consists of the following sections and chapters:

<Theory of Operation section>

OUTLINE: System configuration, product specifications,


unit configuration, and paper path
COMPOSITION/OPERATION: Configuration of each unit, explanation of the operating
system, and explanation of the control system
This section gives, as information for the CE to get a full understanding of the product, a
rough outline of the object and role of each function, the relationship between the electrical
system and the mechanical system, and the timing of operation of each part.

<Field service section>

OUTLINE: System configuration, and product specifications


MAINTENANCE: Service schedule *, maintenance steps,
list of service tools and directions for use *,
firmware version up method *,
and removal/reinstallation methods of major parts
ADJUSTMENT/SETTING: Utility mode *, service mode *, security and mechanical
adjustment
TROUBLESHOOTING*: List of jam codes, their causes, operation when a jam
occurs and its release method, and list of error codes,
their causes, operation when a warning is issued and esti-
mated abnormal parts.
APPENDIX*: Parts layout drawings, connector layout drawings, timing
chart, overall layout drawing

This section gives, as information required by the CE at the site (or at the customer's
premise), a rough outline of the service schedule and its details, maintenance steps, the
object and role of each adjustment, error codes and supplementary information.

The details of items with an asterisk "*" are described only in the service manual of
the main body.

C-1
Notation of the service manual
A. Product name
In this manual, each of the products is described as follows:

(1) IC board: Standard printer


(2) bizhub 500 / 420: Main body
(3) Microsoft Windows 95: Windows 95
Microsoft Windows 98: Windows 98
Microsoft Windows Me: Windows Me
Microsoft Windows NT 4.0: Windows NT 4.0 or Windows NT
Microsoft Windows 2000: Windows 2000
Microsoft Windows XP: Windows XP
When the description is made in combination of the OS's mentioned above:
Windows 95/98/Me
Windows NT 4.0/2000
Windows NT/2000/XP
Windows 95/98/Me/NT/2000/XP

B. Brand name
The company names and product names mentioned in this manual are the brand name or
the registered trademark of each company.

C. Electrical parts and signals


Those listed by way of example below are not exhaustive, but only some instances among
many.

Classification Load symbol Ex. of signal name Description


IN
PS
Sensor PS Door PS1 Sensor detection signal
SIG
102 PS
24V Power to drive the solenoid
Solenoid SD DRV
Drive signal
SOL
24V Power to drive the clutch
Clutch CL DRV
Drive signal
SOL

C-2
Classification Load symbol Ex. of signal name Description
24V Power to drive the motor
CONT Drive signal
DRV1
Motor M
DRV2
Drive signals of two kinds
D1
D2
_U
_V
_W
Drive signals (control signals) of three kinds
DRV1
DRV2
DRV3
D1
D2
D3
D4
DRV A
DRV A
DRV B Drive signals (control signals) of four kinds
DRV B Motor, phases A and B control signals
A
Motor M /A
B
/B
AB
BB
CLK, PLL PLL control signal
LCK, Lock, LD PLL lock signal
FR Forward/reverse rotation signal
EM, Lock, LCK, LD Motor lock abnormality
BLK Drive brake signal
P/S Power/stop
S/S
Operating load start/stop signal
SS
CW/CCW, F/R Rotational direction switching signal
ENB Effective signal
TEMP_ER Motor temperature abnormality detection signal
24V Power to drive the fan motor
CONT, DRIVE Drive signal
Fan FM
HL Speed control signal (2 speeds)
EM, Lock, LCK, FEM Detection signal
Others TH1.S, ANG Analog signal

C-3
Classification Load symbol Ex. of signal name Description
SG, S.GND, S_GND Signal ground
Ground
PG, P.GND Power ground
DCD Data carrier detection
SIN Serial input
SOUT Serial output
DTR Data terminal operation available
GND Signal ground (earth)
Serial com-
DSR, DSET Data set ready
munication
RTS Transmission request signal
CTS Consent transmission signal
RI Ring indicator
TXD Serial transmission data
RXD Serial reception data

D. Paper feed direction


When the direction in which paper is fed is in parallel with the longer side of paper, the
paper feed direction like this is referred to as the longitudinal feed.
And the paper feed direction that is perpendicular to the longitudinal feed is referred to as
the transverse feed.
When specifying the longitudinal feed, "S (abbreviation for Short Edge Feeding)" is added
to the paper size. For the transverse feed, no specific notation is employed.
However, when only the longitudinal feed is specified for one and the same paper size with
no specification made for the transverse feed, "S" is not added even when being fed longi-
tudinally.

<Example>

Paper size Feed direction Notation


Transverse feed A4
A4
Longitudinal feed A4S
A3 Longitudinal feed A3

C-4
SERVICE MANUAL Theory of Operation

500 / 420
Main body

2006.02
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 correspond-
ing page.
A number within 1 represents the number of times the revision has been made.

NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
• When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
• When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.

2006/02 1.0 — Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision
Theory of Operation Ver1.0 Feb.2006 CONTENTS

CONTENTS

bizhub 500 / 420


bizhub 500 / 420

OUTLINE
1. SYSTEM CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. PRODUCT SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. UNIT CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

COMPOSITION/OPERATION
5. OVERALL CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.1 Time chart when the power is turned ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.2 Control block diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6. SCANNER SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.3.1 Scan/exposure lamp control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.3.2 Original size detection control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.3.3 AE control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.3.4 Image processing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7. WRITE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.2.1 Laser beam path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.2.2 Write control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.2.3 Image stabilization control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.2.4 Image processing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8. PHOTO CONDUCTOR SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.2.1 Drum drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.2.2 Drum claw drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.3.1 Image creation control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.3.2 Drum claw control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.3.3 Image stabilization control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9. CHARGING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.2.1 Charging control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.2.2 Erase lamp (EL) control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10. TRANSFER/SEPARATION SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.2.1 Transfer guide control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.2.2 Transfer/separation control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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10.2.3 Transfer exposure lamp (TSL) control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27


11. DEVELOPING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
bizhub 500 / 420

11.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
11.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.3.1 Developer conveyance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.3.2 Developing bias . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11.3.3 Developing suction control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
11.3.4 Image stabilization control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
12. TONER SUPPLY SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
12.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
12.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
12.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.3.1 Toner level detection control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.3.2 Toner supply control to the toner hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.3.3 Toner supply control to the developing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.3.4 Toner conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
13. CLEANING/TONER RECYCLE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
13.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
13.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
13.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
13.3.1 Cleaning operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
13.3.2 Toner collection mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
13.3.3 Toner conveyance operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
14. PAPER FEED SECTION (Tray 1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
14.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
14.1.1 Tray 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
14.1.2 Tray 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
14.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
14.2.1 Paper feed drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
14.2.2 Tray lift drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
14.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
14.3.1 Up/down control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
14.3.2 Paper size detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
14.3.3 Paper feed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
14.3.4 Paper empty control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
14.3.5 Paper remaining detection mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
15. BYPASS SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
15.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
15.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
15.2.1 Paper feed drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
15.2.2 Tray lift drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
15.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
15.3.1 Up/down control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
15.3.2 Paper size detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
15.3.3 Paper feed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
15.3.4 Paper empty control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
16. REGISTRATION SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
16.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
16.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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16.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
16.3.1 Loop control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

bizhub 500 / 420


17. ADU SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
17.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
17.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
17.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
17.3.1 Conveyance path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
17.3.2 Conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
18. FUSING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
18.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
18.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
18.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
18.3.1 Fusing roller drive control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
18.3.2 Web drive control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
18.3.3 Fusing temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
18.3.4 Fusing roller edge cooling control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
18.3.5 Envelope conveyance mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
18.3.6 Protection against abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
18.3.7 Jam detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
19. REVERSE/EXIT SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
19.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
19.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
19.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
19.3.1 Conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
19.3.2 Reverse control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
20. INTERFACE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
20.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
20.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
21. IMAGE STABILIZATION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
21.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
21.2 Operation flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
21.2.1 Image stabilization control flow when the power switch (SW2) is turned ON . . . . . . . . . . . . . . . 83
21.2.2 Image stabilization control flow while in the print and the idle . . . . . . . . . . . . . . . . . . . . . . . . . . 86
22. IMAGE PROCESSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
22.1 Image processing in the scanner section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
22.1.1 Shading correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
22.1.2 AE control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
22.1.3 Area discrimination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
22.1.4 Brightness/density conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
22.1.5 Filter/magnification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
22.1.6 Scanner gamma correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
22.1.7 Halftone processing (error diffusion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
22.1.8 Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
22.1.9 Storage of image data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
22.2 Image processing in the write section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
23. OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
23.1 Fan control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
23.1.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
23.1.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
23.2 Counter control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

iii
CONTENTS Theory of Operation Ver1.0 Feb.2006

23.2.1 Composition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100


23.2.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
bizhub 500 / 420

23.3 Parts that operate when the power switch is turned ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
23.3.1 Parts that operate when the main power switch (SW1) is turned ON . . . . . . . . . . . . . . . . . . . 103
23.3.2 Parts that operate when the power switch (SW2) is turned ON . . . . . . . . . . . . . . . . . . . . . . . . 104

iv
Theory of Operation Ver1.0 Feb.2006 1. SYSTEM CONFIGURATION

„ OUTLINE

bizhub 500 / 420


1. SYSTEM CONFIGURATION
A. System configuration

[23] [27] [28]


[24] [25] [26]

[5]
[1] [6]
[2] [7]
[3] [8]
[4] [9]
[22]
[21]

[20]
[19] [11]
[14]
[17] [15]
[18]
[10] [12]

[16]

[10] [13]

50gat1e001na

[1] Reverse automatic document feeder [15] Dehumidifier heater *2


(DF-607) (standard equipment) [16] Relay unit (RU-502)
[2] Main body [17] Finisher (FS-511)
[3] Image controller (IC-204) [18] Swedish punch kit G *3
[4] Hard disk (HD-505) [19] Job separator (JS-502)
[5] Stamp unit (SP-501) [20] Output tray kit (OT-501)
[6] Spare TX marker stamp 2 [21] Output tray (OT-601)
[7] Key counter kit 4 *1 [22] Finisher (FS-510)
[8] Key counter *1 [23] Mail bin kit (MT-501)
[9] Key counter mount kit *1 [24] Saddle stitcher (SD-502)
[10] Dehumidifier heater 1C [25] Folding unit (included in SD-502)
[11] Paper feed cabinet (PC-402) [26] Punch unit (PU-501)
[12] Paper feed cabinet (PC-202) [27] FAX kit (FK-502)
[13] Desk (DK-501) [28] Mount kit (MK-708)
[14] Large capacity unit (LU-201)

*1 See "6.4 Option counter" in Field Service bizhub 500 / 420 main body for details.
*2 Dehumidifier heater is set up as service part.
*3 Swedish punch kit G is for Europe only.

1
1. SYSTEM CONFIGURATION Theory of Operation Ver1.0 Feb.2006

B. Configuration for optional device connection


bizhub 500 / 420

Note
• Any combination other than those listed below is not available.

No. Combinations for paper feeding Combinations for finishing Remarks


1 DK-501/PC-202/PC-402 *1 OT-501
2 DK-501/PC-202/PC-402 *1 OT-501 JS-502
3 DK-501/PC-202/PC-402 *1 RU-502 + FS-511
4 DK-501/PC-202/PC-402 *1 FS-510 *2*3
5 DK-501/PC-202/PC-402 *1 FS-510 *2*3 SD-502
6 DK-501/PC-202/PC-402 *1 FS-510 *2*3 MT-501
7 PC-202/PC-402 *4 LU-201 OT-501
8 PC-202/PC-402 *4 LU-201 OT-501 JS-502
9 PC-202/PC-402 *4 LU-201 RU-502 + FS-511
10 PC-202/PC-402 *4 LU-201 FS-510 *2*3
11 PC-202/PC-402 *4 LU-201 FS-510 *2*3 SD-502
12 PC-202/PC-402 *4 LU-201 FS-510 *2*3 MT-501

*1 Either one of DK-501, PC-202 and PC-402 can be selected.


*2 FS-510 can be installed optionally with OT-601.
*3 FS-510 can be installed optionally with PU-501.
*4 Either one of PC-202 and PC-402 can be selected.

2
Theory of Operation Ver1.0 Feb.2006 2. PRODUCT SPECIFICATIONS

2. PRODUCT SPECIFICATIONS

bizhub 500 / 420


A. Type

Type Desktop type


Copying method Indirect electrostatic method
Original stand Fixed
Original alignment Left rear standard
Photo conductor OPC
Sensitizing method Laser writing
Paper feed trays Two trays 500 sheet x 2, 80g/m2
Bypass feed 150 sheet x 1, 80g/m2
PC-402 *1 2,500 sheet x 1, 80g/m2
PC-202 *1 500 sheet x 1, 80g/m2
LU-201 *1 2,000 sheet x 1, 80g/m2

*1 PC-402, PC-404, and LU-201 are optional.

3
2. PRODUCT SPECIFICATIONS Theory of Operation Ver1.0 Feb.2006

B. Functions
bizhub 500 / 420

Original Sheet, book, solid object


Max. original size A3 or 11 x 17
Copy size Trays 1, 2 Inch: 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S,
A3, A4, A4S, A5S, Foolscap
Metric: A3, B4, A4, A4S, B5, A5S, 11 x 17, 81/2 x 11,
81/2 x 11S, Foolscap, 8K, 16K
Bypass feed Inch: 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S,
A4
Metric: A3, B4, A4, A4S, B5, B5S, A5S, B6S, 81/2 x 11,
81/2 x 11S, Foolscap, 8K, 16K, 16KS
ADU Inch: 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S,
A3, A4, A4S, A5S, Foolscap
Metric: A3, B4, A4, A4S, B5, B5S, A5S, 11 x 17, 81/2 x 11,
81/2 x 11S, Foolscap
Magnification Fixed magnifica- Inch: x 1.000, x 1.214, x 1.294, x 1.545, x 2.000
tion x 0.500, x 0.647, x 0.772, x 0.785
Metric: x 1.000, x 1.154, x 1.224, x 1.414, x 2.000
x 0.500, x 0.707, x 0.816, x 0.866
Special magnifi- x 0.930
cation setting
Preset zoom set- 3 types
ting
Zoom magnifica- x 0.25 to x 4.00 (at the step of 0.1%)
tion
Vertical magnifi- x 0.25 to x 4.00 (at the step of 0.1%)
cation
Horizontal magni- x 0.25 to x 4.00 (at the step of 0.1%)
fication
Warm-up time 60 seconds or less (bizhub 500)
30 seconds or less (bizhub 420)
First copy out time 3.2 seconds or less (bizhub 500)
3.6 seconds or less (bizhub 420)
Continuous copy speed 50 copies /min. (A4 / 81/2 x 11) (bizhub 500)
42 copies /min. (A4 / 81/2 x 11) (bizhub 420)
Continuous copy count Up to 999 sheets
Original density selection Auto density selection, Manual (9 steps), Manual underprint density (9 steps)
Resolution Scan 600 x 600 dpi
Write Inch: 1,200 (equivalent) x 600 dpi
Metric: 2,400 (equivalent) x 600 dpi
Memory Standard 192 MB Breakdown: 64 MB (on board) + 128 MB (DIMM)
Maximum 320 MB Breakdown: 64 MB (on board) + 256 MB (DIMM) *1
Interface section RJ45 Ethernet, Serial port (RS232-C), Serial port (USB TypeB),
Parallel port (IEEE1284), RJ-11 *2
*1 256 MB (DIMM) is available from distributors.
Specification: 144 pin SO-DIMM, PC100/PC133 MHz Compliant
*2 1 port when MK-708 and FK-502 are optionally installed.

4
Theory of Operation Ver1.0 Feb.2006 2. PRODUCT SPECIFICATIONS

C. Type of paper

bizhub 500 / 420


Plain paper *1 All trays High quality paper of 60 to 90 g/m2
Special paper *2 Bypass feed only OHP film, label paper *3, blueprint master paper *3
High quality paper of 50 to 59 g/m2 (thin paper)
All trays High quality paper of 91 to 105 g/m2 (thick paper)
Bypass feed only High quality paper of 106 to 210 g/m2 (thick paper)

*1 Standard specified paper


Plain paper: Inch: Hammermill Tidal MP (20 lbs)
Metric: Konica Minolta Original (80 g/m2), Konica Minolta Profi (80 g/m2)
Recycle paper: Inch: Weyerhaeuser Recycled Laser Copy (20 lbs)
Metric: Nautilus (80 g/m2)
*2 Special paper/recommended paper
Thick paper: Inch: Weyerhaeuser Cougar Cover 65 lbs
Metric: Xerox colortech 200 g/m2
Thin paper: Inch: SOISE BOND 16 lbs
Metric: NEU 60 g/m2
Label paper: Inch: AVERY 5160, 5352
Metric: AVERY DSP 24
OHP film: Inch: 3M CG3700
Metric: Folex overhead X-500, 3M CG3700
Envelope: Inch: Preservation Wove (24 lbs) #6-3/4, #9, #10 (4-1/8 x 9-1/2)
Metric: Briefhullen 211210 (100 g/m2) #C6
Schneider Soehne Distinction 100 (100 g/m2) #lang
Schneider Soehne (Briefumschlage) (100 g/m2) #C5
*3 Label paper is loaded and fed one sheet at a time.

D. Maintenance

Maintenance Every 250,000 prints


Machine service life 2,250,000 prints or 5 years (whichever earlier) (bizhub 500)
1,800,000 prints or 5 years (whichever earlier) (bizhub 420)

E. Machine data

Power source Inch: AC120V 12A, 60Hz


Metric: AC220-240V 10A, 50Hz
Maximum power consump- 1,560 W or less (full option)
tion
Dimensions Main body 677 (W) x 708 (D) x 1,150 (H) mm *1
+ DF-607
+ PC or DK
Weight Approx. 91.2 kg

*1 Overturning prevention board is not included.

5
2. PRODUCT SPECIFICATIONS Theory of Operation Ver1.0 Feb.2006

F. Operating environment
bizhub 500 / 420

Temperature 10 to 30 °C
Humidity 10 to 80%RH (with no condensation)

Note
• The information herein may be subject to change for improvement without notice.

6
Theory of Operation Ver1.0 Feb.2006 3. UNIT CONFIGURATION

3. UNIT CONFIGURATION

bizhub 500 / 420


[17]

[1]

[2]
[16]

[15] [3]

[14]
[4]
[5]
[13]
[6]
[12]
[7]
[8]

[11]

[9]
[10]

50gat1c002na

[1] Scanner section [10] PC or DK (option)


[2] Paper reverse/exit section [11] Paper feed section (tray 1/2)
[3] Fusing section [12] Developing section
[4] Photo conductor section [13] Writing section
[5] ADU [14] Charging section
[6] Transfer/separation section [15] Toner supply section
[7] Registration section [16] Cleaning/toner recycle section
[8] Bypass tray section [17] DF
[9] LU (option)

7
4. PAPER PATH Theory of Operation Ver1.0 Feb.2006

4. PAPER PATH
bizhub 500 / 420

[1]
[9]

[8]

[7]
[2]

[6]
[3]

[5] [4]

50gat1c003na

[1] Reverse conveyance [6] Tray 2 paper feed


[2] ADU conveyance [7] Tray 1 paper feed
[3] Bypass paper feed [8] Registration conveyance
[4] LU paper feed [9] Paper exit
[5] PC paper feed

8
Theory of Operation Ver1.0 Feb.2006 5. OVERALL CONFIGURATION

„ COMPOSITION/OPERATION

bizhub 500 / 420


5. OVERALL CONFIGURATION
5.1 Time chart when the power is turned ON

[1] [2] [3][4] [5] [6] [7] [8] [9]

Item
Normal
Scanner motor rotation
(M2) Reverse
rotation
Exposure lamp (L1)
Fusing heater lamp /1 (L2)
Fusing heater lamp /2 (L3)
Fusing motor (M11)
Drum motor (M1)
Developing motor (M3)
Polygon motor (M5)
Laser (LDB)
Paper lift motor /1 (M7)
Upper limit sensor /1 (PS6)
Paper lift motor /2 (M8)
Upper limit sensor /2 (PS13)
50gat2e001na

[1] Fusing heater lamps /1 (L2) and /2 (L3) turn [5] Drum motor (M1) turns ON
ON early [6] Dot diameter adjustment starts
[2] Power switch (SW2) turns ON [7] The fusing temperature gets to the pre-
[3] Initial communication between the overall scribed temperature to start the preliminary
control board (OACB) and the printer control rotation for fusing
board (PRCB) [8] Dot diameter adjustment completed
[4] Shading correction [9] Warming up completed

Note
• Each operation varies according to the setting of the software DipSW in the service mode.
• The power is turned ON with DF closed.
• The power is turned ON with the lift plate of the tray down.

9
5. OVERALL CONFIGURATION Theory of Operation Ver1.0 Feb.2006

5.2 Control block diagram


bizhub 500 / 420

CCD HDD IC FK, MK USB RS232C LAN Parallel OB


I/F I/F I/F I/F

OACB

SC
Write
Section DF
M FM CL SD PS

PRCB

SDB DCPU HV

M PS

JS LU PC FS, RU

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


50gat2c090na

[1] Image bus [4] Other buses


[2] Clock synchronous serial bus [5] Individual signal line
[3] UART bus [6] IDE

10
Theory of Operation Ver1.0 Feb.2006 6. SCANNER SECTION

6. SCANNER SECTION

bizhub 500 / 420


6.1 Composition

CCD unit
Mirror unit (CCDB)

Exposure unit

Shading
correction
plate

50gat2c001na

6.2 Drive

[4]
[3]
[5]

[1]

[2]

50gat2c002na

[1] Scanner wire /Rr [4] Exposure unit


[2] Scanner wire /Fr [5] Scanner motor (M2)
[3] V-mirror unit

11
6. SCANNER SECTION Theory of Operation Ver1.0 Feb.2006

6.3 Operation
bizhub 500 / 420

6.3.1 Scan/exposure lamp control


A. Operation when the power is turned ON
A specified period of time after the power switch (SW2) is turned on, the exposure unit conducts the home posi-
tion search. At this time, the exposure unit conducts the shading correction based on the white reference board
attached to the original glass. For shading correction, 2 places on the white reference board are read for correc-
tion. The home position search varies according to the ON/OFF condition of the scanner home sensor (PS30)
when SW2 is turned ON.

(1) Home position search while in PS30 ON

[2] [1]

[3]
[6]
[4]
[5]
50gat2c034na

[1] Exposure unit stand-by position [4] Shading correction position 2


[2] Scanner home sensor (PS30) [5] Movement of the exposure unit
[3] Shading correction position 1 [6] Exposure lamp (L1) ON

(2) Home position search while in PS30 OFF

[2] [1]

[3]
[6]
[4]
[5]

50gat2c035na

[1] Exposure unit stand-by position [4] Shading correction position 2


[2] Scanner home sensor (PS30) [5] Movement of the exposure unit
[3] Shading correction position 1 [6] Exposure lamp (L1) ON

12
Theory of Operation Ver1.0 Feb.2006 6. SCANNER SECTION

B. Operation when the start key is turned ON


For the original read mode, the following two types are available: the platen mode and the DF mode. While in the

bizhub 500 / 420


platen mode, the exposure unit scans the original for reading. And while in the DF mode, since DF conveys the
original, the exposure unit remains at the prescribed position (DF read position) to read the original.

(1) When the platen is used (when DF is opened)


The operation in the platen mode varies depending on which is selected for the print density, the AE print and
the manual print.
• When the AE print is selected

[4] [3] [2] [1]

[5]
[6]
[7]
[8]
50gat2c037na

[1] Exposure unit stand-by position [5] AE scan range


[2] Position at which the image read is started [6] Shading correction position 1
[3] Scanner home sensor (PS30) [7] Shading correction position 2
[4] Position at which the running-up of the [8] Exposure lamp (L1) ON
exposure unit is started

• When the manual print is selected

[4] [3] [2] [1]

[5]
[6]

[7]
50gat2c036na

[1] Exposure unit stand-by position [5] Shading correction position 1


[2] Position at which the image read is started [6] Shading correction position 2
[3] Scanner home sensor (PS30) [7] Exposure lamp (L1) ON
[4] Position at which the running-up of the
exposure unit is started

Note
• When the tray 1 is selected by manual, not by APS, no shading correction is made.

13
6. SCANNER SECTION Theory of Operation Ver1.0 Feb.2006

(2) When DF is used (when DF is closed)


bizhub 500 / 420

[3] [2] [1]

[4]
[5]
[6]

50gat2c038na

[1] Exposure unit stand-by position [4] Shading correction position 1


[2] Scanner home sensor (PS30) [5] Shading correction position 2
[3] DF read position [6] Exposure lamp (L1) ON

14
Theory of Operation Ver1.0 Feb.2006 6. SCANNER SECTION

6.3.2 Original size detection control


A. Detection method

bizhub 500 / 420


The original size detection method varies for the DF mode and the platen mode.

(1) DF mode
See DF-607 Service Manual.

(2) Platen mode


• Main scan direction
Reading is made by the CCD sensor.
• Sub-scan direction
Detection is made according to the ON/OFF of the APS sensor (PS32).

Original size CCD sensor PS32


(Detection length: mm) (ON/OFF)
A3 297 ON
11 x 17 279.4 ON
B4 257 ON
81/2 x 14 *1 215.9 ON
81/2 x 11S 215.9 ON
A4S 210 ON
A4 297 OFF
81/2 x 11 279.4 OFF
B5 257 OFF
A5 210 OFF
B5S 182 OFF
A5 148 OFF
51/2 x 81/2 139.7 OFF
B6 128 OFF

*1 No discrimination is made between 81/2 x 14 and 81/2 x 11S. When the size is 81/2 x 14, this is detected as
81/2 x 11S.

B. Detection timing
(1) Platen mode (while in DF closed)
When the APS timing sensor (PS31) turns on while in DF closed, the original size is detected.

(2) Platen mode (while in DF open)


When the start key is pressed, the original size is detected.

15
6. SCANNER SECTION Theory of Operation Ver1.0 Feb.2006

6.3.3 AE control
When AE is selected, the density level of the original is detected to adjust it to an appropriate density automati-
bizhub 500 / 420

cally. The sampling range of the original density in the AE control varies for the platen mode and the DF mode.

(1) AE sampling range in the platen mode

[5]

[1]
[7]

[6]

[5]

[2] [2]
[4]
[3]
50gat2c039na

[1] Original [5] 10 mm


[2] L/100 mm [6] Leading edge of the original
[3] L mm [7] AE sampling range
[4] 30 mm

(2) AE sampling range in the DF mode

[4]

[1]
[6]
[5]

[4]

[3] [2]
50gat2c040na

[1] Original [4] 20 mm


[2] 2.9 mm [5] Leading edge of the original
[3] 1.5 mm [6] AE sampling range

16
Theory of Operation Ver1.0 Feb.2006 6. SCANNER SECTION

6.3.4 Image processing


The following items are provided for the image processing. For details, See "22. IMAGE PROCESSING".

bizhub 500 / 420


• AOC (Auto offset control)
• AGC (Auto gain control)
• Shading correction
• AE processing
• Range discrimination
• Brightness/density conversion
• Filter/magnification
• Density gamma (conversion)
• Halftone processing (error diffusion)
• Skew adjustment
• Compression
• Storage of image data

17
7. WRITE SECTION Theory of Operation Ver1.0 Feb.2006

7. WRITE SECTION
bizhub 500 / 420

7.1 Composition

Collimator lens unit Cleaner CY2 lens Index lens


Laser drive board (LDB) Dust-proof glass
Index mirror

CY1 lens fθ lens


Polygon mirror Index board (INDEXB)
50gat2c003na

18
Theory of Operation Ver1.0 Feb.2006 7. WRITE SECTION

7.2 Operation

bizhub 500 / 420


7.2.1 Laser beam path

[10]

[9]

[8]

[7] [1]

[6]
[2]

[5]
[3]

[4]

50gat2c041na

[1] Dust-proof glass [6] Polygon mirror


[2] CY2 lens [7] CY1 lens
[3] Drum [8] Collimator lens
[4] Index board (INDEXB) [9] Laser diode
[5] fθ lens [10] Index mirror

7.2.2 Write control


Image data that has been processed is converted into laser beam on the laser drive board (LDB) to be irradiated
on the drum. 1 laser diode emits 2 beams and 2 lines are written per 1 scan.
To prevent the mis-centering of a written image, an INDEX signal detected by the index board (INDEXB) is used
to decide the reference position for writing in the drum shaft direction (main scan direction) to control the starting
position of the laser irradiation onto the drum.

7.2.3 Image stabilization control


The following items are provided for the image stabilization control. For details, See "21. IMAGE STABILIZATION
CONTROL".
• MPC (Maximum power control)
• APC (Auto power control)
• Dot diameter adjustment control

19
7. WRITE SECTION Theory of Operation Ver1.0 Feb.2006

7.2.4 Image processing


The following items are provided for the image processing. For details, See "22.2 Image processing in the write
bizhub 500 / 420

section".
• Rotation/elongation
• 2 dots PWM
• PWM
• Frequency conversion

20
Theory of Operation Ver1.0 Feb.2006 8. PHOTO CONDUCTOR SECTION

8. PHOTO CONDUCTOR SECTION

bizhub 500 / 420


8.1 Composition

Drum Drum claw PGC sensor IDC sensor (IDCS)

50gat2c004na

21
8. PHOTO CONDUCTOR SECTION Theory of Operation Ver1.0 Feb.2006

8.2 Drive
bizhub 500 / 420

8.2.1 Drum drive

[1]

[2]

50gat2c005na

[1] Drum motor (M1) [2] Drum drive shaft

8.2.2 Drum claw drive

[1]

[2]

50gat2c006na

[1] Drum claw [2] Drum claw solenoid (SD2)

22
Theory of Operation Ver1.0 Feb.2006 8. PHOTO CONDUCTOR SECTION

8.3 Operation

bizhub 500 / 420


8.3.1 Image creation control
When the print start signal turns ON [1], various motors turn ON to place each unit in the operating condition. At
the same time, the erase lamp (EL) turns ON to neutralize the drum and the charging corona charges the drum.
A specified period of time after the print start signal turns ON, the developing bias turns ON [2] and then a high
voltage is impressed [3] on the guide plate. When the preparation for image creation is made, an image is cre-
ated on the drum surface by laser irradiation and developing.
A specified period of time after the registration clutch (CL1) turns ON [4], a high voltage is impressed on the
transfer corona [5] and the separation corona [6] to turn ON the transfer exposure lamp (TSL) [8] and the drum
claw solenoid (SD2) [9] sequentially. The ON timing [7] of TSL varies according to the type of paper. And the ON
time period of TSL also varies according to the setting environment. An image created on the drum is transferred
onto paper and then the paper is separated from the drum.
A specified period of time after the registration sensor (PS1) detects the trailing edge of paper and turns OFF
[10], each operation turns OFF. However, some operations turn OFF a specified period of time after PS1 detects
the trailing edge of the last paper and turns OFF [11], or a specified period of time after the fusing exit sensor
(PS3) detects the trailing edge of the last paper and turns OFF [13]. For the charging corona, the developing bias
and the guide plate bias, with the OFF timing [12] by the last paper of the transfer corona used as a starting
point, each of the OFF timing is interlocked.

[1][2] [3] [4][5] [6] [10] [11]

Drum motor (M1)

Developing motor (M3)

Registration sensor (PS1)

Registration clutch (CL1)

Erase lamp (EL)

Charging corona (HV)

Developing bias (HV)

Transfer corona (HV)

Separation corona (HV)

Guide plate bias (HV)

Transfer exposure lamp (TSL)

Drum claw solenoid (SD2)

Fusing exit sensor (PS3)

[13]
[7] [8] [9] [12] 50gat2c103na

[1] Print start signal ON [8] Transfer exposure lamp (TSL) ON (This var-
[2] Developing bias high voltage impressed ies according to the setting environment.)
[3] Guide plate bias high voltage impressed [9] Drum claw solenoid (SD2) ON
[4] Registration clutch (CL1) ON [10] Trailing edge of the 1st paper detected
[5] Transfer corona high voltage impressed [11] Trailing edge of the last paper detected
[6] Separation corona high voltage impressed [12] Transfer of the last paper OFF
[7] Varies according to the type of paper. [13] Trailing edge of the last paper detected

23
8. PHOTO CONDUCTOR SECTION Theory of Operation Ver1.0 Feb.2006

8.3.2 Drum claw control


bizhub 500 / 420

A. Purpose
Two drum claws are employed to prevent paper from winding up around the drum (winding-up jam). The contact
and severance of the drum claws to and from the drum are made by the ON/OFF of the drum claw solenoid
(SD2).

B. Swing operation
To prevent paper from getting stained at specific points and the drum [3] from being damaged, the drum claw [2]
makes a swing operation of about 7 mm against the drum surface.
The drum claw unit [4] is provided with a projection [7]. This projection is pressed by the cam [6] provided on the
gear [5] to push out the drum claw unit backward. When the gear rotates to release the cam, the drum claw unit
is sent back to the original position by the spring [1]. This operation is repeated to swing the drum claw.

[5] [6] [7] [1]

[4] [3] [2]


50gat2c042na

8.3.3 Image stabilization control


The following items are provided for the image stabilization control. For details, See "21. IMAGE STABILIZATION
CONTROL".
• Drum rotation control
• Dot diameter adjustment control

24
Theory of Operation Ver1.0 Feb.2006 9. CHARGING SECTION

9. CHARGING SECTION

bizhub 500 / 420


9.1 Composition

Erase lamp (EL) Charging wire Charging control plate

50gat2c007na

9.2 Operation
9.2.1 Charging control
A. Charging wire
The high voltage unit (HV) pressurizes 24V DC to impress a minus (–) DC voltage on the charging wire for dis-
charge.
Charging output range: –500 to –1100 µA

B. Charging grid
To obtain a uniform charging wire discharge, a minus (–) high voltage is impressed from the high voltage unit
(HV) to the charging grid.
Charging grid voltage output range: –450 to –1090 V

9.2.2 Erase lamp (EL) control


A. Purpose
To neutralize a residual potential on the drum surface and to obtain a uniform potential on the drum surface, the
erase lamp (EL) is irradiated on the drum before charging.

B. Execution timing
The erase lamp (EL) turns ON in synch with the print start signal turning ON. And it turns OFF a specified period
of time after the fusing exit sensor (PS3) detects the trailing edge of the last paper.

25
10. TRANSFER/SEPARATION SECTION Theory of Operation Ver1.0 Feb.2006

10. TRANSFER/SEPARATION SECTION


bizhub 500 / 420

10.1 Composition

Plunging prevention plate Transfer wire

Separation wire Transfer exposure lamp (TSL)


50gat2c008na

26
Theory of Operation Ver1.0 Feb.2006 10. TRANSFER/SEPARATION SECTION

10.2 Operation

bizhub 500 / 420


10.2.1 Transfer guide control
A. Purpose
To prevent the transfer guide plate from getting stained, a minus (–) DC voltage is impressed from the high volt-
age unit (HV).
Voltage impressed: –500 V

B. Execution timing
The impression of a voltage onto the transfer guide plate is made ON a specified period of time after the devel-
oping bias turns ON. And it turns OFF a specified period of time after the developing bias turns OFF.

10.2.2 Transfer/separation control


A. Transfer
The high voltage unit (HV) pressurizes a 24V DC to impress a plus (+) DC voltage on the transfer wire for dis-
charging.
Transfer DC output range: 0 to –450 µA

B. Separation
For separation, an AC high voltage and a minus (–) DC voltage are employed. The high voltage unit (HV)
impresses a voltage onto the separation wire for discharging.
Separation AC output range: 300 to 1000 µA
Separation DC output range: 0 to –200 µA

10.2.3 Transfer exposure lamp (TSL) control


A. Purpose
The transfer exposure lamp (TSL) is turned ON to secure transferability and prevent a reverse charge to the
drum.

B. Execution timing
The transfer exposure lamp (TSL) turns ON a specified period of time after the registration clutch (CL1) turns ON.
And it turns OFF a specified period of time after the registration sensor (PS1) turns OFF.

27
11. DEVELOPING UNIT Theory of Operation Ver1.0 Feb.2006

11. DEVELOPING UNIT


bizhub 500 / 420

11.1 Composition

Developing roller Developer restriction blade

TCR sensor (TCRS) Agitator screw Agitator plate


50gat2c009na

28
Theory of Operation Ver1.0 Feb.2006 11. DEVELOPING UNIT

11.2 Drive

bizhub 500 / 420


[6]

[5]

[4]
[1]

[3]

[2]
50gat2c010na

[1] Drum [4] Agitator screw


[2] Developing roller [5] Developing unit
[3] Developing motor (M3) [6] Agitator plate

29
11. DEVELOPING UNIT Theory of Operation Ver1.0 Feb.2006

11.3 Operation
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11.3.1 Developer conveyance


Developer in the developing unit is supplied by the agitator plate [4] to the developing roller [2]. The thickness of
developer attaching to the developing roller is restricted by the developer restriction blade [5]. After completion
of transfer to the drum [1], developer remaining on the developing roller is sent back to the agitator screws [3].
The 2 agitator screws rotate in the same direction to obtain an improved conveyability when developer is
changed.

[3] [4] [5]

[1]

[2]
50gat2c043na

[1] Drum [4] Agitator plate


[2] Developing roller [5] Developer restriction blade
[3] Agitator screw

30
Theory of Operation Ver1.0 Feb.2006 11. DEVELOPING UNIT

11.3.2 Developing bias


A. Purpose

bizhub 500 / 420


To make toner get easily attached to the drum while in developing, a developing bias is impressed onto the
developing roller [1].

[2] [3] [4]

[1]
50gat2c044na

[1] Developing roller [3] Developing bias shaft


[2] Main pole position adjusting plate [4] Developing bias contact

B. Timing
To prevent unnecessary carriers from attaching to the drum, a developing bias turns ON a specified period of
time after the print start signal turns ON, and it turns OFF a specified period of time after charging turns OFF.

31
11. DEVELOPING UNIT Theory of Operation Ver1.0 Feb.2006

11.3.3 Developing suction control


bizhub 500 / 420

A. Purpose
To prevent the splash of toner from the developing roller, the duct [4] is provided at 2 places of the developing
unit [1]. Toner guided into the duct is sucked in by the developing suction fan (FM6) [3] to be collected by the
suction filter /A [2].

[3]

[4]
[2]

[1]

50gat2c045na

[1] Developing unit [3] Developing suction fan (FM6)


[2] Suction filter /A [4] Duct

B. Developing suction fan (FM6) control


The developing suction fan (FM6) turns ON in synch with the developing motor (M3) turning ON. And it turns
OFF a specified period of time after M3 turns OFF. However, while in the TCR adjustment mode, it turns OFF in
synch with M3 turning OFF.

11.3.4 Image stabilization control


The following item is provided for the image stabilization control. For details, See "21. IMAGE STABILIZATION
CONTROL".
• Toner density control

32
Theory of Operation Ver1.0 Feb.2006 12. TONER SUPPLY SECTION

12. TONER SUPPLY SECTION

bizhub 500 / 420


12.1 Composition

Toner bottle position


Toner remaining sensor Toner supply motor sensor (PS28) Toner bottle sensor (PS4)
(PZS) (M4)

Toner bottle motor (M10) Toner hopper

Toner bottle

50gat2c011na

33
12. TONER SUPPLY SECTION Theory of Operation Ver1.0 Feb.2006

12.2 Drive
bizhub 500 / 420

[5]

[4]

[1]

[2]

[3]

50gat2e003na

[1] Toner agitator plate [4] Toner bottle motor (M10)


[2] Toner conveyance screw [5] Toner supply motor (M4)
[3] Toner solenoid (SD5)

34
Theory of Operation Ver1.0 Feb.2006 12. TONER SUPPLY SECTION

12.3 Operation

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12.3.1 Toner level detection control
A. Toner level detection control
Toner remaining in the toner hopper is detected by the toner remaining sensor (PZS). When toner remaining in
the hopper is found below the prescribed amount, a toner supply signal is issued to the printer control board
(PRCB). This signal is transmitted to the operation board (OB) through the overall control board (OACB). Accord-
ingly, OB displays a message in LCD on the LCD board (LCDB).

B. Detection timing
• At all times while in printing.

12.3.2 Toner supply control to the toner hopper


A. Operation
When the toner remaining sensor (PZS) detects the reduced level of remaining toner, the toner bottle motor
(M10) turns ON and rotates the toner bottle to supply toner in the toner bottle to the toner hopper.
When PZS detects the toner level being restored to its prescribed level, M10 turns OFF to get back to the stand-
by condition.

B. Toner bottle position detection


The toner supply section is provided with the toner bottle position sensor (PS28) to detect the rotational position
of the toner bottle whether it is at the home position.

12.3.3 Toner supply control to the developing unit


A. When the power switch (SW2) is turned ON
A specified period of time after SW2 turns ON, the TCR sensor (TCRS) detects the toner density in the develop-
ing unit. At this time, when a detected value is found below the initial density recorded in the CPU in the overall
control board (OACB), the toner supply motor (M4) and the toner solenoid (SD5) turn ON to supply toner from
the toner hopper to the developing unit.

B. While in printing
While in printing, the toner density is detected by the TCR sensor (TCRS). The ON time periods of the toner sup-
ply motor (M4) and the toner solenoid (SD5) are decided according to the output voltage of TCRS to supply
toner from the toner hopper to the developing unit.

TCRS output voltage Toner supply time period


Less than 2.01 V 0 second
2.01 to 2.14 V 0.10 seconds
2.14 to 2.22 V 0.15 seconds
2.22 to 2.28 V 0.20 seconds
2.28 to 2.32 V 0.25 seconds
2.32 to 2.39 V 0.40 seconds
2.39 V or more 0.50 seconds

35
12. TONER SUPPLY SECTION Theory of Operation Ver1.0 Feb.2006

12.3.4 Toner conveyance control


bizhub 500 / 420

A. Purpose
To convey toner in the toner bottle to the toner hopper.

B. Operation
The exit [1] of the toner bottle is normally closed. However, by setting the bottle to the toner supply section, the
accordion section is pushed and compressed to let the exit open. A bottle set to the toner supply section
rotates when the toner bottle motor (M10) turns ON. When the toner bottle rotates, toner is conveyed to the exit
of the bottle along the spiral groove engraved on the surface of the toner bottle and flows out into the toner hop-
per.

[1]

D C B A

[2]

D C B

A
50gat2e002na

[1] Exit [2] Rotation

36
Theory of Operation Ver1.0 Feb.2006 13. CLEANING/TONER RECYCLE SECTION

13. CLEANING/TONER RECYCLE SECTION

bizhub 500 / 420


13.1 Composition

Collection screw Scraper Collection paddle

Cleaning blade Drum Neutralizing sheet

50gat2c013na

37
13. CLEANING/TONER RECYCLE SECTION Theory of Operation Ver1.0 Feb.2006

13.2 Drive
bizhub 500 / 420

[1]

[2]

[3]

50gat2c014na

[1] Drum motor (M1) [3] Developer agitation drive


[2] Cleaning/recycle section drive

38
Theory of Operation Ver1.0 Feb.2006 13. CLEANING/TONER RECYCLE SECTION

13.3 Operation

bizhub 500 / 420


13.3.1 Cleaning operation
Toner scraped by the cleaning blade [4] is neutralized by the neutralizing sheet [2], then collected by the collec-
tion paddle [1], and finally guided to the collection screw [5]. At this time, toner remaining on the collection pad-
dle is scraped by the scraper [6].

[5] [6]

[1]

[4]

[3]
[2]

50gat2c047na

[1] Collection paddle [4] Cleaning blade


[2] Neutralizing sheet [5] Collection screw
[3] Drum [6] Scraper

13.3.2 Toner collection mechanism


A. Purpose
To reuse toner scraped by the cleaning blade, the toner collection mechanism is provided.

B. Execution timing
The collection paddle to be used to collect toner is driven by the drum motor (M1) and the toner collection oper-
ation is made in synch with the ON/OFF of M1.

13.3.3 Toner conveyance operation


A. Toner conveyance mechanism
Toner collected is conveyed to the hopper in the toner supply section by the collection screw of the cleaning
section.

B. Execution timing
The collection screw is driven by the drum motor (M1) and the toner conveyance operation is made in synch
with the ON/OFF of M1.

39
14. PAPER FEED SECTION (Tray 1/2) Theory of Operation Ver1.0 Feb.2006

14. PAPER FEED SECTION (Tray 1/2)


bizhub 500 / 420

14.1 Composition
14.1.1 Tray 1

Pick-up roller
Lift plate Feed roller

Separation roller

Tray 1
50gat2c015na

14.1.2 Tray 2

Vertical conveyance roller


Pick-up roller

Feed roller
Lift plate

Separation roller

Tray 2
50gat2c104na

40
Theory of Operation Ver1.0 Feb.2006 14. PAPER FEED SECTION (Tray 1/2)

14.2 Drive

bizhub 500 / 420


14.2.1 Paper feed drive

[1]

[13]
[12] [2]

[3]

[4]
[5]

[6]
[7]
[11] [10]

[8]

[9]

50gat2c016na

[1] Feed motor (M9) [8] Feed roller /2


[2] Feed clutch /1 (CL4) [9] Separation roller /2
[3] Feed roller /1 [10] Pick-up roller /2
[4] Separation roller /1 [11] Tray 2
[5] Vertical conveyance roller [12] Tray 1
[6] Vertical conveyance clutch (CL3) [13] Pick-up roller /1
[7] Feed clutch /2 (CL5)

14.2.2 Tray lift drive

[3][4]

[1]

[2] 50gat2c017na

[1] Lift arm [3] Paper lift motor /1 (M7)


[2] Lift plate [4] Paper lift motor /2 (M8)

41
14. PAPER FEED SECTION (Tray 1/2) Theory of Operation Ver1.0 Feb.2006

14.3 Operation
bizhub 500 / 420

14.3.1 Up/down control


A. Up drive operation
The lift drive shaft [3] is rotated by the paper lift motors /1 (M7) [6] and /2 (M8) [7]. The lift drive shaft is provided
with the lift arm [1] and the lift plate [2] is pushed up when the lift drive shaft rotates. In this way, the up drive
operation of the lift plate is conducted.

B. Down drive operation


Pulling out the tray disengages the coupling [8] of the paper lift motors /1 (M7) and /2 (M8) from the lift drive
shaft. In this way, the driving force of M7 or M8 that holds the lift plate at the upper position is released and the
lift plate goes down by its own weight.

[6] [7] [8]

[9][10]

[1]

[4] [5]

[3] [2] 50gat2c051na

[1] Lift arm [6] Paper lift motor /1 (M7)


[2] Lift plate [7] Paper lift motor /2 (M8)
[3] Lift drive shaft [8] Coupling
[4] Tray set sensor /1 (PS8) [9] Upper limit sensor /1 (PS6)
[5] Tray set sensor /2 (PS14) [10] Upper limit sensor /2 (PS13)

C. Operation timing
When the tray is set, the tray set sensors /1 (PS8) and /2 (PS14) turn ON. In this way, the paper lift motors /1
(M7) and /2 (M8) turn ON to raise the lift plate. When the lift plate goes up and the upper most paper that is
loaded turns ON the upper limit sensors /1 (PS6) and /2 (PS13), M7 and M8 turn OFF to stop the up drive oper-
ation.
When the paper feed operation causes PS6 and PS13 to turn OFF from ON while in the print operation, M7 and
M8 turn ON again to raise the lift plate. In this way, when PS6 and PS13 turn ON again, M7 and M8 turn OFF to
stop the up drive operation.

42
Theory of Operation Ver1.0 Feb.2006 14. PAPER FEED SECTION (Tray 1/2)

14.3.2 Paper size detection control


A. Paper size detection mechanism

bizhub 500 / 420


(1) Size detection in the main scan direction
The side guide plate [12] is provided with the size detection actuator [7]. And interlocked with the side guide
plate, this actuator sticks out to the rear side of the tray. The size detection actuator is provided with the 2 lines
of notches, which are detected by the paper size sensors /Fr1 (PS11) [11] and /Rr1 (PS10) [10], or the paper
size sensors /Fr2 (PS17) [3] and /Rr2 (PS16) [4] equipped individually on the rear of the main body. The notches
of the size detection actuator vary for each paper size and the paper size is detected in the main scan direction
by the combination of the ON/OFF of PS10 and PS11, or PS16 and 17.

(2) Size detection in the sub scan direction


The rear guide plate [13] is provided with the size detection actuator [1], which rotates in interlock with the rear
guide plate. The size detection actuator is provided with a projection [2]. When this projection comes at the rear
side of the tray, it pushes the detection levers [9] and [6] of the paper size boards /1 (PSB/1) [8] and /2 (PSB/2)
[6] equipped on the back of the main body. 4 detection levers are equipped on each of the paper size board and
they individually turn ON and OFF the paper size detection switches /1 (SW101) to /4 (SW104) provided on each
board. On the other hand, the projections of the size detection actuator vary in their circumterence and the inter-
vals between each of these projections, and accordingly, either one of the 4 detection levers is to be pushed
according to the position of the guide plate. In this way, the paper size in the sub scan direction is detected by
the combination of the ON/OFF of SW101 to SW104.

[12] [13] [1]

[8] [9] [10] [11]

[7] [6][5] [4] [3] [2] 50gat2c048na

[1] Size detection actuator [8] Paper size board /1 (PSB/1)


[2] Projection [9] Detection lever
[3] Paper size sensor /Fr2 (PS17) [10] Paper size sensor /Rr1 (PS10)
[4] Paper size sensor /Rr2 (PS16) [11] Paper size sensor /Fr1 (PS11)
[5] Detection lever [12] Side guide plate
[6] Paper size board /2 (PSB/2) [13] Rear guide plate
[7] Size detection actuator

43
14. PAPER FEED SECTION (Tray 1/2) Theory of Operation Ver1.0 Feb.2006

B. Paper size detection table


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Paper size Paper size boards /1 (PSB/1), /2 (PSB/2) Paper size sensor Paper size sensor
SW101 SW102 SW103 SW104 /Rr1 (PS10), /Rr2 /Fr1 (PS11), /Fr2
(PS16) (PS17)
B5 ON ON OFF OFF ON OFF
A5S ON/OFF OFF OFF OFF OFF OFF
A4 ON/OFF OFF OFF OFF ON OFF
81/2 x 11 OFF OFF OFF OFF OFF OFF
81/2 x 11S ON OFF OFF ON OFF ON
B5S OFF OFF ON OFF OFF OFF
A4S OFF ON/OFF ON ON OFF ON
81/2 x 14 ON ON ON OFF ON ON
B4 ON ON ON OFF ON OFF
A3 ON ON/OFF ON ON ON OFF

44
Theory of Operation Ver1.0 Feb.2006 14. PAPER FEED SECTION (Tray 1/2)

14.3.3 Paper feed control


A. Pick-up mechanism

bizhub 500 / 420


The pick-up roller [4] is brought up and down mechanically by the lever [6] provided on the rear side of the paper
feed unit. When the tray is set, the lever is pushed by the tray to bring down the pick-up roller. In this way, the
pick-up roller comes in contact with paper to pick it up.

[6]

[1]

[5] [3]

[4] [2]

50gat2c098na

[1] Feed roller [4] Pick-up roller


[2] Separation roller [5] When the tray is not set (with the pick-up
[3] When the tray is set (with the pick-up roller roller brought up)
brought down) [6] Lever

45
14. PAPER FEED SECTION (Tray 1/2) Theory of Operation Ver1.0 Feb.2006

B. Pick-up control
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(1) Tray 1 pick-up control


When the print start signal turn ON [1], the feed motor (M9) and the feed clutch /1 (CL4) also turn ON. In this
way, the driving force of M9 is transmitted to the pick-up roller and the feed roller to pick up [2] the 1st sheet of
paper. When paper is conveyed and the registration sensor (PS1) turns ON, CL4 turns OFF to complete the
pick-up operation. The pick-up [4] operation of the 2nd and succeeding sheets of paper is conducted using the
paper feed request signal [3] as a starting point.

[1] [2] [3] [4]

Feed motor (M9)

Registration sensor (PS1)

Feed clutch /1 (CL4)


50gat2c099na

[1] Print start signal ON [3] Paper feed request signal


[2] Pick-up of the 1st paper [4] Pick-up of the 2nd paper

(2) Tray 2 pick-up control


When the print start signal turns ON [1], M9, the feed clutch /2 (CL5), and the vertical conveyance clutch (CL3)
turn ON. In this way, the driving force of M9 is transmitted to the pick-up roller, the feed roller and the vertical
conveyance roller to conduct the pick-up [2] and the vertical conveyance [3] of the 1st sheet of paper. When
paper is conveyed and the vertical conveyance sensor (PS2) turns ON, CL5 turns OFF to complete the pick-up
operation. However, since CL3 keeps turning ON, paper is conveyed to the registration section by the vertical
conveyance roller. In this manner, when PS1 turns ON, CL3 turns OFF a specified period of time after that. The
pick-up [5] and the vertical conveyance [6] of the 2nd and succeeding sheets of paper are conducted using the
paper feed request signal [4] as a starting point.

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

Feed motor (M9)

Registration sensor (PS1)

Vertical conveyance sensor (PS2)

Feed clutch /2 (CL5)

Vertical conveyance clutch (CL3)


50gat2c100na

[1] Print start signal ON [4] Paper feed request signal


[2] Pick-up of the 1st paper [5] Pick-up of the 2nd paper
[3] Vertical conveyance of the 1st paper [6] Vertical conveyance of the 2nd paper

46
Theory of Operation Ver1.0 Feb.2006 14. PAPER FEED SECTION (Tray 1/2)

C. Separation mechanism
The separation roller [5] is pressed against the feed roller [8] by the operating pressure generated by the pres-

bizhub 500 / 420


sure [2] of the spring [4] and the torque of the torque limiter [3]. This operating pressure of the feed roller, sepa-
ration roller and torque limiter becomes a limit torque to prevent the double feed of paper.
When there is no paper between the separation roller and the feed roller, or when only one sheet of paper is con-
veyed, the operating pressure of the feed roller, the paper and the spring is in excess of the limit torque, and
therefore, the separation roller rotates [6] following the rotation of the feed roller. When two or more sheets of
paper are conveyed between the separation roller and the feed roller, the limit torque is greater than the frictional
force between 2 sheets of paper, and accordingly, the separation roller stops and the lower side paper [7] in
contact with the separation roller is not conveyed.

[8] [1]

[2]

[3]

[7] [6] [5] [4]


50gat2c101na

[1] Paper conveyance direction [5] Separation roller


[2] Pressing [6] Driven rotation
[3] Torque limiter [7] 2nd sheet of paper
[4] Spring [8] Feed roller

47
14. PAPER FEED SECTION (Tray 1/2) Theory of Operation Ver1.0 Feb.2006

14.3.4 Paper empty control


The paper empty of the tray is detected by the paper empty sensors /1 (PS5) [3] and /2 (PS12) [4]. And to
bizhub 500 / 420

prompt the supply of paper before paper in the tray runs out completely, the paper near-empty sensors /1 (PS9)
[7] and /2 (PS15) [8] are equipped. The lift drive shaft [2] that brings up the lift plate [5] is provided with the actu-
ator [1] and PS9 and PS15 are turned ON and OFF by this actuator. When a sufficient amount of paper is loaded
on the tray, the actuator turns ON PS9 and PS15. However, when the amount of paper gets reduced and the lift
plate goes up, the actuator turns OFF PS9 and PS15. In this way, it is detected that the paper loaded in the tray
comes near to an end.

[7] [8]
[1]
[2]

[3][4]

[6] [5]
50gat2c050na

[1] Actuator [5] Lift plate


[2] Lift drive shaft [6] Coupling
[3] Paper empty sensor /1 (PS5) [7] Near-empty sensor /1 (PS9)
[4] Paper empty sensor /2 (PS12) [8] Near-empty sensor /2 (PS15)

48
Theory of Operation Ver1.0 Feb.2006 14. PAPER FEED SECTION (Tray 1/2)

14.3.5 Paper remaining detection mechanism


The front cover [4] of the tray is provided with the paper remaining display window [3], and the paper remaining

bizhub 500 / 420


in the tray can be checked through this window. The inside of the paper remaining display window is provided
with the display lever [2] which is interlocked with the up/down position of the lift plate [1]. The display lever is red
in color and it is indicated that the more the red portion that can be seen through the paper remaining display
window, the less paper there remains in the tray.

[4] [1]

[3]

[2] 50gat2c053na

[1] Lift plate [3] Paper remaining display window


[2] Display lever [4] Front cover

49
15. BYPASS SECTION Theory of Operation Ver1.0 Feb.2006

15. BYPASS SECTION


bizhub 500 / 420

15.1 Composition

Pick-up solenoid /BP (SD1)

Feed roller

Separation roller Lift plate

50gat2c019na

50
Theory of Operation Ver1.0 Feb.2006 15. BYPASS SECTION

15.2 Drive

bizhub 500 / 420


15.2.1 Paper feed drive

[4]

[1] [2]

[3]
50gat2c018na

[1] Feed clutch /BP (CL6) [3] Separation roller


[2] Feed roller [4] Feed motor (M9)

15.2.2 Tray lift drive

[4] [5] [1]

[3] [2]
50gat2c020na

[1] Cam [4] Feed clutch /BP (CL6)


[2] Lift plate [5] Pick-up solenoid /BP (SD1)
[3] Spring

51
15. BYPASS SECTION Theory of Operation Ver1.0 Feb.2006

15.3 Operation
bizhub 500 / 420

15.3.1 Up/down control


A. Up drive operation
The lift plate [4] is of the construction in which it is pushed up by the spring [5] provided on the lower section.
However, while in the stand-by condition, it is hold down by the cam [3] provided on the lift drive shaft [6]. And
the ON/OFF of the gear [7] of the lift drive shaft is controlled by the stopper [1] that is driven by the pick-up sole-
noid /BP (SD1) [2]. When the feed motor (M9) is turned ON by a print start signal, SD1 turns ON a specified
period of time after that. In this way, the stopper is released and the driving force of M9 is transmitted to the lift
drive shaft. When the cam that holds down the lift plate is released by the rotation of the lift drive shaft, the lift
plate is brought up by the force of the spring. When the lift sensor (PS23) [8] is turned ON by the rotation of the
lift drive shaft, SD1 turns OFF to stop the up drive of the lift plate. This up drive operation causes paper loaded in
the tray to come in contact with the feed roller to allow paper to be fed.

[7] [8] [6]

[2] [1]

[6]

[5] [4] [3] 50gat2c054na

[1] Stopper [5] Spring


[2] Pick-up solenoid /BP (SD1) [6] Lift drive shaft
[3] Cam [7] Gear
[4] Lift plate [8] Lift sensor (PS23)

B. Down drive operation


When the vertical conveyance sensor (PS2) detects the leading edge of paper and turns ON, the pick-up sole-
noid /BP (SD1) turns ON a specified period of time after that and turns OFF a specified period of time after the lift
sensor (PS23) turns OFF. In this way, the cam of the lift drive shaft presses down the lift tray to be placed in the
stand-by condition.

52
Theory of Operation Ver1.0 Feb.2006 15. BYPASS SECTION

15.3.2 Paper size detection control


A. Size detection in the main scan direction

bizhub 500 / 420


According to the position of the guide plate connected to the paper size VR/BP (VR1), the paper size is
detected in the main scan direction.

B. Size detection in the sub scan direction


The paper size is detected by the combination of the ON/OFF of the paper size sensors /BP1 (PS19), /BP2
(PS20), /BP3 (PS21) and /BP4 (PS22).

C. Paper size detection table

Paper size Paper size sensors Paper size VR/BP (VR1)


BP1 BP2 BP3 BP4 detection width (mm)
(PS19) (PS20) (PS21) (PS22)
A6S OFF OFF OFF OFF 80 or more - less than 115
B6S 115 or more - 144 or less
A5 196 or more - 225 or less
B5 242 or more - 268 or less
A5S ON OFF OFF OFF 133 or more - 164 or less
B5S 169 or more - less than 196
A4S 196 or more - 225 or less
81/2 x 11 225 or more - less than 288
A4 288 or more - 330 or less
Foolscap ON ON OFF OFF 188 or more - 235 or less
81/2 x 14 ON ON ON OFF 201 or more - 231 or less
B4 242 or more - less than 268
11 x 17 ON ON ON ON 255 or more - less than 288
A3 288 or more - less than 301

53
15. BYPASS SECTION Theory of Operation Ver1.0 Feb.2006

15.3.3 Paper feed control


bizhub 500 / 420

A. Pick-up control
When the feed motor (M9) is turned ON by the print start signal [1], the pick-up solenoid /BP (SD1) and the ver-
tical conveyance clutch (CL3) also turn ON a specified period of time after that. When SD1 turns ON, the lift
plate goes up [2] and paper comes into contact with the feed roller. After that, the feed clutch /BP (CL6) turns
ON. Through these operations, the driving force of M9 is transmitted to the feed roller and the vertical convey-
ance roller to conduct the pick-up [3] and the vertical conveyance [4] of the 1st sheet of paper. When paper is
conveyed and the vertical conveyance sensor (PS2) turns ON, CL6 turns OFF to complete the pick-up opera-
tion. However, since CL3 keeps turning ON, paper is conveyed to the registration section by the vertical convey-
ance roller. In this way, when the registration sensor (PS1) turns ON, CL3 turns OFF a specified period of time
after that. The pick-up [6] and the vertical conveyance [8] of the 2nd and succeeding sheets of paper are con-
ducted using the paper feed request signal [5] as a starting point. When the last paper turns ON PS2, SD1 turns
ON to bring down [7] the lift plate.

[1] [3] [4] [5] [6] [8]

Feed motor (M9)

Registration sensor (PS1)

Vertical conveyance sensor (PS2)

Pick-up solenoid /BP (SD1)

Feed clutch /BP (CL6)

Vertical conveyance clutch (CL3)

[2] [7] 50gat2c102na

[1] Print start signal ON [5] Paper feed request signal


[2] Lift plate goes up [6] Pick-up of the 2nd paper
[3] Pick-up of the 1st paper [7] Lift plate goes down
[4] Vertical conveyance of the 1st paper [8] Vertical conveyance of the 2nd paper

54
Theory of Operation Ver1.0 Feb.2006 15. BYPASS SECTION

B. Separation mechanism
The separation roller [7] is pressed against the feed roller [1] by the operating pressure generated by the pres-

bizhub 500 / 420


sure [4] of the spring [5] and the torque of the torque limiter [6]. This operating pressure of the feed roller, sepa-
ration roller and torque limiter becomes a limit torque to prevent the double feed of paper.
When there is no paper between the separation roller and the feed roller, or when only one sheet of paper is con-
veyed, the operating pressure of the feed roller, the paper and the spring is in excess of the limit torque, and
therefore, the separation roller rotates [3] following the rotation of the feed roller.
When two or more sheets of paper are conveyed between the separation roller and the feed roller, the limit
torque is greater than the frictional force between 2 sheets of paper, and accordingly, the separation roller stops
and the lower side paper [2] in contact with the separation roller is not conveyed.

[8] [1]

[7]

[6]

[5] [4] [3] [2]


50gat2c106na

[1] Feed roller [5] Spring


[2] 2nd sheet of paper [6] Torque limiter
[3] Driven rotation [7] Separation roller
[4] Pressing [8] Paper conveyance direction

15.3.4 Paper empty control


The paper empty of the tray is detected by the paper empty sensor /BP (PS18).

55
16. REGISTRATION SECTION Theory of Operation Ver1.0 Feb.2006

16. REGISTRATION SECTION


bizhub 500 / 420

16.1 Composition

Registration roller

Loop roller
50gat2c021na

56
Theory of Operation Ver1.0 Feb.2006 16. REGISTRATION SECTION

16.2 Drive

bizhub 500 / 420


[1]
[6]

[2]

[3]

[5]
[4]

50gat2c022na

[1] Registration roller [4] Loop roller


[2] Feed motor (M9) [5] Tray 1
[3] Loop clutch (CL2) [6] Registration clutch (CL1)

57
16. REGISTRATION SECTION Theory of Operation Ver1.0 Feb.2006

16.3 Operation
bizhub 500 / 420

16.3.1 Loop control


A. Registration path
Paper fed from the tray 1 [10], the tray 2 [8], the by-pass tray [6], PC/LU [7] and ADU [4] hits against the registra-
tion roller [2] through the loop roller [12]. And until the loop roller turns OFF, a loop is formed [3] and a paper
skew is corrected.
The loop roller is driven by the feed motor (M9) and the loop of paper is controlled by the registration sensor
(PS1) [13] equipped just before the registration roller.

[1]

[13]
[2]

[12]
[3]

[11]
[4]

[10]
[5]

[9]
[6]

[8] [7]
50gat2c055na

[1] Drum [8] Tray 2 paper conveyance


[2] Registration roller [9] Paper feed unit /2
[3] Loop [10] Tray 1 paper conveyance
[4] ADU paper conveyance [11] Paper feed unit /1
[5] Vertical conveyance section [12] Loop roller
[6] By-pass tray paper conveyance [13] Registration sensor (PS1)
[7] PC/LU paper conveyance

58
Theory of Operation Ver1.0 Feb.2006 16. REGISTRATION SECTION

B. Registration operation
The feed motor (M9) and the loop clutch (CL2) are turned ON by the print start signal [1]. In this way, the driving

bizhub 500 / 420


force of M9 is transmitted to the loop roller and paper conveyed from each of the paper feed sections is con-
veyed to the registration roller. When the registration sensor (PS1) detects the leading edge of paper and turns
ON [3], CL2 turns OFF a specified period of time after that. At this time, since paper is being conveyed for a
specified period of time after being hit against the registration roller, a loop [4] is formed and a paper skew is cor-
rected.
The print signal [5] turns ON the registration clutch (CL1) to transmit the driving force of M9 to the registration
roller. At this time, CL2 also turns ON to drive the loop roller for a loop assist [7].
When PS1 detects the trailing edge of paper and turns OFF [8], CL1 also turns OFF a specified period of time
after that to complete the registration operation. However, CL2 keeps tuning ON to conduct a loop formation [9]
of the next paper. After that, the same operations are repeated.
When PS1 detects the trailing edge of the last paper and turns OFF [11], M9, CL1 and CL2 also turn OFF a
specified period of time after that to complete a series of registration operations.

[1] [2] [3] [5] [7] [8] [10] [11]

Feed motor (M9)

Registration sensor (PS1)

Loop clutch (CL2)

Registration clutch (CL1)

[4] [6] [9] 50gat2c056na

[1] Print start signal [8] Detection of the trailing edge of the 1st
[2] Conveyance of the 1st paper paper
[3] Detection of the leading edge of 1st paper [9] Loop formation of the 2nd paper
[4] Loop formation of the 1st paper [10] Print signal for the 2nd paper
[5] Print signal for the 1st paper [11] Detection of the trailing edge of the last
[6] 1st paper registration roller ON paper
[7] Loop assist of the 1st paper, and convey-
ance of 2nd of paper

59
17. ADU SECTION Theory of Operation Ver1.0 Feb.2006

17. ADU SECTION


bizhub 500 / 420

17.1 Composition

Conveyance roller /1

Conveyance roller /2

50gat2c023na

60
Theory of Operation Ver1.0 Feb.2006 17. ADU SECTION

17.2 Drive

bizhub 500 / 420


[1] [2]

[3] [4]

[6]

[5] 50gat2c024na

[1] ADU conveyance clutch /Up (CL7) [4] Conveyance roller /2


[2] Conveyance roller /1 [5] Conveyance roller /3
[3] ADU conveyance clutch /Lw (CL8) [6] Feed motor (M9)

61
17. ADU SECTION Theory of Operation Ver1.0 Feb.2006

17.3 Operation
bizhub 500 / 420

17.3.1 Conveyance path


Paper the one side of which has been printed is conveyed to ADU by the reverse roller [12]. The paper conveyed
to ADU is also conveyed to the loop roller [6], the registration roller [7] and the drum [8] by the conveyance rollers
/1 [2], /2 [3] and /3 [5] and the other side is printed. Paper both sides of which has been printed passes through
the fusing roller [9] and fusing exit roller [10] to be exited from the main body paper exit roller [11].
The conveyance rollers /1, /2 and /3 are driven by the feed motor (M9), but the ON/OFF of the conveyance roller
/1 is controlled by the ADU conveyance clutch /Up (CL7) and that of the conveyance rollers /2 and /3 controlled
by the ADU conveyance clutch /Lw (CL8). This control is used to prevent the interference of each sheet of paper
that circulates through the conveyance path when two or more sheets of paper are printed. And, to detect the
position of paper that is circulating, the ADU conveyance sensor /1 (PS24) [1] and /2 (PS25) [4] are equipped.

[12]
[1]

[11]

[10] [2]

[9]
[3]

[8]

[7]
[4]

[6]
[5]

50gat2c057na

[1] ADU conveyance sensor /1 (PS24) [7] Registration roller


[2] Conveyance roller /1 [8] Drum
[3] Conveyance roller /2 [9] Fusing roller
[4] ADU conveyance sensor /2 (PS25) [10] Fusing exit roller
[5] Conveyance roller /3 [11] Main body paper exit roller
[6] Loop roller [12] Reverse roller

62
Theory of Operation Ver1.0 Feb.2006 17. ADU SECTION

17.3.2 Conveyance control


When printing two or more sheets of paper in the double sided print mode, the conveyance control in ADU var-

bizhub 500 / 420


ies according to the length of paper in the sub scan direction. The following 3 control methods are provided for
the conveyance control.

Conveyance control Length of applicable paper in the sub scan direction


1 sheet self-contained double sided print B4 (364 mm) to Ledger (431.8 mm)
2 sheets self-contained double sided print Letter (215.9 mm) to B4 (364 mm)
3 sheets self-contained double sided print B5 (182 mm) to Letter (215.9 mm)

A. 1 sheet self-contained double sided print operation

Note
• A figure in the illustration (shown in the square) represents the page number.

1. With the 1st sheet of paper fed, the image of the


2nd page (the back side of the 1st sheet of paper
when the original is double sided) is printed.

50gat2c058na

2. The 1st sheet of paper is conveyed to the paper


reverse/exit section, and then conveyed to ADU
2 after being turned over.

50gat2c059na

63
17. ADU SECTION Theory of Operation Ver1.0 Feb.2006

3. The 1st sheet of paper in ADU is conveyed with-


bizhub 500 / 420

out interruption.

50gat2c060na

4. The 1st sheet of paper is fed again and the image


of the 1st page (the front side of the 1st sheet of
paper when the original is double sided) is printed.

1
2

50gat2c061na

5. With the 2nd sheet of paper fed while exiting the


1st sheet of paper, the image of the 4th page (the
back side of the 2nd sheet of paper when the
2
original is double sided) is printed.
1
6. After this, the procedure of steps 2 to 5 is
repeated.

50gat2c062na

64
Theory of Operation Ver1.0 Feb.2006 17. ADU SECTION

B. 2 sheets self-contained double sided print operation

bizhub 500 / 420


Note
• A figure in the illustration (shown in the square) represents the page number.

1. With the 1st sheet of paper fed, the image of the


2nd page (the back side of the 1st sheet of paper
when the original is double sided) is printed.

50gat2c063na

2. The 1st sheet of paper is conveyed to the paper


reverse/exit section and then conveyed to ADU
2 after being turned over. At this time, the 2nd sheet
of paper is fed.

50gat2c064na

3. The image of the 4th page (the back side of the


2nd sheet of paper when the original is double
4 sided) is printed on the 2nd sheet of paper. At this
time, the 1st sheet of paper is conveyed into ADU.

50gat2c065na

65
17. ADU SECTION Theory of Operation Ver1.0 Feb.2006

4. The 1st sheet of paper is fed again and the image


bizhub 500 / 420

of the 1st page (the front side of the 1st sheet of


paper when the original is double sided) is printed.
4
At this time, the 3rd sheet of paper is fed and the
2nd sheet of paper is turned over at the paper
1 2
reverse/exit section to be conveyed into ADU.

50gat2c066na

5. While the 1st sheet of paper is being exited, the


image of the 6th page (the back side of the 3rd
sheet of paper when the original is double sided)
is printed on the 3rd sheet of paper. At this time,
2
the 2nd sheet of paper is standing by on this side
1
6 of the conveyance roller /3.

50gat2c067na

6. The 3rd sheet of paper is conveyed to ADU after


being turned over at the paper reverse/exit sec-
6 tion. At this time, the 2nd sheet of paper that has
been standing by is fed again.
2
1

50gat2c068na

7. The image of the 3rd page (the front side of the


2nd sheet of paper when the original is double
sided) is printed on the 2nd sheet of paper. At this
6
time, the 3rd sheet of paper has been conveyed
2
into ADU and the 4th sheet of paper is fed at the
1 3 4
same time.

50gat2c069na

66
Theory of Operation Ver1.0 Feb.2006 17. ADU SECTION

8. While the 2nd sheet of paper is being exited, the

bizhub 500 / 420


image of the 8th page (the back side of the 4th
sheet of paper when the original is double sided)
is printed on the 4th sheet of paper. At this time,
4
the 3rd sheet of paper is standing by on this side
3 8
of the conveyance roller /3.
2
1
6

50gat2c070na

9. The 4th sheet of paper is turned over at the paper


reverse/exit section to be conveyed to ADU. At
8 this time, the 3rd sheet of paper that has been
standing by is fed again.
4
10. After this, the procedure of steps 7 to 9 is
3
repeated.
2
1
6

50gat2c071na

67
17. ADU SECTION Theory of Operation Ver1.0 Feb.2006

C. 3 sheets self-contained double sided print operation


bizhub 500 / 420

Note
• A figure in the illustration (shown in the square) represents the page number.

1. The 1st sheet of paper is fed and the image of the


2nd page (the back side of the 1st sheet of paper
when the original is double sided) is printed.

50gat2c072na

2. The 1st sheet of paper is conveyed to the paper


reverse/exit section and then conveyed to ADU
2 after being turned over. At this time, the 2nd sheet
of paper is fed and the image of the 4th page (the
back side of the 2nd sheet of paper when the
original is double sided) is printed.
4

50gat2c073na

3. The 1st sheet of paper is standing by at the con-


veyance roller /3. The 2nd sheet of paper is turned
4 over at the paper reverse/exit section to be con-
veyed to ADU. At this time, the 3rd sheet of paper
is fed and the image of the 6th page (the back
side of the 3rd sheet of paper when the original is
6
double sided) is printed.
2

50gat2c074na

68
Theory of Operation Ver1.0 Feb.2006 17. ADU SECTION

4. The 3rd sheet of paper is conveyed to the paper

bizhub 500 / 420


reverse/exit section and the 2nd sheet of paper is
6 4 conveyed in ADU without interruption. However,
the 1st sheet of paper remains standing by at the
conveyance roller /3.

50gat2c075na

5. The 1st sheet of paper is fed again and the image


of the 1st page (the front side of the 1st sheet of
6 paper when the original is double sided) is printed.
At this time, the 3rd sheet of paper is turned over
to be sent to ADU and the 2nd sheet of paper is
standing by at the conveyance roller /3. In this
1 2
way, the 4th sheet of paper is fed.
4

50gat2c076na

6. While the 1st sheet of paper is being exited, the


image of the 8th page (the back side of the 4th
6 sheet of paper when the original is double sided)
is printed on the 4th sheet of paper. At this time,
2 since the 2nd sheet of paper is standing by at the
1 conveyance roller /3, the 3rd sheet of paper stops
8 when the interval between this sheet and the 2nd
4 sheet of paper comes to the prescribed distance.

50gat2c077na

7. The 4th sheet of paper is conveyed to the paper


reverse/exit section. At this time, the conveyance
8 of the 2nd and the 3rd sheets of paper resumes in
6 ADU.
2
1

50gat2c078na

69
17. ADU SECTION Theory of Operation Ver1.0 Feb.2006

8. The 2nd sheet of paper is fed again and the image


bizhub 500 / 420

of the 3rd page (the front side of the 2nd sheet of


8 paper when the original is double sided) is printed.
The 4th sheet of paper is turned over to be sent to
2
ADU with the 3rd sheet of paper standing by at
1 the conveyance roller /3. In this way, the 5th sheet
3 4
of paper is fed.
6

50gat2c079na

9. While the 2nd sheet of paper is being exited, the


image of the 10th page (the back side of the 5th
8 sheet of paper when the original is double sided)
is printed on the 5th sheet of paper. At this time,
4 since the 3rd sheet of paper is standing by at the
3 conveyance roller /3, the 4th sheet of paper stops
2 10 when the interval between this sheet and the 3rd
1 sheet of paper comes to the prescribed distance.
6
10. After this, the procedure of steps 7 to 9 is
repeated.
50gat2c080na

70
Theory of Operation Ver1.0 Feb.2006 18. FUSING SECTION

18. FUSING SECTION

bizhub 500 / 420


18.1 Composition
Fusing heater
Fusing web lamp /1 (L2) Fusing roller Paper exit roller Decurler roller

Fusing heater lamp /2 (L3) Fusing pressure roller Fusing claw


50gat2c025na

18.2 Drive

[1]

[2]

50gat2c026na

[1] Fusing unit drive [2] Fusing motor (M11)

71
18. FUSING SECTION Theory of Operation Ver1.0 Feb.2006

18.3 Operation
bizhub 500 / 420

18.3.1 Fusing roller drive control


A. Speed switchover control
The process speed is switched over between the high speed and the low speed according to the type of paper
selected in the paper setting of the setup menu. However, the low speed is applicable in the thick paper,
envelop, OHP, and label paper mode.

Machine type Normal Thick paper, envelop, OHP


and label paper mode
bizhub 500 250mm/s 125mm/s
bizhub 420 210mm/s

B. Preliminary rotation control


While in the warm-up, the preliminary rotation is conducted for the fusing roller and the fusing pressure roller.
The time of preliminary rotation varies according to the detected temperature of the drum temperature sensor
and the thermistors /1 (TH1) and /2 (TH2). And the starting temperature of the preliminary rotation varies for
bizhub 500 and 420.

C. Rotation control while in the print


The fusing motor (M11) that drives the fusing roller and the fusing pressure roller is turned ON by the print start
signal. And it turns OFF a specified period of time after the fusing exit sensor (PS3) detects the trailing edge of
the last paper.
While in the print with paper stopping at the registration section, the fusing roller and the fusing pressure roller
run idle. In this way, the fusing temperature gets near to the set temperature for each type of paper selected in
the paper setting of the setup menu.

18.3.2 Web drive control


The fusing web is driven by the web solenoid (SD4).
The number of ON times is controlled by SD4 according to the web count of the fixed part counter so that the
web shift amount per print becomes constant.

72
Theory of Operation Ver1.0 Feb.2006 18. FUSING SECTION

18.3.3 Fusing temperature control


The fusing roller is heated by the fusing heater lamps /1 (L2) and /2 (L3). The fusing pressure roller is heated by

bizhub 500 / 420


the thermal conduction from the fusing roller.
The surface temperature of the fusing roller is detected by the thermistors /1 (TH1) [2] and /2 (TH2) [1]. TH1 and
TH2 monitor the surface temperature of the fusing roller at specified intervals to control the ON/OFF of L2 and
L3 through the AC drive circuit in the DC power supply (DCPS) so that a prescribed temperature can be
obtained.

[1] [2]

50gat2c081na

[1] Thermistor /2 (TH2) [2] Thermistor /1 (TH1)

A. Warm-up
Warm-up is conducted when the main power switch (SW1), the power switch (SW2) and the interlock switch
(MS) turn ON, and also when the system returns from the low power mode or the sleep mode.
While in the warm-up, the fusing heater lamps /1 (L2) and /2 (L3) turn ON. And it turns OFF at the prescribed
temperature. The temperature at which the warm-up completes varies for bizhub 500 and 420.

B. While in the print


The set temperature of the fusing roller varies according to the type of paper and the paper size. The ON/OFF of
the fusing heater lamps /1 (L2) and /2 (L3) are controlled so that the prescribed temperature is obtained.
When plain paper or thick paper is selected, to prevent the set temperature from going down due to the pas-
sage of paper, the set temperature is raised up to the prescribed temperature for a specified period of time from
the start of printing for each print.
When the fusing roller and the fusing pressure roller are stopped due to the completion or interruption of the
print, each roller is kept running for a specified period of time after L2 and L3 turn OFF to avoid an overshoot.

C. While in the stand-by


While in the stand-by condition, the temperature of the fusing roller is controlled in 3 steps according to the
elapsed time after the completion of warm-up or printing, whether DF is opened or closed, and whether each
key is pushed down or not.
While in the stand-by, the ON/OFF of the fusing heater lamps /1 (L2) and /2 (L3) are controlled so that the fusing
roller gets to the prescribed temperature.
Through these control operations, an overshoot is avoided and fusibility immediately after the release from the
stand-by condition is secured.

73
18. FUSING SECTION Theory of Operation Ver1.0 Feb.2006

D. Low power mode and sleep mode


When each key is not pressed within a specified period of time after the completion of the last print, the system
bizhub 500 / 420

changes into the low power mode or the sleep mode. The starting time for operation can be set individually for
the low power mode and the sleep mode. When the same starting time for operation is set for both modes, the
sleep mode takes precedence over the low power mode.
When the system changes into the low power mode, the ON/OFF of the fusing heater lamps /1 (L2) and /2 (L3)
is controlled so that the fusing roller gets to the prescribed temperature. The controlled temperature at this time
becomes lower than other controlled temperatures. And when the system changes into the sleep mode, the
power supply to L2 and L3 is shut off to put the system in the stand-by condition.

18.3.4 Fusing roller edge cooling control


A. Purpose
When printing continuously the sheets of paper the size of which is short in the main scan direction, the temper-
ature gets high at both edges of the fusing roller and the fusing pressure roller where no paper passages is
made. So, to prevent the temperature from getting high, the edges of each roller are cooled down by the fusing
cooling fans /Fr (FM2) and /Rr (FM8). This control operation is also conducted to avoid a fusing overshoot when
the main body makes an emergency stop due to the occurrence of a jam.

B. Fusing cooling fan control


The fusing cooling fans /Fr (FM2) and /Rr (FM8) vary depending on whether the size of paper in the main scan
direction is large or small. And their operations also vary when a jam occurs.

(1) Small size


Small size paper refers to the one the size of which is 200 mm or less in the main scan direction.
• ON timing
When the fusing exit sensor (PS3) detects the leading edge of paper exited and turns ON.
• OFF timing
When the fusing motor (M11) turns OFF.

(2) Large size


Large size paper refers to the one the size of which is 201 mm or more in the main scan direction.
• ON timing
When the detected temperature of the thermistor /2 (TH2) is over the prescribed temperature.
• OFF timing
When the detected temperature of TH2 goes down below the prescribed temperature.

(3) When a jam occurs.


• ON timing
A jam is detected inside the main body.
• OFF timing
A specified period of time after the fusing cooling fans /Fr (FM2) and /Rr (FM8) turn ON.

Note
• When the power switch (SW2) turns OFF due to the occurrence of a jam, or when the interlock
switch (MS) is turned OFF by opening ADU, the power supply to each fan is shut off and, even if it
is within a specified period of time, the fan turns OFF. However, when SW2 and MS are turned ON
within a specified period of time, FM2 and FM8 turn ON again.

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Theory of Operation Ver1.0 Feb.2006 18. FUSING SECTION

C. Fusing cooling path


The air inside the machine is sucked in by the fusing cooling fans /Fr (FM2) [6] and /Rr (FM8) [1] to be blown

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against the edges of the fusing roller [3] through the ducts [2] and [5]. In this way, the edges of the fusing roller
are cooled down and the surface temperature of the edges of the fusing pressure roller [4] that is in contact also
goes down.

[1]

[2]
[6]

[3]

[4]

[5]

50gat2c082na

[1] Fusing cooling fan /Rr (FM8) [4] Fusing pressure roller
[2] Duct [5] Duct
[3] Fusing roller [6] Fusing cooling fan /Fr (FM2)

18.3.5 Envelope conveyance mechanism


When printing envelopes, to prevent the occurrence of paper crease due to the thickness of paper, it is possible
to switch the nip pressure of the fusing roller and the fusing pressure roller. The nip pressure is manually
switched by the envelope lever [1].

[1]

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[1] Envelope lever

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18. FUSING SECTION Theory of Operation Ver1.0 Feb.2006

18.3.6 Protection against abnormality


When the thermistors /1 (TH1) and /2 (TH2) detects a stipulated temperature (233°C) 5 times at the prescribed
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intervals, this is deemed to be a high temperature abnormality and the fusing heater lamps /1 (L2) and /2 (L3) are
turned OFF. The thermostat (TS) also monitors an abnormal temperature rise and, when the detected tempera-
ture gets to 220 ± 10°C, the AC power lines to L2 and L3 are shut off.
For each condition in the warm-up, print, stand-by and the low power modes, the detected temperatures of
TH1 and TH2 and the number of times when L2 and L3 turned ON are calculated. And it is considered that a
low temperature abnormality occurs when certain conditions are met. When a low temperature abnormality
occurs, the power supply to L2 and L3 is cut off.
When these fusing temperature abnormalities occur, the system is placed in the SC latch condition with a mes-
sage shown in the touch panel. After repairing with the cause of abnormality identified, it is necessary to release
the SC latch by the software DipSW3-1 for restoration.

RL1 DCPS
TS

CBR NF
RL2
AC L2
drive
section L3

PRCB

TH1
Control
section
RL RL1
drive
section RL2

TH2
50gat2c084na

18.3.7 Jam detection control


Only while in the print, when the detected temperatures of the thermistors /1 (TH1) and /2 (TH2) go down in a
moment more than the prescribed temperature, this is considered as a wind-up jam and the operation of the
main body is stopped with a message shown in the touch panel.

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Theory of Operation Ver1.0 Feb.2006 19. REVERSE/EXIT SECTION

19. REVERSE/EXIT SECTION

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19.1 Composition

Reverse roller Exhaust fan /Fr (FM3)


Exhaust fan /Rr (FM9)

Reverse gate Reverse roller

Reverse gate Reverse solenoid (SD3)


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19.2 Drive

[4] [1]

[3] [2]
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[1] Reverse motor (M6) [3] Reverse gate


[2] Reverse solenoid (SD3) [4] Reverse roller

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19. REVERSE/EXIT SECTION Theory of Operation Ver1.0 Feb.2006

19.3 Operation
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19.3.1 Conveyance control


A. Reverse gate
The reverse gate is driven by the ON/OFF of the reverse solenoid (SD3). Paper conveyed from the fusing section
is switched by the reverse gate between the paper exit section and the reverse section.

B. Conveyance path
(1) Paper exit path
The reverse solenoid (SD3) is normally turned OFF and the reverse gate [1] is held in the position in which it
blocks the conveyance path to the reverse roller [4]. In this manner, paper conveyed from the fusing exit roller
(decurler roller) [2] is guided to the main body paper exit roller [3] along the internal form of the reverse gate to be
exited.

[4]

[1]
[3]

[2]

50gat2c085na

[1] Reverse gate [3] Main body paper exit roller


[2] Fusing exit roller (decurler roller) [4] Reverse roller

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Theory of Operation Ver1.0 Feb.2006 19. REVERSE/EXIT SECTION

(2) Reverse path


While in the double sided print, the reverse solenoid (SD3) turns ON when the print on the back side is com-

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pleted, and the reverse gate [1] is switched in the direction in which the conveyance path to the reverse roller [4]
is opened. In this way, paper conveyed from the fusing exit roller (decurler roller) [2] is guided to the reverse roller
along the external form of the reverse gate.

[4]

[1]
[3]

[2]

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[1] Reverse gate [3] Main body paper exit roller


[2] Fusing exit roller (decurler roller) [4] Reverse roller

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19. REVERSE/EXIT SECTION Theory of Operation Ver1.0 Feb.2006

19.3.2 Reverse control


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A. Switch-back mechanism
While in the double sided print, paper that passes through the reverse gate [3] is conveyed to the outside of the
main body by the reverse roller [5] and then sent back again to the inside of the main body. At this time, the
paper is guided to the conveyance roller /1 [1] side, not to the reverse gate side from the metal frame form of the
conveyance path. In this way, the paper is turned over to be conveyed to the registration section again through
ADU.
The ON/OFF timing of the reverse solenoid (SD3) that drives the reverse gate is controlled by the fusing exit sen-
sor (PS3) [2]. And the switchover between the normal rotation and the reverse rotation of the reverse motor (M6)
that drives the reverse roller is controlled by the reverse sensor (PS27) [4].

[5]

[4]

[1]
[3]

[2]

50gat2c087na

[1] Conveyance roller /1 [4] Reverse sensor (PS27)


[2] Fusing exit sensor (PS3) [5] Reverse roller
[3] Reverse gate

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Theory of Operation Ver1.0 Feb.2006 19. REVERSE/EXIT SECTION

B. Reverse control
While in the double sided print, when the fusing exit sensor (PS3) detects the leading edge of paper of which the

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printing of the back side has been completed and turns ON [1], the reverse solenoid (SD3) turns ON to switch
the reverse gate a specified period of time after the registration clutch (CL1) turns ON for back side printing. In
this manner, the paper is conveyed to the reverse section. A specified period of time after the reverse sensor
(PS27) detects the leading edge of paper and turns ON [2], the reverse motor (M6) rotates in the normal direc-
tion [3] and the reverse roller conveys the paper to the outside of the main body. And then, a specified period of
time after PS3 detects the trailing edge of the paper and turns OFF [4], SD3 turns OFF [5] to bring the reverse
gate back to its original position. And when PS27 detects the trailing edge of the paper and turns OFF [6], the
rotation of M6 is switched [7] from the normal rotation to the reverse rotation and the reverse roller sends the
paper back to the inside of the main body to convey it to ADU. In this manner, the paper is turned over.

[1] [3] [5] [7]

Normal
Reverse motor (M6) rotation
Reverse
rotation
Reverse solenoid (SD3)

Fusing exit sensor (PS3)

Reverse sensor (PS27)

[2] [4] [6] 50gat2c088na

[1] Switchover of the reverse gate [5] Return to the reverse gate
[2] Detection of the leading edge of paper [6] Detection of the trailing edge of paper
[3] Normal rotation of the reverse roller ON [7] Switchover of the reverse roller from the
[4] Detection of the trailing edge of paper normal rotation to the reverse rotation

81
20. INTERFACE SECTION Theory of Operation Ver1.0 Feb.2006

20. INTERFACE SECTION


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20.1 Composition

Serial port (RS-232C)

Parallel port (based on IEEE1284)

USB port (USB TypeB)

RJ45 Ethernet connector

50gat2c089na

20.2 Specifications
Item Specifications
Serial port (RS-232C) For CS Remote Care
Parallel port (based on IEEE1284) For ISW of the copier/printer
USB port (USB TypeB) For ISW of the copier/printer
RJ45 Ethernet connector (Spare)

82
Theory of Operation Ver1.0 Feb.2006 21. IMAGE STABILIZATION CONTROL

21. IMAGE STABILIZATION CONTROL

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21.1 Outline
This machine employs various image stabilization controls to realize the top quality print image at all times. The
operation of the image stabilization control varies between while in the power switch (SW2) ON and while in the
print.

21.2 Operation flow


21.2.1 Image stabilization control flow when the power switch (SW2) is turned ON
The following shows the operation flow of the image stabilization control when the SW2 is turned ON.

Power ON E. Environmental decision control

A. Fusing heater lamp early turn-ON

B. Drum rotation
D. Fusing preliminary rotation
C. Dot diameter adjustment control

Stand-by

A. Fusing heater lamp early turn-ON


(1) Purpose
To meet the warm-up specifications, the fusing heater lamps /1 (L2) and /2 (L3) are turned ON early enough so
that the surface temperature of the fusing roller goes up to the prescribed temperature in its early stage.

(2) Execution timing


When the power switch (SW2) is turned ON, without waiting for the initialization of the overall control, the fusing
heater lamp is turned ON by the signal on the printer control board (PRCB). However, since turning ON the fus-
ing heater lamps /1 (L2) and /2 (L3) at the same time causes an excessive inrush current, turn ON L3 first, and
then turn ON L2 a little after that. After turning ON L2 and L3, conduct the ON/OFF control at specified intervals
to maintain the prescribed temperature of the fusing roller that is stipulated in each operation mode.

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21. IMAGE STABILIZATION CONTROL Theory of Operation Ver1.0 Feb.2006

B. Drum rotation
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(1) Purpose
• Prevent the drum charge leak such as an image flow at high humidity
• When left in the low/normal humidity condition, prevent the uneven density due to the difference in sensitiv-
ity between the section facing the cleaner and the developing of the drum and other sections.

(2) Execution timing


It turns ON a specified period of time after the power switch (SW2) turns ON, and turns OFF when the dot diam-
eter adjustment is completed. However, when the 30 seconds extension of the early morning drum rotation is
selected in the software DipSW setting, it turns OFF 30 seconds after the completion of the dot diameter adjust-
ment.

Note
• For bizhub 420, since the early morning dot diameter adjustment is not selected by default, no
drum rotation is made.

C. Dot diameter adjustment control


(1) Purpose
Stabilize the image over a long period of time by preventing the change of the laser 1 dot diameter due to the
write system being stained or the change of developability.

(2) Method
• Create a dot pattern patch of a fixed density on the drum. The laser PWM at this time is maximum.
• Read this dot pattern patch with the IDC sensor (IDCS) and calculate the difference between the sensor
output and the specified value.
• Determine the correction amount of the laser power based on a value calculated to make corrections of the
laser power.
• Repeat several times the control operations described above.

(3) Execution timing


When left for more than 8 hours, executed a specified period of time after the power switch (SW2) is turned ON.
However, this can be changed with the software DipSW setting.

Note
• For bizhub 420, since the early morning dot diameter adjustment is not selected by default, no
execution is made.

D. Fusing preliminary rotation


(1) Purpose
Make uniform the surface temperature of the fusing roller and the fusing pressure roller.

(2) Execution timing


When the detected temperature of the thermistors /1 (TH1) and /2 (TH2) gets to the stipulated temperature.

Note
• The stipulated temperature at which the fusing preliminary rotation is made varies for bizhub 500
and 420.

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Theory of Operation Ver1.0 Feb.2006 21. IMAGE STABILIZATION CONTROL

E. Environmental decision control


(1) Purpose

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To detect the environmental temperature and humidity to maintain the image quality, feedback is made to vari-
ous controls.

(2) Method
A temperature sensor and a humidity sensor are equipped inside the machine.

(3) Execution timing


When the power switch (SW2) is turned ON, and only when it has been left unused for more than 8 hours after
the SW2 was turned OFF last time and the fusing temperature is considered below the stipulated temperature,
an environmental decision is made based on a value measured by the sensor.

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21. IMAGE STABILIZATION CONTROL Theory of Operation Ver1.0 Feb.2006

21.2.2 Image stabilization control flow while in the print and the idle
The following shows the image stabilization control flow while in the print and the idle.
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Print start signal ON

Every 20 prints
Start of print

A. Toner density control


C. Dot diameter adjustment control
B. Developing potential adjustment control

End of print

Stand-by

A. Toner density control


(1) Method
• Develop on the drum a toner patch once every 5 prints after the main power switch (SW1) is turned ON and
read the patch density with the IDC sensor (IDCS).
• When the patch density is below the reference value, the operation varies based on the developing theta.
a: When the developing theta is below the reference value: Increase the number of control rotations of the
developing roller according to the patch density.
b: When the developing theta gets to the reference value: Drive the toner supply motor (M4) for the time just
calculated based on the patch density and the paper size to supply toner.

B. Developing potential adjustment control


(1) Purpose
Because of developer and photosensitive material being deteriorated due to durability, it becomes difficult to
secure the stable amount of toner on the photosensitive material. For that reason, calculate the correction
amount based on the machine inside temperature and the time period during which the photosensitive material
is driven and make corrections of the output values of the charging grid and the developing bias to secure the
stable amount of toner.

(2) Method
Detect the machine inside humidity with the humidity sensor (HUMS) when turning ON the power switch (SW2)
8 hours or more after turning it OFF.
Calculate the correction amount based on the machine inside humidity detected and the time period during
which the photosensitive material is driven.
Make corrections of the output value of the charging grid and the developing bias based on the correction
amount calculated.
When the time period during which SW2 is turned ON after OFF is less than 8 hours, use the value of the
machine inside humidity detected last time.

(3) Execution timing


For each job print.

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Theory of Operation Ver1.0 Feb.2006 21. IMAGE STABILIZATION CONTROL

C. Dot diameter adjustment


(1) Purpose

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While in the continuous print, reduce the variance in image density for each print.

(2) Method
• Create a dot pattern patch between images of which more than 20 prints have been run off. The laser PWM
at this time is maximum.
• Read this dot pattern patch with the IDC sensor (IDCS) and calculate the difference between the sensor
output and the specified value.
• Determine the correction amount of the laser power based on a value calculated to make corrections of the
laser power.
• Repeat several times the control operations described above.

87
22. IMAGE PROCESSING Theory of Operation Ver1.0 Feb.2006

22. IMAGE PROCESSING


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22.1 Image processing in the scanner section

A. Shading correction

B. AE control

C. Area discrimination

D. Brightness/density conversion

E. Filter/magnification

F. Density gamma (conversion)

G. Half tone processing (error diffusion)

H. Compression

I. Storage of image data (option)

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Theory of Operation Ver1.0 Feb.2006 22. IMAGE PROCESSING

22.1.1 Shading correction


This is the measure to obtain an even distribution from light of the CCD sensor. The following corrections are

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made at the prescribed timing.

a. White correction
The output voltage of each pixel of the CCD sensor when the white reference plate is exposed to the exposure
lamp is stored as the maximum output of the pixel.
b. Black correction
The output voltage of each pixel of the CCD sensor when the exposure lamp is turned off is stored as the mini-
mum output of the pixel.

Conduct calculation to find out what step in this range falls on the image data read from the original based on
the difference between the black and white data for each pixel stored in the steps a. and b. above, and output
the results of the calculation in the 10 bits accuracy.

Voltage at which the read is made


[1]
+1.4 White

0V
Black
Width in which the read is made

[2] After shading correction


255 White

0
Width in which the read is made Black
50gat2c091na

[1] AD conversion input [2] Shading correction output

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22. IMAGE PROCESSING Theory of Operation Ver1.0 Feb.2006

22.1.2 AE control
Through the AE control, a density suitable for the original density is automatically selected and the copy is made
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properly.

A. Sampling area
(1) While in the platen mode

[5]

[1]
[7]

[6]

[5]

[2] [2]
[4]
[3]
50gat2c092na

[1] Original [5] 10 mm


[2] L/100 mm [6] Leading edge of the original
[3] L mm [7] AE sampling range
[4] 30 mm

(2) While in the DF mode

[4]

[1]
[6]
[5]

[4]

[3] [2]
50gat2c093na

[1] Original [4] 20 mm


[2] 2.9 mm [5] Leading edge of the original
[3] 1.5 mm [6] AE sampling range

B. Execution timing
• While in the platen print: At the pre-scan before the actual scan when the print or the read starts.
• While in the DF print : At the same time as when the original is read.

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Theory of Operation Ver1.0 Feb.2006 22. IMAGE PROCESSING

22.1.3 Area discrimination


To make a copy of the original under the correct condition (to make a correct filter processing), check the read

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section to see if it is a character or a dot picture, and use the results at the image processing unit at the later
stage.

22.1.4 Brightness/density conversion


The signal obtained after the shading correction is a signal corresponding to the light reflected from the original,
and this is generally called a brightness signal. In this brightness/density conversion section, the brightness sig-
nal is converted in density as shown in the graph below.

255
Density

0 Brightness 1024 50gat2c094na

91
22. IMAGE PROCESSING Theory of Operation Ver1.0 Feb.2006

22.1.5 Filter/magnification
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A. Filter processing
An appropriate filter processing is made according to the type of an original and the magnification selected.

(1) Character : Make the shading of an original conspicuous.


(2) Dot section : Suppress moire.
(3) Picture : Increase the reproducibility of gradation.

B. Magnification processing
For this machine, the sub scan direction magnification is made by the scan speed of the exposure unit (platen
mode) or by the conveyance speed of the DF (DF mode), and the main scan direction magnification is made by
processing images electrically.

(1) Main scan magnification processing while in enlargement


As shown in the drawing below, if the data of each pixel obtained when the original is read by the CCD are D1 to
D5, the positions of the data read when enlarged are E1 to E5. However, when the write is made only with the
data thus read, the following problems occur.

a. There occurs a clearance between data, and this results in a distorted image.
b. The data position does not fall in exactly with the write position.

As shown with dotted lines in the drawing below, when there is no read data that corresponds exactly to the
write position, a density is decided for the write as shown below and appropriate processing is made.

[1] D1 D2 D3 D4 D5

[2] E1 E2 E3 E4 E5

[3] W1 W2 W3 W4 W5 W6 W7 W8
50gat2c095na

[1] Position at which the original is read [3] Write position


[2] Data position while in enlargement

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Theory of Operation Ver1.0 Feb.2006 22. IMAGE PROCESSING

(2) Main scan magnification processing while in reduction


As shown in drawing below, if the data of each pixel obtained when the original is read by the CCD are D1 to

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D5, the positions of the data read when reduced are R1 to R5. They are overlapping each other and do not cor-
respond to the write position. Therefore, a density is decided for the write as shown below and an appropriate
processing is made.

[1] D1 D2 D3 D4 D5

[2] R1 R2 R3 R4 R5

[3] W1 W2 W3 W4 W5
50gat2c096na

[1] Position at which the original is read [3] Write position


[2] Data position while in reduction

(3) Density adjustment


With the density (256 gradation) shown in the axis of coordinate and the position shown in the axis of abscissas,
when E2-E1 in the drawing of "(1) Main scan magnification processing while in enlargement" is shown in 16
steps in the direction of the axis of abscissas, the following drawing is obtained. When the position to the written
data W2 is " ," the density S can be obtained in the following expression.

S = E1 + {(E2 – E1) / 16} x

255

E2
W2
S
Density

E1

0
0 Position 15 50gat2c097na

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22. IMAGE PROCESSING Theory of Operation Ver1.0 Feb.2006

22.1.6 Scanner gamma correction


To the data obtained after the filter/magnification processing, select a density curve corresponding to the den-
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sity button selected on the operation panel. An appropriate density curve is provided for each of the character/
picture/character and the picture/thin character modes.

22.1.7 Halftone processing (error diffusion)


To make effective use of the installed memory and obtain an excellent copy image, error diffusion processing is
employed, which is one of the pseudo-intermediate processing methods.

22.1.8 Compression
To store more image data, data is stored temporarily in the image memory after the images has been com-
pressed.

22.1.9 Storage of image data


The image/setting of the originals read by the scanner or the images sent from the IC can be stored as a file in
the hard disk in the main body. (option)

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Theory of Operation Ver1.0 Feb.2006 22. IMAGE PROCESSING

22.2 Image processing in the write section

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A. Rotation/elongation

B. PWM

C. Frequency conversion

A. Rotation/elongation
Rotate the image in the direction of 90 degrees and 180 degrees as necessary.
When outputting images from the memory, expand the compressed data to restore them to their original state.

B. PWM
The period of time the laser is turned ON is changed by changing the pulse width.

C. Frequency conversion
Write in the memory once the data after the PWM conversion and read it in accord with the write clock signal of
the printer.

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23. OTHERS Theory of Operation Ver1.0 Feb.2006

23. OTHERS
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23.1 Fan control


23.1.1 Composition

[8] [9] [10]

[7]

[6]

[1]

[5]

[2]

[4]

[3]

50gat2c029na

[1] Exhaust fan /Rr (FM9) [6] Fusing cooling fan /Fr (FM2)
[2] Exhaust fan /Fr (FM3) [7] Fusing cooling fan /Rr (FM8)
[3] Conveyance suction fan (FM5) [8] Power supply cooling fan (FM1)
[4] Drum cooling fan (FM4) [9] Overall control board cooling fan (FM10)
[5] Developing suction fan (FM6) [10] Developing cooling fan (FM7)

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Theory of Operation Ver1.0 Feb.2006 23. OTHERS

23.1.2 Operation
A. Power supply cooling fan (FM1) control

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(1) Purpose
Cool down the DC power supply (DCPS) and the high voltage unit (HV2) with suction air.

(2) ON timing
• It turns ON a specified period of time after the drum motor (M1) turns ON.
• While in the auto toner supply mode and the TCR adjustment mode, it turns ON in synch with the turn-ON
of M1.
• While in the low power mode and the stand-by condition, it turns ON in synch with the turn-ON of the drum
cooling fan (FM4).

(3) OFF timing


• While in the initial charging mode, the auto toner supply mode and the TCR adjustment mode, it turns OFF
in synch with the turn-OFF of the drum motor (M1).
• In cases other than the above, it turns OFF a specified period of time after M1 turns OFF.
• While in the low power mode and the stand-by condition, it turns OFF in synch with the turn-OFF of FM4.

B. Fusing cooling fan /Fr (FM2) and /Rr (FM8) control


(1) Purpose
• While in the continuous print of small size paper (paper width: 200 mm or less), cool down both edges of
the fusing roller to suppress a temperature rise on the section of the fusing roller through which no paper
passes.
• Suppress a temperature rise when printing large size paper (paper width: 201 mm or more).
• Suppress a fusing overshoot caused by an emergency stop when a jam occurs.

(2) ON timing
• While in the print of small size paper, they turn ON when the fusing exit sensor detects the first job paper .
• While in the print of large size paper, they turn ON when the thermistor /2 (TH2) goes over the prescribed
temperature.
• They turn ON when the print operation is stopped by a jam.

(3) OFF timing


• While in the print of small size paper, they turn OFF in synch with the turn-OFF of the fusing motor (M11).
• While in the print of large size paper, they turn OFF when TH2 detects a temperature lower than the pre-
scribed temperature.
• They turn OFF a specified period of time after it turns ON by a jam.

C. Exhaust fan /Fr (FM3) and /Rr (FM9) control


(1) Purpose
With exhaust air, cool down paper conveyed and remove heat around the reverse section in the machine.

(2) ON timing
• They turn ON in synch with the turn-ON of the drum motor (M1).

(3) OFF timing


• While in the initial charging mode and the TCR adjustment mode, they turn OFF in synch with the turn-OFF
of M1.
• In cases other than the above, they turn OFF a specified period of time after the turn-OFF of M1.

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23. OTHERS Theory of Operation Ver1.0 Feb.2006

D. Drum cooling fan (FM4) control


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(1) Purpose
Cool around the drum and the toner bottle with suction air.

(2) ON timing
• After completion of the print, it turns ON a specified period of time after the drum motor (M1) turns OFF.
• It turns ON when the machine inside temperature goes over the prescribed temperature.

(3) OFF timing


• It turns OFF a specified period of time after it turns ON after completion of the print.
• While it turns ON after completion of the print, it turns OFF the moment M1 turns ON.
• It turns OFF when the machine inside temperature goes down below the prescribed temperature.

E. Conveyance suction fan (FM5) control


(1) Purpose
Exhaust by sucking air around the conveyance path between the drum and the fusing unit, and stabilize the
conveyability of paper and remove exhaust heat and ozone at the same time.

(2) ON timing
• It turns ON in synch with the turn-ON of the drum motor (M1).
• While in the low power mode and the stand-by condition, it turns ON in synch with the turn-ON of the drum
cooling fan (FM4).

(3) OFF timing


• While in the initial charging and the TCR adjustment mode, it turns OFF in synch with the turn-OFF of M1.
• In cases other than the above, it turns OFF a specified period of time after M1 turns OFF.
• While in the low power mode and the stand-by condition, it turns OFF in synch with the turn-OFF of FM4.

F. Developing suction fan (FM6) control


(1) Purpose
Suck air from the underside of the developing unit to prevent the splash of toner and exhaust air.

(2) ON timing
• It turns ON in synch with the turn-ON of the developing motor (M3).

(3) OFF timing


• It turns OFF a specified period of time after M3 turns OFF.
• While in the TCR adjustment mode, it turns OFF in synch with the turn-OFF of M3.

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Theory of Operation Ver1.0 Feb.2006 23. OTHERS

G. Developing cooling fan (FM7)


(1) Purpose

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Take in fresh air to cool down the developing motor (M3).

(2) ON timing
• After completion of the print, it turns ON a specified period of time after M3 turns OFF.
• While in the auto toner supply mode, it turns ON in synch with the turn-ON of M3.
• It turns ON when the machine inside temperature goes over the prescribed temperature.

(3) OFF timing


• After completion of the print, it turns OFF a specified period of time after it turns ON.
• While in the auto toner supply mode, it turns OFF in synch with the turn-OFF of M3.
• It turns OFF when the machine temperature goes down below the prescribed temperature.

H. Overall control board cooling fan (FM10) control


(1) Purpose
Cool down the overall control board (OACB) with suction air.

(2) ON timing
• It turns ON when the power switch (SW2) turns ON.

(3) OFF timing


• It turns OFF when SW2 turns OFF.

99
23. OTHERS Theory of Operation Ver1.0 Feb.2006

23.2 Counter control


bizhub 500 / 420

23.2.1 Composition

㨇㨉

CN35 CN36
CN939
OACB PRCB CN30 TCT

OB CN936
SDB CN64
3㨪6 KCT

LCDB

50gat2c030na

[1] Coin vendor /2

100
Theory of Operation Ver1.0 Feb.2006 23. OTHERS

23.2.2 Operation
A. Paper exit counter

bizhub 500 / 420


Item Specifications/mechanism
Total counter (TCT) • Display accumulated number of prints in all print modes.
• Counts up by a paper exit signal.
Electronic counter • Display accumulated number of prints on the touch
panel.
• Data collection *1
• Counts up by a paper exit signal.
Key counter (KCT), optional • Counting the designated number of prints allows no fur-
ther copy operation (can be removed).

*1 For data collected, See "10.6 Counter" in Field service bizhub 500/420 Main body. (See P.178)

[2] [1]
50gat2c031na

[1] CN936 (KCT connecting connector) [2] Total counter (TCT)

101
23. OTHERS Theory of Operation Ver1.0 Feb.2006

B. Coin vendor/2 (Parallel)


The following shows the specifications of the connecting connector.
bizhub 500 / 420

Connector Pin No. Signal name Description Output timing Type of signal
36 1 M1 signal Output from the start L output while in the Open collec-
key being turned ON print operation tor output
up to the completion of
paper exit
2 Paper feed signal Output each time L output each time
paper is supplied paper is supplied from
each tray
3 Paper size signal (0) Signal output by paper When the paper size is
4 Paper size signal (1) sizes *1 changed
5 Paper size signal (2)
6 Paper size signal (3)
7 Double sided print Signal output while in While in the selection
selection signal the double sided print of the double sided
print
8 CPF signal (0) Signal output by CPF While in the selection
9 CPF signal (1) modes of the CPF mode
10 P.GND Ground — —

*1 Output signals by paper sizes

Size Paper size signal


(3) (2) (1) (0)
A3 L L H L
B4 L L L L
A4 L H H L
A4S H L H L
B5 L H L L
B5S H L L L
Special L H L H
11 x 17 L L H H
81/2 x 14 L L L H
81/2 x 11 L H H H
81/2 x 11S H L H H
51/2 x 81/2 / A5 L L H L
8 x 13, 81/8 x 131/4, 81/4 x 13, 81/2 x 13 H L L H

102
Theory of Operation Ver1.0 Feb.2006 23. OTHERS

23.3 Parts that operate when the power switch is turned ON

bizhub 500 / 420


23.3.1 Parts that operate when the main power switch (SW1) is turned ON
A. Composition

SW2

SW1 PSWB

OB
DCPS
5VDC
IC
12VDC
DCPS
CBR NF OACB FK
section
HD

24VDC SC

PC LU PRCB

50gat2c032na

B. Operation
Turning ON the main power switch (SW1) supplies an AC power source to DC power supply (DCPS).
In this way, each power source of 12V DC and 5V DC is supplied to the overall control board (OACB).
OACB supplies 5V DC to the operation board (OB) to be placed in the condition of standing by for the turn-ON
of the power switch (SW2).
When equipped optionally with the FAX kit (FK-502) and the hard disk (HD-505), each power source of 12V DC
and 5V DC is supplied through OACB.

103
23. OTHERS Theory of Operation Ver1.0 Feb.2006

23.3.2 Parts that operate when the power switch (SW2) is turned ON
bizhub 500 / 420

A. Composition

SW2

PSWB

OB

SW1
OACB

24VDC
DCPS

RL1
CBR NF
section
RL2

L2, L3

AC drive
section

DCPS
50gat2c033na

B. Operation
Turning ON the power switch (SW2) transmits an ON signal of SW2 to the overall control board (OACB) through
the operation board (OB). In this way, OACB sends out a control signal to the DC power supply (DCPS) and
DCPS supplies each power source of 12V DC and 5V DC to all boards and optional devices, including the
printer control board (PRCB).
After that, OACB sends out to DCPS a control signal that generates a 24V DC power source, which is supplied
to all drive boards and optional devices. And when the main relay (RL1) and the sub relay (RL2) turn ON, an AC
power source is supplied to the fusing heater lamps /1 (L2) and /2 (L3) to start the initial operation of this
machine.

104
SERVICE MANUAL Theory of Operation

DF-607

2006.02
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 correspond-
ing page.
A number within 1 represents the number of times the revision has been made.

NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
• When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
• When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.

2006/02 1.0 — Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision
Theory of Operation Ver. 1.0 Feb. 2006

CONTENTS

DF-607
DF-607

OUTLINE
1. PRODUCT SPECIFICATIONS ................................................................................1
2. PAPER PATH ...........................................................................................................4
2.1 In 1-sided mode ....................................................................................................4

OUTLINE
2.2 In 2-sided mode ....................................................................................................4

COMPOSITION/OPERATION
3. COMPOSITION .......................................................................................................5
4. DRIVE......................................................................................................................6

COMPOSITION/OPERATION
5. OPERATION............................................................................................................7
5.1 Document pick-up mechanism..............................................................................7
5.1.1 Pick-up operation ..........................................................................................7
5.2 Document feed/conveyance mechanism ..............................................................8
5.3 Raised/lowered position detecting mechanism...................................................12
5.3.1 DF 15° open/close detection mechanism....................................................12
5.3.2 DF open/close detection mechanism ..........................................................12

i
Theory of Operation Ver. 1.0 Feb. 2006
DF-607
OUTLINE
COMPOSITION/OPERATION

Blank Page

ii
Theory of Operation Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS

„ OUTLINE
1. PRODUCT SPECIFICATIONS

DF-607
A. Type

Name Reverse Automatic Document Feeder


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

OUTLINE
Document Alignment Center
Document Loading Left image side up

B. Functions

Modes 1-Sided Mode / 2-Sided Mode

C. Paper type

1-Sided Mode
Standard Mode 35 to 128 g/m2 (9.25 to 34 lbs)
Plain Paper 2-Sided Mode
50 to 128 g/m2 (13.25 to 34 lbs)
Mixed Original Detection
1-Sided / 2-Sided Mode
Type of Document Mode
50 to 128 g/m2 (13.25 to 34 lbs)
Plain Paper
1-Sided Mode
FAX Mode 35 to 128 g/m2 (9.25 to 34 lbs)
Plain Paper 2-Sided Mode
50 to 128 g/m2 (13.25 to 34 lbs)
Inch area
A3, A4S, A4, B4, B5S, B5
Detectable Document 11 x 17, 81/2 x 14, 81/2 x 11S, 81/2 x 11, 81/2 x 51/2S, 81/2 x 51/2
Size*1 Metric area
A3, A4S, A4, A5S, A5, B4, B5S, B5, B6S
11 x 17, 81/2 x 11S, 81/2 x 11
Capacity 80 sheets (80 g/m2) or load height of 11 mm or less.
*1: For the Combined Original Detection Mode, Refer to the Mixed Original Detection Enabled
Size Combination Table.

1
1. PRODUCT SPECIFICATIONS Theory of Operation Ver. 1.0 Feb. 2006

D. Paper feed prohibited originals


• If fed, trouble occurrence will be highly possible.
DF-607

Type of Original Possible Trouble


Feed failure, damage to the original, or drive failure
Original that is stapled or clipped.
due to clip clogging
Book original Feed failure, damage to the original, or drive failure
Original weighing less than 35g/m2 or 128g/m2
Feed failure
or more
Torn original Feed failure, damaged sheet
OUTLINE

Highly curled original (15 mm or more) Original misfeed due to dog-ear or skew
OHP transparencies Feed failure
Label Sheet Feed failure
Offset master Feed failure
Sheets clipped or notched Damaged sheet
Sheets patched Patched part folded or torn sheet

E. Paper feed not guaranteed originals


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

Type of Original Possible Trouble


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

2
Theory of Operation Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS

F. Mixed original feed chart


For Metric

DF-607
Reference original (original with a maximum width)
A3 A4 B4S B5 A4S A5 B5S A5
Other A3 U { — — — — — —
originals A4 { U — — — — — —
B4S ~ ~ U { — — — —
B5 ~ ~ { U — — — —
A4S ~ ~ ~ ~ U { — —

OUTLINE
A5 ~ ~ ~ ~ { U — —
B5S X X ~ ~ ~ ~ U —
A5S X X X X X X X U
U: Same size {: Same group ~: Different group X: Mix prohibited —: No need to set

For Inch

Reference original (original with a maximum width)


11 x 17 81/2 x 11 81/2 x 14 81/2 x 11S 51/2 x 81/2 51/2 x 81/2 S
Other 11 x 17 U { — — — —
originals 81/2 x 11 { U — — — —
81/2 x 14 ~ ~ U { { —
81/2 x 11S ~ ~ { U { —
51/2 x 81/2 ~ ~ { { U —
51/2 x 81/2S X X X X X U
U: Same size {: Same group ~: Different group X: Mix prohibited —: No need to set

G. Maintenance

Maintenance Every 250,000 prints


Machine service life Same as the main body.

H. Machine data

Power Requirements 24V DC ± 10% (supplied from the main body)


Max. Power
48 W or less
Consumption
Dimensions 582 (W) x 558 (D) x 145 mm (H)
Weight Approx. 10 kg

I. Operating environment

Temperature 10 to 30°C
Humidity 10 to 80% RH (with no condensation)

NOTE
• These specifications are subject to change without notice.

3
2. PAPER PATH Theory of Operation Ver. 1.0 Feb. 2006

2. PAPER PATH
2.1 In 1-sided mode
DF-607
OUTLINE

[3] [2] [1]


16eat1c001na

[1] Exit [3] Feed (Scanning the 1st side)


[2] Conveyance and turnover

2.2 In 2-sided mode

[3] [2] [1]


16eat1c002na

[1] Exit [3] Feed (Scanning the 1st side)


[2] Conveyance and switchback Conveyance and turnover (Scanning the 2nd
side)
Conveyance

4
Theory of Operation Ver. 1.0 Feb. 2006 3. COMPOSITION

„ COMPOSITION/OPERATION
3. COMPOSITION

DF-607
Document feed section

Conveyance section Switchback section Document exit section

COMPOSITION/OPERATION
16eat2c001na

5
4. DRIVE Theory of Operation Ver. 1.0 Feb. 2006

4. DRIVE
DF-607

[1]

[2]

16eat2c002na
COMPOSITION/OPERATION

[1] Original Feed Motor (M1) [2] Original Conveyance Motor (M2)

6
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATION

5. OPERATION
5.1 Document pick-up mechanism

DF-607
• The Document Pick-Up Section consists of the Pick-Up Rollers, Feed Roller and Separation
Roller, and this section is driven by the Original Feed Motor (M1).

5.1.1 Pick-up operation


• When the Start key is pressed, the Original Feed Motor (M1) [3] starts rotating backward,
causing the Pick-Up Roller [4] to lower and start rotating at the same time. At the same time,
the Feed Roller [2] starts rotating.
• The Pick-Up Rollers are in the raised position when in the standby state and in the lowered
position during feeding.

[3]
[4]

COMPOSITION/OPERATION
[2]

[1] 16eat2c003na

[1] Separation Roller [3] Original Feed Motor (M1)


[2] Feed Roller [4] Pick-Up Roller

7
5. OPERATION Theory of Operation Ver. 1.0 Feb. 2006

5.2 Document feed/conveyance mechanism


• When the original reaches the Registration Sensor, the Original Feed Motor (M1) [5] starts
DF-607

rotating forward and, at the same time that the Pickup Roller goes up, drive is then supplied
to the Registration Roller [3].
• When the Original Conveyance Motor (M2) [4] starts rotating forward, the two Conveyance
Rollers [2] and the Exit/Turnover Roller [1] feed the document toward the exit direction.

Direction of
Parts Details
Rotation
Backward The Pickup Rollers lower and start rotating and the Feed
rotation Roller rotates.
M1
Forward
The Registration Roller rotates.
rotation
Backward The Conveyance Roller and Exit/Turnover Roller rotate in
rotation the direction to turn over the original.
M2
Forward The Conveyance Roller and Exit/Turnover Roller rotate in
rotation the direction to feed the original out.
COMPOSITION/OPERATION

[5]

[1]
[4]

[3]

[2]

16eat2c004na

[1] Exit/Turnover Roller [4] Original Conveyance Motor (M2)


[2] Conveyance Roller [5] Original Feed Motor (M1)
[3] Registration Roller

8
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATION

A. Operation flow in the 1-sided mode

[4]

DF-607
[1]

[3] [2] 16eat2c005na

[1] Exit [3] Scanning the 1st side


[2] Original Exit Sensor (PS10) [4] Original Detection Sensor (PS8)

1. When the Start key is pressed, the Original Feed Motor (M1) starts rotating backward,
causing the Pick-Up Roller to lower and start a paper take-up sequence.
2. A specified period of time after the leading edge of the original turns ON PS8 [4], the

COMPOSITION/OPERATION
scanning of the 1st side of the original starts.
3. The original is conveyed for a given period of time after the trailing edge of the last
page of the document has deactivated the PS10 [2]. It is then fed into [1] the Exit Tray
and the Original Conveyance Motor (M2) is deenergized.

9
5. OPERATION Theory of Operation Ver. 1.0 Feb. 2006

B. Operation flow in the 2-sided mode


1. When the Start key is pressed, the Original Feed Motor (M1) starts turning backward,
causing the Pick-Up Roller to lower and start feeding the 1st page of the document.
DF-607

A specified period of time after the leading edge of the original turns ON the Original
Detection Sensor (PS8) [4], the scanning of the 1st side of the original starts.
The Original Conveyance Motor (M2) is deenergized to stop [1] the original after the
lapse of a given period of time after the trailing edge of the 1st page has deactivated
the Original Exit Sensor (PS10) [2].

[4]

[1]

[3] [2] 16eat2c006na


COMPOSITION/OPERATION

[1] Stop [3] Scanning the 1st side


[2] Original Exit Sensor (PS10) [4] Original Detection Sensor (PS8)

2. M2 is turned backward to turn over [3] the original. After the Registration Roller, M2 is
turned forward to allow the Scanner to scan the backside of the 1st page.
3. After the conveyance sequence for turnover has been started, the Pressure Roller
Release Solenoid (SD1) is energized so that the Exit/Turnover Roller is retracted.

[3]
[1]

[2] 16eat2c007na

[1] Stop [3] Turnover


[2] Scanning the 2nd side

10
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATION

4. To ensure that pages of the document are in the proper order, the page is turned over
[3] again before being ejected [1] into the Exit Tray.

DF-607
[3]
[1]

[2] 16eat2c008na

[1] Exit [3] Turnover


[2] Scanning the 2nd side

COMPOSITION/OPERATION

11
5. OPERATION Theory of Operation Ver. 1.0 Feb. 2006

5.3 Raised/lowered position detecting mechanism


5.3.1 DF 15° open/close detection mechanism
DF-607

• When DF is closed down to about 15° or less, the Original Cover Angle Detection Lever of
the main body is pressed down to turn ON the APS Timing Sensor (PS31).

5.3.2 DF open/close detection mechanism


• A magnet is provided so that the open/close of DF can be detected on the main body side.
• When DF is closed, the DF Open/Close Switch (SW3) of the main body is turned ON by the
magnet.
COMPOSITION/OPERATION

[1]

16eat2c009na

[1] DF Open/Close Switch (SW3)

12
SERVICE MANUAL Theory of Operation

PC-202
( 500 / 420)

2006.02
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 correspond-
ing page.
A number within 1 represents the number of times the revision has been made.

NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
• When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
• When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.

2006/02 1.0 — Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision
Theory of Operation Ver. 1.0 Feb. 2006

CONTENTS

PC-202
PC-202

OUTLINE
1. PRODUCT SPECIFICATIONS ................................................................................1
2. PAPER PATH ...........................................................................................................2

OUTLINE
COMPOSITION/OPERATION
3. COMPOSITION .......................................................................................................3
4. DRIVE......................................................................................................................4
5. OPERATIONS .........................................................................................................5
5.1 Paper Feed Section ..............................................................................................5

COMPOSITION/OPERATION
5.1.1 Paper feed mechanism..................................................................................5
5.1.2 Paper lifting motion........................................................................................6
5.2 Tray Section ..........................................................................................................7
5.2.1 Paper size detection ......................................................................................7
5.2.2 Paper level indicator mechanism...................................................................8

i
Theory of Operation Ver. 1.0 Feb. 2006
PC-202
OUTLINE
COMPOSITION/OPERATION

Blank Page

ii
Theory of Operation Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS

„ OUTLINE
1. PRODUCT SPECIFICATIONS

PC-202
A. Type

Name 2 way Paper Take-Up Cabinet


Type Front loading type 2 way paper take-up device
Installation Desk type
Document Alignment Center

OUTLINE
B. Paper type

Paper Type Plain paper 56 to 90 g/m2


Metric: A3, B4, A4, A4S, B5, A5S, 11 × 17, 81/2 × 11, 81/2 × 11S, Foolscap
Paper Size
Inch: 11 × 17, 81/2 × 14, 81/2 × 11, 81/2 × 11S, 51/2 × 81/2S, A3, A4, A4S, Foolscap
Tray 3 550 sheets (80 g/m2)
Capacity
Tray 4 550 sheets (80 g/m2)

C. Maintenance

Maintenance Every 250,000 prints


Machine service life Same as the main body.

D. Machine specifications

Power Requirements 24V DC ± 10 %, 5V DC ± 5 % (supplied from the main body)


Power Consumption 15 W or less
Dimensions 570 mm (W) × 548 mm (D) × 263 mm (H)
Weight Approx. 26.0 kg

E. Operating environment

Temperature Same as the main body.


Humidity Same as the main body.

NOTE
• The information herein may be subject to change for improvement without notice.

1
2. PAPER PATH Theory of Operation Ver. 1.0 Feb. 2006

2. PAPER PATH
PC-202

[4]
[1]

[2]
OUTLINE

[3]

4061t1c001na

[1] Convey to the main body [3] Tray 4 paper feed


[2] Vertical conveyance through PC [4] Tray 3 paper feed

2
Theory of Operation Ver. 1.0 Feb. 2006 3. COMPOSITION

„ COMPOSITION/OPERATION
3. COMPOSITION

PC-202
Tray 3

Paper Feed
Section

COMPOSITION/OPERATION
Tray 4 4061t2c001na

3
4. DRIVE Theory of Operation Ver. 1.0 Feb. 2006

4. DRIVE
PC-202

[4] [1]

[3]

[2]
COMPOSITION/OPERATION

4061t2c002na

[1] Vertical Conveyance Motor /3 (M120) [3] Vertical Conveyance Motor /4 (M121)
[2] Paper Feed Motor /4 (M123) [4] Paper Feed Motor /3 (M122)

4
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS

5. OPERATIONS
5.1 Paper Feed Section

PC-202
5.1.1 Paper feed mechanism
• The Paper Feed Motor (M122, M123) drives the Pick-up Roller [8] and Feed Roller [6] to
take up and feed a sheet of paper into the main body.
• Then, the Vertical Conveyance Motor /3, /4 (M120, M121) transports the paper through the
vertical conveyance section.
• The Pick-up Roller takes up sheet of paper and the Feed Roller and Separation Roller [5]
ensure that only one sheet of paper is separated and fed into the main body.
• When the Tray is slid in, the lever [7] is pushed to lower the Pick-up Roller.
• The Upper Limit Sensor /3, /4 (PS114, PS123) [9] then detects the upper limit position when
the paper lifting plate is raised.
• The Paper Empty Sensor /3, /4 (PS115, PS124) [1] detects when paper in the Tray runs out.

[7] [8] [9]

COMPOSITION/OPERATION
[6] [5] [2] [1]

[4] [3]
4061t2c003na

[1] Paper Empty Sensor /3, /4 (PS115, PS124) [6] Feed Roller
[2] Actuator [7] Lever
[3] Pick-up Roller Feed Position [8] Pick-up Roller
[4] Pick-up Roller Home Position [9] Upper Limit Sensor /3, /4 (PS114, PS123)
[5] Separation Roller

5
5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006

5.1.2 Paper lifting motion


• When the Tray is slid into the main body and the Tray Set Sensor /3, /4 (PS112, PS121) is
PC-202

activated, the Paper Lift Motor /3, /4 (M124, M125) starts rotating to raise the Lifting Plate
[3].
• The paper stack of the Tray pushes up the Pick-up Roller [1]. When the upper limit position
is detected by the Upper Limit Sensor /3, /4 (PS114, PS123) [4], it stops raising the lifting
plate.
• As paper is consumed during the print cycle and the Pick-up Roller is lowered, M124, M125
is energized until PS114, PS123 is blocked again.
A. When the Tray is slid in
1. The lifting plate [3] goes up and the top surface of the paper stack pushes up the roller
[1].
2. The lifting motion stops as soon as the Upper Limit Sensor /3, /4 (PS114, PS123)
detects the upper limit position.

[4] [1]
COMPOSITION/OPERATION

[3] [2] 4061t2c004na

[1] Pick-up Roller [3] Lifting Plate


[2] Lift-up Arm [4] Upper Limit Sensor /3, /4 (PS114, PS123)

B. During a print cycle


1. As the paper is consumed, the Upper Limit Sensor /3, /4 (PS114, PS123) [1] is
unblocked.
2. The lifting plate goes up.

[1]

4061t2c005na

[1] Upper Limit Sensor /3, /4 (PS114, PS123)

6
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS

5.2 Tray Section


5.2.1 Paper size detection

PC-202
• Moving the Sub Scan Direction Restriction Plate of the Tray rotates the Circular Plate [1]
provided on the bottom of the Tray.
• The length of paper in the sub scan direction is detected by the Paper Size Detection Switch
[8] provided on the Paper Size Detect Boards /3 and /4 (PSDB3, PSDB49) [7] that is driven
by the Lever interlocked with the Circular Plate.
• The detection of the length of paper in the main scan direction is made by detecting a notch
on the Lever of the Main Scan Direction Restriction Plate by the Paper Size Sensors /Rr3,
/Fr3 (PS118, PS119) [2] or /Rr4, /Fr4 (PS127, PS128) [3].
• The paper size is determined by the combination of the 4 Paper Size Detection Switches
and the 2 Paper Size Sensors.
• The setting of the Tray is detected by the Tray Set Sensors /3, /4 (PS112, PS121) [6].

[9]

COMPOSITION/OPERATION
[7] [8] [1]
[5] [6]

[4] [3] [2]


4061t2c006na

[1] Circular Plate [6] Tray Set Sensor /3, /4 (PS112, PS121)
[2] Paper Size Sensor /Rr3, /Rr4 (PS118, [7] Paper Size Detect Board /3, /4 (PSDB3,
PS127) PSDB4)
[3] Paper Size Sensor /Fr3, /Fr4 (PS119, PS128) [8] Paper Size Detection Switch
[4] Paper Lift Motor /3, /4 (M124, M125) [9] Sub scan direction size detection
[5] Main scan direction size detection

7
5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006

5.2.2 Paper level indicator mechanism


• All Trays are universal paper size tray.
PC-202

• There is a window in the front cover of the Tray that serves as the Paper Level Indicator [3]
showing the amount of paper that is still available for use.
• A red lever [1] is attached to the bottom plate [5] of the Tray and as the lifting plate [4] raises,
the red lever becomes visible in the window.
• The more the red lever is visible, the lesser the amount of paper will be available for use.

[5]
COMPOSITION/OPERATION

[4] [1]

[3] [2]
4061t2c007na

[1] Lever [4] Lifting Plate


[2] Operated by the Lifting Plate [5] Tray Bottom Plate
[3] Paper Level Indicator

8
SERVICE MANUAL Theory of Operation

PC-402
( 500 / 420)

2006.02
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 correspond-
ing page.
A number within 1 represents the number of times the revision has been made.

NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
• When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
• When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.

2006/02 1.0 — Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision
Theory of Operation Ver. 1.0 Feb. 2006

CONTENTS

PC-402
PC-402

OUTLINE
1. PRODUCT SPECIFICATION...................................................................................1
2. PAPER PATH ...........................................................................................................2

OUTLINE
COMPOSITION/OPERATION
3. COMPOSITION .......................................................................................................3
4. DRIVE......................................................................................................................4
5. OPERATIONS .........................................................................................................5
5.1 Paper Feed Section ..............................................................................................5

COMPOSITION/OPERATION
5.1.1 Paper feed mechanism..................................................................................5
5.2 Tray Section ..........................................................................................................6
5.2.1 Up/down mechanism.....................................................................................6
5.2.2 Shift Gate drive mechanism ..........................................................................7
5.2.3 Shifter drive mechanism................................................................................8
5.2.4 Paper empty detection ..................................................................................9

i
Theory of Operation Ver. 1.0 Feb. 2006
PC-402
OUTLINE
COMPOSITION/OPERATION

Blank Page

ii
Theory of Operation Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATION

„ OUTLINE
1. PRODUCT SPECIFICATION

PC-402
A. Type

Name 2500 sheets paper feed cabinet


Type Front loading type LCC
Installation Desk type
Document Alignment Center

OUTLINE
B. Paper type

Paper Type Plain paper 56 to 90 g/m2


Metric: A4
Paper Size
Inch: 81/2 × 11
Capacity 2500 sheets (80 g/m2)

C. Maintenance

Maintenance Every 250,000 prints


Machine service life Same as the main body.

D. Machine specifications

Power Requirements 24V DC ± 10 %, 5V DC ± 5 % (supplied from the main body)


Power Consumption 45 W or less
Dimensions 570 mm (W) × 548 mm (D) × 263 mm (H)
Weight Approx. 26.0 kg

E. Operating environment

Temperature Same as the main body.


Humidity Same as the main body.

NOTE
• The information herein may be subject to change for improvement without notice.

1
2. PAPER PATH Theory of Operation Ver. 1.0 Feb. 2006

2. PAPER PATH
PC-402

[1]
OUTLINE

[2]

[5] [4] [3]


4061t1c201na

[1] Convey to the main body [4] From the Sub Tray to Main Tray
[2] Tray paper feed [5] Sub Tray
[3] Main Tray

2
Theory of Operation Ver. 1.0 Feb. 2006 3. COMPOSITION

„ COMPOSITION/OPERATION
3. COMPOSITION

PC-402
Tray Section Paper Feed Section

COMPOSITION/OPERATION
Sub Tray Main Tray
4061t2c201na

3
4. DRIVE Theory of Operation Ver. 1.0 Feb. 2006

4. DRIVE
PC-402

[7] [8] [9] [10]

[1]

[2]
COMPOSITION/OPERATION

[6]
[3]

[5] [4]
4061t2c202na

[1] Paper Lift Motor (M5) [6] Shift Gate Drive Section
[2] Paper Lift Drive Section [7] Tray Lock Solenoid (SD1)
[3] Shifter Drive Section [8] Paper Feed Motor (M1)
[4] Shift Motor (M4) [9] Vertical Conveyance Motor (M2)
[5] Shift Gate Motor (M3) [10] Vertical Conveyance Drive Section

4
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS

5. OPERATIONS
5.1 Paper Feed Section

PC-402
5.1.1 Paper feed mechanism
• The Paper Feed Motor (M1) drives the Pick-up Roller [8] and Feed Roller [6] to take up and
feed a sheet of paper into the main body.
• Then, the Vertical Conveyance Motor (M2) transports the paper through the vertical convey-
ance section.
• The Pick-up Roller takes up sheet of paper and the Feed and Separation Rollers [5] ensure
that only one sheet of paper is separated and fed into the main body.
• When the Tray is slid in, the lever [7] is pushed to lower the Pick-up Roller.
• The Upper Limit Sensor (PS4) [9] then detects the upper limit position when the paper lifting
plate is raised.
• The Paper Empty Sensor (PS3) [1] detects when paper in the Main Tray runs out.

[7] [8] [9]

COMPOSITION/OPERATION
[6] [5] [2] [1]

[4] [3]
4061t2c203na

[1] Paper Empty Sensor (PS3) [6] Feed Roller


[2] Actuator [7] Lever
[3] Pick-up Roller Feed Position [8] Pick-up Roller
[4] Pick-up Roller Home Position [9] Upper limit Sensor (PS4)
[5] Separation Roller

5
5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006

5.2 Tray Section


5.2.1 Up/down mechanism
PC-402

• The Main Tray [3] is suspended by the cables [1] at the front and rear.
• As the Paper Lift Motor (M5) [5] turns forward or backward, the cables are wound to raise or
lower the Main Tray.
• The Lower Limit Sensor (PS13) [2] detects the Main Tray at its lower limit position.

[1]
COMPOSITION/OPERATION

[5] [2]

[3]
[4]

4061t2c204na

[1] Cables [4] Sub Tray


[2] Lower Limit Sensor (PS13) [5] Paper Lift Motor (M5)
[3] Main Tray

6
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS

5.2.2 Shift Gate drive mechanism


• If the Main Tray runs out of paper, while the Sub Tray is loaded with paper, the paper stack

PC-402
on the Sub Tray is moved to the Main Tray [2].
• At this time, the Shift Gate Motor (M3) [4] is energized to retract the front and rear Shift
Gates [1].

[1]

[4]

[3]
[2]

COMPOSITION/OPERATION
[1] 4061t2c205na

[1] Shift Gate move to outside [3] Shifter


[2] Shifter move [4] Shift Gate Motor (M3)

7
5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006

5.2.3 Shifter drive mechanism


• After completion of the evacuation of the Shift Gate, starts the movement of the Shifter [2].
PC-402

• The movement of paper from the Sub Tray to the Main Tray is made by the Shifter that is
driven by the Shift Motor (M4) [1].
• The stopping of the movement of the Shifter to the Main Tray side is made by the Shift Posi-
tion Sensor (PS11) [4].
• The movement to the home position starts when the Tray Release Key is pressed.
• The stopping of the movement of the Shifter to the home position is made by the Shift Home
Sensor (PS12) [3].

[3]
[2]

[2]

[4]
COMPOSITION/OPERATION

[1] [1]
4061t2c206na

[1] Shift Motor (M4) [3] Shift Home Sensor (PS12)


[2] Shifter [4] Shift Position Sensor (PS11)

8
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS

5.2.4 Paper empty detection


• Paper empty detection of Main Tray is performed by Main Tray Empty Board (MEB) [2].

PC-402
• Paper empty detection of Sub Tray is performed by Sub Tray Empty Sensor (PS9) [3].

[4] [1]

COMPOSITION/OPERATION
[3] [2]
4061t2c207na

[1] Main Tray [3] Sub Tray Empty Sensor (PS9)


[2] Main Tray Empty Board (MEB) [4] Sub Tray

9
5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006
PC-402
COMPOSITION/OPERATION

Blank Page

10
SERVICE MANUAL Theory of Operation

LU-201

2006.02
Ver. 1.0
Revision history
After publication of this service manual, the parts and mechanism may be subject to change for improve-
ment of their performance.
Therefore, the descriptions given in this service manual may not coincide with the actual machine.

When any change has been made to the descriptions in the service manual, a revised version will be
issued with a revision mark added as required.

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.

2006/02 1.0 — Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision
Theory of Operation Ver1.0 Feb.2006 CONTENTS

CONTENTS

LU-201
LU-201

OUTLINE
1. PRODUCT SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

COMPOSITION/OPERATION
3. COMPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. PAPER FEED SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1.1 Paper feed drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2.1 Paper feed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2.2 Remaining paper detection control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5. TRAY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1.1 Tray lift drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.2.1 Tray lift control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

i
CONTENTS Theory of Operation Ver1.0 Feb.2006
LU-201

Blank page

ii
Theory of Operation Ver1.0 Feb.2006 1. PRODUCT SPECIFICATION

„ OUTLINE

LU-201
1. PRODUCT SPECIFICATION
A. Type

Type Side mount type large volume paper feed tray

B. Functions

Maximum tray capacity 2,000 sheets (80 g/m2)

C. Type of paper

Paper type *1 Plain paper, recycled paper, high quality paper of 60 to 105 g/m2
Paper size A4, 81/2 x 11

*1 Recommended paper
Plain paper Inch: Hammermill Tidal MP (20 lbs)
Metric: Konica Profi (80 g/m2), Konica Minolta Original (80 g/m2)
Recycled paper Inch: Weyehaeuser Recycled Laser Copy (20 lbs)
Metric: Nautilus (80 g/m2)

D. Maintenance

Maintenance Same as the main body


Machine service life Same as the main body

E. Machine data

Power source 24/5V DC (supplied from the main body)


Power consumption 30 W or less (internal heater is not used)
Dimensions 424 (W) x 515 (D) x 295 (H) mm
Weight Approx. 16 kg

F. Operating environment

Temperature Same as the main body


Humidity Same as the main body

Note
• The information herein may be subject to change for improvement without notice.

1
2. PAPER PATH Theory of Operation Ver1.0 Feb.2006

2. PAPER PATH
LU-201

[3] [4] [5] [1]

[2]

16aat1c001na

[1] Lift plate [4] Feed roller


[2] Separation roller [5] Pick-up roller
[3] Conveyance roller

2
Theory of Operation Ver1.0 Feb.2006 3. COMPOSITION

„ COMPOSITION/OPERATION

LU-201
3. COMPOSITION

Paper feed section Tray section

16aat2c001na

3
4. PAPER FEED SECTION Theory of Operation Ver1.0 Feb.2006

4. PAPER FEED SECTION


4.1 Drive
LU-201

4.1.1 Paper feed drive


A. Front side drive

[3] [4] [1]

[2]

16aat2c002na

[1] Pick-up solenoid (SD151) [3] Feed roller


[2] Conveyance roller [4] Pick-up roller

B. Rear side drive

[3]

[2]

[1]
16aat2c007na

[1] Feed motor (M150) [3] Feed clutch (CL151)


[2] Conveyance roller

4
Theory of Operation Ver1.0 Feb.2006 4. PAPER FEED SECTION

4.2 Operation
4.2.1 Paper feed control

LU-201
A. Pick-up mechanism
(1) Drive transmission
The driving force of the feed motor (M150) is transmitted to the paper feed gear /3 [4] through various gears. The
paper feed gear /3 is connected with the pick-up solenoid (SD151) [1] through the claw [2]. When SD151 is
turned OFF, the coupling between the paper feed gear /3 and the paper feed coupling gear /B [3] provided on
the front stage is disengaged and the paper feed gear /3 does not rotate. When SD151 turns ON, the claw is
released to engage the paper feed gear /3 to the paper feed coupling gear /B. In this way, the paper feed gear /
3 rotates and the driving force is transmitted to the paper feed roller unit [6] through the paper feed gear [5] to
pick up paper.

[3] [4] [5] [6]

[2] [1]
16aat2c003na

[1] Pick-up solenoid (SD151) [4] Paper feed gear /3


[2] Claw [5] Paper feed gear
[3] Paper feed coupling gear /B [6] Paper feed roller unit

5
4. PAPER FEED SECTION Theory of Operation Ver1.0 Feb.2006

(2) Paper feed roller unit up/down mechanism


On the inside of the paper feed gear /3 [2], the cam [3] is provided. While in the standby, the cam pushes the lift-
up shaft [1]. The lift-up shaft is in contact with the paper feed roller unit [5] and it lifts up the paper feed roller unit
LU-201

while it is being pushed by the cam. When the paper feed gear /3 rotates, the pressure by the cam on the lift-up
shaft is released and the paper feed roller unit goes down. In this way, the paper feed roller unit goes up and
down while the paper feed gear /3 is rotating a full turn to pick up paper.

[2] [3] [4] [5]

[1] [1]
16aat2c004na

[1] Lift-up shaft [4] Paper feed gear


[2] Paper feed gear /3 [5] Paper feed roller unit
[3] Cam

B. Paper feed operation


A specified period of time after a start signal from the main body turns ON, the feed motor (M150), the feed
clutch (CL151) and the pick-up solenoid (SD151) turn ON to pick up paper from the tray. SD151 turns OFF a
specified period of time after that. However, it turns ON and OFF according to the paper feed request signal to
pick up the second and succeeding sheets of paper. Paper thus picked up is conveyed to the PC by the con-
veyance roller to be further conveyed to the registration section of the main body through the vertical convey-
ance roller in the PC.
The conveyance roller is provided with CL151 and, when the registration sensor (PS1) of the main body detects
the leading edge of paper and turns ON, it turns OFF a specified period of time after that to stop the conveyance
roller and the paper feed roller unit. At this time, the registration section of the main body stops temporarily to
control the registration and all the rollers that are positioned upstream of the registration roller also stop. In this
way, paper thus supplied is put in the standby condition in each position of the registration section, the convey-
ance path and the LU exit section.
When a print signal is received, a specified period of time after that, each roller in the conveyance path and
CL151 turn ON to resume the conveyance of paper.

6
Theory of Operation Ver1.0 Feb.2006 4. PAPER FEED SECTION

4.2.2 Remaining paper detection control


As paper in the tray gets reduced, the lift plate goes up gradually. The actuator [1] provided on the rear side of
LU rotates in interlock with the up/down operation of the lift plate. The actuator is provided with the remaining

LU-201
paper sensors /1 (PS154) [3] and /2 (PS151) [2] and the remaining paper is detected by the combination of the
ON/OFF of these sensors. And the no paper detection in the tray is made by the paper empty sensor (PS153)
[5].

Remaining paper quantity PS151 PS154


Full quantity OFF ON
Medium quantity ON ON
Small quantity ON OFF

[5]
[4]

[3]

[1]

[2]

16aat2c005na

[1] Actuator [4] Direction of rotation when the tray goes up


[2] Remaining paper sensor /2 (PS151) [5] Paper empty sensor (PS153)
[3] Remaining paper sensor /1 (PS154)

7
5. TRAY SECTION Theory of Operation Ver1.0 Feb.2006

5. TRAY SECTION
5.1 Drive
LU-201

5.1.1 Tray lift drive

[8]

[1]

[2]

[7]
[3]

[4]
[6]
[5]
16aat2c006na

[1] Actuator [5] Lift plate


[2] Wire [6] Wire
[3] Coupling [7] Spring
[4] Parallel pin [8] Paper lift motor (M151)

8
Theory of Operation Ver1.0 Feb.2006 5. TRAY SECTION

5.2 Operation
5.2.1 Tray lift control

LU-201
When the upper door is closed, a parallel pin for the up drive of the lift plate is pushed out to be coupled to the
coupling of the paper lift motor (M151). Closing the upper door also turn ON the upper door interlock switch
(MS151) to supply a 24V DC to the load of the drive system. In this way, M151 turns ON to bring up the lift plate.
When the lift plate goes up and the upper limit sensor (PS152) detects the upper surface of paper, M151 turns
OFF to stop the up drive of the lift plate. When PS152 turns OFF by the paper feed operation, M151 turns ON
again to keep on bringing up the lift plate until PS152 turns ON.
When the upper door is opened, the wire is pulled to release the coupling for the up drive of the lift plate. In this
way, the lift plate goes down up to the position in which a balance is kept between the weight of paper and the
spring tension.

[4] [1]

[3] [2]
16aat2c008na

[1] Feed roller [3] Pick-up roller


[2] Lift plate [4] Upper limit sensor (PS152)

9
5. TRAY SECTION Theory of Operation Ver1.0 Feb.2006
LU-201

Blank page

10
SERVICE MANUAL Theory of Operation

FS-510/PU-501/
OT-601

2006.02
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 correspond-
ing page.
A number within 1 represents the number of times the revision has been made.

NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
• When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
• When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.

2006/02 1.0 — Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision
Theory of Operation Ver. 1.0 Feb. 2006

FS-510/PU-501/OT-601
CONTENTS

FS-510/PU-501/OT-601

OUTLINE
1. PRODUCT SPECIFICATIONS ................................................................................1
1.1 FS-510 ..................................................................................................................1
1.2 PU-501..................................................................................................................3

OUTLINE
1.3 OT-601 ..................................................................................................................4
2. PAPER PATH ...........................................................................................................5
2.1 Exiting Paper to the Tray /1 ...................................................................................5
2.2 Exiting Paper to the Tray /2 ...................................................................................6
2.3 Exiting Paper to OT...............................................................................................7

COMPOSITION/OPERATION
COMPOSITION/OPERATION
3. COMPOSITION .......................................................................................................9
4. DRIVE....................................................................................................................10
4.1 FS-510 ................................................................................................................10
4.2 PU-501................................................................................................................11
5. OPERATIONS .......................................................................................................12
5.1 Conveyance Section ...........................................................................................12
5.1.1 Entrance/Conveyance section .....................................................................13
5.1.2 Intermediate Conveyance Section...............................................................14
5.1.3 Exit Conveyance Section.............................................................................15
5.2 Up/down Section.................................................................................................16
5.2.1 Up/down mechanism...................................................................................16
5.2.2 Tray Up/Down operation ..............................................................................17
5.2.3 Tray Upper Limit Position Detection Mechanism .........................................18
5.2.4 Shutter Open/Close Mechanism .................................................................21
5.3 Stacker section....................................................................................................22
5.3.1 Paper aligning mechanism (sub scan direction)..........................................22
5.3.2 Paper aligning mechanism (main scan direction)........................................23
5.3.3 Exit mechanism ...........................................................................................25
5.4 Stapling ...............................................................................................................27
5.4.1 Stapling mechanism ....................................................................................27
5.4.2 Stapling Unit moving mechanism ................................................................28
5.4.3 Stapling Position..........................................................................................28
5.4.4 Staple empty detection................................................................................29

i
Theory of Operation Ver. 1.0 Feb. 2006
FS-510/PU-501/OT-601

6. PU-501.................................................................................................................. 30
6.1 Composition ....................................................................................................... 30
6.2 Operation............................................................................................................ 30
6.2.1 Registration mechanism ............................................................................. 30
6.2.2 Punch mechanism ...................................................................................... 31
6.2.3 Punch status detection ............................................................................... 31
6.2.4 Punch Scraps Box full detection mechanism.............................................. 32
7. OT-601 .................................................................................................................. 33
OUTLINE

7.1 Composition ....................................................................................................... 33


7.2 Operation............................................................................................................ 33
7.2.1 Overview..................................................................................................... 33
COMPOSITION/OPERATION

ii
Theory of Operation Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS

„ OUTLINE

FS-510/PU-501/OT-601
1. PRODUCT SPECIFICATIONS
1.1 FS-510
A. Type

Name Multi tray finisher built into the main body


Installation Installed in the main body
Document Alignment Center

OUTLINE
Consumables Staples (5,000 staples/cartridge)

B. Functions

Modes Non sort, sort, group, sort staple, and punch (when PU-501 is mounted)

C. Paper type
(1) Non sort

Type Size Weight Max. Capacity


Tray /1 200 sheets
Metric:
A4S, 81/2 x 11S 1000
A3, B4, A4, A4S, B5,
Plain paper 50 to 90 g/m2 or less sheets
B5S, A5, A5S, B6S Tray /2
11 x 17, 81/2 x 11, B4, 81/2 x 14 500
81/2 x 11S, Foolscap or greater sheets
Thick paper 91 to 210 g/m2
Inch:
OHP transparencies -
11 x 17, 81/2 x 14,
Translucent paper 81/2 x 11, 81/2 x 11S, -
20 sheets
Envelope 51/2 x 81/2S -
A3, A4, A4S, A5S,
Label -
Foolscap
Letterhead -

(2) Sort/Group

Type Size Weight Max. Capacity


Metric: Tray /1 200 sheets
A3, B4, A4, A4S, B5,
B5S, A5
11 x 17, 81/2 x 11, A4S, 81/2 x 11S 1000
81/2 x 11S, Foolscap or less sheets

Plain paper 50 to 90 g/m2


Inch: Tray /2
11 x 17, 81/2 x 14,
81/2 x 11, 81/2 x 11S, B4, 81/2 x 14 500
51/2 x 81/2S or greater sheets
A3, A4, A4S, A5S,
Foolscap

1
1. PRODUCT SPECIFICATIONS Theory of Operation Ver. 1.0 Feb. 2006
FS-510/PU-501/OT-601

(3) Sort Staple

Type Size Weight Max. Capacity


Metric: Tray /1 200 sheets
A3, B4, A4, A4S, B5,
B5S, A5, A5S, B6S
11 x 17, 81/2 x 14, A4S, 81/2 x 11S 1000
81/2 x 11, 81/2 x 11S, or less sheets
Foolscap
Plain paper 50 to 90 g/m2
Inch: Tray /2
11 x 17, 81/2 x 14,
OUTLINE

81/2 x 11, 81/2 x 11S, B4, 81/2 x 14 500


51/2 x 81/2S or greater sheets
A3, A4, A4S, A5S,
Foolscap

D. Stapling

Staple Filling Mode Dedicated Staple Cartridge (5000 staples)


Staple Detection Available (Nearly Empty: 20 remaining staples)
Front: Diagonal 45° 1 point *1 A3, B4, A4, B5
Rear: Diagonal 45° 1 point *1 11 x 17, 81/2 x 11
Front: Parallel 1 point A4S, B5S, A5
Stapling Position
Rear: Parallel 1 point 81/2 x 14, 81/2 x 11S, 51/2 x 81/2S
A3, B4, A4, A4S, B5, B5S, A5
Side: Parallel 2 point
11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S
*1: Diagonal 30° for B5 and B4
E. Maintenance

Maintenance Every 250,000 prints


Machine service life Same as the main body.

F. Machine specifications

Power Requirements 24/5V DC (supplied from the main body)


Power Consumption 66 W or less
Dimensions 319 (W) x 558 (D) x 573 mm (H)
Weight Approx. 21.4 kg

G. Operating environment

Temperature Same as the main body.


Humidity Same as the main body.

2
Theory of Operation Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS

FS-510/PU-501/OT-601
1.2 PU-501
A. Type

Type FS built-in type punching operation device


Installation Screwed to the FS
Metric:
A3, B4, A4, A4S, B5, B5S
11 x 17, 81/2 x 11, 81/2 x 11S, Foolscap

Paper Size Inch:


2 holes: 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S

OUTLINE
A3, A4, A4S, A5S, Foolscap
3 holes: 11 x 17, 81/2 x 11
A3, A4
Paper Type Plain Paper (60 to 130 g/m2), Recycled Paper (60 to 130 g/m2)
Metric: 4 holes, Swedish 4 holes (φ 6.5 mm)
Punch Hole
Inch: 2 and 3 holes (can be switched) (φ 8 mm)
Number of Stored Metric (4 holes): For 1,500 sheets of paper (80 g/m2)
Punch Wastes Inch (2, 3 holes): For 1,000 sheets of paper (20 lbs)
Document Alignment Center

B. Maintenance

Maintenance Every 250,000 prints


Machine service life Same as the main body.

C. Machine specifications

Power Requirements 24/5V DC (Supplied from FS)


Dimensions 114 (W) x 461 (D) x 136 mm (H)
Weight Approx. 1.9 kg

D. Operating environment

Temperature Same as the main body.


Humidity Same as the main body.

3
1. PRODUCT SPECIFICATIONS Theory of Operation Ver. 1.0 Feb. 2006
FS-510/PU-501/OT-601

1.3 OT-601
A. Type

Type Additional Tray to FS


Installation Screwed to the FS
Mode Non sort, sort, group, and sort staple
Number of Bins 1 bin
Document Alignment Center

B. Paper Type
OUTLINE

Mode Size Type Capacity


Metric: Plain Paper, Recycled Paper
200 sheets
A3, B4, A4, A4S, B5, (56 to 90 g/m2,15 to 24 lb)
B5S, A5, A5S, B6S
OHP transparencies
11 x 17, 81/2 x 11,
81/2 x 11S, Foolscap Thick paper
Non sort (91 to 210 g/m2)
Inch:
11 x 17, 81/2 x 14, Special Envelope 20 sheets
81/2 x 11, 81/2 x 11S, Label paper
51/2 x 81/2S
Letterhead
A3, A4, A4S, A5S,
Foolscap Translucent paper
Metric:
A3, B4, A4, A4S, B5,
Sort / group B5S, A5 200 sheets
11 x 17, 81/2 x 11,
81/2 x 11S, Foolscap
Plain Paper, Recycled paper
Inch: (56 to 90 g/m2)
11 x 17, 81/2 x 14,
81/2 x 11, 81/2 x 11S,
Sort staple 200 sheets or 20 copies
51/2 x 81/2S
A3, A4, A4S, A5S,
Foolscap

C. Maintenance

Maintenance Every 250,000 prints


Machine service life Same as the main body.

D. Machine specifications

Dimensions 282 (W) x 368 (D) x 57 mm (H)


Weight Approx. 0.7 kg

E. Operating environment

Temperature Same as the main body.


Humidity Same as the main body.

NOTE
• The information herein may be subject to change for improvement without notice.

4
Theory of Operation Ver. 1.0 Feb. 2006 2. PAPER PATH

FS-510/PU-501/OT-601
2. PAPER PATH
2.1 Exiting Paper to the Tray /1

[2] [1]

[3]

OUTLINE
4349t1c001na

[1] From the main body [3] Exiting paper to the Tray /1
[2] Convey to the Tray /1

5
2. PAPER PATH Theory of Operation Ver. 1.0 Feb. 2006
FS-510/PU-501/OT-601

2.2 Exiting Paper to the Tray /2


OUTLINE

[2] [1]

[3]

4349t1c002na

[1] From the main body [3] Exiting paper to the Tray /2
[2] Convey to the Tray /2

6
Theory of Operation Ver. 1.0 Feb. 2006 2. PAPER PATH

FS-510/PU-501/OT-601
2.3 Exiting Paper to OT

[2] [1]

[3]

OUTLINE
4349t1c003na

[1] From the main body [3] Exiting paper to OT


[2] Convey to OT

7
2. PAPER PATH Theory of Operation Ver. 1.0 Feb. 2006
FS-510/PU-501/OT-601
OUTLINE

Blank Page

8
Theory of Operation Ver. 1.0 Feb. 2006 3. COMPOSITION

„ COMPOSITION/OPERATION

FS-510/PU-501/OT-601
3. COMPOSITION

Up/down Section

Conveyance Section
PU

OT

COMPOSITION/OPERATION
Staple Section

4349t2c001na

9
4. DRIVE Theory of Operation Ver. 1.0 Feb. 2006
FS-510/PU-501/OT-601

4. DRIVE
4.1 FS-510

[5] [6]
[4] [7]
COMPOSITION/OPERATION

[1]

[3]

[2]
4349t2c002na

[1] Stapler Drive Section [5] Paper Exit Opening Drive Section
[2] Exit Drive Section [6] Conveyance/Alignment Drive Section
[3] Up/down Drive Section [7] Entrance Drive Section
[4] Shutter Drive Section

10
Theory of Operation Ver. 1.0 Feb. 2006 4. DRIVE

FS-510/PU-501/OT-601
4.2 PU-501

COMPOSITION/OPERATION
[1]

4512t2c001na

[1] Punch Drive Section

11
5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006
FS-510/PU-501/OT-601

5. OPERATIONS
5.1 Conveyance Section
• The Conveyance Section is divided into the entrance conveyance section [3], intermediate
conveyance section [1], and the exit conveyance section [2]. It controls to convey the paper
fed from the main body, stop the paper at the punching and folding positions, and drive the
paper for feeding into the exit section.

[3]
COMPOSITION/OPERATION

[1]

[2]

4349t2c003na

[1] Intermediate Conveyance Section [3] Entrance Conveyance Section


[2] Exit Conveyance Section

12
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS

FS-510/PU-501/OT-601
5.1.1 Entrance/Conveyance section
• A paper [5] fed from the main body is conveyed to the intermediate conveyance section.
• The Entrance Motor (M3) [3] provides the drive for conveying a paper.
• When the M3 is energized, the Entrance Roller [1] and Registration Roller [2] are driven to
rotate.
• The Entrance Sensor (PS4) [4] detects a paper in the conveyance section.

[4]

[5]

[1]

[3]

COMPOSITION/OPERATION
[2]
4349t2c004na

[1] Entrance Roller [4] Entrance sensor (PS4)


[2] Registration Roller [5] Paper
[3] Entrance motor (M3)

13
5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006
FS-510/PU-501/OT-601

5.1.2 Intermediate Conveyance Section


• A paper conveyed from the entrance conveyance section is brought to a stop at the punch-
ing and folding position.
• A paper is also conveyed to the exit conveyance section.
• Drive for the intermediate conveyance section is provided by the Conveyance Motor (M2)
[3]. Drive of the Intermediate Conveyance Roller /1 [4] and Intermediate Conveyance Roller
/2 [2] is controlled.
• The Conveyance Sensor (PS5) [1] detects paper in the intermediate conveyance section.

[4]
COMPOSITION/OPERATION

[1]
[3]

[2]
4349t2c005na

[1] Conveyance Sensor (PS5) [3] Conveyance Motor (M2)


[2] Intermediate Conveyance Roller /2 [4] Intermediate Conveyance Roller /1

14
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS

FS-510/PU-501/OT-601
5.1.3 Exit Conveyance Section
• The paper is exited onto each of the trays.
• The Exit Motor (M1) [1] provides drive for the Exit Roller [3], Stacker Paddle [5], and Exit
Paddle [2].

[4]

[5]

[3]

COMPOSITION/OPERATION
[2] [1]

4349t2c006na

[1] Exit motor (M1) [4] Exit roller release motor (M6)
[2] Exit Paddle [5] Stacker Paddle
[3] Exit Roller

15
5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006
FS-510/PU-501/OT-601

5.2 Up/down Section


5.2.1 Up/down mechanism
• The Up/down mechanism is operated to select a specific tray, thereby feeding the paper exit
onto a specific tray.

[1]
COMPOSITION/OPERATION

4349t2c007na

[1] Tray Lift Motor (M11)

16
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS

FS-510/PU-501/OT-601
5.2.2 Tray Up/Down operation
• The Tray is moved up or down by the Tray Lift Motor (M11) that turns forward or backward
to drive the front and rear belts.
• The Lower Limit Sensor (PS14) [1] detects the Tray at its lower limit position.
• The Tray Overrun Switch (SW3) [2] is provided for protection when the trays overruns nor-
mal position.

[2]

COMPOSITION/OPERATION
[1]
4349t2c008na

[1] Lower Limit Sensor (PS14) [2] Tray Overrun Switch (SW3)

17
5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006
FS-510/PU-501/OT-601

5.2.3 Tray Upper Limit Position Detection Mechanism


• Each of the Tray moves up or down according to the amount of paper fed onto it.
• When the Upper Limit Sensor (PS15) [1] turns ON for each exit of paper, bring down once
the Lift Tray until PS15 turns OFF so that the upper surface of paper on the Tray is kept at
the same level at all times while in the paper exit.
• Bring up again the Tray until PS15 turns ON.

[1]
COMPOSITION/OPERATION

4349t2c009na

[1] Upper Limit Sensor (PS15)

18
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS

FS-510/PU-501/OT-601
A. Tray Position Detection
• Tray position detection is controlled according to the number of times the Tray Position Sen-
sor (PS3) [1] is activated after the Lower Limit Sensor (PS14) [2] has been activated.

(1) Tray position detection operation


1. During the initial operation sequence, the Tray is subjected to a descent motion until
the Lower Limit Sensor (PS14) is activated.

[2] [1]

COMPOSITION/OPERATION
4349t2c010na

[1] Tray Position Sensor (PS3) [2] Lower Limit Sensor (PS14)

19
5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006
FS-510/PU-501/OT-601

2. After PS14 has been activated, the Up/Down Section is subjected to an ascent motion.
3. When PS3 [1] is activated a first time after the ascent motion of the Up/Down Section
has been started, it is determined that the Up/Down Section is now located at the
paper exit opening for the Tray /1.
COMPOSITION/OPERATION

[1]

4349t2c011na

[1] Tray Position Sensor (PS3)

4. When PS3 is activated a second time after the ascent motion of the Up/Down Section
has been started, it is determined that the Up/Down Section is now located at the
paper exit opening for the Tray /2.
5. Drive is stopped when PS3 is activated with Upper Limit Sensor (PS15) of the target
tray in the activated position.
* If OT is installed, OT is at the exit port when the position sensor is activated twice and the
Tray /2 is at the exit port when the position sensor is activated three times.

B. Paper Full Detection


• When the Tray Position Sensor (PS3) changes from the activated to deactivated state with
the Upper Limit Sensor (PS15) in the activated state, a paper full condition is detected and
the corresponding message will appear on the operation panel.

20
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS

FS-510/PU-501/OT-601
5.2.4 Shutter Open/Close Mechanism
• The paper exit section is provided with the Shutter [3] and this Shutter is normally in the up
condition (the condition in which the Paper Exit Opening is opened). However, when the Tray
goes up and down, the Paper Exit Opening is closed to prevent an accident such as hands
getting caught in the Paper Exit Opening.
• The Shutter is opened or closed by the Shutter Motor (M12) [2] that turns a gear train for
raising or lowering the Shutter.
• The Shutter Home Sensor (PS16) [4] detects the position of the gear, thereby determining
the position of the Shutter.
• When the Shutter does not close while in the Tray up/down operation, the Shutter Switch
(SW2) [1] turns OFF to shut off a 24V DC and stop the up/down of the Tray at once.

[4]

COMPOSITION/OPERATION
[1]

[3] [2]
4349t2c012na

[1] Shutter Switch (SW2) [3] Shutter


[2] Shutter Motor (M12) [4] Shutter Home Sensor (PS16)

21
5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006
FS-510/PU-501/OT-601

5.3 Stacker section


5.3.1 Paper aligning mechanism (sub scan direction)
• Sheets of paper are aligned properly and stapled together inside the stacker section before
being fed out onto the corresponding tray.
• In the Sort, Group, Staple, or Half Fold/Fold & Staple mode, each copy set is stored in the
Stacker with the Upper Exit Roller separated from the Lower Exit Roller.
• The Stacker Sensor (PS8) detects paper in the Stacker.
• The Stacker Paddle and Aligning Belt are driven when the Exit Motor (M1) is rotated in
reverse.
A. Operation
1. The paper fed out from the main body is held downward by the Drop Lever [7] and
dropped down into the Stacker by the Intermediate Conveyance Roller /2 [4].
2. The paper dropped into the Stacker is pressed against the Paper Stopper [5] by the
Paddle [3] and Aligning Belt [1] so that it is aligned properly in the sub scan direction.

[3] [7] [3] [7] [1]


COMPOSITION/OPERATION

[5]

[4]
[6]

[1]

[3]

[2]
4349t2c013na

[1] Aligning Belt [5] Paper Stopper


[2] Exit Motor (M1) [6] Stacker sensor (PS8)
[3] Stacker Paddle [7] Drop Lever
[4] Intermediate Conveyance Roller /2

22
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS

FS-510/PU-501/OT-601
5.3.2 Paper aligning mechanism (main scan direction)
• Aligning Plates are moved and the Paddle is rotated so as to align the paper at the stapling
position.
• The paper in the Stacker is aligned in the main scan direction by two Alignment Motors and
aligning plates.

A. Aligning plates
• The aligning plates [6] are moved to the front or rear in accordance with the paper size.
• The Alignment Sensor /Rr (PS6) [4], /Fr (PS7) [1] detects the position of each aligning plate.

[6]
[5]

[7]

COMPOSITION/OPERATION
[4]

[3]

[2]

[1]
4349t2c014na

[1] Alignment sensor /Fr (PS7) [5] Paper Aligning Portion


[2] Alignment motor /Fr (M5) [6] Aligning Plate
[3] Alignment motor /Rr (M4) [7] Paper Stoppers
[4] Alignment sensor /Rr (PS6)

23
5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006
FS-510/PU-501/OT-601

B. Paper aligning sequence


• In normal print and staple mode, the paper is fed into the tray at its center position.
• If no stapling is involved in the Sort or Group Print mode, the aligning plate shifts 15 mm to
the front or rear from the center. This stacks papers in a saw tooth manner, each being off-
set by about 30 mm with respect to the others.
This shifting motion is not performed when papers are fed into the MT or the SD.

[5]

[1]

[2]
COMPOSITION/OPERATION

[4] [3]
4349t2c015na

[1] 30mm [4] Normal/Staple


[2] Center [5] Aligning Plate
[3] Shift (Sort/Group)

24
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS

FS-510/PU-501/OT-601
5.3.3 Exit mechanism
• The paper exit roller section is provided with the Paper Holding Paddle [3] to hold the paper
exited onto the Tray while in the sort mode so that the paper does not have an uneven edge.
• The subsequent copy set is fed out with the copy sets previously resident on the tray being
held down by the paper holding paddle.
• The Exit Paddle Home Sensor (PS11) [1], Spring Clutch [4], and Exit Paddle Solenoid (SD2)
[2] control the retracted position and paper holding position of the paper holding paddle.

COMPOSITION/OPERATION
[4] [1]

[3] [2]
4349t2c016na

[1] Exit Paddle Home Sensor (PS11) [3] Paper Holding Paddle
[2] Exit Paddle Solenoid (SD2) [4] Spring Clutch

25
5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006
FS-510/PU-501/OT-601

A. Exit Roller up/down mechanism


• While in the sort mode and the staple mode, the Exit Roller /Up is pressed to the Exit Roller
/Lw after the paper is stacked in the Stacker.
• The press/release of the Exit Roller /Up is driven by the Exit Roller Release Motor (M6) [3].
• The Exit Roller Home Sensor (PS12) [4] detects the position of the Exit Roller /Up, whether
it is in the released or pressed position.

[4]

[3] [2] [1]


COMPOSITION/OPERATION

4349t2c017na

[1] Unblocked (Released) [3] Exit Roller Release Motor (M6)


[2] Blocked (Pressed) [4] Exit Roller Home Sensor (PS12)

26
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS

FS-510/PU-501/OT-601
5.4 Stapling
5.4.1 Stapling mechanism
• Stapling is performed by the Stapling Unit.
• When the Stapling Motor [1] is rotated, the Clinch Arm [3] lowers. The Stapler [2] thereafter
goes up to drive a staple in the paper.
• Five different types of stapling are available: parallel front one point, parallel rear one point,
slant front one point, slant rear one point and parallel two points.

[3]

COMPOSITION/OPERATION
[1]

[2]

4349t2c018na

[1] Stapling Motor [3] Clinch Arm


[2] Stapler

27
5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006
FS-510/PU-501/OT-601

5.4.2 Stapling Unit moving mechanism


• The Stapling Unit is moved by the Stapler Movement Motor (M7) [3].
• M7 drives the belt so that the Stapling Unit is moved to the corresponding stapling position.
• The stapling stop position is controlled by the period of time during which the M7 is kept
energized, as counted from the time when the Stapler Home Sensor (PS10) [4] has been
activated.

[1]
[5]
COMPOSITION/OPERATION

[4]

[2]
[3]
4349t2c019na

[1] Home [4] Stapler Home Sensor (PS10)


[2] Staple change position [5] Stapling Unit
[3] Stapler Movement Motor (M7)

5.4.3 Stapling Position


• A single stapling unit is moved to perform 2-point stapling.

[3] [2] [1]

4349t2c020na

[1] Parallel two points [3] Parallel one point


[2] Slant one point

28
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS

FS-510/PU-501/OT-601
5.4.4 Staple empty detection
• Staple Empty Sensor [2] detect whether or not there are staples still left.
• When the number of staples left in the staple cartridge becomes about 20, a staple sheet
empty condition results, causing a corresponding empty message to appear on the opera-
tion panel.
• When the empty condition is detected, the corresponding empty indication is given on the
operation panel. At the same time, the Stapling Unit moves to the front.
• When a new staple cartridge is loaded, the stapling motor is energized until the Stapler
Ready Sensor [1] detects a staple, which results in the staple to be fed up to the stapling
position.

COMPOSITION/OPERATION
[1]

[2]

4349t2c021na

[1] Stapler Ready Sensor [2] Staple Empty Sensor

29
6. PU-501 Theory of Operation Ver. 1.0 Feb. 2006
FS-510/PU-501/OT-601

6. PU-501
6.1 Composition
COMPOSITION/OPERATION

4512t2c002na

6.2 Operation
6.2.1 Registration mechanism
• For punch and holding operations, a loop is formed in the paper at the Registration Roller [2]
to correct skew of the paper.
• The Entrance Sensor (PS4) [1] detects the leading edge of the paper and the Registration
Roller forms a loop in the paper.
• The Registration Clutch (CL1) is then energized after a given period of time after the PS4 is
activated by the leading edge of the paper, this causes the Registration Roller to start turn-
ing.

[2]

[1]
4512t2c003na

[1] Entrance Sensor (PS4) [2] Registration Roller

30
Theory of Operation Ver. 1.0 Feb. 2006 6. PU-501

FS-510/PU-501/OT-601
6.2.2 Punch mechanism
• After a given period of time after the Entrance Sensor (PS4) [3] has detected the trailing
edge of the paper, the Conveyance Motor (M2) of FS is deenergized and a punch hole oper-
ation is made at the trailing edge portion in each sheet of paper.
• Punch holes are made when the slide cam [1] makes a reciprocating motion, as driven by
the drive cam which is rotated by the Punch Motor (M1) [2] provided in the punch unit.

[1]

[4]

COMPOSITION/OPERATION
[2]

[3]
4512t2c004na

[1] Slide Cam [3] Entrance Sensor (PS4)


[2] Punch Motor (M1) [4] Puncher

6.2.3 Punch status detection


• The punch status is detected by using the Punch Position Sensor /1 (PS2) [1], /2 (PS3) [2],
Punch Home Sensor, and the Encoder Sensor (PS4) [3].

[1] [2]

[3]
4512t2c005na

[1] Punch Position Sensor /1 (PS2) [3] Encoder Sensor (PS4)


[2] Punch Position Sensor /2 (PS3)

31
6. PU-501 Theory of Operation Ver. 1.0 Feb. 2006
FS-510/PU-501/OT-601

6.2.4 Punch Scraps Box full detection mechanism


• Punch scraps produced as a result of punching operation is stored in the Punch Scraps
Box.
• The Punch Scraps Box is provided with the Punch Scraps Full Sensor (PS1) [1]. When a
punch waste is detected, the corresponding message is displayed on the operation panel.
• PS1 is a reflector type sensor that detects height of the punch scraps.
• PS1 also detects whether a Punch Scraps Box is loaded.

[1]
COMPOSITION/OPERATION

4512t2c006na

[1] Punch Scraps Full Sensor (PS1)

32
Theory of Operation Ver. 1.0 Feb. 2006 7. OT-601

FS-510/PU-501/OT-601
7. OT-601
7.1 Composition

COMPOSITION/OPERATION
4625t2c001na

7.2 Operation
7.2.1 Overview
• Mounting the optional OT provides a total of three trays.
• The OT is attached at different positions depending on whether options SD or MT is
mounted or not.
The capacity of each tray is different depending on the position of the OT is attached.
• When the short-circuit connector shipped with OT is mounted, the machine determines that
OT has been mounted.

[5] [6]

[4] [7]

[3] [8]

[2] [1]
4625t2c002na

[1] When MT/SD is installed [5] 200 sheets


[2] FS only [6] 200 sheets
[3] 500 sheets [7] 200 sheets
[4] 200 sheets [8] 200 sheets

33
7. OT-601 Theory of Operation Ver. 1.0 Feb. 2006
FS-510/PU-501/OT-601
COMPOSITION/OPERATION

Blank Page

34
SERVICE MANUAL Theory of Operation

FS-511/RU-502

2006.02
Ver. 1.0
Revision history
After publication of this service manual, the parts and mechanism may be subject to change for improve-
ment of their performance.
Therefore, the descriptions given in this service manual may not coincide with the actual machine.

When any change has been made to the descriptions in the service manual, a revised version will be
issued with a revision mark added as required.

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.

2006/02 1.0 — Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision
Theory of Operation Ver1.0 Feb.2006 CONTENTS

CONTENTS

FS-511/RU-502
FS-511/RU-502

OUTLINE
1. PRODUCT SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 FS-511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 RU-502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

COMPOSITION/OPERATION
3. COMPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 FS-511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 RU-502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1 RU conveyance section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1.1 Conveyance mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2 FS conveyance section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2.1 Entrance conveyance mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2.2 Gate mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2.3 Sub tray conveyance mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2.4 Main tray/handling tray conveyance mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2.5 Roller separation mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2.6 Conveyance operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.3 Main tray section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.3.1 Main tray up/down mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.3.2 Main tray shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.4 Punch section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.4.1 Punch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.4.2 Punch hole switchover mechanism (for inch area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.5 Staple section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.5.1 Alignment mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.5.2 Stapler movement mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.5.3 Stapling mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.5.4 Staple sheet empty control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

i
CONTENTS Theory of Operation Ver1.0 Feb.2006
FS-511/RU-502

Blank page

ii
Theory of Operation Ver1.0 Feb.2006 1. PRODUCT SPECIFICATION

„ OUTLINE

FS-511/RU-502
1. PRODUCT SPECIFICATION
1.1 FS-511
A. Type

Type Multi staple finisher


Installation Floor-mounted type
Document alignment Center
Consumables Staples

B. Functions

Mode Normal Non-sort, sort, group, sort-staple


Punch Non-sort-punch, sort-punch, group-punch,
sort-staple-punch

C. Type of paper
• Maximum load capacity: (80 g/m2) when loaded with paper of the same size.

(1) Straight

Type of paper Size of paper Weight Max. capacity Exit tray Max. number of
sheets stapled
Plain paper A3, B4, A4, A4S, B5, 60 to 90 g/m2 250 sheets Sub tray —
Recycled paper B5S, A5S, and B6S
Thick paper 51/2 x 81/2S, 81/2 x 11, 91 to 130 g/m2 20 sheets
81/2 x 11S, 81/2 x 14,
Thin paper 50 to 59 g/m2
11 x 17
OHP —
transparencies
Label
Envelope
Label sheet
Letterhead

1
1. PRODUCT SPECIFICATION Theory of Operation Ver1.0 Feb.2006

(2) Non-sort, sort, group


FS-511/RU-502

Type of paper Size of paper Weight Max. capacity Exit tray Max. number of
sheets stapled
Plain paper A3, B4, A4, A4S, B5, 50 to 130 g/m2 3000 sheets Main tray —
Recycled paper B5S (A4S or smaller)
Thick paper 81/2 x 11, 81/2 x 11S, 1500 sheets
81/2 x 14, 11 x 17 (B4 or larger)
Thin paper

(3) Sort-staple, group-staple

Type of paper Size of paper Weight Max. capacity Exit tray Max. number of
sheets stapled
Plain paper A3, B4, A4, A4S, B5, 60 to 90 g/m2 3000 sheets Main tray 50 sheets
Recycled paper B5S (A4S or smaller)
81/2 x 11, 81/2 x 11S, 1500 sheets
81/2 x 14, 11 x 17 (B4 or larger)

(4) Punch
a. Metric/Swedish

Type of paper Size of paper Weight Max. capacity Exit tray Max. number of
sheets stapled
Plain paper A3, B4, A4, A4S, B5, 60 to 90 g/m2 — Main tray —
Recycled paper B5S Sub tray

b. Inch 2 holes

Type of paper Size of paper Weight Max. capacity Exit tray Max. number of
sheets stapled
Plain paper 81/2 x 11S, 81/2 x 14 60 to 90 g/m2 — Main tray —
Recycled paper Sub tray

c. Inch 3 holes

Type of paper Size of paper Weight Max. capacity Exit tray Max. number of
sheets stapled
Plain paper 81/2 x 11S, 11 x 17 60 to 90 g/m2 — Main tray —
Recycled paper Sub tray

2
Theory of Operation Ver1.0 Feb.2006 1. PRODUCT SPECIFICATION

D. Stapling

FS-511/RU-502
Staple filling method Dedicated staple cartridge (5000 staples)
Staple detection Available (near empty: 20 remaining staples)
Staple position *1 Rear: Diagonal 45° 1 point Metric: A3, B4, A4, B5
Front: Diagonal 45° 1 point Inch: 81/2 x 11, 11 x 17
Rear: Diagonal 28° 1 point Metric: B4, B5
Front: Diagonal 28° 1 point Inch: —
Rear: Parallel 1 point Metric: A4S, B5S
Front: Parallel 1 point Inch: 81/2 x 11S, 81/2 x 14
Side: 2 points A4, A4S, A3, B5, B5S, B4, 81/2 x 11, 81/2 x 11S,
81/2 x 14, 11 x 17
Manual staple None

*1 In case of the 1-staple mode, conduct a parallel and a skew adjustment according to the length in the
main scan direction.
Parallel: main scan direction 182 to 216 mm
Diagonal: main scan direction 216 to 297 mm

E. Punch

No. of holes Inch: 2 holes, 3 holes


Metric: 4 holes
Punch scraps full detection None

F. Maintenance

Maintenance Same as the main body.


Machine service life Same as the main body.

G. Machine data

Power source 24V DC ± 10 % (supplied from the main body)


Power consumption 64 W or less
Dimensions 538 (W) x 637 (D) x 978 (H) mm
Weight 39.2 kg

H. Operating environment

Temperature 10 to 30 °C
Humidity 10 to 80 % RH (with no condensation)

Note
• The information herein may be subject to change for improvement without notice.

3
1. PRODUCT SPECIFICATION Theory of Operation Ver1.0 Feb.2006

1.2 RU-502
FS-511/RU-502

A. Type

Type Roller method relay conveyance unit

B. Functions

Conveyance Paper conveyance from the main body to FS

C. Type of paper

Paper size Same as the main body.


Paper type Same as the main body.
Amount of curling b = 10 mm or less
(5 sheets)
h

16fat1c001na

D. Maintenance

Maintenance Same as the main body.


Machine service life Same as the main body.

E. Machine data

Power source 5.1V DC ± 5 % (supplied from FS)


Dimensions 474.5 (W) x 469.5 (D) x 254.4 (H) mm
Weight Approx. 4.5 kg

F. Operating environment

Temperature 10 to 30 °C
Humidity 20 to 80 % RH (with no condensation)

Note
• The information herein may be subject to change for improvement without notice.

4
Theory of Operation Ver1.0 Feb.2006 2. PAPER PATH

2. PAPER PATH

FS-511/RU-502
A. Non-sort mode (sub tray paper exit)

[4] [5] [6] [7]

[1]
[3] [2]
4521t1c004na

[1] Paper exit roller (main body) [5] FS-511


[2] Bypass gate [6] Punch
[3] Main gate [7] RU-502
[4] Sub tray

Note: Even when mixed with the punch mode, the paper path is the same.

B. Non-sort/sort/group mode

[3] [4] [5] [6] [7]

[1]
[2]
4521t1c005na

[1] Paper exit roller (main body) [5] Main gate


[2] Bypass gate [6] Punch
[3] Main tray [7] RU-502
[4] FS-511

Note: Even when mixed with the punch mode, the paper path is the same.

5
2. PAPER PATH Theory of Operation Ver1.0 Feb.2006

C. Staple mode
FS-511/RU-502

[6] [7] [8] [9] [10] [11]

[1]
[5] [4] [3] [2]
4521t1c006na

[1] Paper exit roller (main body) [7] Paper path for other than the 1st paper of
[2] Bypass gate the 2nd and succeeding copies.
[3] Paper path for the 1st paper of the 2nd and [8] FS-511
succeeding copies [9] Main gate
[4] Stapler [10] Punch
[5] Handling tray [11] RU-502
[6] Main tray

Note: Even when the A, B or C mode mentioned above is mixed with the punch mode, the paper path is the
same.

6
Theory of Operation Ver1.0 Feb.2006 3. COMPOSITION

„ COMPOSITION/OPERATION

FS-511/RU-502
3. COMPOSITION

Conveyance
Sub tray section Punch section RU-502

Main tray section

Staple section

4521t2c001na

7
4. DRIVE Theory of Operation Ver1.0 Feb.2006

4. DRIVE
FS-511/RU-502

4.1 FS-511

[12] [13] [14]


[11]
[10]
[9]

[8] [1]

[7] [2]

[6]

[5]
[3]

[4]
4521t2e001na

[1] Paddle motor /Lw (M9) [8] Paper exit motor (M3)
[2] Hole punch selector motor (M14) (for inch [9] Paddle motor /Up (M15)
area) [10] Paper exit roller release motor (M13)
[3] Tray lift motor (M7) [11] Conveyance motor /Lw (M2)
[4] Shift motor (M8) [12] Conveyance motor /Up (M4)
[5] Stapler moving motor (M6) [13] Entrance conveyance motor (M1)
[6] Alignment motor (M5) [14] Punch motor (M11)
[7] Intermediate conveyance roller release
motor (M12)

8
Theory of Operation Ver1.0 Feb.2006 4. DRIVE

4.2 RU-502

FS-511/RU-502
[3] [4] [5]
[2]

[1]

16fat2c001na

[1] Main body - fusing motor (M11) [4] Conveyance roller


[2] Entrance conveyance roller (FS-511) [5] Coupling gear
[3] Belt

9
5. OPERATION Theory of Operation Ver1.0 Feb.2006

5. OPERATION
FS-511/RU-502

5.1 RU conveyance section


5.1.1 Conveyance mechanism
• The driving force from the fusing motor (M11) is transmitted through the coupling gear [2] to rotate the con-
veyance roller [5].
• Paper conveyed from the paper exit roller [1] on the main body side is conveyed by the conveyance roller to
the entrance roller [3] on the FS side.
• A jam is detected by the path sensor (PS2) [4].

[4] [5]

[1]
[3]

[2]
16fat2c003na

[1] Paper exit roller (main body) [4] Path sensor (PS2)
[2] Coupling gear [5] Conveyance roller
[3] Entrance roller (FS-511)

10
Theory of Operation Ver1.0 Feb.2006 5. OPERATION

5.2 FS conveyance section

FS-511/RU-502
• The conveyance section is made up of the entrance conveyance mechanism [6] that conducts the convey-
ance drive, the main route conveyance mechanism [2], the sub tray conveyance mechanism [5], the han-
dling/paper exit conveyance mechanism [3], the gate mechanism [1] that switches the paper path and the
roller separation mechanism [4] that conducts the pressure/release of the roller.

[4] [5] [6]

[3]

[2] [1] 4521t2c004na

[1] Gate mechanism [4] Roller separation mechanism


[2] Main route conveyance mechanism [5] Sub tray conveyance mechanism
[3] Main tray/handling tray conveyance mecha- [6] Entrance conveyance mechanism
nism

11
5. OPERATION Theory of Operation Ver1.0 Feb.2006

5.2.1 Entrance conveyance mechanism


• The driving force of the entrance conveyance motor (M1) [4] rotates the entrance roller [1] to convey [3]
FS-511/RU-502

paper [2] into FS.

[4]
[1]

[3] [2]

4521t2c005na

[1] Entrance roller [3] Paper conveyance direction


[2] Paper [4] Entrance conveyance motor (M1)

A. Control
(1) Sub tray paper exit
• When the FS start signal turns ON, the entrance conveyance motor (M1) turns ON. And it turns OFF a
specified period of time after the sub tray exit sensor (PS1) detects the trailing edge of the last paper.

(2) Sort/staple
• When the FS start signal turns ON, M1 turns ON. And it turns OFF a specified period of time after the inter-
mediate conveyance sensor (PS3) detects the trailing edge of the last paper.

12
Theory of Operation Ver1.0 Feb.2006 5. OPERATION

5.2.2 Gate mechanism


• On the conveyance path, the following 2 types of gates are provided: the bypass gate [6] and the main gate

FS-511/RU-502
[3].
• The bypass gate is driven by the bypass gate solenoid (SD1) [5].
• The main gate is driven by the main gate solenoid (SD2) [2].

[6]

[1]

[5]

[4]

[3]
[2]

4521t2c006na

[1] Paper [4] Paper conveyance direction when the


[2] Main gate solenoid (SD2) bypass gate solenoid (SD1) turns ON and
[3] Main gate the main gate solenoid (SD2) turns ON.

[5] Bypass gate solenoid (SD1)


[6] Bypass gate

13
5. OPERATION Theory of Operation Ver1.0 Feb.2006

A. Operation
• The paper conveyance path of the bypass gate [1] is switched over in the bypass route direction [2] when
FS-511/RU-502

the bypass gate solenoid (SD1) turns OFF and switched over in the main gate direction [10] when it turns
ON.
• The paper conveyance path of the main gate [9] is switched over in the main route direction [4] when the
main gate solenoid (SD2) turns OFF and switched over in the sub tray route direction [8] when SD2 turns
ON.
• The paper conveyance to the bypass route is used when conveying each of the 1st sheets of paper of the
2nd and succeeding copies in the staple mode to increase the handling capacity of paper even while in the
stapling operation.

Conveyance path SD1 SD2


Sub tray ON ON
Main tray ON OFF
Bypass route OFF —

[5] [6] [7] [8] [9] [10]

[4] [3] [2] [1]

4521t2c007na

[1] Bypass gate [6] Main route conveyance sensor (PS4)


[2] Bypass route [7] Sub tray exit sensor (PS1)
[3] Bypass route conveyance sensor (PS2) [8] Sub tray route
[4] Main route [9] Main gate
[5] Intermediate conveyance sensor (PS3) [10] Main gate direction conveyance path

B. Control
(1) Sub tray paper exit
• A specified period of time after the fusing exit sensor (PS3) of the main body turns ON and detects the lead-
ing edge of paper, the bypass gate solenoid (SD1) turns ON and the main gate solenoid (SD2) also turns
ON to switch over the conveyance path to the sub tray route.
• A specified period of time after the sub tray exit sensor (PS1) turns ON with the trailing edge of paper
detected, SD1 and SD2 turn OFF.

14
Theory of Operation Ver1.0 Feb.2006 5. OPERATION

5.2.3 Sub tray conveyance mechanism


• The paper conveyance to the sub tray is made while in the non-sort mode.

FS-511/RU-502
• The conveyance motor /Up (M4) [5] drives the conveyance roller /Up [1] and the sub tray paper exit roller [2]
to convey [3] paper [4] to the sub tray.

[5]

[1]

[4]

[3]
[2]

4521t2c008na

[1] Conveyance roller /Up [4] Paper


[2] Sub tray paper exit roller [5] Conveyance motor /Up (M4)
[3] Paper conveyance direction

A. Control
(1) Sub tray paper exit (with no punch)/staple mode (with no punch)
• A specified period of time after the FS start signal turns ON, the conveyance motor /Up (M4) turns ON. And
it turns OFF a specified period of time after the sub tray exit sensor (PS1) turns OFF with the trailing edge of
paper detected.

(2) Sub tray paper exit (punch mode)


• When the FS start signal turns ON, M4 turns ON. However it stops while in the punch operation. M4 turns
ON again after completion of the punch and it turns OFF a specified period of time after PS1 turns OFF.

15
5. OPERATION Theory of Operation Ver1.0 Feb.2006

5.2.4 Main tray/handling tray conveyance mechanism


• The conveyance motor /Lw (M2) [7] drives the conveyance roller /Lw [1] and the intermediate conveyance
FS-511/RU-502

roller [9] to convey paper in the main tray direction [4]. When rotating M2 in the reverse direction, paper is
switched back [10].
• The switch back is made for the 1st paper of each of the 2nd and succeeding copies when printing contin-
uously 2 or more copies in the staple mode to convey the 1st and the 2nd sheets of paper overlapped each
other.
• The paper exit motor (M3) [6] drives the paper exit roller [2] to convey paper in the main tray direction. When
rotating M3 in the reverse direction, paper is conveyed [3] to the handling tray [8].
• The paper conveyance to the handling tray is made while in the staple mode.

[7]
[8] [9] [10]
[6]

[1]

[5]

[4]
[3] [2]
4521t2c009na

[1] Conveyance roller /Lw [6] Paper exit motor (M3)


[2] Paper exit roller [7] Conveyance motor /Lw (M2)
[3] Conveyance to the handling tray [8] Handling tray
[4] Main tray paper exit direction [9] Intermediate conveyance roller
[5] Paper [10] Switch back direction

16
Theory of Operation Ver1.0 Feb.2006 5. OPERATION

A. Switch back control


1. When the FS start signal turns ON, the conveyance motor /Lw (M2) rotates in the normal direction. And

FS-511/RU-502
when the bypass route conveyance sensor (PS2) [3] detects the trailing edge of the 1st paper [1] of the 2nd
copy that has been conveyed to the bypass route, M2 turns OFF.
2. A specified period of time after M2 turns OFF, M2 rotates in the reverse direction to switch back the convey-
ance [2]. And a specified period of time after that, M2 stops to stand by for the 2nd paper.
3. A specified period of time after the main route conveyance sensor (PS4) [7] detects the leading edge of the
2nd paper [8] that has been conveyed through the main route by the conveyance motor /Up (M4), M2
rotates again in the normal direction to convey the 1st and the 2nd sheets of paper overlapped each other.
4. A specified period of time after the intermediate conveyance sensor (PS3) [6] detects the trailing edge of the
last paper, M2 turns OFF.

[5] [6] [7] [8]

[1]

[4] [3] [2]


4521t2c010na

[1] 1st paper of the 2nd copy [5] Paper of the 1st copy
[2] Switch back [6] Intermediate conveyance sensor (PS3)
[3] Bypass route conveyance sensor (PS2) [7] Main route conveyance sensor (PS4)
[4] Handling tray [8] 2nd paper of the 2nd copy

17
5. OPERATION Theory of Operation Ver1.0 Feb.2006

B. Handling tray conveyance operation


(1) Sort mode
FS-511/RU-502

• When the FS start signal turns ON, the paper exit motor (M3) rotates in the normal direction to convey
paper to the main tray. M3 turns OFF a specified period of time after the intermediate conveyance sensor
(PS3) detects the trailing edge of the last paper.

(2) Staple mode


1. When the FS start signal turns ON, M3 rotates in the normal direction. It stops a specified period of time after
PS3 [1] detects the trailing edge of paper.
2. A specified period of time after the stop, M3 rotates in the reverse direction to convey [1] paper to the han-
dling tray [2].
3. After completion of the stapling operation, M3 rotates in the normal direction to exit [6] the stapled paper [5]
to the main tray. At this time, the 1st [4] and the 2nd [7] sheets of paper of the next copy are also conveyed
to the main tray simultaneously.
4. A specified period of time after PS3 detects the trailing edge of the 1st and the 2nd sheets of paper of the
next copy, M3 stops and rotates again in the reverse direction to convey paper to the handling tray.

[3] [6] [7]

[2] [1] [5] [4] 4521t2c011na

[1] Paper stack [5] Paper that has been stapled


[2] Handling tray [6] Paper exit to main tray
[3] Intermediate conveyance sensor (PS3) [7] 2nd paper of the next copy
[4] 1st paper of the next copy

18
Theory of Operation Ver1.0 Feb.2006 5. OPERATION

5.2.5 Roller separation mechanism


• The intermediate conveyance roller and the paper exit roller are provided with a separation mechanism that

FS-511/RU-502
releases the pressure from the roller.
• The intermediate conveyance roller release motor (M12) [1] drives the cam [5] to pressure/release the inter-
mediate conveyance roller [2]. The home position is detected by the roller release home sensor (PS12) [4].
• The paper exit roller release motor (M13) [8] drives the crank [7] to pressure/release the paper exit roller [3].
The home position is detected by the paper exit roller home sensor (PS13) [6].

[8]

[7]
[1]
[6]

[2]
[5]

[4]

[3]

4521t2c012na

[1] Intermediate conveyance roller release [5] Cam


motor (M12) [6] Paper exit roller home sensor (PS13)
[2] Intermediate conveyance roller [7] Crank
[3] Paper exit roller [8] Paper exit roller release motor (M13)
[4] Roller release home sensor (PS12)

19
5. OPERATION Theory of Operation Ver1.0 Feb.2006

A. Intermediate conveyance roller separation control


1. When printing continuously a large size paper (217 mm or larger) in the staple mode, the leading edge of the
FS-511/RU-502

2nd paper [4] gets to the intermediate conveyance roller [2] while in the switch back [1] of the 1st paper of
the 2nd and succeeding copies. To prevent this, release the pressure of the intermediate conveyance roller
and separate [3] the roller to get the 2 sheets of paper overlapped each other.
2. When the 2nd paper stops, the intermediate conveyance roller is pressured to convey the 2 sheets of paper
overlapped each other to the handling tray.

[2] [3] [4]

[1]

4521t2c013na

[1] 1st paper of the 2nd copy [3] Separation


[2] Intermediate conveyance roller [4] 2nd paper of the 2nd copy

20
Theory of Operation Ver1.0 Feb.2006 5. OPERATION

B. Paper exit roller separation control


1. To stack [1] paper in the handling tray [2] while in the staple mode, FS start signal turns ON, and the paper

FS-511/RU-502
exit roller release motor (M13) turns ON. After the pressure of the paper exit roller [3] is released and the
paper exit roller is separated [4], M13 turns OFF.
2. After completion of the stapling operation, M13 turns ON again when the fusing exit sensor (PS3) of the main
body detects the trailing edge of the 2nd paper of the next copy. M13 pressures [7] the paper exit roller to
nip the paper [5], then M13 stops and the paper exits.

[3] [4] [6] [7]

[2] [1] [5] 4521t2c014na

[1] Conveyance to the handling tray [5] Paper


[2] Handling tray [6] Paper exit
[3] Paper exit roller [7] Pressure
[4] Release the pressure of the paper exit roller

21
5. OPERATION Theory of Operation Ver1.0 Feb.2006

5.2.6 Conveyance operation


A. Continuous copy in the staple mode (in case of A4S, 3 originals, and 2 copies)
FS-511/RU-502

1. The 1st paper [2], the 2nd paper [3] and the 3rd paper [4] of the 1st copy are conveyed to the handling tray
[1].
2. While in the conveyance of the last paper [7] of the 1st copy, the 1st paper of the 2nd copy is conveyed [6]
to the bypass route.

[2] [3] [4] [5] [7] [6]

[1] 4521t2c015na

[1] Handling tray [5] 1st paper of the 2nd copy


[2] 1st paper of the 1st copy [6] 1st paper of the 2nd copy
[3] 2nd paper of the 1st copy [7] 3rd paper of the 1st copy
[4] 3rd paper of the 1st copy

3. The 1st paper [1] of the 2nd copy thus conveyed to the bypass route is switched back by the conveyance
roller /Lw [2] and the storage roller [3], and then it stops.
4. The 1st paper [4] of the 2nd copy is overlapped with the 2nd paper [5] of the 2nd copy to be conveyed.

[3] [5]

[2] [1] [4]


4521t2c016na

[1] 1st paper of the 2nd copy [4] 1st paper of the 2nd copy
[2] Conveyance roller /Lw [5] 2nd paper of the 2nd copy
[3] Storage roller

22
Theory of Operation Ver1.0 Feb.2006 5. OPERATION

5. After completion of the stapling operation of the paper [1] of the 1st copy, the paper exit roller [2] is pres-
sured to exit the paper of the 1st copy. At this time, the moment the paper of the 1st copy is exited, the 1st

FS-511/RU-502
and the 2nd sheets of paper [3] of the 2nd copy are also conveyed in the main tray direction.
6. After completion of the exit of the paper [6] of the 1st copy, the pressure of the paper exit roller is released [7]
and the paper exit roller [5] rotates in the reverse direction to convey the 1st and the 2nd sheets of paper [4]
of the 2nd copy to the handling tray.

[2] [3] [6] [7]

[1] [5] [4] 4521t2c017na

[1] Paper of the 1st copy [4] 1st and the 2nd sheets of paper of the 2nd
[2] Pressure the paper exit roller copy
[3] 1st and the 2nd sheets of paper of the 2nd [5] Paper exit roller
copy [6] Paper of the 1st copy
[7] Separation of the paper exit roller

23
5. OPERATION Theory of Operation Ver1.0 Feb.2006

5.3 Main tray section


FS-511/RU-502

5.3.1 Main tray up/down mechanism


• The up/down of the main tray is made by the normal/reverse rotation of the tray lift motor (M7) [2].

[5]
[4]

[1]

[3]

[2]

4521t2c018na

[1] Main tray upper limit LED (LED19) [4] Main tray upper limit sensor (PS19)
[2] Tray lift motor (M7) [5] Main tray reset sensor (PS8)
[3] Main tray

A. Control
(1) While in the print operation
• While in the paper exit, when the main tray upper limit sensor (PS19) turns ON, the tray lift motor (M7)
rotates in the reverse direction to bring down the main tray. And M7 turns OFF when PS19 turns OFF. This
operation is repeated and stopped when the tray gets to the bottom according to the amount of paper
exited.

(2) Paper removal control


• When paper loaded on the main tray is removed with the main tray reset sensor (PS8) OFF, M7 rotates in
the normal direction to bring up the main tray, and when PS8 turns ON, M7 turns OFF.

(3) Paper full detection


• For the main tray, when the main tray full sensor (PS7) turns ON, this is detected as the tray being full of
paper and M7 turns OFF.
• When the main tray goes up and the current of M7 is in excess of a prescribed value, this is detected as the
tray being full of paper and M7 turns OFF.

24
Theory of Operation Ver1.0 Feb.2006 5. OPERATION

5.3.2 Main tray shift mechanism


• While in the sort/group mode, the shift motor (M8) [4] is driven to shift the main tray [5] 30 mm in the main

FS-511/RU-502
scan direction through the shift plate [3].
• The home position is detected by the shift home sensor (PS10) [2].

[1]

[5]

[4]

[2]

[3]

4521t2c019na

[1] Shift encoder sensor (PS11) [4] Shift motor (M8)


[2] Shift home sensor (PS10) [5] Main tray
[3] Shift plate

A. Control
(1) Sort mode
• A specified period of time after the intermediate conveyance sensor (PS3) detects the trailing edge of the
last paper of the copy, the shift motor (M8) turns ON to start the shift operation, and when the shift home
sensor (PS10) detects the shift position, M8 turn OFF.

(2) Staple mode


• A specified period of time after the paper exit roller release motor (M13) turns ON to start the pressure oper-
ation, M8 turns ON to start the shift operation, and when PS10 detects the shift position, M8 turns OFF.

25
5. OPERATION Theory of Operation Ver1.0 Feb.2006

5.4 Punch section


FS-511/RU-502

5.4.1 Punch mechanism


• For the punch, a hole is punched on the rear side of paper for each paper.
• The driving force from the punch motor (M11) [5] is transmitted to the eccentric cam [6] by the punch clutch
(CL1) [4]. And when the eccentric cam makes a full turn, the cam holder [3] makes a round trip to punch a
hole.
• The position of the reciprocating operation of the punch is detected by the punch encoder sensor (PS15).

[6]
[1]
[5]

[4]

[3]

[2] 4521t2c020na

[1] Entrance roller [4] Punch clutch (CL1)


[2] Punch blade [5] Punch motor (M11)
[3] Cam holder [6] Eccentric cam

A. Operation
1. A specified period of time after the path sensor (PS2) of the RU detects the trailing edge of paper, the con-
veyance motor /Up (M4) or conveyance motor /Lw (M2) turns OFF to stop at the prescribed punch position.
2. The punch clutch (CL1) turns ON to punch a hole.
3. M4 or M2 turns ON to convey paper.

26
Theory of Operation Ver1.0 Feb.2006 5. OPERATION

5.4.2 Punch hole switchover mechanism (for inch area)


• The hole punch selector motor (M14) [5] and the hole punch position switch (SW4) [4] are employed to

FS-511/RU-502
move the lock holder [2] as necessary to select the hole positions (2 or 3 holes [1][6]).

[1]

[2] [3]

S4

[4]

[5]

[6]

S4 [7]

4521t2e002na

[1] 2 holes [5] Hole punch selector motor (M14)


[2] Lock holder [6] 3 holes
[3] Punch bars in locked position [7] Punch bars in locked position
[4] Hole punch position switch (SW4)

27
5. OPERATION Theory of Operation Ver1.0 Feb.2006

5.5 Staple section


FS-511/RU-502

5.5.1 Alignment mechanism


• While in the staple mode, paper is conveyed to the handling tray for alignment operation.
• The alignment in the main scan direction is made by the movement of the alignment plate, and the align-
ment in the sub scan direction is made by the rotation of the paddle.

A. Alignment plate
• The movement of the alignment plates /Fr [5] and /Rr [1] is made by the normal/reverse drive of the align-
ment motor (M5) [2].
• The alignment plates /Fr and /Rr move with the position at the center of paper as a reference and the home
position is detected by the alignment home sensor (PS9) [4].
• The distance of movement of the alignment plate is variable according to the paper size.
• The alignment operation is made each time paper is conveyed to the handling tray.

[5] [6] [1]

[4] [3] [2] 4521t2c021na

[1] Alignment plate /Rr [4] Alignment home sensor (PS9)


[2] Alignment motor (M5) [5] Alignment plate /Fr
[3] Handling tray [6] Paper exit roller

(1) Control
1. When the intermediate conveyance sensor (PS3) detects the leading edge of the 1st paper of the job, M5
rotates in the normal direction to conduct a size movement.
2. A specified period of time after PS3 detects the trailing edge of paper, M5 rotates in the normal direction to
conduct the paper alignment. And it rotates in the reverse direction to return to the size standby position.

28
Theory of Operation Ver1.0 Feb.2006 5. OPERATION

B. Paddle
• The paddle /Up [3] and /Lw [6] hit paper against the stopper to conduct the alignment in the sub scan

FS-511/RU-502
direction.
• The drive of the paddle /Up is made by the paddle motor /Up (M15) [5] and the paddle solenoid (SD3) [4].
• The drive of the paddle /Lw is made by the paddle motor /Lw (M9) [1].

[4] [5]

[6]

[1]

[3]

[2]

4521t2c022na

[1] Paddle motor /Lw (M9) [4] Paddle solenoid (SD3)


[2] Paper exit roller [5] Paddle motor /Up (M15)
[3] Paddle /Up [6] Paddle /Lw

(1) Control
1. When the FS start signal turns ON, M15 and M9 also turn ON.
2. A specified period of time after the intermediate conveyance sensor (PS3) detects the leading edge of paper,
SD3 turns ON while a specified period of time.
3. A specified period of time after PS3 detects the trailing edge of the last paper of the copy, M15 and M9 turn
OFF.
4. In case of the last copy, the moment the paper exit motor (M3) turns OFF, M15 and M9 turn OFF.

29
5. OPERATION Theory of Operation Ver1.0 Feb.2006

5.5.2 Stapler movement mechanism


• The movement/rotation of the staplers /Fr [4] and /Rr [1] are made by the stapler moving motor (M6) [3].
FS-511/RU-502

• The home position is detected by the stapler home sensor (PS14) [2] and the position is decided according
to the drive amount of M6.
• The 1 stapling at the front corner is made by the stapler /Fr, the 1 stapling at the rear corner made by the
stapler /Rr, and the 2 stapling operations are made by the staplers /Fr and /Rr.

[4] [3] [2] [1] 4521t2c023na

[1] Stapler /Rr [3] Stapler moving motor (M6)


[2] PS14 [4] Stapler /Fr

A. Control
• When the FS start signal turns ON, the stapler moving motor (M6) turns ON, and it stops at the stapling
position.
• After completion of the job, the moment the paper exit motor (M3) turns OFF, it returns to the home posi-
tion.

30
Theory of Operation Ver1.0 Feb.2006 5. OPERATION

5.5.3 Stapling mechanism


• The stapling operation is made by the stapler.

FS-511/RU-502
• When the stapler motors /Rr (M16) and /Fr (M17) [1] are driven, the clinch arm [3] goes down to drive the
staple blade [2] and hit in a staple.

[3]

[1]

[2]
4521t2c024na

[1] Stapler motors /Rr, /Fr (M16, M17) [3] Clinch arm
[2] Staple blade

A. Control
• A specified period of time after the intermediate conveyance sensor (PS3) detects the trailing edge of the
last paper of the copy, the stapler motors /Rr (M16) and /Fr (M17) turn ON. After completion of the stapling
operation, the motors stop.

31
5. OPERATION Theory of Operation Ver1.0 Feb.2006

5.5.4 Staple sheet empty control


A. Detection mechanism
FS-511/RU-502

• The detection of the staple sheet [6] is made by the staple empty sensors /Rr (PS20) and /Fr (PS23) [4].
• The detection of the staple ready is made by the staple ready sensors /Rr (PS21) and /Fr (PS24) [2].

[5] [6]

[4] [2]
[3] [1] 4521t2c025na

[1] No staple condition [4] Staple empty sensors /Rr, /Fr (PS20, PS23)
[2] Stapler ready sensors /Rr, /Fr (PS21, PS24) [5] Stapler cartridge
[3] Staple set condition [6] Staples

B. Empty detection control


• When the remaining staples get reduced to about 20, the staple empty sensors /Rr (PS20) and /Fr (PS23)
turn ON with a message displayed on the main body LCD.
• In the middle of the stapling operation, when an empty condition is detected, the empty display is shown
after completion of a series of operations.

C. Staple ready detection control


• After replacing (installing) a staple cartridge, the stapler motors /Rr (M16) and /Fr (17) drive until the stapler
ready sensors /Rr (PS21) and /Fr (PS24) turn ON, and then send staples to the stapling position.

32
SERVICE MANUAL Theory of Operation

SD-502
( 500 / 420)

2006.02
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 correspond-
ing page.
A number within 1 represents the number of times the revision has been made.

NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
• When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
• When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.

2006/02 1.0 — Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision
Theory of Operation Ver. 1.0 Feb. 2006

CONTENTS

SD-502
SD-502

OUTLINE
1. PRODUCT SPECIFICATIONS ................................................................................1
2. PAPER PATH ...........................................................................................................2

OUTLINE
COMPOSITION/OPERATION
3. COMPOSITION .......................................................................................................3
4. DRIVE......................................................................................................................4
4.1 Half-fold section ....................................................................................................4
4.2 Saddle Stitching Section .......................................................................................4

COMPOSITION/OPERATION
5. OPERATIONS .........................................................................................................5
5.1 Paper Conveyance mechanism ............................................................................5
5.2 Conveyance roller pressure/release .....................................................................6
5.2.1 Pressure/release mechanism........................................................................6
5.2.2 Operation.......................................................................................................7
5.3 Stapling mechanism..............................................................................................8
5.4 Staple guide ..........................................................................................................9
5.4.1 Staple guide mechanism ...............................................................................9
5.4.2 Operation timing ............................................................................................9
5.5 Half-folding mechanism ......................................................................................10
5.5.1 Operation.....................................................................................................11
5.6 Paper guide.........................................................................................................12
5.6.1 Paper guide mechanism..............................................................................12
5.7 Tray paper detection............................................................................................13

i
Theory of Operation Ver. 1.0 Feb. 2006
SD-502
OUTLINE
COMPOSITION/OPERATION

Blank Page

ii
Theory of Operation Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS

„ OUTLINE
1. PRODUCT SPECIFICATIONS

SD-502
A. Type

Type FS built-in saddle-stitching device


Installation Screwed to the FS
Document Alignment Center
Center parallel two points
Stapling Function
No. of sheets to be stapled together: 2 to 15

OUTLINE
Consumables Staples (2000 staples/cartridge)

B. Paper type

Type Plain Paper 56 to 90 g/m2


Metric: A3, B4, A4S, B5S
Size
Inch: 11 x 17, 81/2 × 11S
Capacity 200 sheets or 20 copies

C. Maintenance

Maintenance Every 250,000 prints


Machine service life Same as the main body.

D. Machine specifications

Power Requirements 24/5V DC (supplied from FS)


Power Consumption 9.5 W or less
Dimensions 445 (W) x 203 (D) x 478 mm (H)
Weight Approx. 9.3 kg

E. Operating environment

Temperature Same as the main body.


Humidity Same as the main body.

NOTE
• The information herein may be subject to change for improvement without notice.

1
2. PAPER PATH Theory of Operation Ver. 1.0 Feb. 2006

2. PAPER PATH
SD-502
OUTLINE

4511t1c001na

2
Theory of Operation Ver. 1.0 Feb. 2006 3. COMPOSITION

„ COMPOSITION/OPERATION
3. COMPOSITION

SD-502
Saddle-Stitching Section

Half-Fold Section

COMPOSITION/OPERATION
4511t2c001na

3
4. DRIVE Theory of Operation Ver. 1.0 Feb. 2006

4. DRIVE
4.1 Half-fold section
SD-502

[3]

[2]
COMPOSITION/OPERATION

[1]
4511t2c013na

[1] Folding Roller [3] Half-folding Blade


[2] Folding Motor (M10)

4.2 Saddle Stitching Section

[3]

[1]

[2]

4511t2c003na

[1] Conveyance Roller /Up [3] Exit Open/Close Motor (M9)


[2] Conveyance Motor (M8)

4
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS

5. OPERATIONS
5.1 Paper Conveyance mechanism

SD-502
• Paper is conveyed by the Exit Rollers of FS and Conveyance Roller /Up [5], /Lw [2].
• The Conveyance Motor (M8) [3] provides the drive for the Conveyance Roller /Lw [2].
• If a center stapling operation is made with a bundle papers stored in the Stacker, a bundle
papers is conveyed to the center stapling position, through a pulse control of the Exit Roller
of FS.
• A bundle papers is thereafter fed out by the Conveyance Roller /Up and /Lw.

[5]

[1]

COMPOSITION/OPERATION
[4]

[2]

[3]

4511t2c004na

[1] Exit Rollers of FS [4] Exit Open/Close Motor (M9)


[2] Conveyance Roller /Lw [5] Conveyance Roller /Up
[3] Conveyance Motor (M8)

5
5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006

5.2 Conveyance roller pressure/release


5.2.1 Pressure/release mechanism
SD-502

• The Conveyance Roller /Up [1] is moved away from, or pressed up against, the Conveyance
Roller /Lw [2], when the paper is fed out as a bundle of papers.
• The Saddle Exit Home Sensor (PS18) [3] is used to control the pressure/release position of
the Conveyance Roller /Up.

[1]
COMPOSITION/OPERATION

[3] [2]
4511t2c005na

[1] Conveyance Roller /Up [3] Saddle Exit Home Sensor (PS18)
[2] Conveyance Roller /Lw

6
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS

5.2.2 Operation
1. The Conveyance Roller /Up [5] is moved up or down by the cams which are driven by

SD-502
the Exit Open/Close Motor (M9) [6].
2. When a bundle papers moves past the Conveyance Roller /Up and /Lw, the motor is
energized to press the Conveyance Roller /Up up against the Conveyance Roller /Lw,
thereby feeding a bundle papers out into the tray.

[6]

[1]

[1]

COMPOSITION/OPERATION
[5]

[4] [3] [2]


4511t2c006na

[1] Cam [4] Cams are rotated.


[2] Cams are rotated. + The Conveyance Roller [5] Conveyance Roller /Up
/Up is moved downward (pressing). [6] Exit Open/Close Motor (M9)
[3] The Conveyance Roller /Up is moved upward
(retraction).

7
5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006

5.3 Stapling mechanism


• The Staple units [2] position are fixed.
SD-502

• Since the unit are for center stapling only, it is made up of the upper clincher portion [1] and
the lower stapling portion. A bundle papers moves through the space between the upper
and lower portions of the staplers.
• When stapling, the clincher portion moves downward to perform the stapling operation.

[3]

[1]
COMPOSITION/OPERATION

[2]

4511t2c007na

[1] Clincher Portion [3] Clincher Unit


[2] Staple Unit

8
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS

5.4 Staple guide


• The Staple Guide is used to guide the leading edge of the first sheet of paper when the first

SD-502
sheet of paper is stored, thereby preventing the leading edge from contacting the Stapling
Unit and jamming.

5.4.1 Staple guide mechanism


• The Staple Guide Motor (M14) [3] turns the cams at the front and rear, thereby moving the
Staple Guide up or down.
• The Staple Guide Home Sensor (PS26) [2] detects the position of the Staple Guide.

[3]

COMPOSITION/OPERATION
[2] [1]
4511t2c008na

[1] Cam [3] Staple Guide Motor (M14)


[2] Staple Guide Home Sensor (PS26)

5.4.2 Operation timing


1. Raising the Staple Guide
(power ON, Sleep cancelled, error reset, paper removed from tray)
2. Lowering the Staple Guide
(When the conveyance of a bundle papers to the center stapling position is completed)
3. Raising the Staple Guide
(When the trailing edge of a bundle papers deactivates the Exit Sensor (PS20))

9
5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006

5.5 Half-folding mechanism


• The Entrance Sensor (PS4) [2] of FS detects the trailing edge of the paper.
SD-502

• The paper feed amount is determined for each paper size as counted from the timing when
the trailing edge is detected. Half-folding is effected as follows. Specifically, the paper
undergoes a switchback operation and is conveyed to the half-folding position as the motor
is turned backward.
• The Half-Folding Blade [3] is lowered and the center of the paper is pinched between the
Folding Rollers and this creates a crease in the paper.
• After the half-folding, the paper is conveyed by the Conveyance Roller [7] and then the Reg-
istration Roller [1] as they are driven in that order.

[7] [1]
[3]
COMPOSITION/OPERATION

[6] [2]

[5]
[3]

[4]
4511t2c009na

[1] Registration Roller [5] Folding Motor (M10)


[2] Entrance Sensor (PS4) [6] Conveyance Sensor (PS5)
[3] Half-Folding Blade [7] Conveyance Roller
[4] Folding Roller Home Sensor (PS22)

10
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS

5.5.1 Operation
• When the Folding Motor (M10) is energized for one cycle of operation, the Conveyance

SD-502
Guides /Lw [2] are retracted to the right and left and the Half-folding Blade [3] makes one
up-and-down reciprocating motion. In synchronism with the sequence of these operations,
the Folding Roller [1] turns one complete turn to pull the paper downward at its center.
• At the same time that the Conveyance Guides /Lw returns to their original position, the Half-
folding Blade goes up.

COMPOSITION/OPERATION
[1]

[3]

[2]

4511t2c010na

[1] Folding Roller [3] Half-folding Blade


[2] Conveyance Guides /Lw

11
5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006

5.6 Paper guide


• When a bundle papers is fed onto the tray, the Paper Guide supports the leading edge of the
SD-502

paper of a large size so as to prevent it from pushing the trailing edge of the paper that has
previously been fed out.
• The Paper Guide is driven only when paper with a length of 257 mm or more will be stored.
• The Paper Guide advances when the Entrance Sensor (PS4) of FS is OFF and retracts
when the trailing edge of the paper passes the Exit Sensor (PS20).

5.6.1 Paper guide mechanism


• The Paper Guide Motor (M13) [3] drives the Paper Guide [2].
• The Paper Guide Home Sensor (PS23) [1] is used to control the home position of the Paper
Guide.

[3]
COMPOSITION/OPERATION

[2]

[2] [1]
4511t2c011na

[1] Paper Guide Home Sensor (PS23) [3] Paper Guide Motor (M13)
[2] Paper Guide

12
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS

5.7 Tray paper detection


• When paper is fed onto the tray, it pushes the actuator, which causes the Tray Empty Sen-

SD-502
sor (PS21) [1] to detect the paper.

[1]

COMPOSITION/OPERATION
4511t2c012na

[1] Tray Empty Sensor (PS21)

13
5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006
SD-502
COMPOSITION/OPERATION

Blank Page

14
SERVICE MANUAL Theory of Operation

MT-501
( 500 / 420)

2006.02
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 correspond-
ing page.
A number within 1 represents the number of times the revision has been made.

NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
• When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
• When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.

2006/02 1.0 — Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision
Theory of Operation Ver. 1.0 Feb. 2006

CONTENTS

MT-501
MT-501

OUTLINE
1. PRODUCT SPECIFICATIONS ................................................................................1
2. PAPER PATH ...........................................................................................................2

OUTLINE
COMPOSITION/OPERATION
3. COMPOSITION .......................................................................................................3
4. DRIVE......................................................................................................................4
5. OPERATIONS .........................................................................................................5
5.1 Paper conveyance mechanism .............................................................................5

COMPOSITION/OPERATION
5.2 Paper path selection mechanism ..........................................................................6
5.3 Paper detection .....................................................................................................7

i
Theory of Operation Ver. 1.0 Feb. 2006
MT-501
OUTLINE
COMPOSITION/OPERATION

Blank Page

ii
Theory of Operation Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS

„ OUTLINE
1. PRODUCT SPECIFICATIONS

MT-501
A. Type

Type 4 bins Mailbin (available only for printing from PC)


Installation Screwed to the FS
Number of Bins 4 bins
Number of Sheets
125 sheets (80 g/m2)
Stored per Bin

OUTLINE
Storable Paper Plain Paper (56 to 90 g/m2)
Metric: A4, B5, 81/2 x 11
Storable Paper Size
Inch: 81/2 x 11, 51/2 x 81/2S

B. Maintenance

Maintenance Every 250,000 prints


Machine service life Same as the main body.

C. Machine specifications

Power Requirements 24V DC (supplied from FS)


Dimensions 624 (W) x 503 (D) x 390 mm (H)
Weight Approx. 8 kg

D. Operating environment

Temperature Same as the main body.


Humidity Same as the main body.

NOTE
• The information herein may be subject to change for improvement without notice.

1
2. PAPER PATH Theory of Operation Ver. 1.0 Feb. 2006

2. PAPER PATH
MT-501
OUTLINE

4510t1c001na

2
Theory of Operation Ver. 1.0 Feb. 2006 3. COMPOSITION

„ COMPOSITION/OPERATION
3. COMPOSITION

MT-501
COMPOSITION/OPERATION
4510t2c001na

3
4. DRIVE Theory of Operation Ver. 1.0 Feb. 2006

4. DRIVE
MT-501

[3]

[1]
COMPOSITION/OPERATION

[2]
4510t2c003na

[1] Conveyance Roller [3] Conveyance Motor (M1)


[2] Exit Roller

4
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS

5. OPERATIONS
5.1 Paper conveyance mechanism

MT-501
• When the Mailbin is selected as the exit source, paper is fed off from the Finisher (FS-510)
and toward the Mailbin.
• Drive for the Conveyance Rollers [2] of the Mailbin is transmitted from the Conveyance
Motor (M1) [1] by way of a belt.
• As each of the Conveyance Rollers is driven, paper fed off from the Finisher is conveyed into
the Mailbin.

[1]

COMPOSITION/OPERATION
[2]
4510t2c004na

[1] Conveyance Motor (M1) [2] Conveyance Roller

5
5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006

5.2 Paper path selection mechanism


• The Gate Solenoid /1, /2, /3 (SD1, SD2, SD3) [1] are energized or deenergized to direct
MT-501

paper fed from the Finisher into a specific tray.


• There are SD1, SD2, SD3 provided that will be energized or deenergized to operate the cor-
responding Gate [2], thereby selecting a specific paper path into a specific tray.

[1]
COMPOSITION/OPERATION

[2]

4510t2c005na

[1] Gate Solenoid /1, /2, /3 (SD1, SD2, SD3) [2] Gate

6
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS

5.3 Paper detection


• The Paper Detection Sensor /1, /2, /3, /4 (PS1, PS2, PS3, PS4) [2] detects any sheet of

MT-501
paper that is fed into the tray, causing the DF LED to light up green steadily to inform the
user that a sheet of paper has been fed into the tray.
• As the paper stacks up and eventually deactivates the Paper Full Sensor /1, /2, /3, /4 (PS5,
PS6, PS7, PS8) [1], at which time a paper full condition is detected.

[1]

COMPOSITION/OPERATION
[2]
4510t2c006na

[1] Paper Full Sensor /1, /2, /3, /4 (PS5, PS6, [2] Paper Detection Sensor /1, /2, /3, /4 (PS1,
PS7, PS8) PS2, PS3, PS4)

7
5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006
MT-501
COMPOSITION/OPERATION

Blank Page

8
SERVICE MANUAL Theory of Operation

JS-502
( 500 / 420)

2006.02
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 correspond-
ing page.
A number within 1 represents the number of times the revision has been made.

NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
• When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
• When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.

2006/02 1.0 — Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision
Theory of Operation Ver. 1.0 Feb. 2006

CONTENTS

JS-502
JS-502

OUTLINE
1. PRODUCT SPECIFICATIONS ................................................................................1
2. PAPER PATH ...........................................................................................................2

OUTLINE
COMPOSITION/OPERATION
3. COMPOSITION .......................................................................................................3
4. OPERATIONS .........................................................................................................4
4.1 Job Tray Conveyance/Exit.....................................................................................4

COMPOSITION/OPERATION

i
Theory of Operation Ver. 1.0 Feb. 2006
JS-502
OUTLINE
COMPOSITION/OPERATION

Blank Page

ii
Theory of Operation Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS

„ OUTLINE
1. PRODUCT SPECIFICATIONS

JS-502
A. Type

Name Job Separator


Type Expansion tray
Installation Installed in the main body
Document Alignment Center

OUTLINE
B. Paper type

Exit Tray Size Type Capacity


Inch: 11 x 17, 81/2 x 14, Plain Paper (56 to 90 g/m2) 250 sheets
81/2 x 11, 81/2 x 11S,
OHP transparencies
51/2 x 81/2S
Tray 1 A3, A4, A4S, A5S, Thick paper (91 to 210g/m2)
(Main 8 x 13
Envelope
Body Metric: A3, B4, A4, A4S, B5, Special 20 sheets
Tray) B5S, A5S Label
11 x 17, 81/2 x 11,
81/2 x 11S, 8 x 13 Letterhead

Inch:
11 x 17, 81/2 x 14,
81/2 x 11, 81/2 x 11S,
Tray 2
51/2 x 81/2S Plain Paper (56 to 90 g/m2) 100 sheets
(Job Tray)
Metric: A3, B4, A4, A4S, B5,
B5S, A5S

C. Maintenance

Maintenance None
Machine service life Same as the main body.

D. Machine specifications

Power Requirements 5V DC ± 5 % (supplied from the main body)


Power Consumption 0.2 W or less
Dimensions 450 (W) x 443 (D) x 75 mm (H)
Weight Approx. 1.7 kg

E. Operating environment

Temperature Same as the main body.


Humidity Same as the main body.

NOTE
• The information herein may be subject to change for improvement without notice.

1
2. PAPER PATH Theory of Operation Ver. 1.0 Feb. 2006

2. PAPER PATH
JS-502
OUTLINE

[1]

4347t1c001na

[1] Conveyance from the main body

2
Theory of Operation Ver. 1.0 Feb. 2006 3. COMPOSITION

„ COMPOSITION/OPERATION
3. COMPOSITION

JS-502
Job Separator section Switchback Unit section

COMPOSITION/OPERATION
4347t2c001na

3
4. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006

4. OPERATIONS
4.1 Job Tray Conveyance/Exit
JS-502

• The Switchback Unit functions to convey paper through, and feed it out from, the Job Tray.
• The paper sensor section of the Job Tray is mounted to the Switchback Unit, thereby detect-
ing paper.
• When paper stacks up on the Tray [3], the actuator [2] is pushed up by the paper, indicating
that there is paper at the exit port.

[1]

[3]
COMPOSITION/OPERATION

[2]
4347t2c002na

[1] Paper Full Sensor (PS1) [3] Tray


[2] Actuator

4
© 2006 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.
Printed in Japan
Use of this manual should be strictly supervised to avoid
NN50GAPE1-0900
disclosure of confidential information.
SERVICE MANUAL Field Service

500 / 420

2006.02
Ver. 1.0
FIELD SERVICE TOTAL CONTENTS

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


IMPORTANT NOTICE ................................................................................................S-1
DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION .........................S-1
SAFETY WARNINGS .................................................................................................S-2
SAFETY INFORMATION ...............................................................................................S-12
IMPORTANT NOTICE ..............................................................................................S-12
INDICATION OF WARNING ON THE MACHINE .....................................................S-13
MEASURES TO TAKE IN CASE OF AN ACCIDENT ....................................................S-15
Composition of the service manual ................................................................................. C-1
Notation of the service manual ....................................................................................... C-2

bizhub 500 / 420 Main Body


OUTLINE ........................................................................................................................ 1
MAINTENANCE.............................................................................................................. 7
ADJUSTMENT/SETTING ........................................................................................... 147
TROUBLESHOOTING................................................................................................ 273
APPENDIX.................................................................................................................. 311
* For particulars, see the contents of the main body.

DF-607
OUTLINE ........................................................................................................................ 1
MAINTENANCE.............................................................................................................. 5
ADJUSTMENT/SETTING ............................................................................................. 19
* For particulars, see the contents of DF-607.

PC-202
OUTLINE ........................................................................................................................ 1
MAINTENANCE.............................................................................................................. 3
ADJUSTMENT/SETTING ............................................................................................. 15
* For particulars, see the contents of PC-202.

PC-402
OUTLINE ........................................................................................................................ 1
MAINTENANCE.............................................................................................................. 3
ADJUSTMENT/SETTING ............................................................................................. 19
* For particulars, see the contents of PC-402.

i
LU-201
OUTLINE ........................................................................................................................ 1
MAINTENANCE ............................................................................................................. 3
ADJUSTMENT/SETTING ............................................................................................. 21
* For particulars, see the contents of LU-201.

FS-510/PU-501/OT-601
OUTLINE ........................................................................................................................ 1
MAINTENANCE ............................................................................................................. 5
ADJUSTMENT/SETTING ............................................................................................. 21
* For particulars, see the contents of FS-510/PU-501/OT-601.

FS-511/RU-502
OUTLINE ........................................................................................................................ 1
MAINTENANCE ............................................................................................................. 5
ADJUSTMENT/SETTING ............................................................................................. 17
* For particulars, see the contents of FS-511/RU-502.

SD-502
OUTLINE ........................................................................................................................ 1
MAINTENANCE ............................................................................................................. 3
ADJUSTMENT/SETTING ............................................................................................. 23
* For particulars, see the contents of SD-502.

MT-501
OUTLINE ........................................................................................................................ 1
MAINTENANCE ............................................................................................................. 3
* For particulars, see the contents of MT-501.

JS-502
OUTLINE ........................................................................................................................ 1
MAINTENANCE ............................................................................................................. 3
* For particulars, see the contents of JS-502.

IC-204
OUTLINE ........................................................................................................................ 1
MAINTENANCE ............................................................................................................. 3
ADJUSTMENT / SETTING ............................................................................................. 7
TROUBLESHOOTING ................................................................................................... 9
* For particulars, see the contents of IC-204.

ii
SAFETY AND IMPORTANT WARNING ITEMS

SAFETY AND IMPORTANT WARNING ITEMS


Read carefully the Safety and Important Warning Items described below to understand
them before doing service work.

IMPORTANT NOTICE
Because of possible hazards to an inexperienced person servicing this product as well as
the risk of damage to the product, Konica Minolta Business Technologies, INC. (hereafter
called the KMBT) strongly recommends that all servicing be performed only by KMBT-
trained service technicians.
Changes may have been made to this product to improve its performance after this Service
Manual was printed. Accordingly, KMBT does not warrant, either explicitly or implicitly, that
the information contained in this Service Manual is complete and accurate.
The user of this Service Manual must assume all risks of personal injury and/or damage to
the product while servicing the product for which this Service Manual is intended.
Therefore, this Service Manual must be carefully read before doing service work both in the
course of technical training and even after that, for performing maintenance and control of
the product properly.
Keep this Service Manual also for future service.

DESCRIPTION ITEMS FOR DANGER,


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

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

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

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


trouble and property damage

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

:Precaution when using the


copier. General Electric hazard High
precaution temperature

:Prohibition when using the


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

:Direction when using the


copier. General Unplug Ground/Earth
instruction

S-1
SAFETY AND IMPORTANT WARNING ITEMS

SAFETY WARNINGS
[1] MODIFICATIONS NOT AUTHORIZED BY KONICA MINOLTA
BUSINESS TECHNOLOGIES, INC.

Konica Minolta brand products are renowned for their high reliability. This reliability is
achieved through high-quality design and a solid service network.
Product design is a highly complicated and delicate process where numerous mechanical,
physical, and electrical aspects have to be taken into consideration, with the aim of arriving
at proper tolerances and safety factors. For this reason, unauthorized modifications involve
a high risk of degradation in performance and safety. Such modifications are therefore
strictly prohibited. The points listed below are not exhaustive, but they illustrate the reason-
ing behind this policy.

Prohibited Actions

DANGER
• Using any cables or power cord not specified by KMBT.

• Using any fuse or thermostat not specified by KMBT.


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

• Disabling fuse functions or bridging fuse terminals with


wire, metal clips, solder or similar object.

• Disabling relay functions (such as wedging paper between


relay contacts)

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


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

• Making any modification to the product unless instructed


by KMBT

• Using parts not specified by KMBT

S-2
SAFETY AND IMPORTANT WARNING ITEMS

[2] POWER PLUG SELECTION


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

Power Cord Set or Power Plug

WARNING
• Use power supply cord set which meets the following
criteria:
AC230V
- provided with a plug having configuration intended for
the connection to wall outlet appropriate for the prod-
uct's rated voltage and current, and
- the plug has pin/terminal(s) for grounding, and
- provided with three-conductor cable having enough cur-
rent capacity, and
AC208V 240V
- the cord set meets regulatory requirements for the area.
Use of inadequate cord set leads to fire or electric shock.
• Attach power plug which meets the following criteria:
- having configuration intended for the connection to wall
outlet appropriate for the product's rated voltage and
current, and
- the plug has pin/terminal(s) for grounding, and
- meets regulatory requirements for the area.
Use of inadequate cord set leads to the product connect-
ing to inadequate power supply (voltage, current capacity,
grounding), and may result in fire or electric shock.

• Conductors in the power cable must be connected to ter-


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

S-3
SAFETY AND IMPORTANT WARNING ITEMS

[3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE


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

1. Power Supply

Connection to Power Supply

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

• Connect power plug directly into wall outlet having same


configuration as the plug.
Use of an adapter leads to the product connecting to kw
inadequate power supply (voltage, current capacity,
grounding), and may result in fire or electric shock.
If proper wall outlet is not available, advice the customer
to contact qualified electrician for the installation.
• Plug the power cord into the dedicated wall outlet with a
capacity greater than the maximum power consumption.
If excessive current flows in the wall outlet, fire may
result.

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


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

• Make sure the power cord is plugged in the wall outlet


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

S-4
SAFETY AND IMPORTANT WARNING ITEMS

Connection to Power Supply

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

Power Plug and Cord

WARNING
• When using the power cord set (inlet type) that came with
this product, make sure the connector is securely inserted
in the inlet of the product.
When securing measure is provided, secure the cord with
the fixture properly.
If the power cord (inlet type) is not connected to the prod-
uct securely, a contact problem may lead to increased
resistance, overheating, and risk of fire.

• Check whether the power cord is not stepped on or


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

• Check whether the power cord is damaged. Check


whether the sheath is damaged.
If the power plug, cord, or sheath is damaged, replace
with a new power cord or cord set (with plug and connec-
tor on each end) specified by KMBT.
Using the damaged power cord may result in fire or elec-
tric shock.

• Do not bundle or tie the power cord.


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

S-5
SAFETY AND IMPORTANT WARNING ITEMS

Power Plug and Cord

WARNING
• Check whether dust is collected around the power plug
and wall outlet.
Using the power plug and wall outlet without removing
dust may result in fire.

• Do not insert the power plug into the wall outlet with a wet
hand.
The risk of electric shock exists.
• When unplugging the power cord, grasp the plug, not the
cable.
The cable may be broken, leading to a risk of fire and
electric shock.

Wiring

WARNING
• Never use multi-plug adapters to plug multiple power cords
in the same outlet.
If used, the risk of fire exists.

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


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

S-6
SAFETY AND IMPORTANT WARNING ITEMS

2. Installation Requirements

Prohibited Installation Places

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

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


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

When not Using the Product for a long time

WARNING
• When the product is not used over an extended period of
time (holidays, etc.), switch it off and unplug the power
cord.
Dust collected around the power plug and outlet may
cause fire.

Ventilation

CAUTION
• The product generates ozone gas during operation, but it
will not be harmful to the human body.
If a bad smell of ozone is present in the following cases,
ventilate the room.
a. When the product is used in a poorly ventilated room
b. When taking a lot of copies
c. When using multiple products at the same time

Fixing

CAUTION
• Be sure to lock the caster stoppers.
In the case of an earthquake and so on, the product may
slide, leading to a injury.

S-7
SAFETY AND IMPORTANT WARNING ITEMS

Inspection before Servicing

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

• Before conducting an inspection, be sure to disconnect


the power plugs from the product and options.
When the power plug is inserted in the wall outlet, some
units are still powered even if the POWER switch is
turned OFF. A risk of electric shock exists.

• The area around the fixing unit is hot.


You may get burnt.

Work Performed with the Product Powered On

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

• Take every care when servicing with the external cover


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

S-8
SAFETY AND IMPORTANT WARNING ITEMS

Safety Checkpoints

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

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


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

• Check wiring for squeezing and any other damage.


Current can leak, leading to a risk of electric shock or
fire.
• Carefully remove all toner remnants and dust from electri-
cal parts and electrode units such as a charging corona
unit.
Current can leak, leading to a risk of product trouble or
fire.

• Check high-voltage cables and sheaths for any damage.


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

• Check electrode units such as a charging corona unit for


deterioration and sign of leakage.
Current can leak, leading to a risk of trouble or fire.
• Before disassembling or adjusting the write unit (P/H unit)
incorporating a laser, make sure that the power cord has
been disconnected.
The laser light can enter your eye, leading to a risk of
loss of eyesight.

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


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

S-9
SAFETY AND IMPORTANT WARNING ITEMS

Safety Checkpoints

WARNING
• When replacing a lithium battery, replace it with a new lith-
ium battery specified in the Parts Guide Manual. Dispose
of the used lithium battery using the method specified by
local authority.
Improper replacement can cause explosion.

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


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

• Check the interlock switch and actuator for loosening and


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

• Make sure the wiring cannot come into contact with sharp
edges, burrs, or other pointed parts.
Current can leak, leading to a risk of electric shock or
fire.
• Make sure that all screws, components, wiring, connec-
tors, etc. that were removed for safety check and mainte-
nance have been reinstalled in the original location. (Pay
special attention to forgotten connectors, pinched cables,
forgotten screws, etc.)
A risk of product trouble, electric shock, and fire exists.

Handling of Consumables

WARNING
• Toner and developer are not harmful substances, but care
must be taken not to breathe excessive amounts or let the
substances come into contact with eyes, etc. It may be
stimulative.
If the substances get in the eye, rinse with plenty of water
immediately. When symptoms are noticeable, consult a
physician.

S-10
SAFETY AND IMPORTANT WARNING ITEMS

Handling of Consumables

WARNING
• Never throw the used cartridge and toner into fire.
You may be burned due to dust explosion.

Handling of Service Materials

CAUTION
• Unplug the power cord from the wall outlet.
Isopropyl alcohol and acetone are highly flammable and
must be handled with care. A risk of fire exists.

• Do not replace the cover or turn the product ON before


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

• Use only a small amount of cleaner at a time and take


care not to spill any liquid. If this happens, immediately
wipe it off.
A risk of fire exists.

• When using any solvent, ventilate the room well.


Breathing large quantities of organic solvents can lead to
discomfort.

S-11
SAFETY INFORMATION

SAFETY INFORMATION
IMPORTANT NOTICE
The Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Admin-
istration implemented regulations for laser products manufactured since August 1, 1976.
Compliance is mandatory for products marketed in the United States.

This copier is certified as a "Class 1" laser product under the U.S.
Department of Health and Human Services (DHHS) Radiation Performance Standard
according to the Radiation Control for Health and Safety Act of 1968. Since radiation emit-
ted inside this copier is completely confined within protective housings and external covers,
the laser beam cannot escape during any phase of normal user operation.

S-12
SAFETY INFORMATION

INDICATION OF WARNING ON THE MACHINE


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

50gap0e001na

S-13
SAFETY INFORMATION

50gap0e002na

CAUTION:
• You may be burned or injured if you touch any area that you are advised by any
caution label to keep yourself away from. Do not remove caution labels. And also,
when the caution label is peeled off or soiled and cannot be seen clearly, replace
it with a new caution label.

S-14
MEASURES TO TAKE IN CASE OF AN ACCIDENT

MEASURES TO TAKE IN CASE OF


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

S-15
MEASURES TO TAKE IN CASE OF AN ACCIDENT

Blank Page

S-16
Composition of the service manual
This service manual consists of the following sections and chapters:

<Theory of Operation section>

OUTLINE: System configuration, product specifications,


unit configuration, and paper path
COMPOSITION/OPERATION: Configuration of each unit, explanation of the operating
system, and explanation of the control system
This section gives, as information for the CE to get a full understanding of the product, a
rough outline of the object and role of each function, the relationship between the electrical
system and the mechanical system, and the timing of operation of each part.

<Field service section>

OUTLINE: System configuration, and product specifications


MAINTENANCE: Service schedule *, maintenance steps,
list of service tools and directions for use *,
firmware version up method *,
and removal/reinstallation methods of major parts
ADJUSTMENT/SETTING: Utility mode *, service mode *, security and mechanical
adjustment
TROUBLESHOOTING*: List of jam codes, their causes, operation when a jam
occurs and its release method, and list of error codes,
their causes, operation when a warning is issued and esti-
mated abnormal parts.
APPENDIX*: Parts layout drawings, connector layout drawings, timing
chart, overall layout drawing

This section gives, as information required by the CE at the site (or at the customer's
premise), a rough outline of the service schedule and its details, maintenance steps, the
object and role of each adjustment, error codes and supplementary information.

The details of items with an asterisk "*" are described only in the service manual of
the main body.

C-1
Notation of the service manual
A. Product name
In this manual, each of the products is described as follows:

(1) IC board: Standard printer


(2) bizhub 500 / 420: Main body
(3) Microsoft Windows 95: Windows 95
Microsoft Windows 98: Windows 98
Microsoft Windows Me: Windows Me
Microsoft Windows NT 4.0: Windows NT 4.0 or Windows NT
Microsoft Windows 2000: Windows 2000
Microsoft Windows XP: Windows XP
When the description is made in combination of the OS's mentioned above:
Windows 95/98/Me
Windows NT 4.0/2000
Windows NT/2000/XP
Windows 95/98/Me/NT/2000/XP

B. Brand name
The company names and product names mentioned in this manual are the brand name or
the registered trademark of each company.

C. Electrical parts and signals


Those listed by way of example below are not exhaustive, but only some instances among
many.

Classification Load symbol Ex. of signal name Description


IN
PS
Sensor PS Door PS1 Sensor detection signal
SIG
102 PS
24V Power to drive the solenoid
Solenoid SD DRV
Drive signal
SOL
24V Power to drive the clutch
Clutch CL DRV
Drive signal
SOL

C-2
Classification Load symbol Ex. of signal name Description
24V Power to drive the motor
CONT Drive signal
DRV1
Motor M
DRV2
Drive signals of two kinds
D1
D2
_U
_V
_W
Drive signals (control signals) of three kinds
DRV1
DRV2
DRV3
D1
D2
D3
D4
DRV A
DRV A
DRV B Drive signals (control signals) of four kinds
DRV B Motor, phases A and B control signals
A
Motor M /A
B
/B
AB
BB
CLK, PLL PLL control signal
LCK, Lock, LD PLL lock signal
FR Forward/reverse rotation signal
EM, Lock, LCK, LD Motor lock abnormality
BLK Drive brake signal
P/S Power/stop
S/S
Operating load start/stop signal
SS
CW/CCW, F/R Rotational direction switching signal
ENB Effective signal
TEMP_ER Motor temperature abnormality detection signal
24V Power to drive the fan motor
CONT, DRIVE Drive signal
Fan FM
HL Speed control signal (2 speeds)
EM, Lock, LCK, FEM Detection signal
Others TH1.S, ANG Analog signal

C-3
Classification Load symbol Ex. of signal name Description
SG, S.GND, S_GND Signal ground
Ground
PG, P.GND Power ground
DCD Data carrier detection
SIN Serial input
SOUT Serial output
DTR Data terminal operation available
GND Signal ground (earth)
Serial com-
DSR, DSET Data set ready
munication
RTS Transmission request signal
CTS Consent transmission signal
RI Ring indicator
TXD Serial transmission data
RXD Serial reception data

D. Paper feed direction


When the direction in which paper is fed is in parallel with the longer side of paper, the
paper feed direction like this is referred to as the longitudinal feed.
And the paper feed direction that is perpendicular to the longitudinal feed is referred to as
the transverse feed.
When specifying the longitudinal feed, "S (abbreviation for Short Edge Feeding)" is added
to the paper size. For the transverse feed, no specific notation is employed.
However, when only the longitudinal feed is specified for one and the same paper size with
no specification made for the transverse feed, "S" is not added even when being fed longi-
tudinally.

<Example>

Paper size Feed direction Notation


Transverse feed A4
A4
Longitudinal feed A4S
A3 Longitudinal feed A3

C-4
SERVICE MANUAL Field Service

500 / 420
Main body

2006.02
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 correspond-
ing page.
A number within 1 represents the number of times the revision has been made.

NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
• When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
• When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.

2006/02 1.0 — Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision
Field Service Ver1.0 Feb.2006 CONTENTS

CONTENTS

bizhub 500 / 420


bizhub 500 / 420

OUTLINE
1. SYSTEM CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. PRODUCT SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

MAINTENANCE
3. PERIODIC CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1.1 Main body (bizhub 500) / DF / PC / LU / FS / MT / SD / RU . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1.2 Main body (bizhub 420) / DF / PC / LU / FS / MT / SD / RU . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Maintenance item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2.1 Main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2.2 DF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2.3 PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.4 LU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2.5 FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2.6 MT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2.7 SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2.8 RU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3 Replacement parts list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3.1 Periodically replacement parts list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4 Life value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4.1 Life value of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5 Maintenance procedure of the external section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5.1 Replacing the ozone filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5.2 Replacing the filter cover assy and the suction filter /A assy . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5.3 Replacing the paper exit suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.6 Maintenance procedure of the write section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.6.1 Replacing the write unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.7 Maintenance procedure of the photosensitive material section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.7.1 Replacing the drum unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.7.2 Replacing the drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.8 Maintenance procedure of the transfer/separation corona section. . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.8.1 Replacing the transfer/separation corona unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.9 Maintenance procedure of the developing section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.9.1 Replacing the developing unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.9.2 Replacing developer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.10 Maintenance procedure of the toner supply section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.10.1 Replacing the filter mounting plate assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.10.2 Replacing the suction cover /2 assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.11 Cleaning/toner recycle section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.11.1 Replacing the cleaning blade assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.12 Maintenance procedure of the paper feed section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.12.1 Replacing the feed roller/pick-up roller (tray 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.12.2 Replacing the separation roller assy (tray 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

i
CONTENTS Field Service Ver1.0 Feb.2006

3.12.3 Replacing the feed roller/pick-up roller (tray 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51


3.12.4 Replacing the separation roller assy (tray 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
bizhub 500 / 420

3.13 Maintenance procedure of the bypass tray section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60


3.13.1 Removing/reinstalling the bypass unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.13.2 Replacing the separation roller assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.13.3 Replacing the feed roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.14 Maintenance procedure of the registration section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.14.1 Cleaning the paper dust removing brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.14.2 Replacing the loop roller, the loop bearing, the registration roller /Rt,
and the registration bearings /Rt and /Lt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.15 Maintenance procedure of the fusing section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.15.1 Removing/reinstalling the fusing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.15.2 Replacing the fusing claw assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.15.3 Replacing the fusing web . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.15.4 Replacing the fusing driven roller assy /A and /B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.15.5 Removing/reinstalling the fusing heater lamps /1 (L2) and /2 (L3) . . . . . . . . . . . . . . . . . . . . . . . 84
3.15.6 Replacing the fusing roller, the fusing pressure roller, the heat insulating sleeve /A,
the fusing bearings /Up and /Lw and the fusing input gear assy . . . . . . . . . . . . . . . . . . . . . . . . 86
3.15.7 Replacing the fusing sensor assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.15.8 Replacing the fuse holder assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4. SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.1 Service material list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.2 Jig list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.3 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5. FIRMWARE VERSION UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.1 ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.1.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.1.2 Firmware data flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.1.3 Settings on the main body side while in ISW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.2 ISWTrns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.2.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.2.2 Installation of the ISWTrns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.2.3 Usage of the ISWTrns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.2.4 Error list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6. OTHERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.1 Items not allowed to be disassembled and adjusted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.1.1 Scanner section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.1.2 Write section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.1.3 Developing unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
6.1.4 Drum unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.2 List of parts to be disassembled and reassembled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.3 Disassembling/assembling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.3.1 Removing/reinstalling the rear cover /1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.3.2 Removing/reinstalling the rear cover /2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.3.3 Removing/reinstalling the rear cover /3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6.3.4 Removing/reinstalling the right cover /Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
6.3.5 Removing/reinstalling the right cover /Lw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
6.3.6 Removing/reinstalling the left cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
6.3.7 Removing/reinstalling the front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.3.8 Removing/reinstalling the original glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.3.9 Removing/reinstalling the upper covers /Fr and /Lt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

ii
Field Service Ver1.0 Feb.2006 CONTENTS

6.3.10 Removing/reinstalling the upper cover /Rr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127


6.3.11 Removing/reinstalling the front cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

bizhub 500 / 420


6.3.12 Removing/reinstalling the operation panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
6.3.13 Removing/reinstalling the CCD unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
6.3.14 Replacing the exposure lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.3.15 Removing/reinstalling the exposure unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
6.3.16 Stretching the scanner wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
6.3.17 Removing/reinstalling the toner supply unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.3.18 Removing/reinstalling the trays 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6.4 Option counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
6.4.1 Configuration of the key counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
6.4.2 Installation procedure of the key counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

ADJUSTMENT/SETTING
7. HOW TO USE THE ADJUSTMENT/SETTING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
8. UTILITY MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
8.1 List of utility mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
9. LIST OF ADJUSTMENT ITEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
10. SERVICE MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
10.1 List of service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
10.2 Setting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
10.2.1 Start and exit of the service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
10.3 Machine Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
10.3.1 Print Positioning: Leading Edge (Printer Area). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
10.3.2 Print Positioning: Side Edge (Printer Area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
10.3.3 Paper Feed Direction Adj. (Printer Area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
10.3.4 Printer Resist Loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
10.3.5 Bypass Tray Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
10.3.6 Image Position: Leading Edge (Scan Area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
10.3.7 Image Position: Side Edge (Scan Area). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
10.3.8 Cross Direction Adjustment (Scan Area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
10.3.9 Feed Direction Adjustment (Scan Area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
10.3.10 Lead Edge Erase Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
10.3.11 Non-Image Area Erase Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
10.4 Imaging Process Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.1 Charging Main Manual Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.2 Transfer Manual Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.3 Separation (AC) Manual Adj.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.4 Separation (DC) Manual Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.5 Grid Charging Manual Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.6 Bias Voltage Manual Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.7 TCR Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.8 Toner Auto Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.9 Toner Density Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
10.4.10 Laser Diameter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
10.4.11 LD1 Offset Adj. / LD2 Offset Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
10.4.12 LD1 Bias Adj. / LD2 Bias Adj.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
10.5 System 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
10.5.1 Marketing Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

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10.5.2 Tel/Fax Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174


10.5.3 Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
bizhub 500 / 420

10.5.4 Trouble Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175


10.5.5 No Sleep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
10.5.6 Foolscap Size Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
10.5.7 Original Size Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
10.5.8 Detected Size Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
10.5.9 Install Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
10.5.10 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
10.6 Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
10.6.1 Display of the Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
10.6.2 Present Parts Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
10.6.3 PM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
10.7 State Confirmation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
10.7.1 Sensor Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
10.7.2 Load Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
10.7.3 Memory/HDD Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
10.7.4 Memory Check (Memory/HDD Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
10.7.5 HDD R/W Check (Memory/HDD Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
10.7.6 HDD Format (Memory/HDD Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
10.7.7 Adj. Data Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
10.7.8 Adj. Data Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
10.8 ADF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
10.8.1 Paper Feed Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
10.8.2 Lead Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
10.8.3 Side Edge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
10.8.4 Resist Loop Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
10.8.5 Original Size Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
10.8.6 Density Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
10.8.7 Scan Position Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
10.8.8 Sensor Auto Adjust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
10.9 Finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
10.9.1 Center Staple Position (SD-502) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
10.9.2 Half-Fold Position (SD-502) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
10.9.3 Punch Horizontal Position (PU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
10.9.4 Punch Resist Loop (PU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
10.10 Firmware Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
10.11 CS Remote Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
10.11.1 Outlines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
10.11.2 Setting Up the CS Remote Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
10.11.3 Software SW setting for CS Remote Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
10.11.4 Setup confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
10.11.5 Calling the Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
10.11.6 Calling the Center from the Administrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
10.11.7 Checking the transmission log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
10.11.8 Detail on settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
10.11.9 List of the CS Remote Care error code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
10.11.10 Troubleshooting for CS Remote Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
10.12 System 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
10.12.1 Data Capture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

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10.12.2 Paper Size Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238


10.12.3 DipSW Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

bizhub 500 / 420


10.12.4 ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
10.12.5 Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
10.12.6 Trouble Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
10.13 List Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
10.13.1 List output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
10.14 Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
10.14.1 Test pattern list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
10.14.2 Test pattern output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
10.14.3 Running Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
10.15 Fax setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
10.16 Enhanced Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
10.16.1 List of the security setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
10.16.2 Start and termination of the security mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
10.16.3 CE Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
10.16.4 Administrator Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
10.16.5 Administrator Feature Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
10.16.6 CE Authentication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
10.17 Billing Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
10.17.1 List of the billing setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
10.17.2 Start and termination of the billing setting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
10.17.3 Counter Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
10.17.4 Management Function Choice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
11. MECHANICAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
11.1 Mis-centering adjustment of the trays 1 and 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
11.2 Mis-centering adjustment of the bypass tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

TROUBLESHOOTING
12. JAM CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
12.1 Jam code list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
13. MALFUNCTION CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
13.1 Malfunction code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

APPENDIX
14. PARTS LAYOUT DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
14.1 Main body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
14.1.1 Switch/sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
14.1.2 Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
14.1.3 Boards and others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
14.2 DF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
14.3 PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
14.3.1 PC-202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
14.3.2 PC-402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
14.4 LU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
14.5 FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
14.5.1 FS-510. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
14.5.2 FS-511. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
14.6 PU-501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
14.7 SD-502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

v
CONTENTS Field Service Ver1.0 Feb.2006

14.8 MT-501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342


14.9 RU-502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
bizhub 500 / 420

14.10 JS-502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344


15. CONNECTOR LAYOUT DRAWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
15.1 Main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
15.1.1 Connector in the board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
15.2 DF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
15.2.1 Connector in the board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
15.3 PC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
15.3.1 Connector in the board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
15.4 LU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
15.4.1 Connector in the board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
15.5 FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
15.5.1 Connector in the board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
15.6 SD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
15.6.1 Connector in the board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
15.7 MT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
15.7.1 Connector in the board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
16. TIMING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
16.1 Main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
16.2 DF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
16.3 LU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
16.4 FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
16.4.1 FS-510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
16.4.2 FS-511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
17. OVERALL WIRING DIAGRAM
17.1 Main body 1/4
17.2 Main body 2/4
17.3 Main body 3/4
17.4 Main body 4/4
17.5 DF
17.6 PC
17.6.1 PC-202
17.6.2 PC-402
17.7 LU
17.8 FS
17.8.1 FS-510/PU-501
17.8.2 FS-511
17.9 SD
17.10 MT

vi
Field Service Ver1.0 Feb.2006 1. SYSTEM CONFIGURATION

„ OUTLINE

bizhub 500 / 420


1. SYSTEM CONFIGURATION
A. System configuration

[23] [27] [28]


[24] [25] [26]

[5]
[1] [6]
[2] [7]
[3] [8]
[4] [9]
[22]
[21]

[20]
[19] [11]
[14]
[17] [15]
[18]
[10] [12]

[16]

[10] [13]

50gat1e001na

[1] Reverse automatic document feeder [15] Dehumidifier heater *2


(DF-607) (standard equipment) [16] Relay unit (RU-502)
[2] Main body [17] Finisher (FS-511)
[3] Image controller (IC-204) [18] Swedish punch kit G *3
[4] Hard disk (HD-505) [19] Job separator (JS-502)
[5] Stamp unit (SP-501) [20] Output tray kit (OT-501)
[6] Spare TX marker stamp 2 [21] Output tray (OT-601)
[7] Key counter kit 4 *1 [22] Finisher (FS-510)
[8] Key counter *1 [23] Mail bin kit (MT-501)
[9] Key counter mount kit *1 [24] Saddle stitcher (SD-502)
[10] Dehumidifier heater 1C [25] Folding unit (included in SD-502)
[11] Paper feed cabinet (PC-402) [26] Punch unit (PU-501)
[12] Paper feed cabinet (PC-202) [27] FAX kit (FK-502)
[13] Desk (DK-501) [28] Mount kit (MK-708)
[14] Large capacity unit (LU-201)

*1 See "6.4 Option counter" in Field Service bizhub 500 / 420 main body for details.
*2 Dehumidifier heater is set up as service part.
*3 Swedish punch kit G is for Europe only.

1
1. SYSTEM CONFIGURATION Field Service Ver1.0 Feb.2006

B. Configuration for optional device connection


bizhub 500 / 420

Note
• Any combination other than those listed below is not available.

No. Combinations for paper feeding Combinations for finishing Remarks


1 DK-501/PC-202/PC-402 *1 OT-501
2 DK-501/PC-202/PC-402 *1 OT-501 JS-502
3 DK-501/PC-202/PC-402 *1 RU-502 + FS-511
4 DK-501/PC-202/PC-402 *1 FS-510 *2*3
5 DK-501/PC-202/PC-402 *1 FS-510 *2*3 SD-502
6 DK-501/PC-202/PC-402 *1 FS-510 *2*3 MT-501
7 PC-202/PC-402 *4 LU-201 OT-501
8 PC-202/PC-402 *4 LU-201 OT-501 JS-502
9 PC-202/PC-402 *4 LU-201 RU-502 + FS-511
10 PC-202/PC-402 *4 LU-201 FS-510 *2*3
11 PC-202/PC-402 *4 LU-201 FS-510 *2*3 SD-502
12 PC-202/PC-402 *4 LU-201 FS-510 *2*3 MT-501

*1 Either one of DK-501, PC-202 and PC-402 can be selected.


*2 FS-510 can be installed optionally with OT-601.
*3 FS-510 can be installed optionally with PU-501.
*4 Either one of PC-202 and PC-402 can be selected.

2
Field Service Ver1.0 Feb.2006 2. PRODUCT SPECIFICATIONS

2. PRODUCT SPECIFICATIONS

bizhub 500 / 420


A. Type

Type Desktop type


Copying method Indirect electrostatic method
Original stand Fixed
Original alignment Left rear standard
Photo conductor OPC
Sensitizing method Laser writing
Paper feed trays Two trays 500 sheet x 2, 80g/m2
Bypass feed 150 sheet x 1, 80g/m2
PC-402 *1 2,500 sheet x 1, 80g/m2
PC-202 *1 500 sheet x 1, 80g/m2
LU-201 *1 2,000 sheet x 1, 80g/m2

*1 PC-402, PC-404, and LU-201 are optional.

3
2. PRODUCT SPECIFICATIONS Field Service Ver1.0 Feb.2006

B. Functions
bizhub 500 / 420

Original Sheet, book, solid object


Max. original size A3 or 11 x 17
Copy size Trays 1, 2 Inch: 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S,
A3, A4, A4S, A5S, Foolscap
Metric: A3, B4, A4, A4S, B5, A5S, 11 x 17, 81/2 x 11,
81/2 x 11S, Foolscap, 8K, 16K
Bypass feed Inch: 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S,
A4
Metric: A3, B4, A4, A4S, B5, B5S, A5S, B6S, 81/2 x 11,
81/2 x 11S, Foolscap, 8K, 16K, 16KS
ADU Inch: 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S,
A3, A4, A4S, A5S, Foolscap
Metric: A3, B4, A4, A4S, B5, B5S, A5S, 11 x 17, 81/2 x 11,
81/2 x 11S, Foolscap
Magnification Fixed magnifica- Inch: x 1.000, x 1.214, x 1.294, x 1.545, x 2.000
tion x 0.500, x 0.647, x 0.772, x 0.785
Metric: x 1.000, x 1.154, x 1.224, x 1.414, x 2.000
x 0.500, x 0.707, x 0.816, x 0.866
Special magnifi- x 0.930
cation setting
Preset zoom set- 3 types
ting
Zoom magnifica- x 0.25 to x 4.00 (at the step of 0.1%)
tion
Vertical magnifi- x 0.25 to x 4.00 (at the step of 0.1%)
cation
Horizontal magni- x 0.25 to x 4.00 (at the step of 0.1%)
fication
Warm-up time 60 seconds or less (bizhub 500)
30 seconds or less (bizhub 420)
First copy out time 3.2 seconds or less (bizhub 500)
3.6 seconds or less (bizhub 420)
Continuous copy speed 50 copies /min. (A4 / 81/2 x 11) (bizhub 500)
42 copies /min. (A4 / 81/2 x 11) (bizhub 420)
Continuous copy count Up to 999 sheets
Original density selection Auto density selection, Manual (9 steps), Manual underprint density (9 steps)
Resolution Scan 600 x 600 dpi
Write Inch: 1,200 (equivalent) x 600 dpi
Metric: 2,400 (equivalent) x 600 dpi
Memory Standard 192 MB Breakdown: 64 MB (on board) + 128 MB (DIMM)
Maximum 320 MB Breakdown: 64 MB (on board) + 256 MB (DIMM) *1
Interface section RJ45 Ethernet, Serial port (RS232-C), Serial port (USB TypeB),
Parallel port (IEEE1284), RJ-11 *2
*1 256 MB (DIMM) is available from distributors.
Specification: 144 pin SO-DIMM, PC100/PC133 MHz Compliant
*2 1 port when MK-708 and FK-502 are optionally installed.

4
Field Service Ver1.0 Feb.2006 2. PRODUCT SPECIFICATIONS

C. Type of paper

bizhub 500 / 420


Plain paper *1 All trays High quality paper of 60 to 90 g/m2
Special paper *2 Bypass feed only OHP film, label paper *3, blueprint master paper *3
High quality paper of 50 to 59 g/m2 (thin paper)
All trays High quality paper of 91 to 105 g/m2 (thick paper)
Bypass feed only High quality paper of 106 to 210 g/m2 (thick paper)

*1 Standard specified paper


Plain paper: Inch: Hammermill Tidal MP (20 lbs)
Metric: Konica Minolta Original (80 g/m2), Konica Minolta Profi (80 g/m2)
Recycle paper: Inch: Weyerhaeuser Recycled Laser Copy (20 lbs)
Metric: Nautilus (80 g/m2)
*2 Special paper/recommended paper
Thick paper: Inch: Weyerhaeuser Cougar Cover 65 lbs
Metric: Xerox colortech 200 g/m2
Thin paper: Inch: SOISE BOND 16 lbs
Metric: NEU 60 g/m2
Label paper: Inch: AVERY 5160, 5352
Metric: AVERY DSP 24
OHP film: Inch: 3M CG3700
Metric: Folex overhead X-500, 3M CG3700
Envelope: Inch: Preservation Wove (24 lbs) #6-3/4, #9, #10 (4-1/8 x 9-1/2)
Metric: Briefhullen 211210 (100 g/m2) #C6
Schneider Soehne Distinction 100 (100 g/m2) #lang
Schneider Soehne (Briefumschlage) (100 g/m2) #C5
*3 Label paper is loaded and fed one sheet at a time.

D. Maintenance

Maintenance Every 250,000 prints


Machine service life 2,250,000 prints or 5 years (whichever earlier) (bizhub 500)
1,800,000 prints or 5 years (whichever earlier) (bizhub 420)

E. Machine data

Power source Inch: AC120V 12A, 60Hz


Metric: AC220-240V 10A, 50Hz
Maximum power consump- 1,560 W or less (full option)
tion
Dimensions Main body 677 (W) x 708 (D) x 1,150 (H) mm *1
+ DF-607
+ PC or DK
Weight Approx. 91.2 kg

*1 Overturning prevention board is not included.

5
2. PRODUCT SPECIFICATIONS Field Service Ver1.0 Feb.2006

F. Operating environment
bizhub 500 / 420

Temperature 10 to 30 °C
Humidity 10 to 80%RH (with no condensation)

Note
• The information herein may be subject to change for improvement without notice.

6
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

„ MAINTENANCE

bizhub 500 / 420


3. PERIODIC CHECK
3.1 Schedule
3.1.1 Main body (bizhub 500) / DF / PC / LU / FS / MT / SD / RU

Guarantee period: 5 years or 2,250,000 prints

Service item x 10,000 prints No. of


0 25 50 75 100 125 150 175 200 executions
Maintenance 1 z z z z z z z z 8 times
Main body (bizhub 500)

Every 250,000 prints


Maintenance 2 z z z z 4 times
Every 500,000 prints
Maintenance 3 z z 2 times
Every 750,000 prints
Maintenance 4 z 1 times
Every 1,250,000 prints
Maintenance 1 z z z z z z z z 8 times
DF

Every 250,000 prints


Maintenance 2 z z z z 4 times
Every 500,000 prints
Maintenance 1 z z z z z z z z 8 times
PC

Every 250,000 prints


Maintenance 2 z z 2 times
Every 750,000 prints
Maintenance 1 z z z z z z z z 8 times
LU

Every 250,000 prints


Maintenance 2 z z z z 4 times
Every 500,000 prints
Maintenance 1 z z z z z z z z 8 times
FS

Every 250,000 prints


Maintenance 1 z z z z z z z z 8 times
MT

Every 250,000 prints


Maintenance 1 z z z z z z z z 8 times
SD

Every 250,000 prints


Maintenance 1 z z z z z z z z 8 times
RU

Every 250,000 prints

7
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

3.1.2 Main body (bizhub 420) / DF / PC / LU / FS / MT / SD / RU


bizhub 500 / 420

Guarantee period: 5 years or 1,800,000 prints

Service item x 10,000 prints No. of


0 25 50 75 100 125 150 175 executions
Maintenance 1 z z z z z z z 7 times
Main body (bizhub 420)

Every 250,000 prints


Maintenance 2 z z z 3 times
Every 500,000 prints
Maintenance 3 z z 2 times
Every 750,000 prints
Maintenance 4 z 1 times
Every 1,250,000 prints
Maintenance 1 z z z z z z z 7 times
DF

Every 250,000 prints


Maintenance 2 z z z 3 times
Every 500,000 prints
Maintenance 1 z z z z z z z 7 times
PC

Every 250,000 prints


Maintenance 2 z z 2 times
Every 750,000 prints
Maintenance 1 z z z z z z z 7 times
LU

Every 250,000 prints


Maintenance 2 z z z 3 times
Every 500,000 prints
Maintenance 1 z z z z z z z 7 times
FS

Every 250,000prints
Maintenance 1 z z z z z z z 7 times
MT

Every 250,000 prints


Maintenance 1 z z z z z z z 7 times
SD

Every 250,000 prints


Maintenance 1 z z z z z z z 7 times
RU

Every 250,000 prints

8
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

3.2 Maintenance item

bizhub 500 / 420


Note
• For the replacement procedure of periodically replaced parts, see "3.5 Maintenance procedure of
the external section" to "3.15 Maintenance procedure of the fusing section".
• The alcohol described in this section represents the isopropyl alchol.

3.2.1 Main body


A. Maintenance 1 (Every 250,000 prints)

No. Unit Description Quantity Implementation classification Materials


classification Cleaning Check Lubrication Replacement Tools used
1 Preparations Image check z
Exterior z z Alcohol/cleaning pad
2 Photo con- Drum 1 z
ductor sec- DR510
tion • Drum count reset
(Service mode)
Cleaning blade assy 1 z Setting powder
50GA-209
Charge unit z z Cotton swab (wire),
Alcohol/cleaning pad
3 Transfer/sep- Transfer/separation z z Cotton swab (wire)
aration sec- unit
tion
4 Developing Developer 1 z
section DV511
• TCR adjustment
(Service mode)
5 Main body Filter mounting plate 1 z
assy
50GA-336
Ozon filter 1 z
50GA1031
Suction filter /A assy 1 z
40LA-318
Filter cover assy 1 z
50GA-314
Suction cover /2 assy 2 z
50GA-311
6 Scanner Original glass (includ- z Alcohol/cleaning pad
section ing slit glass)
Mirror 1 to mirror 3 z Alcohol/cleaning pad
7 Paper feed Pick-up roller, feed z Alcohol/cleaning pad
section roller (Tray 1, 2)
Separation roller assy z Alcohol/cleaning pad
(Tray 1, 2)

9
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

No. Unit Description Quantity Implementation classification Materials


bizhub 500 / 420

classification Cleaning Check Lubrication Replacement Tools used


8 Bypass tray Feed roller z Alcohol/cleaning pad
section
Separation roller z Alcohol/cleaning pad
9 Fusing Fusing roller 1 z
section 50GE5303
(bizhub 500)
50GA5303
(bizhub 420)
Fusing pressure roller 1 z
50GA5304
Fusing web 1 z
50GA-540
• Fusing counter
reset
Heat insulating sleeve /A 2 z
26NA5372
Fusing bearing /Up 2 z
26NA5371
Fusing bearing /Lw 2 z
50GA5359
Fusing driven roller /A 2 z
assy
40400326
Fusing driven roller /B 2 z
assy
40400328
Fusing sensor z Alcohol/cleaning pad
Fusing claw z Alcohol/cleaning pad
Thermostat z Alcohol/cleaning pad
10 Paper reverse Paper exit suction filter 1 z
section 50GA4406
11 Registration Paper dust removing z Blower brush
section brush
Registration roller /Rt z Alcohol/cleaning pad
Registration roller /Lt z Alcohol/cleaning pad
Loop roller z Alcohol/cleaning pad
Reflective sensor z Blower brush
12 Final check Paper through, Image z
check
PM count reset z
Exterior cleaning z

10
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

B. Maintenance 2 (Every 500,000 prints)

bizhub 500 / 420


No. Unit Description Quantity Implementation classification Materials
classification Cleaning Check Lubrication Replacement Tools used
1 Transfer/sep- Transfer/separation 1 z
aration sec- unit
tion 50GA-260
2 Fusing Fusing sensor assy 1 z
section 50GA-544
Fuse holder assy 1 z
26NA-535
Fusing claw assy 1 z
50GA-533
Fusing input gear assy 1 z z
50GA-546

C. Maintenance 3 (Every 750,000 prints)

No. Unit Description Quantity Implementation classification Materials


classification Cleaning Check Lubrication Replacement Tools used
1 Photo con- Drum unit 1 z
ductor sec- 50GA-200
tion
2 Developing Developing unit 1 z
section 50GA-300
3 Paper feed Pick-up roller 2 z Actual: 300,000 feeds
section 40303005
Feed roller 2 z Actual: 300,000 feeds
40303005
Separation roller assy 2 z Actual: 300,000 feeds
(Tray 1, 2)
40300151
4 Bypass tray Paper feed roller 1 z Actual: 200,000 feeds
section 41313001
Separation roller assy 1 z Actual: 200,000 feeds
40340151

11
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

D. Maintenance 4 (Every 1,250,000 prints)


bizhub 500 / 420

No. Unit Description Quantity Implementation classification Materials


classification Cleaning Check Lubrication Replacement Tools used
1 Registration Registration bearing /Rt 2 z
section 26NA4536
Registration bearing /Lt 2 z
26NA4537
Loop roller 1 z
50GA3865
Registration roller /Rt 1 z
50GA3848
Loop bearing 2 z
26NA4082
2 Write section Write unit 1 z
50GA-650

3.2.2 DF
A. Maintenance 1 (Every 250,000 prints)

No. Unit Description Quantity Implementation classification Materials


classification Cleaning Check Lubrication Replacement Tools used
1 Preparations Paper through, mage z
condition
Appearance z
2 Paper feed Pick-up roller z Alcohol/cleaning pad
section Actual: 50,000 faces
Feed roller z Alcohol/cleaning pad
Actual: 50,000 faces
Separation roller z Alcohol/cleaning pad
Actual: 50,000 faces
Other rollers z Alcohol/cleaning pad
Actual: 50,000 faces
Each sensor z Blower brush
Actual: 30,000 faces
3 Paper con- Scanning guide z Alcohol/cleaning pad
veyance sec- Actual: 50,000 faces
tion
4 Final check Paper through, image z
check
Exterior cleaning z

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Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

B. Maintenance 2 (Every 500,000 prints)

bizhub 500 / 420


No. Unit Description Quantity Implementation classification Materials
classification Cleaning Check Lubrication Replacement Tools used
1 Paper feed Pick-up roller 1 z Actual: 200,000 faces
section 43445003
Feed roller 1 z Actual: 200,000 faces
45823014
Separation roller 1 z Actual: 200,000 faces
45823047

3.2.3 PC
A. Maintenance 1 (Every 250,000 prints)

No. Unit Description Quantity Implementation classification Materials


classification Cleaning Check Lubrication Replacement Tools used
1 Preparations Paper through check z
2 Paper feed Pick-up roller z
section Feed roller z
Separation roller z
3 Final check Paper through check z
Exterior cleaning z

B. Maintenance 2 (Every 750,000 prints)

No. Unit Description Quantity Implementation classification Materials


classification Cleaning Check Lubrication Replacement Tools used
1 Paper feed Pick-up roller 1 z Actual: 300,000 feeds
section 40303005
Feed roller 1 z Actual: 300,000 feeds
40303005
Separation roller assy 1 z Actual: 300,000 feeds
40300151

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3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

3.2.4 LU
bizhub 500 / 420

A. Maintenance 1 (Every 250,000 prints)

No. Unit Description Quantity Implementation classification Materials


classification Cleaning Check Lubrication Replacement Tools used
1 Preparations Paper through check z
2 Paper feed Pick-up rubber z Alcohol/cleaning pad
section
Feed rubber z Alcohol/cleaning pad
Separation rubber z Alcohol/cleaning pad
3 Final check Paper through check z
Exterior cleaning z

B. Maintenance 2 (Every 500,000 prints)

No. Unit Description Quantity Implementation classification Materials


classification Cleaning Check Lubrication Replacement Tools used
1 Paper feed Pick-up rubber 1 z Actual: 200,000 feeds
section 40LA1009
Feed rubber 1 z Actual: 200,000 feeds
26NA4011
Separation rubber 1 z Actual: 200,000 feeds
26NA4012

3.2.5 FS
A. Maintenance 1 (Every 250,000 prints)

No. Unit Description Quantity Implementation classification Materials


classification Cleaning Check Lubrication Replacement Tools used
1 Preparations Paper through check z
2 Conveyance Each roller z Alcohol/cleaning pad
section, sta-
ple section
3 Staple Paddle z Alcohol/cleaning pad
section
4 Final check Paper through check z
Exterior cleaning z

14
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

3.2.6 MT
A. Maintenance 1 (Every 250,000 prints)

bizhub 500 / 420


No. Unit Description Quantity Implementation classification Materials
classification Cleaning Check Lubrication Replacement Tools used
1 Preparations Paper through check z
2 Conveyance Each roller z Alcohol/cleaning pad
section
3 Final check Paper through check z
Exterior cleaning z

3.2.7 SD
A. Maintenance 1 (Every 250,000 prints)

No. Unit Description Quantity Implementation classification Materials


classification Cleaning Check Lubrication Replacement Tools used
1 Preparations Paper through check z
2 Conveyance Each roller z Alcohol/cleaning pad
section
3 Final check Paper through check z
Exterior cleaning z

3.2.8 RU
A. Maintenance 1 (Every 250,000 prints)

No. Unit Description Quantity Implementation classification Materials


classification Cleaning Check Lubrication Replacement Tools used
1 Preparations Paper through check z
2 Conveyance Each roller z Alcohol/cleaning pad
section
3 Final check Paper through check z
Exterior cleaning z

15
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

3.3 Replacement parts list


bizhub 500 / 420

3.3.1 Periodically replacement parts list

Note
• For the replacement procedure of periodically replaced parts, see "3.5 Maintenance procedure of
the external section" to "3.15 Maintenance procedure of the fusing section".
• The parts count No. given in the table below represents the number of the fixed parts number in
the Service mode.

A. Main body

No. Classification Part name Part number Qt. Actual replace- Parts count Page
ment cycle No. referred to
1 Photo con- Drum DR510 1 250,000 P.28
2 ductor section Cleaning blade assy 50GA-209 1 250,000 P.42
3 Drum unit (without drum) 50GA-200 1 750,000 P.27
4 Transfer/ Transfer/separation unit 50GA-260 1 500,000 P.34
separation
section
5 Developing Developer DV511 1 250,000 P.36
6 section Developing unit 50GA-300 1 750,000 P.35
7 Main body Filter mounting plate assy 50GA-336 1 250,000 P.39
8 Ozon filter 50GA1031 1 250,000 P.19
9 Suction filter /A assy 40LA-318 1 250,000 P.20
10 Filter cover assy 50GA-314 2 250,000 P.20
11 Suction cover /2 assy 50GA-311 4 250,000 P.40
12 Paper feed Pick-up roller 40303005 2 300,000 P.44
section P.51
13 Feed roller 40303005 2 300,000 P.44
P.51
14 Separation roller assy 40300151 2 300,000 P.49
(Tray 1, 2) P.58
15 Bypass tray Paper feed roller 41313001 1 200,000 P.66
16 section Separation roller assy 40340151 1 200,000 P.63
17 Registration Loop roller 50GA3865 1 1,250,000 P.69
18 section Registration roller /Rt 50GA3848 1 1,250,000 P.69
19 Registration bearing /Rt 26NA4536 2 1,250,000 P.69
20 Registration bearing /Lt 26NA4537 2 1,250,000 P.69
21 Loop bearing 26NA4082 1 1,250,000 P.69
22 Fusing Fusing roller 50GE5303 1 250,000 P.86
section (bizhub 500)
50GA5303
(bizhub 420)

16
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

No. Classification Part name Part number Qt. Actual replace- Parts count Page

bizhub 500 / 420


ment cycle No. referred to
23 Fusing Fusing pressure roller 50GA5304 1 250,000 P.86
section (bizhub 500)
50GA5304
(bizhub 420)
24 Fusing web 50GA-540 1 250,000 P.80
(bizhub 500)
50GA-540
(bizhub 420)
25 Heat insulating sleeve /A 26NA5372 2 250,000 P.86
26 Fusing bearing /Up 26NA5371 2 250,000 P.86
27 Fusing bearing /Lw 50GA5359 2 250,000 P.86
28 Fusing sensor assy 50GA-544 1 500,000 P.89
29 Fuse holder assy 26NA-535 1 500,000 P.91
30 Fusing claw assy 50GA-533 1 500,000 P.78
31 Fusing driven roller /A assy 40400326 2 250,000 P.82
32 Fusing driven roller /B assy 40400328 2 250,000 P.82
33 Fusing input gear assy 50GA-546 1 500,000 P.86
34 Paper reverse Paper exit suction filter 50GA4406 1 250,000 P.22
section
35 Write section Write unit 50GA-650 1 1,250,000 P.23

B. Option

No. Classification Part name Part number Qt. Actual replace- Parts count Page
ment cycle No. referred to
1 DF Pick-up roller 43445003 1 200,000 *1
2 Feed roller 45823014 1 200,000 *1
3 Separation roller 45823047 1 200,000 *2
4 PC Pick-up roller 40303005 1 300,000 *3
5 Feed roller 40303005 1 300,000 *4
6 Separation roller assy 40300151 1 300,000 *5
7 LU Pick-up rubber 40LA4009 1 200,000 *6
8 Feed rubber 26NA4011 1 200,000 *6
9 Separation rubber 26NA4012 1 200,000 *7

*1 (See P.5 in "Field Service DF-607")


*2 (See P.6 in "Field Service DF-607")
*3 (See P.7 in "Field Service PC-202 (bizhub 500/420)" / See P.7 in "Field Service PC-402 (bizhub 500/420)")
*4 (See P.4 in "Field Service PC-202 (bizhub 500/420)" / See P.4 in "Field Service PC-402 (bizhub 500/420)")
*5 (See P.3 in "Field Service PC-202 (bizhub 500/420)" / See P.3 in "Field Service PC-402 (bizhub 500/420)")
*6 (See P.3 in "Field Service LU-201")
*7 (See P.7 in "Field Service LU-201")

17
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

3.4 Life value


bizhub 500 / 420

3.4.1 Life value of materials

Item Number of prints Remarks


Drum 250,000 The life value is defined only by the number of prints.
Developer 250,000

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Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

3.5 Maintenance procedure of the external section

bizhub 500 / 420


3.5.1 Replacing the ozone filter
A. Periodically replaced part/cycle
• Ozone filter: Every 250,000 prints

B. Procedure
1. Remove the right cover /Up.
(See P.122)
2. Remove the ozone filter [1].

Note
• When removing the ozone filter, be sure to
pull it out by holding it at the section indicated
by [2].

3. Reinstall the above parts following the removal


steps in reverse.

[1]

[2]

50gaf2c014na

19
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

3.5.2 Replacing the filter cover assy and the suction filter /A assy
bizhub 500 / 420

A. Periodically replaced parts/cycle


• Filter cover assy: Every 250,000 prints
• Suction filter /A assy: Every 250,000 prints

B. Procedure
1. Remove the screw [1] and then remove the filter
cover assy [2].

[1]

[2]

50gaf2c015na

2. Remove the suction filter /A assy [1].

[1] 50gaf2c016na

20
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

Note

bizhub 500 / 420


• Be sure to install the suction filter /A assy
with the white filter face [1] inside.

3. Reinstall the above parts following the removal


steps in reverse.

[1] 50gaf2c017na

21
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

3.5.3 Replacing the paper exit suction filter


bizhub 500 / 420

A. Periodically replaced part/cycle


• Paper exit suction filter: Every 250,000 prints

B. Procedure
1. Remove the screw [1] and then remove the paper
exit suction filter cover [2].

[1]

[2]

50gaf2c018na

2. Remove the paper exit suction filter [1].


[1] 3. Reinstall the above parts following the removal
steps in reverse.

50gaf2c019na

22
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

3.6 Maintenance procedure of the write section

bizhub 500 / 420


3.6.1 Replacing the write unit

Warning
• Be sure not to turn on the write unit with it shifted from its regular installation position.
• Be absolutely sure not to remove the write unit cover. Otherwise, laser beams get in your eyes and
you may suffer loss of sight.
• Be absolutely sure not to remove the write unit for about 2 minutes after you turn off the main
power switch (SW1) or the power switch (SW2).

A. Periodically replaced part/cycle


• Write unite: Every 1,250,000 prints

B. Procedure
1. Remove the developing unit from the main body.
[1]
(See P.35)
2. Remove the drum unit from the main body.
(See P.27)
3. Pull out the dust-proof glass cleaning rod [1].
4. Remove the cleaning knob [4] from the dust-proof
glass cleaning rod [1] by rotating it in the arrow-
marked direction [3] with the section indicated by
[2] as a fulcrum.
5. Replace the dust-proof glass cleaning rod [1] to its
original position.

Note
[2] • Be sure to push in fully the dust-proof glass
cleaning rod [1] so that it does not come in
contact with the main body frame when
[4] removing the unit.

[3]

50gaf2c020na

23
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

6. Remove the 6 screws [1] and then remove the


[1]
bizhub 500 / 420

write cover [2].

Note
• When installing the write cover, be sure to set
the projections [3] at 3 places into each of the
holes [4] of the frame.

[1] [4] [3] [2] 50gaf2c021na

7. Remove the 2 screws [1].


[1] [2] [3]
8. Remove the connector [2] and then remove the
drum cooling fan assy [3].

50gaf2c022na

9. Remove the screws [1], 1 each, and then remove


[1]
the 2 write section mounting member assy's [2].

Note
• When installing the write section mounting
member assy [2], be sure to install it so that
the spring [3] gets straight.

[2] [3] 50gaf2c023na

24
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

10. Remove the 3 connectors [1].


11. Remove the 3 screws [2] and then remove the

bizhub 500 / 420


write unit [3].

Note
• When removing the write unit, be sure to
avoid touching the dust-proof glass.

[3] [2]

[1]
50gaf2c024na

Note
• When installing the write unit [1], be sure to
take note of the position into which the dust-
proof sheet /A [2] is inserted.
• When checking the insertion of the sheet, be
sure to check it with the drum unit removed.

[1] [2]

50gaf2c025na

25
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

Note
[1]
bizhub 500 / 420

• When installing the write unit, be sure to set


the projections [1] at 2 places provided on the
bottom to the 2 holes [2] of the main body
frame for positioning.

12. Reinstall the above parts following the removal


steps in reverse.

[2] 50gaf2c026na

26
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

3.7 Maintenance procedure of the photosensitive material section

bizhub 500 / 420


3.7.1 Replacing the drum unit

Note
• When removing the drum unit, be sure to hold it at both ends.
• When removing the drum unit, be sure to avoid holding it at the separation claw unit section.
• Be sure to avoid touching the drum with bare hands, and also be careful not to damage it.
• Be sure to avoid turning the drum in any direction other than in the specified direction.
• When storing the drum unit, be sure to store it in the dark place with a drum cover attached.

A. Periodically replaced part/cycle


• Drum unit: Every 750,000 prints

B. Procedure
1. Open ADU.
(See P.122)
2. Pull the lock release lever [1] to open the convey-
ance unit [2].

[1] [2] 50gaf2c027na

3. Remove the developing unit from the main body.


[2] [1]
(See P.35)
4. Loosen the screw [1] and remove the drum unit
[2].
5. Reinstall the above parts following the removal
steps in reverse.

50gaf2c028na

27
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

3.7.2 Replacing the drum


bizhub 500 / 420

Note
• Be sure to avoid touching the drum and the cleaning blade with bare hands, and also be careful
not to damage them.
• When storing the drum, be sure to store it in the dark place with a drum cover attached.
• When installing the drum and the cleaning blade, be sure to apply setting powder to the circumfer-
ence of the drum and the cleaning blade, regardless of these parts being new or used ones.
• When setting powder is applied to the drum, be sure to conduct the following operations before
installing the drum unit to the main body.
1) With the charging corona unit removed, rotate the drum one full turn (to prevent setting powder
from splashing onto the charging corona unit and the image from getting defective.)
2) When installing a new drum, be sure to reset the drum counter in the service mode. Failing to
reset it may result in image fogging and toner splashing. (See P.187)

28
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

A. Periodically replaced part/cycle


• Drum: Every 250,000 prints

bizhub 500 / 420


B. Procedure
1. Remove the drum unit from the main body.
(See P.27)
2. Remove the C-clip [1] and pull out the cleaning
[1]
rod [2].

Note
• When installing the cleaning rod, be sure to
take note of the direction of the C-clip.

3. Remove the spring [3].

[2]

[3]

50gaf2c029na

29
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

4. Remove the connector [1].


5. Open the lock lever [2] and remove the charging
bizhub 500 / 420

corona unit [3].

[1] [3]

[2]

50gaf2c030na

30
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

6. Remove the screw [1] and then remove the shaft


NG OK

bizhub 500 / 420


mounting plate [2].
7. Pull out the drum shaft [3] for removal.

Note
• When installing the drum shaft, be sure to
[2] [2]
insert the drum shaft until the shaft mounting
plate comes into contact firmly with it as
shown in the drawing.
[3] [3]
8. Remove the 2 screws [4] and then remove the
[1] bearing [5].

[2]

[3]

[4]

[5]

50gaf2c031na

31
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

9. Remove the seal blocks [1] and [2].


10. Hold the drum [3] at both ends and remove it.
bizhub 500 / 420

Note
[1] • When removing the drum, be careful not to
damage the photosensitive surface.
• When removing the drum, be careful not to hit
it against the metal frame section [4] of the
cleaning blade.

[3]

[4]

[2]

50gaf2c032na

32
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

Note
[1]

bizhub 500 / 420


• When installing the drum, using the attached
jig [2] with the drum unit cover [1] before
[2] installing the charging corona unit, rotate the
drum 1 full turn in the arrow-marked direction
[3]. And then check to see if setting powder is
not scraped off, and also if the toner collec-
tion sheet and the cleaning blade do not
turned up.

11. Reinstall the above parts following the removal


steps in reverse.

[2]

[3]

50gaf2c033na

33
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

3.8 Maintenance procedure of the transfer/separation corona section


bizhub 500 / 420

3.8.1 Replacing the transfer/separation corona unit


A. Periodically replaced part/cycle
• Transfer/separation corona unit: Every 500,000 prints

B. Procedure
1. Open ADU.
[3]
(See P.122)
2. Open the conveyance unit.
(See P.27)
3. Release the lock levers [1] and [2] and remove the
transfer/separation corona unit [3].
4. Reinstall the above parts following the removal
steps in reverse.

[1] [2] 50gaf2c034na

34
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

3.9 Maintenance procedure of the developing section

bizhub 500 / 420


3.9.1 Replacing the developing unit
A. Periodically replaced part/cycle
• Developing unit: Every 750,000 prints

B. Procedure
1. Open the front door [1].
2. Loosen the screw [2] and remove the developing
unit [3].
3. Reinstall the above parts following the removal
steps in reverse.

[3] [1]

[2]

50gaf2c035na

35
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

3.9.2 Replacing developer


bizhub 500 / 420

A. Periodically replaced part/cycle


• Developer: Every 250,000 prints

B. Procedure
1. Remove the developing unit from the main body.
[2]
(See P.35)
2. Release the locks [1] at 2 places and remove the
developing unit cover /1 [2].

[1]

50gaf2c036na

36
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

Note

bizhub 500 / 420


• When installing the developing unit cover /1
[1], be sure to install it so that the splash pre-
vention sheet [2] does not get caught into the
developing roller [3].

[1] [2] [3]

[3] [2]

50gaf2c037na

37
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

3. Tilt the developing unit [1], and rotate the develop-


[1] [4]
bizhub 500 / 420

ing gear [2] in the arrow-marked direction [3] to


discharge thoroughly developer in the developing
unit [1].
4. Clean developer and toner that adhere to the
developing roller [4].

Note
• Be absolutely sure not to turn the developing
gear [2] in any direction other than in the
arrow-marked direction [3]. (Never rotate it
clockwise as seen from the direction indi-
cated by [5].)
• If there remains any used developer on the
developing roller, this may cause image fog-
ging.
[5] [3] [2] 50gaf2c041na

5. Put in new developer [1] evenly from above the


[1] agitator screw [2].
[3]
6. Rotate the developing gear [4] in the arrow-
marked direction [5] so that developer [1] gets
deep into the developing unit [3].
7. Repeat steps 8 and 9 to put in the developer [1]
[2] thoroughly.
8. Rotate the developing gear [4] in the arrow-
[6] marked direction [5] and check to see if the spik-
ing of developer is found on the entire surface of
the developing roller [6].
9. Reinstall the above parts following the removal
steps in reverse.
[5] [4]
50gaf2c042na
Note
• When developer [1] is replaced, be sure to
conduct the TCR adjustment in the service
mode.
(See P.169)

38
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

3.10 Maintenance procedure of the toner supply section

bizhub 500 / 420


3.10.1 Replacing the filter mounting plate assy
A. Periodically replaced part/cycle
• Filter mounting plate assy: Every 250,000 prints

B. Procedure
1. Remove the developing unit from the main body.
[2] [1]
(See P.35)
2. Open ADU.
(See P.122)
3. Open the conveyance unit.
(See P.27)
4. Remove the drum unit from the main body.
(See P.27)
5. Release the lock levers [1] at 2 places and remove
the filter mounting plate assy [2].
6. Reinstall the above parts following the removal
procedure in reverse.

[1] [2]

50gaf2c043na

39
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

3.10.2 Replacing the suction cover /2 assy


bizhub 500 / 420

A. Periodically replaced part/cycle


• Suction cover /2 assy: Every 250,000 prints

B. Procedure
1. Remove the developing unit from the main body.
(See P.35)
2. Open ADU.
(See P.122)
3. Open the conveyance unit.
(See P.27)
4. Remove the drum unit from the main body.
[3] (See P.27)
5. Remove the screw [1] and then remove the rail [2].

Note
• When installing the rail, be sure first to insert
the tip into the notch [3].

[2]

[1]

50gaf2c044na

40
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

6. Remove the 2 suction cover /2 assy's [1].


[1]
7. Reinstall the above parts following the removal

bizhub 500 / 420


steps in reverse.

50gaf2c045na

41
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

3.11 Cleaning/toner recycle section


bizhub 500 / 420

3.11.1 Replacing the cleaning blade assy

Note
• Be sure to avoid touching the edge section of the cleaning blade assy with bare hands.
• When installing the cleaning blade assy, be sure to apply setting powder to the circumference of
the drum and the cleaning blade, regardless of these parts being new or used ones.
• When setting powder is applied to the drum, be sure to conduct the following operations before
installing the drum unit to the main body.
1) With the charging corona unit removed, rotate the drum 1 full turn (to prevent setting powder
from splashing onto the charging corona unit and the image from getting defective.)

A. Periodically replaced part/cycle


• Cleaning blade assy: Every 250,000 prints

B. Procedure
1. Remove the developing unit from the main body.
[1] (See P.35)
2. Open ADU.
(See P.122)
3. Open the conveyance unit.
(See P.27)
4. Remove the drum unit from the main body.
(See P.27)
5. Remove the drum from the drum unit.
[2] (See P.28)
50gaf2c046na
6. Remove the 2 screws [1] and then remove the
cleaning blade presser plate [2].

7. Remove the cleaning blade assy [1].


[1]

50gaf2c047na

42
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

Note
[1]

bizhub 500 / 420


• When installing the cleaning blade assy [1], be
sure to insert the transparent sheet section
[2] of the unit the between the collection
screw [3] and the collection paddle [4].

8. Reinstall the above parts following the removal


steps in reverse.

[3] [2]

[4]

[1]

50gaf2c048na

43
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

3.12 Maintenance procedure of the paper feed section


bizhub 500 / 420

3.12.1 Replacing the feed roller/pick-up roller (tray 1)


A. Periodically replaced parts/cycle
• Feed roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints)
• Pick-up roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints)

B. Procedure
1. Remove the front cover.
(See P.128)
2. Remove the tray 1.
(See P.143)
3. Remove the connector [1] and the 2 screws [2],
and then remove the paper feed unit /1 [3].

[2]

[1]

[3]

[2]
50gaf2c108na

44
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

Note
[3] [2]

bizhub 500 / 420


• When installing the paper feed unit /1 [1], be
sure to set the shafts [2] and [3] to the holes
[4] and [5].

[5] [1]

[4] 50gaf2c109na

45
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

4. Remove the 2 screws [1] and then remove the


bizhub 500 / 420

separation roller unit /1 [2].


[3][4]
Note
• When installing the separation roller unit /1,
[1]
be sure to set the projections [3], 1 each, to
each of the holes [4].

[2] [3][4]

[1]
50gaf2c110na

5. Remove the 2 screws [1].


[2] 6. Detach the convex section [2] from the hole [3]
and remove the paper feed unit cover [4].

[3]

[1]

[4]
50gaf2c111na

46
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

7. Remove the C-ring [1] and then remove the bear-

bizhub 500 / 420


ing [2].
[1] 8. Detach the hook [4] of the spring [3] from the
oblong hole [5].
9. Remove the bearing [6] and then remove the
paper feed roller unit [7].
[2]
Note
• When attaching the spring, be sure to put the
hook into the oblong hole (not into the round
hole [8]).

[8] [7]
[5]

[4]

[6]
[3]

50gaf2c161na

10. Remove the E-ring [1] and then remove the bear-
[4] [1]
ing [2].
11. Remove the bearing [3] and then remove the feed
roller assy [4].

[2]
[3] 50gaf2c162na

47
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

12. Remove the C-ring [1] and then remove the feed
bizhub 500 / 420

roller [2].

[1]
[2] 50gaf2c163na

13. Remove the C-rings [1], 1 each, and then remove


the 2 bearings [2].
14. Remove the pick-up roller assy [3].

[1] [2]

[1]
[3] [2] 50gaf2c164na

15. Remove the C-ring [1] and then remove the pick-
[2] [1] up roller [2].
16. Reinstall the above parts following the removal
steps in reverse.

50gaf2c113na

48
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

3.12.2 Replacing the separation roller assy (tray 1)


A. Periodically replaced part/cycle

bizhub 500 / 420


• Separation roller assy: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints)

B. Procedure
1. Remove the tray 1.
[1] (See P.143)
2. Remove the paper feed unit /1.
(See P.44)
3. Remove the separation roller unit /1.
(See P.44)
4. Remove the 2 screws [1] and then remove the
[2] [3] separation roller mounting plate assy [2].
50gaf2c117na

Note
• When installing the separation roller mount-
ing plate assy, be sure to fasten it with screws
while pressing it in the arrow-marked direc-
tion [3].

5. Remove the 2 C-rings [1] and pull out the shaft [2].
6. Remove the separation roller mounting plate [3].
[1]
Note
• When removing the separation roller mount-
[2] ing plate, be careful that the spring [4] does
[1] not get lost since it is apt to come off.
• When installing the separation roller mount-
ing plate, be sure to install it so that it comes
under the projection [5].

[5] [4] [3]


50gaf2c118na

49
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

7. Remove the guide [1].


8. Remove the C-ring [2] and then remove the sepa-
bizhub 500 / 420

ration roller assy [3].


9. Reinstall the above parts following the removal
steps in reverse.

[1] [3]

[2]
50gaf2c119na

50
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

3.12.3 Replacing the feed roller/pick-up roller (tray 2)


A. Periodically replaced parts/cycle

bizhub 500 / 420


• Feed roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints)
• Pick-up roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints)

B. Procedure
1. Remove the bypass unit.
(See P.60)
2. Pull out the tray 2 [1].

[1]
50gaf2c120na

3. Push the lever [1] to open the vertical conveyance


door [2].
4. Detach the fulcrum [3] of the vertical conveyance
[4]
door from the mounting plate [4] and remove the
vertical conveyance door.

[3]

[1] [2] 50gaf2c121na

51
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

5. Remove the 2 screws [1] and then remove the


bizhub 500 / 420

conveyance roller cover [2].

[1] [2] [1]


50gaf2c122na

6. Remove 2 screws [1] and then remove the paper


[2] [3] feed guide /2 [2] in the arrow-marked direction [3].

[1]

[1]

50gaf2c123na

52
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

7. Remove the 2 connectors [1].


[2]
8. Remove the 3 screws [2] and then remove the

bizhub 500 / 420


paper feed unit /2 [3].

[1]

[3]

[2]

50gaf2c124na

53
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

9. Remove the 2 screws [1] and then remove the


bizhub 500 / 420

separation roller unit /2 [2].


[1]
Note
• When installing the separation roller unit /2,
be sure to set the projection [3] to the hole [4].

[3] [4]

[1] [3] [4] [2]


50gaf2c125na

10. Remove the 2 screws [1].


[4] [1] 11. Detach the convex section [2] from the hole [3]
and remove the paper feed roller cover [4].

[2] [3]

50gaf2c126na

54
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

12. Remove the connector [1].


13. Remove the C-ring [2] and then remove the feed

bizhub 500 / 420


clutch /2 (CL5) [3].

Note
• When installing CL5, be sure to set the stop-
per [4] to the guide plate [5].

[3]

[2] [5]

[4]

[1]

50gaf2c127na

55
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

14. Detach the hook [2] of the spring [1] from the
[3]
bizhub 500 / 420

oblong hole [3].


[7]
15. Remove the C-rings [4], 1 each, and then remove
the 2 bearings [5].
16. Remove the paper feed roller unit [6].
[2]
Note
• When attaching the spring, be sure to put the
[1] hook into the oblong hole (not into the round
hole [7]).

[6]

[4]
[4] [5] 50gaf2c165na

17. Remove the E-ring [1] and then remove the bear-
[4] [1]
ing [2].
18. Remove the bearing [3] and then remove the feed
roller assy [4].

[3] [2] 50gaf2c166na

56
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

19. Remove the C-ring [1] and then remove the feed

bizhub 500 / 420


roller [2].

[1]
[2] 50gaf2c167na

20. Remove the C-rings [1], 1 each, and then remove


the 2 bearings [2].
21. Remove the pick-up roller assy [3].

[1] [2]

[1]
[3] [2] 50gaf2c168na

22. Remove the C-ring [1] and then remove the pick-
[2] [1] up roller [2].
23. Reinstall the above parts following the removal
steps in reverse.

50gaf2c129na

57
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

3.12.4 Replacing the separation roller assy (tray 2)


bizhub 500 / 420

A. Periodically replaced part/cycle


• Separation roller assy: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints)

B. Procedure
1. Remove the bypass unit.
(See P.60)
2. Pull out the tray 2.
3. Remove the vertical conveyance door.
(See P.51)
4. Remove the conveyance roller cover.
(See P.51)
5. Remove the paper feed guide /2.
[1] [2] [1]
(See P.51)
6. Remove the paper feed unit /2.
(See P.51)
7. Remove the separation roller unit /2.
(See P.51)
8. Remove the 2 screws [1] and then remove the
separation roller mounting plate assy [2].

Note
[3] • When installing the separation roller mount-
50gaf2c133na
ing plate assy, be sure to fasten it with screws
while pressing it in the arrow-marked direc-
tion [3].

9. Remove the 2 C-rings [1] and pull out the shaft [2].
10. Remove the separation roller mounting plate [3].
[1]

Note
• When removing the separation roller mount-
[2] ing plate, be careful that the spring [4] does
[1] not get lost since it is apt to come off.
• When installing the separation roller mount-
ing plate, be sure to install it so that it comes
under the projection [5].

[5] [4] [3]


50gaf2c134na

58
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

11. Remove the guide [1].


12. Remove the C-ring [2] and then remove the sepa-

bizhub 500 / 420


ration roller assy [3].
13. Reinstall the above parts following the removal
steps in reverse.

[1] [3]

[2]
50gaf2c135na

59
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

3.13 Maintenance procedure of the bypass tray section


bizhub 500 / 420

3.13.1 Removing/reinstalling the bypass unit


A. Procedure
1. Remove the right cover /Lw.
[2] [1]
(See P.123)
2. Remove the screw [1] and then remove the
bypass cover /Fr [2].
3. Loosen the screw [3] and then remove the screw
[4] to remove the bypass cover /Rr [5].

[5]

[3] [4] 50gaf2c001na

60
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

4. Remove the 3 connectors [1].


[4]
5. Remove the screw [2] and then remove the

bizhub 500 / 420


ground terminal [3].
6. Remove the 5 screws [4] and then remove the
bypass unit [5].

[2] [3] [1]

[5]

[4] 50gaf2c002na

61
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

7. Reinstall the above parts following the removal


bizhub 500 / 420

steps in reverse.
8. After installing the bypass unit, open the tray 2
paper feed guide [1] and the bypass feed guide [2]
in the arrow-marked direction [3] to check to see if
they operate smoothly.

[1] [3] [2]

50gaf2c003na

62
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

3.13.2 Replacing the separation roller assy


A. Periodically replaced part/cycle

bizhub 500 / 420


• Separation roller assy: Every 750,000 prints (Actual replacement cycle: Every 200,000 prints)

Note
• When replacing the separation roller assy, be sure also to replace the feed roller at the same time.

B. Procedure
1. Remove the bypass unit.
[2] [2]
(See P.60)
2. Remove the 2 springs [1].
3. Remove the 5 screws [2].

[2]

[1] 50gaf2c004na

63
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

4. Detach the hook [1] from the hole [2] and remove
[3]
bizhub 500 / 420

the push-up plate assy [3].

[1] [2]

50gaf2c005na

Note
[1] [3] [1]
• When installing the push-up plate assy, be
sure to install it while pressing the push-up
plate [3] so that each of the springs [1] does
not comes off each cross-headed boss [2].

[2] [2] 50gaf2c006na

64
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

5. Remove the 2 screws [1] and then remove the


[2] [1]

bizhub 500 / 420


separation roller fixing plate assy [2].

50gaf2c007na

6. Detach the support axis [2] of the holder [1] from


[3] [5] [4] [1]
the mounting plate [3] and remove the holder.

Note
• When removing the holder [1], the spring [4]
provided under the holder is apt to come off.
Be careful that it does not get lost.
• When installing the holder [1], be sure to
install it so that it comes under the projection
[5].

[2] 50gaf2c008na

7. Remove the C-ring [1] and then remove the sepa-


[3] [1]
ration roller assy [3] from the holder [2].
8. Reinstall the above parts following the removal
steps in reverse.

[2] 50gaf2c009na

65
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

3.13.3 Replacing the feed roller


bizhub 500 / 420

A. Periodically replaced part/cycle


• Feed roller: Every 750,000 prints (Actual replacement cycle: Every 200,000 prints)

Note
• When replacing the feed roller, be sure also to replace the separation roller assy at the same time.

B. Procedure
1. Remove the bypass unit.
(See P.60)
2. Remove the push-up plate assy.
(See P.63)
3. Press the conveyance guide [1] in the arrow-
marked direction [2] to remove the support axis [3]
from the hole [4], and then remove the convey-
ance guide.

[4] [3] [2]

[1] 50gaf2c010na

4. Open the lever [1]. Remove the 2 screws [2] and


[3]
then remove the paper roller cover [3].

[2] [1] 50gaf2c169na

66
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

5. Remove the C-ring [1] and then remove the feed


[1] [2] [3]

bizhub 500 / 420


clutch /BP (CL6) [2].

Note
• When installing CL6, be sure to set the stop-
per [3] to the guide plate [4].

[4] 50gaf2c170na

6. Remove the gear [1].

[1] 50gaf2c171na

67
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

7. Remove the C-ring [1] and then remove the bear-


bizhub 500 / 420

ing [2].
8. Remove the bearing [3] and slide the shaft [4].

[3] [4] [2] [1]

50gaf2c172na

9. Remove the C-ring [1] and then remove the feed


roller [2] from the shaft [3].

Note
• When installing the feed roller, be sure to take
note of the direction of the arrow mark [4].

10. Reinstall the above parts following the removal


steps in reverse.

[2] [4] [1] [3]

50gaf2c173na

68
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

3.14 Maintenance procedure of the registration section

bizhub 500 / 420


3.14.1 Cleaning the paper dust removing brush
A. Periodic cleaning cycle
• Paper dust removing brush: Every 250,000 prints

B. Procedure
1. Open ADU.
[2]
(See P.122)
2. Open the conveyance unit.
(See P.27)
3. Remove the developing unit from the main body.
(See P.35)
4. Remove the drum unit from the main body.
(See P.27)
5. Remove the suction cover /2 assy.
(See P.40)
6. With the lever [1] pulled, remove the paper dust
removing brush [2] and clean the paper dust
removing brush with a blower brush.
[1]
7. Reinstall the above parts following the removal
50gaf2c174na
steps in reverse.

3.14.2 Replacing the loop roller, the loop bearing, the registration roller /Rt, and the registration
bearings /Rt and /Lt
A. Periodically replaced parts/cycle
• Loop roller: Every 1,250,000 prints
• Loop bearing: Every 1,250,000 prints
• Registration roller /Rt: Every 1,250,000 prints
• Registration bearing /Rt: Every 1,250,000 prints
• Registration bearing /Lt: Every 1,250,000 prints

B. Procedure
1. Open ADU.
(See P.122)
2. Open the conveyance unit.
(See P.27)
3. Remove the developing unit from the main body.
(See P.35)
4. Remove the drum unit from the main body.
(See P.27)
5. Remove the suction cover /2 assy.
(See P.40)
6. Remove the 2 connectors [1].

[1]
50gaf2c175na

69
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

7. Remove the 5 screws [1] and then remove the


bizhub 500 / 420

ADU drive assy [2].

Note
• When installing the ADU drive assy, be sure to
set the stopper [4] of the registration clutch
(CL1) [3] to the guide plate [5].

[2] [1]

[3]

[1]

[3]

[4]

[5]

50gaf2c154na

70
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

8. Remove the connector [1].


[5] [6] [1]
9. Remove the screw [2].

bizhub 500 / 420


10. Remove the C-clip [3] and slide CL1 [4] in the
arrow-marked direction [5].
11. Remove the 2 C-clips [6] to release the bearing
[7].

Note
• When installing the 2 C-clips [6], be sure to
install them with their collars come face to
face each other.

12. Remove the C-clip [8] and then remove the bear-
ing [9].
[10] [3] [4] [7] 13. Remove the registration unit [10].

[2] [9] [8]


50gaf2c155na

71
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

14. Remove the bearing [1] and CL1 [2].


[6] [5] [4] [3]
15. Remove the E-ring [3] and then remove the loop
bizhub 500 / 420

clutch (CL2) [4].

Note
• When installing CL2, be sure to set the stop-
per [5] to the screw [6].

16. Remove the screw [7] and then remove the regis-
tration main body assy [8].

[7] [2] [1]

[8]
50gaf2c156na

72
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

17. Remove the E-rings [1], 1 each, and release the 2


[3]

bizhub 500 / 420


loop bearings [2].
18. Remove the loop roller [3].
19. Remove the 2 loop bearings from the loop roller.

[2] [1] [2]

50gaf2c157na

73
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

20. Remove the 2 springs [1].


21. Remove the E-rings [2], 1 each, and then remove
bizhub 500 / 420

the 2 registration bearings /Lt [3].


22. Remove the registration roller /Lt [4].

Note
• When attaching the spring, be sure to couple
the hook [5] of the spring at the position as
shown in the drawing left.

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

[1] [3] [2]


50gaf2c158na

74
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

23. Remove the E-rings [1], 1 each, and then remove

bizhub 500 / 420


the 2 registration bearings /Rt [2].
24. Remove the registration roller /Rt [3].
25. Reinstall the above parts following the removal
steps in reverse.

[1] [2] [3]

[2] [1]
50gaf2c159na

75
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

3.15 Maintenance procedure of the fusing section


bizhub 500 / 420

3.15.1 Removing/reinstalling the fusing unit

Caution
• Since the fusing section gets hot immediately after turning off the main power switch (SW1) or the
power switch (SW2), you may suffer a burn. Be sure to conduct the operations when the tempera-
ture goes down sufficiently.

A. Procedure
1. Open ADU.
[2] [1]
(See P.122)
2. Remove the right cover /Up.
(See P.122)
3. Open the conveyance unit.
(See P.27)
4. Loosen the screw [1] and remove the front auxil-
iary cover [2].

50gaf2c085na

76
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

5. Remove the 2 connectors [1].


6. Remove the screw [2] and then remove the filter

bizhub 500 / 420


[4]
cover [3].
7. Remove the 2 screws [4].
[1]
8. Loosen the 2 screws [5]. And after sliding the
entire reverse unit [6] in the arrow-marked direc-
tion [7], tilt the front side in the arrow-marked
direction [8] for removal.

[8] [3] [2] [5]

[6] [5] [7]

[4]
50gaf2c086na

77
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

9. Remove the 2 screws [1] and then remove the


[2]
bizhub 500 / 420

fusing unit [2].

Note
• When lifting the fusing unit, be sure to hold it
at both ends.
• When installing/removing it, be careful not to
damage rollers.

10. Reinstall the above parts following the removal


steps in reverse.

[1] 50gaf2c087na

3.15.2 Replacing the fusing claw assy


A. Periodically replaced part/cycle
• Fusing claw assy: Every 500,000 prints

B. Procedure
1. Remove the fusing unit.
(See P.76)
2. Remove the C-clip [1].
3. Open the fusing front guide assy [2].

[1] [2] 50gaf2c088na

4. Slide the fusing front guide assy [1] for removal.

[1] 50gaf2c089na

78
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

5. Remove the connector [1].


6. Remove the screw [2] and raise the fusing claw

bizhub 500 / 420


assy [3].
7. Remove the connector [4] from the fusing claw
assy.

Note
• The fusing claw assy varies for bizhub 500
[1] and 420. Be sure to check a punch mark [5]
and replace it with a right fusing claw assy.
bizhub 500: 50 GA
bizhub 420: 42 GA
• When installing the fusing claw assy, be care-
ful not to neglect attaching the connector [4].
• When installing the fusing claw assy, be sure
to insert the positioning sections [6] at 2
[2] [5] [4] places into each of the projections [7].
• When installing the fusing claw assy, be care-
ful not to damage the roller surface with the
tip of the claw.

8. Reinstall the above parts following the removal


steps in reverse.

[3] [7] [6]

50gaf2c091na

79
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

3.15.3 Replacing the fusing web


bizhub 500 / 420

A. Periodically replaced part/cycle


• Fusing web: Every 250,000 prints

B. Procedure
1. Remove the fusing unit.
[4] [2]
(See P.76)
2. Remove the fusing claw assy.
(See P.78)
3. Remove the screw [1].
4. Remove the 5 screws [2].
5. Apply pressure from the inside of the ducts [3] at 2
places to release the lock and remove the fusing
web [4].

Note
• The fusing web varies for bizhub 500 and 420.
[1] [5] [3] Be sure to check a punch mark [5] and
50gaf2c092na
replace it with a right fusing web.
bizhub 500: 50 GA
bizhub 420: 42 GA
• When installing the fusing web, be sure to
install the screw [1] first.

Note
[2]
• When installing the fusing web, be sure to
insert the projections [1] at 2 places into the
positioning holes [2].

[1] 50gaf2c093na

80
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

• The performance of a new fusing web [1] is


[1] [2] [5] [8]

bizhub 500 / 420


guaranteed from the position at which a
brown line [2] is broken. When replacing the
fusing web, be sure to take up the fusing web
up to the position at which the distance [5]
from the nip section [4] of the fusing roller [3]
and the fusing web to the brown line becomes
0 to 10 mm or less.
• When taking up the fusing web, be sure to
[4] [3]
bring down the release lever [6] to release the
cleaner lock gear [7] and rotate the web drive
gear [8].
• When replacing the fusing web, be sure to
reset the fusing web counter in the service
mode.
(See P.187)

6. Reinstall the above parts following the removal


step in reverse.

[1]

[7] [6] [6] 50gaf2c094na

81
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

3.15.4 Replacing the fusing driven roller assy /A and /B


bizhub 500 / 420

A. Periodically replaced parts/cycle


• Fusing driven roller assy /A: Every 250,000 prints
• Fusing driven roller assy /B: Every 250,000 prints

B. Procedure

[1] [2] [4] [3] 1. Remove the fusing unit.


(See P.76)
2. Remove the fusing claw assy from the fusing unit.
(See P.78)
3. Remove the fusing web from the fusing unit.
(See P.80)
4. Remove the screw [1] and then remove the fusing
unit cover /Fr [2].
5. Remove the 2 screws [3] and then remove the
fusing unit cover /Rr [4].

Note
[8] • When removing the fusing unit cover /Rr, be
careful that the internal gear does not fall
down.

6. Remove the 2 screws [5] and the 2 screws [6].


7. Release the 2 envelope levers [7].
8. Remove the fusing casing [8] without touching the
envelope lever.

Note
• When installing the fusing casing [8], be sure
to install first the screw [5] (upper side).

[6] [7] [5] 50gaf2c095na

82
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

9. Remove the 4 screws [1].


[3] [2] [3]
10. Remove the 2 fusing driven roller assy's /A [2] and

bizhub 500 / 420


the 2 fusing driven roller assy's /B [3].

Note
• The gear [4] is not fixed. Take care when mov-
ing it.

11. Reinstall the above parts following the removal


steps in reverse.

[1]
[4]

50gaf2c096na

83
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

3.15.5 Removing/reinstalling the fusing heater lamps /1 (L2) and /2 (L3)


bizhub 500 / 420

Note
• Be careful not to touch the lamp sections of L2 and L3 with bare hands. When touched, be sure to
clean them with a roller cleaner.

A. Procedure
1. Remove the fusing unit.
[1]
(See P.76)
2. Remove the fusing claw assy from the fusing unit.
(See P.78)
3. Remove the fusing web from the fusing unit.
(See P.80)
4. Remove the fusing casing.
(See P.82)
5. Remove the fastons [1] and [2], 2 each.

Note
• When removing the faston, be sure to remove
it by holding the connector section. Be abso-
lutely sure not to pull out by holding the wiring
harness section.

[2] 50gaf2c097na

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Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

[8] [1]
6. Remove the screw [1] and then remove the lamp

bizhub 500 / 420


fixing plate /Fr [2].
7. Pull out the fusing heater lamps /1 (L2) [3] and /2
(L3) [4] in the arrow-marked direction [5] and
remove them.

Note
• When installing each of the fusing heater
lamps, be sure to set the projections [6] of
each lamp to the notch [7] of the lamp fixing
plate /Fr [2].
• After installing each of the fusing heater
lamps, be sure to check to see if it is not in
touch with the inner face of the fusing roller
[8].

[5] [3] [2] • Be sure to install the fusing heater lamp L2 [3]
(main) on the upper side with L3 [4] (sub) on
the lower side.

8. Reinstall the above parts following the removal


steps in reverse.

Note
• When installing the fusing heater lamp, be
sure to take note of the direction of installa-
tion.

Lamp Destination
North America Europe/Others
[7] [6] [4] 50gaf2c098na
Fr Rr Fr Rr
L2 Red Red Blue Blue
L3 Red Black Blue Black

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3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

3.15.6 Replacing the fusing roller, the fusing pressure roller, the heat insulating sleeve /A, the fusing
bizhub 500 / 420

bearings /Up and /Lw and the fusing input gear assy
A. Periodically replaced parts/cycle
• Fusing roller: Every 250,000 prints
• Fusing pressure roller: Every 250,000 prints
• Heat insulating sleeve /A: Every 250,000 prints
• Fusing bearing /Up: Every 250,000 prints
• Fusing bearing /Lw: Every 250,000 prints
• Fusing input gear assy: Every 500,000 prints

B. Procedure
1. Remove the fusing unit.
[7] [8] [6] [5] (See P.76)
2. Remove the fusing claw assy from the fusing unit.
(See P.78)
3. Remove the fusing web from the fusing unit.
(See P.80)
4. Remove the fusing casing.
(See P.82)
[1] [4] 5. Remove the fusing heater lamps /1 (L2) and /2
(L3).
(See P.84)
6. Remove the 2 screws [1] and then remove the
lamp fixing plate /Rr [2].
7. Remove the 2 screws [3] and then remove the
fusing input gear assy [4].

Note
• When installing the fusing input gear assy, be
sure to set the D cut section [6] of the shaft
[5] to the D cut hole [8] of the frame [7].

8. Release the 2 envelope levers [9].


[2] [3]
Note
• The envelope lever varies in the number of the
release steps for bizhub 500 and 420. Be sure
to release it up to the limit in either case.
bizhub 500: 2 steps
bizhub 420: 3 steps

[9] 50gaf2c099na

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Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

9. Remove the C-ring [1] and then remove the gear


[5] [2] [1]

bizhub 500 / 420


[2].
10. Remove the heat insulating sleeve /A [3] and the
fusing bearing /Up [4].

Note
• When installing the heat insulating sleeve /A
and the fusing bearing /Up, be sure to install
[4] [3] [10]
them with their respective collar [5] outside.
• When installing the heat insulating sleeve /A,
be sure to apply Multemp FF-RM to its inside
and outside peripheries.

11. Remove the C-ring [6] and then remove the heat
insulating sleeve /A [7] and the fusing bearing /Up
[8].

Note
• When installing the heat insulating sleeve /A
[12] [11] [7] [8] and the fusing bearing /Up, be sure to install
them with their respective collar [9] outside.
• When installing the heat insulating sleeve /A,
be sure to apply Multemp FF-RM to its inside
and outside peripheries.

12. After sliding once the fusing roller [10] in the


arrow-marked direction [11], remove it in the
[9]
[6] arrow-marked direction [12].
50gaf2c100na

Note
• According to the model, the fusing roller var-
ies in the diameter and the wall thickness.
When replacing it with a new one, be sure to
install one that is suitable for the model.

Model Diameter Wall thickness


bizhub 500 φ 35 mm t 2.0 mm
bizhub 420 φ 35 mm t 0.8 mm

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3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

13. Remove the fusing pressure roller [1].


bizhub 500 / 420

Note
• The fusing pressure roller varies in the diame-
ter for bizhub 500 and 420. When replacing it
with a new one, be sure to install one that is
suitable for the model.

Model Diameter
bizhub 500 φ 35 mm
bizhub 420 φ 35 mm

[1] 50gaf2c101na

14. Remove the 2 fusing bearings /Lw [2] from the


fusing pressure roller [1].

Note
• When installing the fusing bearing /Lw, be
sure to install it with its collar section [3]
inside. Coat the cored bar section with
grease.

[2] [3] [3] [2]


15. Reinstall the above parts following the removal
steps in reverse.

[1] 50gaf2c102na

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Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

3.15.7 Replacing the fusing sensor assy

bizhub 500 / 420


Caution
• After installing the fusing sensor assy, be sure to check to see if it is in touch with the fusing roller.

A. Periodically replaced part/cycle


• Fusing sensor assy: Every 500,000 prints

B. Procedure
1. Remove the fusing unit.
[1] [3] [2]
(See P.76)
2. Remove the fusing claw assy from the fusing unit.
(See P.78)
3. Remove the fusing web from the fusing unit.
(See P.80)
4. Remove the fusing casing.
(See P.82)
5. Remove the fusing heater lamps /1 (L2) and /2
(L3).
(See P.84)
6. Remove the fusing roller and the fusing pressure
roller.
[4] (See P.86)
7. Remove the faston [1].

Note
• When removing the faston, be sure to remove
it by holding its base section. Be absolutely
sure not to pull it out by holding the wiring
harness section.

8. Remove the connector [2].


[5] [3] 9. Remove the 3 screws [3].
10. Remove the web support assy /2 [4] and pull it
out in the arrow-marked direction [5].

50gaf2c104na

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3. PERIODIC CHECK Field Service Ver1.0 Feb.2006

11. Remove the screws [1], 1 each, and then remove


[2]
bizhub 500 / 420

the fusing sensor assy [2].

Note
• When installing the fusing sensor assy, be
careful not to deform the sensor section.
• After installing the fusing sensor assy, be sure
to check to see if the wiring harness is not in
touch with the fusing roller.

Caution
• After installing the fusing sensor assy, be sure
[1] 50gaf2c105na
to check to see if the thermistors /1 (TH1) and
/2 (TH2) are in touch with the fusing roller.

Note
[1]
• The fusing sensor assy is made up of TH1 and
TH2. The sections of TH1 and TH2 have been
adjusted when they were assembled, and be
absolutely sure not to loosen the screw [1].

12. Reinstall the above parts following the removal


steps in reverse.

50gaf2c106na

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Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK

3.15.8 Replacing the fuse holder assy

bizhub 500 / 420


Caution
• After installing the fuse holder assy, be sure to check to see if it is in touch with the fusing roller.

A. Periodically replaced part/cycle


• Fuse holder assy: Every 500,000 prints

B. Procedure
1. Remove the fusing unit.
[1] [4] [3]
(See P.76)
2. Remove the fusing claw assy from the fusing unit.
(See P.78)
3. Remove the fusing web from the fusing unit.
(See P.80)
4. Remove the fusing casing.
(See P.82)
5. Remove the fusing heater lamps /1 (L2) and /2
(L3).
(See P.84)
6. Remove the fusing roller and the fusing pressure
[2] 50gaf2c107na
roller.
(See P.86)
7. Pull out the web support assy /2.
(See P.89)
8. Remove the faston [1].

Note
• When removing the faston, be sure to remove
it by holding its base section. Be absolutely
sure not to pull it out by holding the wiring
harness section.

9. Remove the 2 screws [2] and then remove the


fuse holder assy [3].

Note
• When installing the fuse holder assy, be care-
ful not to deform the thermostat section.
• After installing the fuse holder assy, be sure
to check to see if the wiring harness is not in
touch with the fusing roller.

Caution
• After installing the fuse holder assy, be sure
to check to see if the thermostat (TS) [4] is in
touch with the fusing roller.

10. Reinstall the above parts following the removal


steps in reverse.

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4. SERVICE TOOLS Field Service Ver1.0 Feb.2006

4. SERVICE TOOLS
bizhub 500 / 420

4.1 Service material list


Material No. Name Shape Remark
000V-19-0 Setting powder 25 g

000V-18-0 Cleaning pad 10 pcs/1 pack

00GR0026 Multemp FF-RM 25 g

00GR0021 Solvest 240 Multemp FF-RM is rec-


ommended.

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Field Service Ver1.0 Feb.2006 4. SERVICE TOOLS

4.2 Jig list

bizhub 500 / 420


Parts No. Name Shape Quantity Remark
26NA2134 Drum rotation mem- 1 Mounted to the drum
ber unit

26NAJG01 Optic unit positioning 2


jig

40347940 Test chart 1 Without a KONICA


(A3 size) MINOLTA logo

40347942 Test chart 1 Without a KONICA


(A3 size) MINOLTA logo

40347940 Test chart 1


(11 x 17 size)

120A9711 Adjustment chart 1 For DF adjustment


(A3 size)

120AJG02 Adjustment chart 1 For DF adjustment


(11 x 17 size)

120A9712 White chart 1 For DF adjustment


(A4 size)

120AJG03 White chart 1 For DF adjustment


(81/2 x 11 size)

00VC-2-0 Drum cover 1

00VD-100 Blower brush 1

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4. SERVICE TOOLS Field Service Ver1.0 Feb.2006

Parts No. Name Shape Quantity Remark


bizhub 500 / 420

00VE-100 Tester 1

14G54631 Stapler unit position- 1 For SD staple adjust-


ing jig ment

4.3 Materials
A. Item

Parts name Useful life Type name


Toner bottle 32,200 prints TN511
Drum 250,000 prints DR510
Developer 250,000 prints DV511

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Field Service Ver1.0 Feb.2006 5. FIRMWARE VERSION UP

5. FIRMWARE VERSION UP

bizhub 500 / 420


5.1 ISW
5.1.1 Outline
A. ISW (In-System Writer)
The operation to rewrite firmware stored in the flash ROM that is built in each control board in the main body
with the board left built in the main body is called an ISW. Executing ISW allows you to upgrade the firmware ver-
sion without replacing the board, or install the latest firmware when replacing the board. As a tool to execute
ISW, there is ISWTrns (PC software) that rewrites firmware with the personal computer (PC) locally connected to
the main body.

(1) ISWTrns
This is a software for Windows to rewrite flash ROM of the main body and rewrites firmware with the main body
and the PC locally connected with a parallel cable or UBS cable.

Note
• When upgrading the ISWTrns version, be sure to uninstall the old version of ISWTrns before install-
ing the new version of ISWTrns. When installed by overwriting, this may result in the installation by
the USB driver unavailable.
• When the main body uses the USB to conduct the ISW, it is necessary to install the USB driver of
the ISWTrns. For procedure for installation, see "5.2.3 Usage of the ISWTrns A. Installation of the
USB driver (Windows2000/XP)." After installing the ISWTrns, be absolutely sure to install the USB
driver of the ISWTrns.
(See P.100)

5.1.2 Firmware data flow


The following shows the flow of the ISW data.

PC Overall control board (OACB) Printer control board (PRCB) DF control board (DFCB)
FS control board (FSCB)
FAX control board (FK-502)

When executing the ISW over the entire system, be sure to execute it in the order given below. (To minimize the
occurrence of troubles resulting from the mismatch of the firmware version)

Step Type of programs


1 Fax board controller 1, Fax board controller 2, Finisher, DF
2 Image controller
3 Operation panel message data
4 MFP controller

Note
• When replacing the OACB, be sure to conduct the ISW of the MFP controller first. When the firm-
ware of the MFP controller is not contained in the OACB, no display is shown on the touch panel.
• The finisher above refers to the FS-510. The ISW of the FS-511 is conducted by changing the
EPROM.

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5. FIRMWARE VERSION UP Field Service Ver1.0 Feb.2006

5.1.3 Settings on the main body side while in ISW


Following the description given below, be sure to make appropriate settings on the main body side to conduct
bizhub 500 / 420

the operations of the firmware version upgrade and writing.

A. Types of the setting


• Power ON mode
This mode is used when the firmware of the MFP controller is not installed to the overall control board
(OACB) or when it is damaged. In a case like this, it is not possible to enter the service mode. The firmware
writing of the MFP controller can be made with the power switch ON.
• Service mode