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SERVICE MANUAL THEORY OF OPERATION

THEORY OF OPERATION
2005.04 Ver.1.0

2005 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.


Printed in Japan
Use of this manual should be strictly supervised to
DD4035CE1-1000
2005.04
avoid disclosure of confidential information.
Ver. 1.0
bizhub_162_210_TO.book 1

SAFETY AND IMPORTANT WARNING ITEMS

SAFETY AND IMPORTANT WARNING ITEMS


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

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

DESCRIPTION ITEMS FOR DANGER,


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

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

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

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


trouble, and property damage

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

:Precaution when servicing the


product. General Electric hazard High temperature
precaution

:Prohibition when servicing the


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

:Direction when servicing the


product. General Unplug Ground/Earth
instruction

S-1
bizhub_162_210_TO.book 2

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
bizhub_162_210_TO.book 3

SAFETY AND IMPORTANT WARNING ITEMS

[2] POWER PLUG SELECTION


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

Power Cord Set or Power Plug

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

Attach power plug which meets the following criteria:


- having configuration intended for the connection to wall
outlet appropriate for the product's rated voltage and
current, and
- the plug has pin/terminal(s) for grounding, and
- meets regulatory requirements for the area.
Use of inadequate cord set leads to the product connect-
ing to inadequate power supply (voltage, current capacity,
grounding), and may result in fire or electric shock.

Conductors in the power cable must be connected to ter-


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

S-3
bizhub_162_210_TO.book 4

SAFETY AND IMPORTANT WARNING ITEMS

[3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE


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

1. Power Supply

Connection to Power Supply

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

Connect power plug directly into wall outlet having same


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

Plug the power cord into the dedicated wall outlet with a
capacity greater than the maximum power consumption.
If excessive current flows in the wall outlet, fire may
result.
If two or more power cords can be plugged into the wall
outlet, the total load must not exceed the rating of the wall
outlet.
If excessive current flows in the wall outlet, fire may
result.

Make sure the power cord is plugged in the wall outlet


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

Check whether the product is grounded properly.


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

S-4
bizhub_162_210_TO.book 5

SAFETY AND IMPORTANT WARNING ITEMS

Power Plug and Cord

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

Check whether the power cord is not stepped on or


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

Check whether the power cord is damaged. Check


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

Do not bundle or tie the power cord.


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

Check whether dust is collected around the power plug


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

Do not insert the power plug into the wall outlet with a wet
hand.
The risk of electric shock exists.

When unplugging the power cord, grasp the plug, not the
cable.
The cable may be broken, leading to a risk of fire and
electric shock.

S-5
bizhub_162_210_TO.book 6

SAFETY AND IMPORTANT WARNING ITEMS

Wiring

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

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


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

2. Installation Requirements

Prohibited Installation Places

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

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


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

When not Using the Product for a long time

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

S-6
bizhub_162_210_TO.book 7

SAFETY AND IMPORTANT WARNING ITEMS

Ventilation

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

Stability

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

Inspection before Servicing

CAUTION
Before conducting an inspection, read all relevant docu-
mentation (service manual, technical notices, etc.) and
proceed with the inspection following the prescribed pro-
cedure, using only the prescribed tools. Do not make any
adjustment not described in the documentation.
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.

S-7
bizhub_162_210_TO.book 8

SAFETY AND IMPORTANT WARNING ITEMS

Work Performed with the Product Powered On

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

Take every care when servicing with the external cover


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

Safety Checkpoints

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

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


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

Check wiring for squeezing and any other damage.


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

Check high-voltage cables and sheaths for any damage.


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

S-8
bizhub_162_210_TO.book 9

SAFETY AND IMPORTANT WARNING ITEMS

Safety Checkpoints

WARNING
Check electrode units such as a charging corona unit for
deterioration and sign of leakage.
Current can leak, leading to a risk of trouble or fire.

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


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

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


power with the write unit shifted from the specified mount-
ing position.
The laser light can enter your eye, leading to a risk of
loss of eyesight.
When replacing a lithium battery, replace it with a new lith-
ium battery specified in the Parts Guide Manual. Dispose
of the used lithium battery using the method specified by
local authority.
Improper replacement can cause explosion.

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


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

Check the interlock switch and actuator for loosening and


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

Make sure the wiring cannot come into contact with sharp
edges, burrs, or other pointed parts.
Current can leak, leading to a risk of electric shock or
fire.

S-9
bizhub_162_210_TO.book 10

SAFETY AND IMPORTANT WARNING ITEMS

Safety Checkpoints

WARNING
Make sure that all screws, components, wiring, connec-
tors, etc. that were removed for safety check and mainte-
nance have been reinstalled in the original location. (Pay
special attention to forgotten connectors, pinched cables,
forgotten screws, etc.)
A risk of product trouble, electric shock, and fire exists.

Handling of Consumables

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

Never throw the used cartridge and toner into fire.


You may be burned due to dust explosion.

Handling of Service Materials

CAUTION
Unplug the power cord from the wall outlet.
Drum cleaner (isopropyl alcohol) and roller cleaner (ace-
tone-based) are highly flammable and must be handled
with care. A risk of fire exists.

Do not replace the cover or turn the product ON before


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

S-10
bizhub_162_210_TO.book 11

SAFETY AND IMPORTANT WARNING ITEMS

Handling of Service Materials

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

When using any solvent, ventilate the room well.


Breathing large quantities of organic solvents can lead to
discomfort.

S-11
bizhub_162_210_TO.book 12

SAFETY AND IMPORTANT WARNING ITEMS

[4] Laser Safety


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

4.1 Internal Laser Radiation

semiconductor laser
Maximum power of the laser diode 5 mW
Maximum average radiation power (*) 6.32 W
Wavelength 770-795 nm
*at laser aperture of the Print Head Unit

This product employs a Class 3b laser diode that emits an invisible laser beam. The laser
diode and the scanning polygon mirror are incorporated in the print head unit.
The print head unit is NOT A FIELD SERVICEABLE ITEM. Therefore, the print head unit
should not be opened under any circumstances.

Laser Aperture of
the Print Head Unit

4035D507AA

This figure shows the view inside the Right Door.

S-12
bizhub_162_210_TO.book 13

SAFETY AND IMPORTANT WARNING ITEMS

U.S.A., Canada
(CDRH Regulation)
This machine is certified as a Class 1 Laser product under Radiation Performance Stan-
dard according to the Food, Drug and Cosmetic Act of 1990. Compliance is mandatory
for Laser products marketed in the United States and is reported to the Center for
Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration of
the U.S. Department of Health and Human Services (DHHS). This means that the device
does not produce hazardous laser radiation.

The label shown on page S-16 indicates compliance with the CDRH regulations and
must be attached to laser products marketed in the United States.

CAUTION
Use of controls, adjustments or performance of procedures other than those
specified in this manual may result in hazardous radiation exposure.

semiconductor laser
Maximum power of the laser diode 5 mW
Wavelength 770-795 nm

All Areas

CAUTION
Use of controls, adjustments or performance of procedures other than those
specified in this manual may result in hazardous radiation exposure.

semiconductor laser
Maximum power of the laser diode 5 mW
Wavelength 770-795 nm

Denmark

ADVARSEL
Usynlig laserstrling ved bning, nr sikkerhedsafbrydere er ude af funktion.
Undg udsttelse for strling. Klasse 1 laser produkt der opfylder IEC60825-1
sikkerheds kravene.

halvlederlaser
Laserdiodens hjeste styrke 5 mW
blgelngden 770-795 nm

S-13
bizhub_162_210_TO.book 14

SAFETY AND IMPORTANT WARNING ITEMS

Finland, Sweden

LUOKAN 1 LASERLAITE
KLASS 1 LASER APPARAT

VAROITUS!
Laitteen kyttminen muulla kuin tss kyttohjeessa mainitulla tavalla saat-
taa altistaa kyttjn turvallisuusluokan 1 ylittvlle nkymttmlle laser-
steilylle.

puolijohdelaser
Laserdiodin suurin teho 5 mW
aallonpituus 770-795 nm

VARNING!
Om apparaten anvnds p annat stt n i denna bruksanvisning specificerats,
kan anvndaren utsttas fr osynlig laserstrlning, som verskrider grnsen fr
laserklass 1.

halvledarlaser
Den maximala effekten fr laserdioden 5 mW
vglngden 770-795 nm

VARO!
Avattaessa ja suojalukitus ohitettaessa olet alttiina nkymttomlle laser-
steilylle. l katso steeseen.

VARNING!
Osynlig laserstrining nr denna del r ppnad och sprren r urkopplad.
Betrakta ej strien.

Norway

ADVERSEL
Dersom apparatet brukes p annen mte enn spesifisert i denne bruksanvisn-
ing, kan brukeren utsettes fr unsynlig laserstrlning, som overskrider grensen
for laser klass 1.

halvleder laser
Maksimal effekt till laserdiode 5 mW
blgelengde 770-795 nm

S-14
bizhub_162_210_TO.book 15

SAFETY AND IMPORTANT WARNING ITEMS

4.2 Laser Safety Label


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

4035D510CA

4.3 Laser Caution Label


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

4035D509AA

S-15
bizhub_162_210_TO.book 16

SAFETY AND IMPORTANT WARNING ITEMS

4.4 PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT


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

4.5 OTHER PRECAUTIONS

CAUTION

Double pole / neutral fusing

ATTENTION

Double ple / fusible sur le neutre.

A fuse is installed in each of both L and N lines of the power source of this machine. If the
machine is brought to a stop as a result of the fuse on the N line having been blown for
some reason, there is still the power source voltage being applied to the primary circuit of
the machine. To prevent an electric shock, be sure to unplug the power cord of the
machine before attempting to service the machine.

S-16
bizhub_162_210_TO.book 17

SAFETY AND IMPORTANT WARNING ITEMS

WARNING INDICATIONS ON THE MACHINE


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

High voltage

High temperature

High voltage

4034P0J501DA

CAUTION:
You may be burned or injured if you touch any area that you are advised not to
touch by any caution label. Do not remove caution labels. If any caution label has
come off or become dirty and therefore the caution cannot be read, contact our
Service Office.

S-17
bizhub_162_210_TO.book 18

SAFETY AND IMPORTANT WARNING ITEMS

S-18
bizhub_162_210_TO.book 1

SERVICE MANUAL THEORY OF OPERATION

Main Unit

2005.04
Ver. 1.0
bizhub_162_210_TO.book 2
bizhub_162_210_TO.book 1

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.

2005/04 1.0 Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision
bizhub_162_210_TO.book 2
bizhub_162_210_TO.book i

Theory of Operation Ver. 1.0 Apr. 2005

CONTENTS

bizhub 162
bizhub 210
Outline
1. System configuration............................................................................................... 1
1.1 bizhub 210 ............................................................................................................ 1
1.2 bizhub 162 ............................................................................................................ 2
2. Product specification ............................................................................................... 3
2.1 Copier ................................................................................................................... 3
2.2 Fax Kit (FK-505): (Option) .................................................................................... 6

Outline
3. Cross sectional view................................................................................................ 7
4. Paper path............................................................................................................... 8
5. Copy process .......................................................................................................... 9
5.1 Copy Process Overview ....................................................................................... 9

Composition/Operation
5.2 Image Forming Process...................................................................................... 11
5.3 Drum Charging (Step 1) ..................................................................................... 11
5.4 Exposure Process (Step 2)................................................................................. 12
5.5 Developing Process (Step 3) .............................................................................. 12
5.6 Image Transfer Process (Step 4) ........................................................................ 13
5.7 Paper Separating Process (Step 5) .................................................................... 13
5.8 Fusing Process (Step 6) ..................................................................................... 14
5.9 PC Drum Cleaning Process (Step 7) .................................................................. 14
5.10 Charge Neutralizing Process (Step 8) ................................................................ 15
5.11 Image Transfer Roller Cleaning Process (Step 9)............................................... 15
5.12 Toner Recovery Process (Step 10)..................................................................... 16

Composition/Operation
6. Overall configuration ............................................................................................. 17
6.1 Timing Chart at Power ON.................................................................................. 17
6.2 Control Block Diagram ........................................................................................ 18
7. Scanner (IR).......................................................................................................... 19
7.1 Construction ....................................................................................................... 19
7.2 Mechanism and Control for Moving the Scanner and Mirrors Carriage.............. 20
7.2.1 Scanner Moving Mechanism/Control .......................................................... 20
7.2.2 Operation .................................................................................................... 20
7.3 Original Size Detection ....................................................................................... 22
7.4 Determination of Original Size............................................................................ 23
7.4.1 For Inch area............................................................................................... 23
7.4.2 For Metric and China area .......................................................................... 23
7.4.3 For Latin America area (Inch) ..................................................................... 24

i
bizhub_162_210_TO.book ii

Theory of Operation Ver. 1.0 Apr. 2005

7.4.4 For Latin America area (Metric) .................................................................. 25


8. PH (Writing section) .............................................................................................. 26
bizhub 162
bizhub 210

8.1 Construction ....................................................................................................... 26


8.2 Operation............................................................................................................ 27
9. Imaging unit .......................................................................................................... 28
9.1 Construction ....................................................................................................... 28
9.2 Operation............................................................................................................ 29
9.3 PC Drum............................................................................................................. 30
9.4 Grounding of the PC Drum................................................................................. 30
Outline

10. PC Drum charging ................................................................................................ 31


11. Developing ............................................................................................................ 32
11.1 Developing Roller ............................................................................................... 32
11.2 Developing Bias.................................................................................................. 32
11.3 ATDC Sensor...................................................................................................... 33
Composition/Operation

11.4 ATDC Sensor Automatic Adjustment.................................................................. 33


12. Toner replenishing................................................................................................. 34
12.1 Toner Replenishing Mechanism ......................................................................... 34
12.2 Toner Replenishing Control ................................................................................ 35
12.3 T/C Recovery Mode ........................................................................................... 36
12.4 Toner Bottle Home Position Detection................................................................ 37
13. Toner recovery ...................................................................................................... 38
14. Synchronizing roller section .................................................................................. 39
14.1 Construction ....................................................................................................... 39
14.2 Operation............................................................................................................ 40
14.3 Paper Dust Remover .......................................................................................... 40
15. Image transfer and paper separation section........................................................ 41
15.1 Image Transfer Section....................................................................................... 41
15.2 Paper Separation Section................................................................................... 41
16. Paper take-up........................................................................................................ 42
16.1 Construction ....................................................................................................... 42
16.2 Operation............................................................................................................ 43
16.2.1 Paper Separating Mechanism..................................................................... 44
16.3 Drawer in Position Detection .............................................................................. 45
16.4 Paper Empty Detection Mechanism ................................................................... 45
16.5 Paper Lifting Plate .............................................................................................. 46
16.6 Universal Tray Paper Size Detection Mechanism ............................................... 46
16.6.1 ON/OFF Positions of Paper Size Detecting Switches and
Corresponding Paper Size Detected .......................................................... 47
16.7 Paper Take Up Control ....................................................................................... 48
16.7.1 Paper Take Up Retry Control ...................................................................... 48

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bizhub_162_210_TO.book iii

Theory of Operation Ver. 1.0 Apr. 2005

17. Manual bypass section.......................................................................................... 49


17.1 Operation ............................................................................................................ 49

bizhub 162
bizhub 210
17.2 Paper Detection Mechanism............................................................................... 49
17.3 Manual Feed Take Up Control ............................................................................ 50
18. Fusing unit section ................................................................................................ 51
18.1 Construction (for bizhub 162) ............................................................................. 51
18.2 Construction (for bizhub 210) ............................................................................. 52
18.3 Operation ............................................................................................................ 53
18.4 Fusing Roller Pressure Mechanism.................................................................... 53

Outline
18.5 Fusing Temperature Control (for bizhub 162) ..................................................... 54
18.6 Fusing Temperature Control (for bizhub 210) ..................................................... 55
18.7 PPM Control (bizhub 162 Only) .......................................................................... 56
19. Paper exit (for bizhub 162) .................................................................................... 57
19.1 Construction ....................................................................................................... 57

Composition/Operation
19.2 Operation ............................................................................................................ 57
20. Paper exit (for bizhub 210) .................................................................................... 58
20.1 Construction ....................................................................................................... 58
20.2 Operation ............................................................................................................ 58
21. Image stabilization system .................................................................................... 59
22. Others ................................................................................................................... 60
22.1 Fan Control ......................................................................................................... 60
22.1.1 Power Supply Section Cooling Mechanism................................................. 60
22.1.2 Fusing Section Cooling Mechanism............................................................ 61

iii
bizhub_162_210_TO.book iv

Theory of Operation Ver. 1.0 Apr. 2005


bizhub 162
bizhub 210
Outline
Composition/Operation

Blank page

iv
bizhub_162_210_TO.book 1

Theory of Operation Ver. 1.0 Apr. 2005 1. System configuration

Outline

bizhub 162
bizhub 210
1. System configuration
1.1 bizhub 210

2
1 3

Outline
11
5
4
12 13 14
6

15 7
16 17

8
9
10

4034F1E501DA

[1] Automatic Document Feeder (DF-502) [10] Copy Table (DK-703)*3


[2] Duplexing Document Feeder (DF-605) [11] Key Counter Kit
[3] Original Cover Kit (OC-504)*1 [12] 32MB Memory (EM-101)
[4] Job Separator (JS-503) [13] 64MB Memory (EM-102)
[5] Duplex Unit (AD-504) [14] Printer Controller (IC-205)
[6] Multiple Bypass (MB-501) [15] Network Interface Card (NC-502)
[7] Paper Feed Unit (PF-502)*2 [16] Internet Fax & Network Scan Kit (SU-502)
[8] Copy Desk (DK-701)*3 [17] Fax Kit (FK-505)
[9] Copy Desk (DK-702)*3 [18] Shifting Unit (SF-501) (Illustration none)

*1: Standard for the Chinese market


*2: One drawer PF-502 is standard for the Chinese market.
*3: 3rd area only

1
bizhub_162_210_TO.book 2

1. System configuration Theory of Operation Ver. 1.0 Apr. 2005

1.2 bizhub 162


bizhub 162
bizhub 210

1 2

3
Outline

10 11 12
4

13 5
14 15

6
7
8

4035T1E501DA

[1] Automatic Document Feeder (DF-502) [9] Key Counter Kit


[2] Original Cover Kit (OC-504)*1 [10] 32MB Memory (EM-101)
[3] Job Separator (JS-503) [11] 64MB Memory (EM-102)
[4] Multiple Bypass (MB-501) [12] Printer Controller (IC-205)
[5] Paper Feed Unit (PF-502)*2 [13] Network Interface Card (NC-502)
[6] Copy Desk (DK-701)*3 [14] Internet Fax & Network Scan Kit (SU-502)
[7] Copy Desk (DK-702)*4 [15] Fax Kit (FK-505)
[8] Copy Table (DK-703)*4 [16] Shifting Unit (SF-501) (Illustration none)

*1: Standard
*2: One drawer PF-502 is standard for the Chinese market.
*3: 3rd area only
*4: Optional by dealer

2
bizhub_162_210_TO.book 3

Theory of Operation Ver. 1.0 Apr. 2005 2. Product specification

2. Product specification

bizhub 162
bizhub 210
2.1 Copier

Type Console/Desktop Type


Platen Stationary
Original Scanning System CCD Line Sensor
Photoconductor Organic Photoconductor
Copying System Electrostatic Dry Powdered Image Transfer to Plain Paper with a Laser
Resolution 600 600 dpi

Outline
Paper Feeding System Max. Six-way System
Exposure System Mirror Scanning
Developing System HMT System
Charging System Comb Electrode (1) DC Negative Corona with Scorotron System
Image Transfer System Roller Image Transfer
Paper Separating System Paper Separator Fingers and Charge Neutralizing Plate
Fusing System Heat Roller
Paper Discharging System Charge Neutralizing Brush
Max. Original Size A3

Copy Medium

Paper Feed Tray/1 Manual Bypass


Plain Paper (60 to 90 g/m2)
Transparencies
Type Thick Paper (91 to 157 g/m )2
Postcards, Labels, and Envelopes
Recycled Paper (60 to 90 g/m2)
Width 90 297 mm* 90 297 mm
Size
Length 140 432 mm* 140 432 mm

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

Multiple Copies 1 to 99
Warm-up Time bizhub 210: 15 sec. or less (23 C, Rated Voltage)
bizhub 162: 30 sec. or less (23 C, Rated Voltage)
First Copy Time 7 sec. or less (A4/Letter, Paper Feed Tray/1, full size mode)

3
bizhub_162_210_TO.book 4

2. Product specification Theory of Operation Ver. 1.0 Apr. 2005

Continuous Copy Speed (copies/min)


Zoom ratio 1.000, Paper Feed Tray/1
bizhub 162
bizhub 210

Speed
Size
bizhub 210 bizhub 162
A3 12 10
A4 R 16 13
A4 21 16
B4 13 11
B5 23 18
Outline

B5 R 18 15
Letter 20 16
Letter R 17 14
11 17 11 10
Legal 14 12
11 14 14 12

Zoom Ratios

Full Size 1.00


0.81
0.70
Reduction
0.50
Fixed 0.25
1.15
1.41
Enlargement
2.00
4.00
Variable 0.25 to 4.00 (in 0.01 increments)

Lens Through Lens


Exposure Lamp Rare Gas Fluorescent Lamp

Power/Current Consumption

1250 W (bizhub 210: 200 V area)


Max. Current Consumption 1200 W (bizhub 210: 120 V area)
(full system) 1050 W (bizhub 162: 200 V area)
1000 W (bizhub 162: 120 V area)
5.5 A (bizhub 210: 200 V area)
Current Consumption 10 A (bizhub 210: 120 V area)
(full system) 4.5 A (bizhub 162: 200 V area)
8.5 A (bizhub 162: 120 V area)

Power Requirements 110 V, 120 V, 127 V, 220 V to 240 V, 50/60 Hz

4
bizhub_162_210_TO.book 5

Theory of Operation Ver. 1.0 Apr. 2005 2. Product specification

Environmental Conditions

bizhub 162
bizhub 210
Temperature 10 to 30 C with a fluctuation of 10 C or less per hour
Humidity 15 to 85 % RH with a fluctuation of 20 % RH or less per hour
Ambient Illumination 3000 lux or less
Levelness 1 or less

Copier Dimensions Width = 599 mm, Depth = 620 mm, Height = 487 mm (Copier Only)
Copier Mass 38 kg

<GDI Printer Functions>

Outline
Printing Speed bizhub 210: 21 printed pages/min (A4, 300 dpi)
12 printed pages/min (A4, 600 dpi)
bizhub 162: 16 printed pages/min (A4, 300 dpi)
12 printed pages/min (A4, 600 dpi)
Memory Shared with the copier
Interface IEEE 1284 (parallel), USB Revision 1.1 (except for Windows 95 and
Windows NT)
Printer Language GDI
Font Windows
Complying OS Windows XP (SP1 or later), Windows 2000 (SP3 or later), Windows NT
Workstation Version 4.0 (SP6a or later), Windows ME, Windows 98
(SP1), Windows 98 SE, and Windows 95 OSR2.5
Web Browser Internet Explorer 4.0 or later

5
bizhub_162_210_TO.book 6

2. Product specification Theory of Operation Ver. 1.0 Apr. 2005

2.2 Fax Kit (FK-505): (Option)


General
bizhub 162
bizhub 210

Compatibility G3

Scanning Resolution

TX Mode Resolution CD direction (dpi) FD direction (dpi)


STD 204 98
Memory TX FINE 204 196
S_FINE 204 392
Outline

STD 204 98
Non memory TX FINE 204 196
S_FINE 408 392

Line PSTN/ PBX


Data Transmission Rate 33.6 kbps (V.34 JBIG)
Coding Method MH/ MR/ MMR/ JBIG
Document Size CCD Scanning
- A3/11 17 (297 mm)
Sheet Through Scanning
- STD/FINE: Max. 297 mm width 1,000 mm
- Super Fine: Max. 297 mm width 900 mm
Internet fax Enable when the optional Internet Fax & Network Scan Kit SU-502 and
Network Interface Card NC-502 are installed.

Dialing

One touch dial 27 keys


Speed dial 200 fax numbers
Group dial 27 groups (50 destination/group)
Program dial 4 keys (No. 24 ~ 27)
Other dialing On-hook dial, Automatic redial, Manual redial, Chain dial, Combination dial

Transmission

Transmission mode ADF TX, Memory TX, Batch TX, Broadcast TX, Manual TX, Polling TX,
Quick Memory TX, Book TX, Relay initiate TX, Timer TX, Relay Broadcast

Receiving

Receiving mode Mailbox RX, Manual RX, Memory RX, Substitute RX, Polling RX
RX resolution 204 dpi 98 dpi, 204 dpi 196 dpi, 204 dpi 392 dpi
Max. recording paper size A3/ 11 17

6
bizhub_162_210_TO.book 7

Theory of Operation Ver. 1.0 Apr. 2005 3. Cross sectional view

3. Cross sectional view

bizhub 162
bizhub 210
1

Outline
3
12

4
11

5
10 6

4034G502BA

[1] Automatic Document Feeder DF-502 [7] Paper Feed Unit PF-502 (Option)
(Option)
[2] Scanner [8] Copy Table DK-703 (Option)
[3] Job Separator JS-503 (Option) [9] Paper Feed Tray/1
[4] Fusing Unit [10] PH Unit
[5] Image Transfer Section [11] Imaging Unit
[6] Multiple Bypass MB-501 (Option) [12] Exit Section

7
bizhub_162_210_TO.book 8

4. Paper path Theory of Operation Ver. 1.0 Apr. 2005

4. Paper path
bizhub 162
bizhub 210
Outline

4034G503BA

8
bizhub_162_210_TO.book 9

Theory of Operation Ver. 1.0 Apr. 2005 5. Copy process

5. Copy process

bizhub 162
bizhub 210
5.1 Copy Process Overview

Outline
4034M544CA

1. PC Drum
Made up of an aluminum pipe coated with a photoconductive layer, on which an electro-
static latent image is formed.
2. Drum Charging
A uniform negative DC charge is deposited across the entire surface of the PC Drum.
3. Photoelectric Conversion
A CCD sensor is used to convert the image data represented by light reflected off the
original to a corresponding electric signal which, in turn, is output to the IR image pro-
cessing section.
4. IR Image Processing
The analog electric signal is converted to an 8-bit digital image signal (A/D conversion)
which, in turn, goes through appropriate corrections before being output to the PH image
processing section.
5. PH Image Processing
After going through corrections, the digital image signal is converted to a corresponding
electric signal (D/A conversion), with which the laser is turned ON or OFF as necessary.
6. Laser Exposure
The laser beam strikes the surface of the PC Drum, forming an electrostatic latent image.
7. Developing
Toner negatively charged in the Developer Mixing Chamber is attracted onto the electro-
static latent image changing it to a visible, developed image.
A developing bias (Vb) is applied to the Developing Roller to prevent toner from being
attracted onto those areas of the PC Drum which correspond to the background areas of
the original.
8. Paper Take-up
Paper is supplied from the paper feed tray.
9. Bypass Paper Take-up
Paper is supplied by way of the Manual Bypass, one sheet at a time.
The optional Multiple Bypass (MB-501), when mounted on the copier, permits continu-
ous paper supply.

9
bizhub_162_210_TO.book 10

5. Copy process Theory of Operation Ver. 1.0 Apr. 2005

10. Image Transfer


A DC positive charge is applied to the Image Transfer Roller to transfer the visible image
bizhub 162
bizhub 210

on the surface of the PC Drum onto the paper.


11. Paper Separation
The PC Drum Paper Separator Fingers remove paper from the surface of the PC Drum.
The Charge Neutralizing Plate neutralizes any charge left on the paper.
12. Cleaning
Residual toner on the surface of the PC Drum is scraped off.
The toner is then recycled back to the Developing Unit.
13. Main Erase
The surface of the PC Drum is irradiated with light and any surface potential remaining
there after cleaning is neutralized.
Outline

14. Paper Transport


The paper is transported to the Fusing Unit.
15. Fusing
The developed image is permanently fused to the paper by the combination of heat and
pressure applied by the Fusing Roller.
16. Paper Exit
The paper is fed out onto the Exit Tray.
The optional Job Separator (JS-503), when mounted on the copier, allows a specific tray,
in which paper is fed, to be selected according to the operating mode.

10
bizhub_162_210_TO.book 11

Theory of Operation Ver. 1.0 Apr. 2005 5. Copy process

5.2 Image Forming Process

bizhub 162
bizhub 210
Step Process Function
Step 1 Drum charging Forms a charge layer on the surface of the PC Drum.
Forms an electrostatic latent image on the surface of
Step 2 Exposure
the PC Drum.
Changes the electrostatic latent image to a visible,
Step 3 Developing
developed image.
Transfers the toner image on surface of the PC Drum to
Step 4 Image transfer
paper.

Outline
Separates the paper, onto which the toner image has
Step 5 Paper separating
been transferred, from the surface of the PC Drum.
Step 6 Fusing Fuses the toner on the paper permanently.
Step 7 PC Drum cleaning Removes toner left on the surface of the PC Drum.
Neutralizes any residual charge left on the surface of
Step 8 Charge neutralizing
the PC Drum after the PC Drum cleaning process.
Removes toner sticking to the surface of the Image
Step 9 Image Transfer Roller cleaning
Transfer Roller after image transfer.
Recovers toner removed during the PC Drum cleaning
Step 10 Toner recovery
process.

5.3 Drum Charging (Step 1)


A compact comb electrode is used for drum charging to reduce the amount of ozone pro-
duced and save space. The Drum Charge Corona deposits a charge evenly across the
entire surface of the PC Drum.
The Scorotron system is used and the grid mesh provided between the corona wire and
the PC Drum ensures that a uniform charge is deposited across the entire surface of the
PC Drum.

Grid Mesh

PC Drum

Corona Wire

4034G505AA

11
bizhub_162_210_TO.book 12

5. Copy process Theory of Operation Ver. 1.0 Apr. 2005

5.4 Exposure Process (Step 2)


The surface of the PC Drum is irradiated with light reflected off the original, which forms
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bizhub 210

an electrostatic latent image.

PH Unit
Outline

4034G506AA
Laser Beam

5.5 Developing Process (Step 3)


Toner is attracted onto the electrostatic latent image produced through the exposure pro-
cess, thereby forming a visible, developed image.

Toner

Developing Roller

4034G504AA

12
bizhub_162_210_TO.book 13

Theory of Operation Ver. 1.0 Apr. 2005 5. Copy process

5.6 Image Transfer Process (Step 4)


The Image Transfer Roller applies charge from the backside of the paper, thereby trans-

bizhub 162
bizhub 210
ferring toner on the surface of the PC Drum to the paper.

Charge Neutralizing Plate

Outline
Image Transfer Roller
Paper

4034G507AA

5.7 Paper Separating Process (Step 5)


Employed is the paper separating system using curvature separation and mechanical
separation by means of the Paper Separator Fingers.

Paper Separator Finger

PC Drum

Image Transfer Roller

4034G508AA

13
bizhub_162_210_TO.book 14

5. Copy process Theory of Operation Ver. 1.0 Apr. 2005

5.8 Fusing Process (Step 6)


The Fusing Unit consists of the Fusing Roller and the Fusing Roller/rt.
bizhub 162
bizhub 210

The Fusing Roller is provided with two Fusing Heater Lamps, thereby shortening the
time required for warming-up and saving energy.
The main heater, or the Fusing Roller Heater Lamp, heats the center of the Fusing
Roller. The sub heater, or the Fusing Roller Sub Heater Lamp, on the other hand, heats
both end portions of the Fusing Roller. The Fusing Roller Thermistor located at the cen-
tral portion controls the Fusing Roller Heater Lamp. The Fusing Roller Sub Thermistor
located in the rear control the Fusing Roller Sub Heater Lamp.
Outline

Fusing Paper Separator


Finger

Fusing Heater Lamp

Fusing Roller Fusing Roller/rt

Toner 4034G509AA

5.9 PC Drum Cleaning Process (Step 7)


The Cleaning Blade scrapes residual toner off the surface of the PC Drum.

Residual Toner

Cleaning Blade
PC Drum

4034G510AA

14
bizhub_162_210_TO.book 15

Theory of Operation Ver. 1.0 Apr. 2005 5. Copy process

5.10 Charge Neutralizing Process (Step 8)


Any potential remaining on the surface of the PC Drum is neutralized by the Erase Lamp.

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bizhub 210
Residual Potential

Outline
Erase Lamp

PC Drum
4030G511AA

5.11 Image Transfer Roller Cleaning Process (Step 9)


A charge of the same polarity as that of toner (negative) is applied to clean the surface of
the Image Transfer Roller.

Toner

Image Transfer Roller

Potential

4034G512AA

15
bizhub_162_210_TO.book 16

5. Copy process Theory of Operation Ver. 1.0 Apr. 2005

5.12 Toner Recovery Process (Step 10)


Toner scraped off by the Cleaning Blade is transported back to the Developing Unit by
bizhub 162
bizhub 210

the Toner Recycling Coil.

Recycled Toner Agitating Blade


Outline

Recycled Toner Conveying Screw

PC Drum

4021M039AA

Recycling Duct

Recycling Coil

Cleaning Blade
4021M038AB

16
bizhub_162_210_TO.book 17

Theory of Operation Ver. 1.0 Apr. 2005 6. Overall configuration

Composition/Operation

bizhub 162
bizhub 210
6. Overall configuration
6.1 Timing Chart at Power ON

Composition/Operation

4034M537CA

17
bizhub_162_210_TO.book 18

6. Overall configuration Theory of Operation Ver. 1.0 Apr. 2005

6.2 Control Block Diagram


bizhub 162
bizhub 210
Composition/Operation

4034M538CA

18
bizhub_162_210_TO.book 19

Theory of Operation Ver. 1.0 Apr. 2005 7. Scanner (IR)

7. Scanner (IR)

bizhub 162
bizhub 210
7.1 Construction

1
9
8 2

Composition/Operation
5

6
4035M528AC

No. Name Function/System


1 Scanner Motor (M5) Drives the Scanner Assy and the 2nd/3rd Mirrors Carriage.
Converts light reflected off the mirror to a corresponding
2 CCD Board (PWB-J)
electric signal.
Detects the size of the original, validates the original size
3 Size Reset Switch (S5) detection and resets the size of the original according to
combination with the Original Cover Sensor.
Driven by the Scanner Motor to let light from the Exposure
4 Scanner Assy
Lamp hit against the original.
5 Exposure Lamp Irradiates the original with light.
Lets the light reflected off the original travel to reach the
6 2nd/3rd Mirrors Carriage
CCD Board.
Scanner Home Position Sensor
7 Detects the Scanner Assy at its home position.
(PC10)
Detects the size of the original, validates the original size
8 Original Cover Sensor (PC100) detection and resets the size of the original according to
combination with the Size Reset Switch.
9 Original Size Sensor 1 (UN2) Detects the size of the original.

19
bizhub_162_210_TO.book 20

7. Scanner (IR) Theory of Operation Ver. 1.0 Apr. 2005

7.2 Mechanism and Control for Moving the Scanner and Mirrors
Carriage
bizhub 162
bizhub 210

7.2.1 Scanner Moving Mechanism/Control


The Scanner is moved by the Scanner Motor at a given speed.
The Scanner Home Position Sensor detects the Scanner at its home position.
The 2nd/3rd Mirrors Carriage moves at a speed half that of the Scanner. It thereby keeps
constant the optical path length between the original and the PC Drum.

7.2.2 Operation
<Marking copies through the Original Glass>
Composition/Operation

4034M547CA

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


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

20
bizhub_162_210_TO.book 21

Theory of Operation Ver. 1.0 Apr. 2005 7. Scanner (IR)

<Making copiers using DF-502>

bizhub 162
bizhub 210
4034T2E501DA

1. When the original is loaded and the Start key pressed, the Scanner performs shad-
ing.

Composition/Operation
2. The Scanner then moves to the scanning position under the ADF glass.
The original is scanned as it is moved.
3. After the original has been scanned, the home position of the Scanner is detected.
Then, the Scanner moves to, and stops at, the home position.

21
bizhub_162_210_TO.book 22

7. Scanner (IR) Theory of Operation Ver. 1.0 Apr. 2005

7.3 Original Size Detection


Original Size Sensor 1 and the CCD mounted in the optical section are used to detect
bizhub 162
bizhub 210

the size of the original.

UN3 (Option)

UN2
Composition/Operation

4035M528AA

22
bizhub_162_210_TO.book 23

Theory of Operation Ver. 1.0 Apr. 2005 7. Scanner (IR)

7.4 Determination of Original Size


The Original Size Sensor is used to determine the size of the original.

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Two size conversion patterns are available depending on the applicable marketing area.
Refer to the Field Service (CCD APS SIZE) for setting.
89

7.4.1 For Inch area


Pattern 1

Original Size
~144.7 ~220.9 ~221.0
Sensor mm mm mm
UN2 *UN3
Invoice
OFF Letter R Letter
R
ON Legal Legal 1117

Composition/Operation
Pattern 2

Original Size
~143.9 ~153.0 ~187.0 ~213.0 ~220.9 ~225.0 ~262.0 ~284.4 284.5
Sensor mm mm mm mm mm mm mm mm mm~
UN2 *UN3
Invoice
OFF OFF A5 R B5 R A4 R Letter R B5 B5 Letter A4
R
ON OFF FLS FLS FLS FLS FLS FLS B4 1117 A3
OFF ON Legal Legal Legal Legal Legal B4 B4 1117 A3
ON ON Legal Legal Legal Legal Legal B4 B4 1117 A3

UN3 is an option.

7.4.2 For Metric and China area


Pattern 1

Original Size
~153.0 ~187.0 ~200.0 ~215.0 ~225.0 ~262.0 ~275.0 275.1
Sensor mm mm mm mm mm mm mm mm~
UN2 *UN3
OFF A5 R B5 R 16K R A4 R B5 B5 16K A4
ON FLS FLS FLS FLS FLS B4 8K A3

23
bizhub_162_210_TO.book 24

7. Scanner (IR) Theory of Operation Ver. 1.0 Apr. 2005

Pattern 2
bizhub 162
bizhub 210

Original
Size
~143.9 ~153.0 ~187.0 ~200.0 ~213.0 ~220.9 ~225.0 ~262.0 ~274.7 ~284.4 284.5
Sensor mm mm mm mm mm mm mm mm mm mm mm~

UN2 *UN3
Invoice Letter
OFF OFF A5 R B5 R 16K R A4 R B5 B5 16K Letter A4
R R
ON OFF FLS FLS FLS FLS FLS FLS FLS B4 8K 1117 A3
OFF ON Legal Legal Legal Legal Legal Legal B4 B4 8K 1117 A3
ON ON Legal Legal Legal Legal Legal Legal B4 B4 8K 1117 A3

UN3 is an option.

7.4.3 For Latin America area (Inch)


Pattern 1
Composition/Operation

Original Size
~144.7 ~220.9 ~221.0
Sensor mm mm mm
UN2 *UN3
Invoice
OFF Letter R Letter
R
ON Legal Legal 1117

Pattern 2

Original Size
~143.9 ~153.0 ~213.0 ~220.9 ~225.0 ~262.0 ~284.4 284.5
Sensor mm mm mm mm mm mm mm mm~
UN2 *UN3
Invoice
OFF OFF A5 R A4 R Letter R B5 B5 Letter A4
R
ON OFF FLS FLS FLS FLS FLS 1117 1117 A3
OFF ON Legal Legal Legal Legal 1117 1117 1117 A3
ON ON Legal Legal Legal Legal 1117 1117 1117 A3

24
bizhub_162_210_TO.book 25

Theory of Operation Ver. 1.0 Apr. 2005 7. Scanner (IR)

7.4.4 For Latin America area (Metric)


Pattern 1

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bizhub 210
Original Size
~153.0 ~187.0 ~200.0 ~215.0 ~225.0 ~262.0 ~275.0 275.1
Sensor mm mm mm mm mm mm mm mm~
UN2 *UN3
OFF A5 R B5 R 16K R A4 R B5 B5 16K A4
ON FLS FLS FLS FLS FLS B4 8K A3

Pattern 2

Original Size
~143.9 ~153.0 ~213.0 ~220.9 ~225.0 ~262.0 ~284.4 284.5
Sensor mm mm mm mm mm mm mm mm~
UN2 *UN3
Invoice
OFF OFF A5 R A4 R Letter R B5 B5 Letter A4

Composition/Operation
R
ON OFF FLS FLS FLS FLS FLS 1117 1117 A3
OFF ON Legal Legal Legal Legal 1117 1117 1117 A3
ON ON Legal Legal Legal Legal 1117 1117 1117 A3

25
bizhub_162_210_TO.book 26

8. PH (Writing section) Theory of Operation Ver. 1.0 Apr. 2005

8. PH (Writing section)
bizhub 162
bizhub 210

8.1 Construction

4
Composition/Operation

4035M003AB
3

No. Name Function/System


Allows the surface of the PC Drum to be irradiated with a laser
1 Polygon Motor (M1)
beam so that an image is formed.
Keeps constant the polarization angular velocity of the laser
2 f Lens
beam.
3 SOS Sensor Detects the timing at which the laser beam is emitted.
4 LD Board (PWB-B) -

26
bizhub_162_210_TO.book 27

Theory of Operation Ver. 1.0 Apr. 2005 8. PH (Writing section)

8.2 Operation
When a laser beam strikes the Polygon Mirror, light reflected off the Polygon Mirror is

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directed at the PC Drum by way of the lens and return mirror.
The Polygon Mirror has seven faces, being turned at high speeds by the Polygon Motor.
The SOS Mirror and SOS Sensor keep constant the timing, at which emission of a laser
beam is started for each main scanning line.

1
2

Composition/Operation
6

4035M004AD
5

[1] Polygon Motor (M2) [4] PC Drum


[2] f Lens [5] SOS Sensor
[3] SOS Mirror [6] LD Board (PWB-B)

27
bizhub_162_210_TO.book 28

9. Imaging unit Theory of Operation Ver. 1.0 Apr. 2005

9. Imaging unit
bizhub 162
bizhub 210

9.1 Construction

2
7
Composition/Operation

4034M539AA

6 5 4

No. Name Function/System


PC Drum Paper Separator Fin- Mechanically separate the paper from the surface of the PC
1
gers Drum.
Forms an electrostatic latent image on the surface of the PC
2 PC Drum
Drum.
Toner is attracted onto the electrostatic latent image produced
3 Developing Roller through the exposure process, thereby forming a visible,
developed image.
4 1st Toner Conveying Roller
Convey toner in the Developer Mixing Chamber to the devel-
5 2nd Toner Conveying Roller
oping section.
6 3rd Toner Conveying Roller
The surface of the PC Drum is deposited with charge through
7 PC Drum Charge Corona
corona discharge from the PC Drum Charge Corona.
The Cleaning Blade scrapes residual toner off the surface of
8 Cleaning Blade
the PC Drum.

28
bizhub_162_210_TO.book 29

Theory of Operation Ver. 1.0 Apr. 2005 9. Imaging unit

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

bizhub 162
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cal components.

Composition/Operation
3

4035M006AA

[1] Recycled Toner Conveying Screw [4] Developing Roller


[2] Recycled Toner Recycling Coil [5] Main Motor (M1)
[3] 2nd Toner Conveying Roller

29
bizhub_162_210_TO.book 30

9. Imaging unit Theory of Operation Ver. 1.0 Apr. 2005

9.3 PC Drum
The PC Drum used in this copier is the organic photoconductor (OPC).
bizhub 162
bizhub 210

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

Handling Precaution
The PC Drum of this type exhibits light fatigue after being exposed to light for a
long time, which results in its sensitivity being changed. Always, therefore, wrap
the drum in the PC Drum Cloth or a soft cloth immediately after it has been
removed from the copier. Utmost care should also be used when handling the PC
Drum to ensure that its surface is not contaminated.

(PC Drum Cross-Section)

Charge Generation Layer


PC Drum Charge Transport Layer
Aluminum Base
Composition/Operation

1167M007AA
1139M007AA

9.4 Grounding of the PC Drum


The ground contact (Ground Plate) of the PC Drum is located on the inside on its left-
hand side. It remains in contact with the drum shaft at all times. When the Imaging Unit is
loaded in the copier, the drum shaft comes into contact with the Ground Plate of the PC
Drum. The potential on the surface of the PC Drum exposed to the laser beam is then
grounded through the Ground Plate to the frame of the copier.

PC Drum

Frame

4021M010AA
Ground Plate

30
bizhub_162_210_TO.book 31

Theory of Operation Ver. 1.0 Apr. 2005 10. PC Drum charging

10. PC Drum charging

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The surface of the PC Drum is deposited with charge through corona discharge from the
PC Drum Charge Corona.
The grid mesh interposed between the corona wire and the PC Drum ensures that a uni-
form charge is deposited across the entire surface of the PC Drum.
The corona unit has a comb electrode that discharges only toward the grid mesh. This
results in the amount of ozone produced being smaller than with the wire electrode.

Comb Electrode

Composition/Operation
4021M011AA

Grid Mesh

31
bizhub_162_210_TO.book 32

11. Developing Theory of Operation Ver. 1.0 Apr. 2005

11. Developing
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11.1 Developing Roller


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

Toner/Carrier PC Drum

1st Toner Conveying Roller Point of Development

Toner
2nd Toner Conveying Roller
Carrier
Composition/Operation

Developing Roller

4021M062AA

11.2 Developing Bias


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

PC Drum

Developing Roller

Developing Bias
Terminal

4021M018AB

32
bizhub_162_210_TO.book 33

Theory of Operation Ver. 1.0 Apr. 2005 11. Developing

11.3 ATDC Sensor


The ATDC Sensor detects the toner-to-carrier ratio (T/C) of the developer in the Devel-

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oper Mixing Chamber.

3rd Toner Conveying Roller Developing Roller


2nd Toner Conveying Roller

ATDC Sensor 1st Toner Conveying Roller

Composition/Operation
4021M019AA

11.4 ATDC Sensor Automatic Adjustment


The reference value for the ATDC Sensor is automatically adjusted as detailed below
using the ATDC Sensor Automatic Adjustment mode.

With the copier set in the ATDC Sensor Automatic Adjustment mode, press the Start key.

The developer is mixed.

The ATDC Sensor converts the reference T/C (14 %) to a corresponding voltage
value and outputs it.

Does the output voltage fall within the range from 2.28 to 2.36 V?

YES NO
The voltage input to the ATDC Sensor The voltage input to the ATDC Sensor from
from the Master Board at this time is fixed the Master Board is varied.
as the reference voltage. 2.37 V or more: Decrease the voltage.
2.29 V or less: Increase the voltage.

33
bizhub_162_210_TO.book 34

12. Toner replenishing Theory of Operation Ver. 1.0 Apr. 2005

12. Toner replenishing


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12.1 Toner Replenishing Mechanism


Toner is supplied from the Toner Bottle to the Developer Mixing Chamber.
1. The Toner Replenishing Motor (M6) turns the coupling, which turns the Toner Bot-
tle.
2. To regulate the amount of toner supplied from the Toner Bottle, there is a Metering
Chamber provided in the outer race of the coupling.
3. When the Toner Bottle turns, toner in the Metering Chamber drops.
4. Toner from the metering chamber is conveyed by the Toner Conveying Screw into
the Developer Mixing Chamber.
5. The Toner Conveying Screw is turned by the Toner Replenishing Motor (M6).

Coupling Toner Bottle


Composition/Operation

Metering
Chamber

4021M020AB 4034M527AA

Toner Replenishing
Motor (M6)

Toner Conveying Screw

4021M022AA
Developer Mixing Chamber

4021M023AA

34
bizhub_162_210_TO.book 35

Theory of Operation Ver. 1.0 Apr. 2005 12. Toner replenishing

12.2 Toner Replenishing Control


Replenishing of the supply of toner is determined based on the T/C ratio and B/W ratio.

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If T/C is 14 % or more, toner replenishing is not carried out regardless of the B/W value.
If T/C is less than 14 %, toner replenishing is determined according to the B/W value.
Toner is replenished until T/C becomes 14 %.

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


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

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

Composition/Operation
original).

35
bizhub_162_210_TO.book 36

12. Toner replenishing Theory of Operation Ver. 1.0 Apr. 2005

12.3 T/C Recovery Mode


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

Toner is replenished for 90 sec.

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


or T/C is less than 12 %.

Toner is replenished for 60 sec.


Composition/Operation

T/C is recovered by 2 % or more, T/C is not recovered by 2 % or more,


or is 12 % or more. or T/C is less than 12 %.

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


complete the T/C recovery mode.

T/C is less than 8 %.

A toner-empty-stop condition results and


the initiation of any new copy cycle is pro-
hibited.

A toner-empty condition is reset when the Front Cover is opened and closed after a T/C
of 10 % or more is detected with the supply of toner replenished.
A toner-empty-stop condition is reset when the Front Cover is opened and closed after a
T/C of 8 % or more is detected with the supply of toner replenished. A toner-empty con-
dition results, however, if T/C falls within the range between 8 % and 10 % when the
Front Cover is opened and closed.

36
bizhub_162_210_TO.book 37

Theory of Operation Ver. 1.0 Apr. 2005 12. Toner replenishing

12.4 Toner Bottle Home Position Detection


The Toner Supply Port is on the upper side whenever the Toner Bottle is at its home posi-

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tion. The Toner Bottle Home Position Sensor (PC7) detects the Toner Bottle at its home
position.

Toner Supply Port

Composition/Operation
Toner Bottle Home Position
Sensor (PC7)

4021M024AA

37
bizhub_162_210_TO.book 38

13. Toner recovery Theory of Operation Ver. 1.0 Apr. 2005

13. Toner recovery


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The Cleaning Blade is used to scrape residual toner off the surface of the PC Drum.
The spent toner is conveyed through the Recycling Duct and eventually back to the
Developer Mixing Chamber.
The following control is provided to prevent paper dust from being wedged between the
Cleaning Blade and the PC Drum. When the cumulative period of time through which the
PC Drum has been driven reaches a predetermined value, the PC Drum is turned back-
ward (by turning the Main Motor backward). Shoulder gears comprising two different
parts are provided on the copier. This ensures that the drive is transmitted only to the
Imaging Unit, but not any other parts, during backward rotation.

Cumulative Time Through Which PC Drum Has Been Driven PC Drum Backward Rotation Time
Approx. 330 sec. 50 ms
Composition/Operation

Spent Toner Conveying Screw 1

Spent Toner Conveying Screw 2

PC Drum

4021M039AA

Spent Toner Recycling Coil

Spent Toner Recycling Duct

Cleaning Blade

4021M038AB
Developer Mixing Chamber

38
bizhub_162_210_TO.book 39

Theory of Operation Ver. 1.0 Apr. 2005 14. Synchronizing roller section

14. Synchronizing roller section

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14.1 Construction
The Synchronizing Roller ensures that the paper is fed off from the transport section in
time with the exposure timing of the exposure section (PH).

1
5

Composition/Operation
3 4035M011AA

No. Name Function/System


1 Synchronizing Roller
Transports the paper onto the developing section.
2 Transport Roller
Prevents paper dust from sticking to the surface of the
3 Paper Dust Remover
PC Drum.
Determines the condition of the paper being trans-
4 Synchronizing Roller Sensor (PC1) ported, thereby detecting a paper misfeed and paper
transport timing.
5 Synchronizing Roller Clutch (CL1) Controls drive of the Synchronizing Roller.

39
bizhub_162_210_TO.book 40

14. Synchronizing roller section Theory of Operation Ver. 1.0 Apr. 2005

14.2 Operation
Drive from the Main Motor (M1) is transmitted through a gear train to the Synchronizing
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Roller Clutch (CL1).

2
Composition/Operation

4035M012AA

[1] Main Motor (M1) [2] Synchronizing Roller Clutch (CL1)

14.3 Paper Dust Remover


The Paper Dust Remover collects paper dust on the paper.

Paper Dust Remover

4035M012AA

40
bizhub_162_210_TO.book 41

Theory of Operation Ver. 1.0 Apr. 2005 15. Image transfer and paper separation section

15. Image transfer and paper separation section

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

15.2 Paper Separation Section


Paper separation is accomplished through the curvature separation system that works

Composition/Operation
on the diameters of the PC Drum and the Image Transfer Roller.
Since the PC Drum has a small diameter, there is no likelihood that the paper will be
wound around the PC Drum. The paper is separated by its own weight.
The Charge Neutralizing Plate neutralizes any charge left on the paper after image trans-
fer, thereby preventing discharge noise that could otherwise occur when the paper is
separated.
The PC Drum Paper Separator Fingers properly separate from the surface of the PC
Drum thin paper or other type of paper that is hard to separate.

PC Drum Paper Separator Fingers

PC Drum

Charge Neutralizing Plate

4021M037AA
Image Transfer Roller

41
bizhub_162_210_TO.book 42

16. Paper take-up Theory of Operation Ver. 1.0 Apr. 2005

16. Paper take-up


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16.1 Construction

3
2
1 4

6
Composition/Operation

4021M025AA

[1] Paper Size Detecting Board (PWB-I) [4] Feed Roller/1


[2] Paper Size Detecting Sensor (S11) [5] Separation Roller/1
[3] Paper Empty Sensor/1 (PC4) [6] Paper Lifting Plate

42
bizhub_162_210_TO.book 43

Theory of Operation Ver. 1.0 Apr. 2005 16. Paper take-up

16.2 Operation
The Main Motor (M1) provides the drive for paper take-up operations.

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The drive is transmitted through the Paper Take-up Solenoid/1.

Main Motor (M1)

Paper Take-up Solenoid/1 (SL1)

Feed Roller

Composition/Operation
4021M027AA

43
bizhub_162_210_TO.book 44

16. Paper take-up Theory of Operation Ver. 1.0 Apr. 2005

16.2.1 Paper Separating Mechanism


The coefficient of friction between the Feed Roller and Separation Roller is effectively
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used to prevent double feed of paper.


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

When two or more sheets of paper are taken up:


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

Feed Roller

Paper
Composition/Operation

Separation Roller

4021M060AB

44
bizhub_162_210_TO.book 45

Theory of Operation Ver. 1.0 Apr. 2005 16. Paper take-up

16.3 Drawer in Position Detection


When the drawer is slid into the copier, the light blocking plate blocks the Set Sensor.

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The copier then knows that the drawer has been slid in position.

Composition/Operation
Drawer Set Sensor (PC5)
4021M026AA

16.4 Paper Empty Detection Mechanism


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

Paper Empty Sensor/1 (PC4)

1167M073AD

45
bizhub_162_210_TO.book 46

16. Paper take-up Theory of Operation Ver. 1.0 Apr. 2005

16.5 Paper Lifting Plate


The Paper Lifting Plate is locked into position when it is pressed down. It is unlocked
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when the tray is slid into the unit.


The Paper Lifting Plate is pushed upward by the Paper Lifting Springs at all times.

Spring
Composition/Operation

Paper Lifting Plate


4021M063AA

16.6 Universal Tray Paper Size Detection Mechanism


Both the width (in the crosswise direction) and length (in the feeding direction) of the
paper are detected and the copier CPU determines the paper size based on the combi-
nation of the two readings.
The width (CD) of the paper is detected when the lever that is operatively connected to
the Edge Guide activates or deactivates the Paper Size (CD) Detection Sensor.
The length (FD) of the paper is detected when the lever that is operatively connected to
the Trailing Edge Stop actuates or deactuates the switches on the Paper Size (FD)
Detection Board.

Paper Size Detecting Sensor (S11)


Paper Size Detecting Board (PWB-I)

1 2 3 4

4011M009AA

46
bizhub_162_210_TO.book 47

Theory of Operation Ver. 1.0 Apr. 2005 16. Paper take-up

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


Paper Size Detected

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<For Metric>

Paper Size Detecting Board


PWB-I Paper Size Detecting
Paper Size
Sensor S11
SW1 SW2 SW3 SW4
B4
ON Activated A3
ON ON A5 R
ON ON Activated A4
ON A5, postcards
ON ON ON A5 R
ON ON ON Activated A4
ON ON B5
ON ON ON A4 R

Composition/Operation
ON ON ON ON B5 R

<For Inch>

Paper Size Detecting Board


PWB-I Paper Size Detecting
Paper Size
Sensor S11
SW1 SW2 SW3 SW4
B4, Legal

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

47
bizhub_162_210_TO.book 48

16. Paper take-up Theory of Operation Ver. 1.0 Apr. 2005

16.7 Paper Take Up Control


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Start Key ON

Main Motor M1 ON
OFF

Paper Take-Up ON
Solenoid SL1 OFF

Synchronizing Roller H
Sensor PC1 L
4021M515CA

16.7.1 Paper Take Up Retry Control


Composition/Operation

To minimize the occurrence of a paper misfeed, the paper take-up sequence is tempo-
rarily halted if the paper fails to reach the Synchronizing Roller Sensor within a given
period of time after the sequence has been started. The paper take-up sequence is then
performed again. These paper take-up sequences are repeated a given number of times.

No. of Paper Take-Up Retry Sequences


Paper Take-Up Retry 2

1st Paper Take-Up


Retry Sequence

Paper Take-Up ON
Solenoid SL1 OFF

Synchronizing Roller H
Sensor PC1 L

Successful paper take-up


4021M514CA

48
bizhub_162_210_TO.book 49

Theory of Operation Ver. 1.0 Apr. 2005 17. Manual bypass section

17. Manual bypass section

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17.1 Operation
Drive for bypass paper take-up is provided by the Main Motor (M1).
The drive is transmitted through the Paper Take-up Solenoid/Bypass.

Main Motor (M1)

Paper Set Sensor/Bypass (PC2)

Composition/Operation
Paper Take-up Solenoid/Bypass (SL2)

4021M028AA

17.2 Paper Detection Mechanism


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

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

Paper Set Sensor/Bypass (PC2)

Paper

4021M061AA 4021M029AA

49
bizhub_162_210_TO.book 50

17. Manual bypass section Theory of Operation Ver. 1.0 Apr. 2005

17.3 Manual Feed Take Up Control


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4034M539CA
Composition/Operation

50
bizhub_162_210_TO.book 51

Theory of Operation Ver. 1.0 Apr. 2005 18. Fusing unit section

18. Fusing unit section

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18.1 Construction (for bizhub 162)
Heat and pressure from the Fusing Roller permanently fuse toner onto the paper.

Composition/Operation
5
3

4034M523BA
4

[1] Fusing Roller Heater Lamp (H1) [4] Fusing Roller Thermostat (TS1)
[2] Fusing Roller/rt [5] Fusing Roller Thermistor (TH1)
[3] Pressure Lever [6] Fusing Roller

51
bizhub_162_210_TO.book 52

18. Fusing unit section Theory of Operation Ver. 1.0 Apr. 2005

18.2 Construction (for bizhub 210)


Heat and pressure from the Fusing Roller permanently fuse toner onto the paper.
bizhub 162
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1
2

8
Composition/Operation

4
4034M523CA
5, 6

[1] Fusing Roller Sub Heater Lamp (H2) [5] Fusing Roller Thermistor (TH1)
[2] Fusing Roller Heater Lamp (H1) [6] Fusing Roller Sub Thermistor (TH2)
[3] Fusing Roller/rt [7] Fusing Roller Thermostat
[4] Pressure Lever [8] Fusing Roller

52
bizhub_162_210_TO.book 53

Theory of Operation Ver. 1.0 Apr. 2005 18. Fusing unit section

18.3 Operation
The Main Motor (M1) provides the drive for the Fusing Unit.

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Main Motor (M1)

Fusing Roller/rt

Composition/Operation
Fusing Roller

4035M007AA

18.4 Fusing Roller Pressure Mechanism


To provide a nip width between the rollers, a Pressure Spring is used functioning to press
the Fusing Roller/rt up against the Fusing Roller.

Fusing Roller/rt

Pressure Lever

Fusing Roller
4034M508BA

Pressure Spring

53
bizhub_162_210_TO.book 54

18. Fusing unit section Theory of Operation Ver. 1.0 Apr. 2005

18.5 Fusing Temperature Control (for bizhub 162)


The Fusing Roller Heater Lamp is turned ON and OFF to keep a set temperature on the
bizhub 162
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surface of the Fusing Roller.


The Fusing Roller surface temperature is detected by using a thermistor that translates
the temperature to a corresponding electrical signal.
If the Fusing Roller temperature becomes excessively high, the Fusing Roller Heater
Lamp is shut down.

<Temperature Control in Standby State>

Warm-up completed
Composition/Operation

4034M541CA

Machine Condition or Paper Type Mode 1 Mode 2 Mode 3


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

54
bizhub_162_210_TO.book 55

Theory of Operation Ver. 1.0 Apr. 2005 18. Fusing unit section

18.6 Fusing Temperature Control (for bizhub 210)


The Fusing Roller Heater Lamp is turned ON and OFF to keep a set temperature on the

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surface of the Fusing Roller.
The Fusing Roller surface temperature is detected by using a thermistor that translates
the temperature to a corresponding electrical signal.
If the Fusing Roller temperature becomes excessively high, the Fusing Roller Heater
Lamp is shut down.

<Temperature Control in Standby State>

Warm-up completed

Composition/Operation
4034M507CA

Machine Condition or Paper Type Mode 1 Mode 2 Mode 3


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

55
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18. Fusing unit section Theory of Operation Ver. 1.0 Apr. 2005

18.7 PPM Control (bizhub 162 Only)


If paper of a small size (width of 250 mm or less) or thick paper is used to run a multi-
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copy cycle, the temperature on the edges of the Fusing Rollers tends to run high, mean-
ing that the temperature of the Fusing Rollers varies among different spots of the rollers.
When the cumulative number of copies made through continuous copy cycles* exceeds
30, the paper take-up interval is made longer, thereby allowing the temperatures of the
Fusing Rollers at different spots to be uniform.
Continuous copy cycle: Continuous copy cycles run with an interval of 2 min. or less
between cycles.
Composition/Operation

56
bizhub_162_210_TO.book 57

Theory of Operation Ver. 1.0 Apr. 2005 19. Paper exit (for bizhub 162)

19. Paper exit (for bizhub 162)

bizhub 162
bizhub 210
19.1 Construction

Composition/Operation
4035M008AB

[1] Main Motor (M1) [2] Exit Roller

19.2 Operation
The Main Motor (M1) provides the drive for the exit section.

4035M009AC

57
bizhub_162_210_TO.book 58

20. Paper exit (for bizhub 210) Theory of Operation Ver. 1.0 Apr. 2005

20. Paper exit (for bizhub 210)


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20.1 Construction

2
Composition/Operation

4034M545CA

[1] Duplex Unit Switchback Motor (M31) [2] Exit Roller

20.2 Operation
The exit rollers are driven by the Duplex Unit Switchback Motor (M31).

4034M546CA

58
bizhub_162_210_TO.book 59

Theory of Operation Ver. 1.0 Apr. 2005 21. Image stabilization system

21. Image stabilization system

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The following image stabilization controls are provided to ensure stabilized copy image.

Purpose Means Control


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

Composition/Operation

4034M540CA

59
bizhub_162_210_TO.book 60

22. Others Theory of Operation Ver. 1.0 Apr. 2005

22. Others
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22.1 Fan Control


22.1.1 Power Supply Section Cooling Mechanism
A cooling fan motor draws air from the area around the Power Supply Unit to the outside
to prevent the Power Supply Unit temperature from running high.
The cooling fan motor is turned at full speed when the Main Motor turns and at a speed
reduction during other timings, thereby making the machine quieter without sacrificing
cooling performance.
Composition/Operation

Power Unit Cooling Fan


Motor (M4)
4034M535AA

60
bizhub_162_210_TO.book 61

Theory of Operation Ver. 1.0 Apr. 2005 22. Others

22.1.2 Fusing Section Cooling Mechanism


A fan motor draws air from the area around the Fusing Unit to the outside to prevent the

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machine interior temperature from running high. In addition, the fan motor pulls paper
being transported up through suction force to help stabilize paper transport.
Ozone produced from the PC Drum Charge Corona is absorbed by the Ozone Filter from
the air drawn by a fan motor to the outside.
The fan motor is turned at full speed during a print cycle and at a speed reduction during
other timings, thereby making the machine quieter without sacrificing cooling perfor-
mance.

Composition/Operation
Fusing Cooling Fan Motor (M3)

Ozone Filter

4034M521AA

61
bizhub_162_210_TO.book 62

22. Others Theory of Operation Ver. 1.0 Apr. 2005


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Composition/Operation

Blank page

62
bizhub_162_210_TO.book 1

SERVICE MANUAL THEORY OF OPERATION

DF-502

2005.04
Ver. 1.0
bizhub_162_210_TO.book 2
bizhub_162_210_TO.book 1

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.

2005/04 1.0 Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision
bizhub_162_210_TO.book 2
bizhub_162_210_TO.book i

Theory of Operation Ver. 1.0 Apr. 2005

CONTENTS

DF-502
Outline
1. Product specification ............................................................................................... 1

Composition/Operation
2. Automatic Document Feeder (DF-502) ................................................................... 3
2.1 Construction ......................................................................................................... 3

Outline
2.2 Operation .............................................................................................................. 4
2.2.1 Document Take-Up and Feed ....................................................................... 4
2.2.2 Document Transport...................................................................................... 5
2.3 Electrical Parts Layout .......................................................................................... 6
2.4 Document Separating Mechanism........................................................................ 7

Composition/Operation
2.5 Document Exit Mechanism ................................................................................... 8
2.6 Document Size Detection Mechanism.................................................................. 9
2.7 Raised/Lowered Position Detection Mechanism................................................... 9

i
bizhub_162_210_TO.book ii

Theory of Operation Ver. 1.0 Apr. 2005


DF-502
Outline
Composition/Operation

Blank page

ii
bizhub_162_210_TO.book 1

Theory of Operation Ver. 1.0 Apr. 2005 1. Product specification

Outline
1. Product specification

DF-502
Name Automatic Document Feeder
Installation Inserted in top portion of the copier
Modes Standard = 1-sided original
Mixed Original = 1-sided original
Document Loading Left-hand side, face up

Outline
Types and Sizes of Document

Standard Mixed Original


Type Plain paper (50 to 110 g/m2) Plain paper (60 to 90 g/m2)
A3, A4 R, A4, A5 R, B4, B5 R, B5, A3 and A4, B4 and B5, 11 x 17 and
Sizes 11 x 17, 11 x 14, Legal, Letter R, Letter, Letter, Legal and Letter R, Legal and
Invoice R, and Invoice Invoice, Letter R and Invoice

Document Alignment Center


Capacity 50 sheets max. (80 g/m2)
Power Requirements DC24 V, DC5 V (supplied from the copier)
Power Consumption 36 W or less
Dimensions Width = 598 mm, Depth = 483 mm, Height = 102 mm
Mass 6.3 kg
Operating Environment Conforms to that of the copier

Types of Originals Not Guaranteed for Reliable Feeding

Type of Original Possible Problems


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

1
bizhub_162_210_TO.book 2

1. Product specification Theory of Operation Ver. 1.0 Apr. 2005


DF-502
Outline

Blank page

2
bizhub_162_210_TO.book 3

Theory of Operation Ver. 1.0 Apr. 2005 2. Automatic Document Feeder (DF-502)

Composition/Operation
2. Automatic Document Feeder (DF-502)

DF-502
2.1 Construction

Composition/Operation
5

4688M502AA

[1] Main Motor [4] Registration Rollers


[2] Pick-Up Roller [5] Take-Up Roller
[3] Exit Rollers [6] Take-Up Clutch

3
bizhub_162_210_TO.book 4

2. Automatic Document Feeder (DF-502) Theory of Operation Ver. 1.0 Apr. 2005

2.2 Operation
2.2.1 Document Take-Up and Feed
DF-502

The document is taken up as the Pick-Up Roller and Take-Up Roller turn.
The Pick-Up Roller transports the document up to the Take-Up Roller.
After a scan is completed, the Main Motor is turned backward to raise the Pick-Up Roller.
The Pick-Up Roller and the Take-Up Roller are turned through the Paper Take-Up Clutch
and by a gear train and a belt driven by the Main Motor.
The Paper Empty Sensor is used to detect a document loaded on the Document Loading
Tray.
The Document Stoppers determine the leading edge position of the document loaded on
the Document Loading Tray. They are in the lowered, swung-down position in the
standby state and swing upward when the document is to be taken up.
The swing-up and swing-down motion of the Document Stoppers is operatively con-
nected to the raising and lowering of the Pick-Up Roller.

Paper Take-Up Clutch (CL1)


Composition/Operation

Main Motor (M1)

Pick-Up Roller

Paper Empty Sensor (PC2)


4688M005AA
Take-Up Roller
Document Stoppers

4
bizhub_162_210_TO.book 5

Theory of Operation Ver. 1.0 Apr. 2005 2. Automatic Document Feeder (DF-502)

2.2.2 Document Transport


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

DF-502
by the Registration Rollers.
The Registration Rollers are turned by a gear train and belts which are driven by the
Main Motor.

Main Motor (M1)

Composition/Operation
Registration Rollers

4688M007AA

5
bizhub_162_210_TO.book 6

2. Automatic Document Feeder (DF-502) Theory of Operation Ver. 1.0 Apr. 2005

2.3 Electrical Parts Layout


DF-502

PC9
PC12
PC8
PWB PC6

PC11 PC7

PC1
CL1 PC10

PC2
PC4

PC5
Composition/Operation

PC3

4688M505CA

Symbol Name Symbol Name


PWB Interface Board PC5 Paper Exit Sensor
M1 Main Motor PC6 Length Size Detection Sensor 1
CL1 Paper Take-Up Clutch PC7 Length Size Detection Sensor 2
PC1 Take-Up Cover Open/Close PC8 Length Size Detection Sensor 3
Detecting Sensor PC9 Length Size Detection Sensor 4
PC2 Paper Empty Sensor PC10 Width Size Detection Sensor 1
PC3 Registration Sensor PC11 Width Size Detection Sensor 2
PC4 Separator Sensor PC12 Width Size Detection Sensor 3

6
bizhub_162_210_TO.book 7

Theory of Operation Ver. 1.0 Apr. 2005 2. Automatic Document Feeder (DF-502)

2.4 Document Separating Mechanism


The coefficient of friction between the Take-Up Roller and Separation Roller is effectively

DF-502
used to prevent double feed of paper.

Since the friction coefficient on the top side of the paper is equal to that
When one sheet of paper is
on the underside of the paper, the Separation Roller is turned by the
taken up
Take-up Roller. This feeds the paper forward.
The friction coefficient between the sheets of paper is smaller than that
When two or more sheets of between the paper and Separation Roller. This stops the Separation
paper are taken up Roller, allowing only the first sheet of paper to be transported by the
Take-up Roller.

Composition/Operation
Take-Up Roller

Separation Roller 4688M006AA

7
bizhub_162_210_TO.book 8

2. Automatic Document Feeder (DF-502) Theory of Operation Ver. 1.0 Apr. 2005

2.5 Document Exit Mechanism


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

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

Main Motor (M1)

Exit Rollers
Composition/Operation

4688M008AA

8
bizhub_162_210_TO.book 9

Theory of Operation Ver. 1.0 Apr. 2005 2. Automatic Document Feeder (DF-502)

2.6 Document Size Detection Mechanism


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

DF-502
detection and document length detection.

Document Width Detection


The width of an original is detected by the combination of Paper Width Sensors as
detected while the original is being taken up.
Each sensor is located as follows with reference to the Document Edge Guide in the rear.

Document Length Detection


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

2.7 Raised/Lowered Position Detection Mechanism


There is a magnet installed in the ADF body to allow the copier to know that the ADF is
raised or lowered.

Composition/Operation
This magnet actuates the Size Reset Switch on the copier.

Magnet

4034M521AA
Size Reset Switch (S5)

9
bizhub_162_210_TO.book 10

2. Automatic Document Feeder (DF-502) Theory of Operation Ver. 1.0 Apr. 2005
DF-502
Composition/Operation

Blank page

10
bizhub_162_210_TO.book 1

SERVICE MANUAL THEORY OF OPERATION

DF-605

2005.04
Ver. 1.0
bizhub_162_210_TO.book 2
bizhub_162_210_TO.book 1

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.

2005/04 1.0 Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision
bizhub_162_210_TO.book 2
bizhub_162_210_TO.book i

Theory of Operation Ver. 1.0 Apr. 2005

CONTENTS

DF-605
Outline
1. Product specification ............................................................................................... 1

Composition/Operation
2. Duplexing Document Feeder (DF-605) ................................................................... 5
2.1 Construction ......................................................................................................... 5

Outline
2.2 Operation .............................................................................................................. 6
2.3 Electric Parts Layout............................................................................................. 7
2.4 Document Size Detection ..................................................................................... 8
2.5 Document Transport ............................................................................................. 8
2.5.1 In 1-sided mode ............................................................................................ 8

Composition/Operation
2.6 In 2-sided mode .................................................................................................... 9

i
bizhub_162_210_TO.book ii

Theory of Operation Ver. 1.0 Apr. 2005


DF-605
Outline
Composition/Operation

Blank page

ii
bizhub_162_210_TO.book 1

Theory of Operation Ver. 1.0 Apr. 2005 1. Product specification

Outline
1. Product specification

DF-605
Name Duplexing Document Feeder
Type Paper take-up = U-turn upper exit system
Turnover = Switchback turnover system
Exit = Straight exit system
Installation Screwed to the copier
Types of Document Standard mode

Outline
Plain paper: 1-sided mode = 35 to 128 g/m2
2-sided mode = 50 to 128 g/m2
Mixed Original mode
Plain paper: 1-sided/2-sided mode = 50 to 128 g/m2
FAX mode
Plain paper: 1-sided mode = 35 to 128 g/m2
2-sided mode = 50 to 128 g/m2
Detectable Document Sizes Standard mode
B6 R, A5 R, A5, B5 R, B5, A4 R, A4, B4, A3, Ledger, 11 x 15, Letter R,
Letter, FLS (210 mm x 330 mm)
FAX mode
A5 R, A5, B5 R, B5, A4 R, A4, B4, A3, Ledger, 11 x 15, Letter R, Letter,
FLS (210 mm x 330 mm)
Width: 128 mm to 297 mm
Length: 1-sided mode = 100 mm to 1000 mm
2-sided mode = 139.7 mm to 431.8 mm
The original measuring more than 431.8 mm and up to 1000 mm can be
loaded one sheet at a time, and no guarantees are given for good image
quality or reliable feeding.
See the table of permissible combination of sizes in Mixed Original
mode.
Capacity 80 sheets (80 g/m2) or load height of 11 mm or less
Document Alignment Center
Document Loading Left-hand side, face up
Modes 1-sided mode and 2-sided mode
Power Requirements DC24 V 10% (supplied from the copier)
DC5 V 5% (generated inside the AFR)
Max. Power Consumption 48 W or less
Dimensions Width = 582 mm, Depth = 558 mm, Height = 145 mm
Mass 10 kg or less
Operating Environment Conforms to that of the copier

1
bizhub_162_210_TO.book 2

1. Product specification Theory of Operation Ver. 1.0 Apr. 2005

<Table of Permissible Combination of Sizes in Mixed Original Mode>


For Inch
DF-605

Maximum Original Width


Mixed Original Size 11 8-1/2 5-1/2
11 X 17 8-1/2 x 11 8-1/2 x 14 8-1/2 x 11 8-1/2 x 5-1/2 8-1/2 x 5-1/2R
11 X 17 - - - -
11
8-1/2 x 11 - - - -
8-1/2 x 14 -
8-1/2
8-1/2 x 11 -

Outline

8-1/2 x 5-1/2 -
5-1/2
8-1/2 x 5-1/2R

For Metric

Max. Original Width


Mixed Original
297 mm 257 mm 210 mm 182 mm 148 mm 123 mm
Size
A3 A4 B4 B5 A4 R A5 B5 R A5 R B6 R
A3 - - - - - - -
297 mm
A4 - - - - - - -
B4 - - - - -
257 mm
B5 - - - - -
A4 R - - -
210 mm
A5 - - -
182 mm B5 R - -
148 mm A5 R -
123 mm B6 R

Same width
Leading edge tilt 1.5 % or less
Combination allowed
Leading edge tilt 2 % or less is 80 % or more
Combination not allowed
- Cannot be set

2
bizhub_162_210_TO.book 3

Theory of Operation Ver. 1.0 Apr. 2005 1. Product specification

Prohibited original: Original that has a high possibility of causing problems if used.

Type of Document Expected Problem

DF-605
Paper take-up failure, damage to the original, or drive
Original that is stapled or clipped.
failure due to clip clogging
Glued original Paper take-up failure or damage to the original
Paper take-up failure, damage to the original, or drive
Book original
failure
Original weighing less than 35g/m2 or 129g/m2
Paper take-up failure
or more
Original with many dog-ears, tears, or wrinkles. Paper take-up failure or damage to the original

Outline
Highly curled original (15 mm or more) Original misfeed due to dog-ear or skew
OHP film Paper take-up failure
Label Sheet Paper take-up failure
Offset master Paper take-up failure
Original with cutouts Damage to the original
Cut-and-pasted original Dog-ear or tear at the cut-and-paste section

Originals not guaranteed for reliable feeding: Original that can be fed to some extent but is
highly prone to cause problems if used.

Type of Document Expected Problem


Original with small curls (amount of curl 10 or
Dog-ear or output failure
15 mm)
Leading edge crease, output failure, or paper trans-
Thermosensitive paper
port failure
Inkjet paper Paper take-up failure or paper transport failure
Paper with smooth surface (coated paper) Paper take-up failure or paper transport failure
Translucent original Paper take-up failure or paper transport failure
Paper immediately after it is output from the
Paper take-up failure or paper transport failure
copier
Paper with many holes (restricted to vertical
Multi-page feed due to flashes from holes
feeding of loose leaf, etc.)
Original with 2 to 4 holes Paper Transport Failure
Folded or Z-fold Original (amount of float 15 Paper take-up failure, paper transport failure, or dis-
mm or less) torted image
Original with bumpy surface (letterhead, etc.) Paper take-up failure
Original written in pencil Smudged original
Distorted image, multi-page feeding, or paper take-up
Folded original
failure

3
bizhub_162_210_TO.book 4

1. Product specification Theory of Operation Ver. 1.0 Apr. 2005


DF-605
Outline

Blank page

4
bizhub_162_210_TO.book 5

Theory of Operation Ver. 1.0 Apr. 2005 2. Duplexing Document Feeder (DF-605)

Composition/Operation
2. Duplexing Document Feeder (DF-605)

DF-605
2.1 Construction

1
4

Composition/Operation
5
7

6
4344M001AB

[1] Transport Motor (M2-ADF) [5] Exit/Turnover Roller


[2] Take-up Motor (M1-ADF) [6] Transport Roller
[3] Feed Roller [7] Registration Roller
[4] Pickup Rollers

5
bizhub_162_210_TO.book 6

2. Duplexing Document Feeder (DF-605) Theory of Operation Ver. 1.0 Apr. 2005

2.2 Operation
When the Start key is pressed with a document loaded in the AFR, the Take-up Motor
DF-605

starts turning backward, causing the Pickup Roller to lower and start turning at the same
time. At the same time, the Take-up Roller starts turning.
When the document reaches the Registration Sensor, the Feed Roller starts turning for-
ward and, at the same time that the Pickup Roller goes up, drive is then supplied to the
Registration Roller.
When the Transport Motor starts turning forward, the two Transport Rollers and the Exit/
Turnover Roller feed the document toward the exit direction.
During turnover, the Transport Motor turns backward to turn the two Transport Rollers
and the Exit/Turnover Roller backward.

Transport Motor
Take-up Motor
Composition/Operation

4034M520AA

6
bizhub_162_210_TO.book 7

Theory of Operation Ver. 1.0 Apr. 2005 2. Duplexing Document Feeder (DF-605)

2.3 Electric Parts Layout

DF-605
PBA-TRAY

PBA-CONT

M3-ADF

PC7-ADF PC4-ADF

PC3-ADF

PC1-ADF PC2-ADF

PBA-VR
M1-ADF PC6-ADF
M2-ADF

Composition/Operation
PBA-SIZE
PC9-ADF
PBA-LED
PC10-ADF
PC8-ADF SL1-ADF
SL2-ADF PC5-ADF
4344M002AB

Symbol Name Symbol Name


PBA-CONT Control Board PC1-ADF FD Paper Size Detection Sensor 1
PBA-LED Print Lamp Board PC2-ADF FD Paper Size Detection Sensor 2
PBA-SIZE Mix Document Size Detection Board PC3-ADF FD Paper Size Detection Sensor 3
Interface Board PC4-ADF FD Paper Size Detection Sensor 4
PBA-TRAY Variable Resistor PC5-ADF Empty Sensor
PBA-VR Paper Take-Up Motor PC6-ADF Separator Sensor
M1-ADF Transport Motor PC7-ADF Upper Door Open/Close Sensor
M2-ADF Cooling Fan Motor PC8-ADF Original Detection Sensor
M3-ADF Exit Roller Retraction Solenoid PC9-ADF Regist Sensor
SL1-ADF Stamp Solenoid PC10-ADF Exit/Turnover Sensor
SL2-ADF*1

*1: When Complete Stamp Unit 2 is installed.

7
bizhub_162_210_TO.book 8

2. Duplexing Document Feeder (DF-605) Theory of Operation Ver. 1.0 Apr. 2005

2.4 Document Size Detection


DF-605

Mixed Document Size Detection Sensor

Original Feed Sensor Document Size VR

Empty Sensor FD Paper Size Detection Sensors

4034M536AA
Registration Sensor Exit/Turnover Sensor

Original Detection Sensor


Composition/Operation

<Ordinary Copying>
The document size is detected by three FD Paper Size Detection Sensors and one Doc-
ument Size VR.
<Mixed Original Mode>
The Registration Sensor detects the length of the document, while the three Mixed Doc-
ument Size Detection Sensors detect the width of the document.

2.5 Document Transport


2.5.1 In 1-sided mode

Exit

Scanning the 1st side 4034M537AA

1. When the Start key is pressed, the Take-up Motor starts turning backward, causing
the Pickup Roller to lower and start a paper take-up sequence.
2. The scanning of the 1st side is started after the lapse of a given period of time after
the Original Detection Sensor has been activated by the leading edge of the origi-
nal.
3. The original is transported for a given period of time after the trailing edge of the
last page of the document has deactivated the Exit/Turnover Sensor. It is then fed
into the Exit Tray and the Transport Motor is deenergized.

8
bizhub_162_210_TO.book 9

Theory of Operation Ver. 1.0 Apr. 2005 2. Duplexing Document Feeder (DF-605)

2.6 In 2-sided mode


1. When the Start key is pressed, the Take-up Motor starts turning backward, causing

DF-605
the Pickup Roller to lower and start feeding the 1st page of the document.
The scanning of the 1st side is started after the lapse of a given period of time after
the Original Detection Sensor has been activated by the leading edge of the 1st
page.
The Transport Motor is deenergized to stop the original after the lapse of a given
period of time after the trailing edge of the 1st page has deactivated the Exit/Turn-
over Sensor.

Stop

Composition/Operation
Scanning the 1st side 4034M537AA

2. The Transport Motor is turned backward to turn over the original. After the Registra-
tion Roller, the Transport Motor is turned forward to allow the Scanner to scan the
backside of the 1st page.
3. After the transport sequence for turnover has been started, the Exit Roller Retrac-
tion Solenoid is energized so that the Exit/Turnover Roller is retracted.

Turnover
Stop

Scanning the 2nd side 4034M538AA

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

Turnover
Stop

4034M538AA

9
bizhub_162_210_TO.book 10

2. Duplexing Document Feeder (DF-605) Theory of Operation Ver. 1.0 Apr. 2005
DF-605
Composition/Operation

Blank page

10
bizhub_162_210_TO.book 1

SERVICE MANUAL THEORY OF OPERATION

AD-504

2005.04
Ver. 1.0
bizhub_162_210_TO.book 2
bizhub_162_210_TO.book 1

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.

2005/04 1.0 Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision
bizhub_162_210_TO.book 2
bizhub_162_210_TO.book i

Theory of Operation Ver. 1.0 Apr. 2005

CONTENTS

AD-504
Outline
1. Product specification ............................................................................................... 1

Composition/Operation
2. Duplex Unit (AD-504) .............................................................................................. 3
2.1 Construction ......................................................................................................... 3

Outline
2.2 Operation .............................................................................................................. 4
2.3 Electric Parts Layout............................................................................................. 4
2.4 Switchback Operation........................................................................................... 5
2.5 2-sided Copying with a Single Sheet of Paper Resident in the Unit ..................... 6
2.5.1 Operation ...................................................................................................... 6

Composition/Operation
2.6 2-sided Copying with Two Sheets of Paper Resident in the Unit .......................... 7
2.6.1 Operation ...................................................................................................... 7

i
bizhub_162_210_TO.book ii

Theory of Operation Ver. 1.0 Apr. 2005


AD-504
Outline
Composition/Operation

Blank page

ii
bizhub_162_210_TO.book 1

Theory of Operation Ver. 1.0 Apr. 2005 1. Product specification

Outline
1. Product specification

AD-504
Name Duplex Unit
Type Sheet duplex paper take-up section
Installation Installed to the right side door
Paper Size A3, A4 R, A4, A5 R, A5, B4, B5 R, B5, FLS, Ledger, Legal, Letter,
Invoice R, Invoice
Paper Type Plain paper (60 to 90 g/m2), recycled paper (60 to 90 g/m2)

Outline
Document Alignment Center
Power Requirements DC24 V (supplied from the copier)
DC5 V
Max. Power Consumption 9 W or less
Dimensions Width = 412 mm
Depth = 215 mm
Height = 88 mm
Mass 2.5 kg (Duplex Unit + Manual Bypass Assy
Operating Environment Conforms to that of the copier

1
bizhub_162_210_TO.book 2

1. Product specification Theory of Operation Ver. 1.0 Apr. 2005


AD-504
Outline

Blank page

2
bizhub_162_210_TO.book 3

Theory of Operation Ver. 1.0 Apr. 2005 2. Duplex Unit (AD-504)

Composition/Operation
2. Duplex Unit (AD-504)

AD-504
2.1 Construction

3
4

Composition/Operation
4532M503AA

[1] Duplex Unit Transport Roller 1 [3] Duplex Unit Transport Roller 2
[2] Duplex Unit Transport Roll 1 [4] Duplex Unit Transport Roll 2

3
bizhub_162_210_TO.book 4

2. Duplex Unit (AD-504) Theory of Operation Ver. 1.0 Apr. 2005

2.2 Operation
The Duplex Unit Transport Motor provides the drive for the Duplex Unit.
AD-504
Composition/Operation

4532M501AA

2.3 Electric Parts Layout

4532M001AA
2

[1] Duplex Unit Transport Motor (M2/AD) [3] Control Board (PWB-A/AD)
[2] Duplex Unit Transport Sensor (PC2/AD)

4
bizhub_162_210_TO.book 5

Theory of Operation Ver. 1.0 Apr. 2005 2. Duplex Unit (AD-504)

2.4 Switchback Operation


The paper printed on one side is switched back by the exit rollers on copier to transport it

AD-504
into the duplex unit.
The switchback operation of transport rollers is carried out by the Duplex Unit Switch-
back Motor.

Composition/Operation
4532M502CA

5
bizhub_162_210_TO.book 6

2. Duplex Unit (AD-504) Theory of Operation Ver. 1.0 Apr. 2005

2.5 2-sided Copying with a Single Sheet of Paper Resident in the


Unit
AD-504

2.5.1 Operation

1. The first sheet of paper is taken up


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

4034M510AA

2. Immediately before the first sheet of


paper leaves the Paper Exit Roller,
the direction of rotation of the Paper
Exit Roller is reversed and the first
Composition/Operation

sheet of paper is transported toward


and into the Duplex Unit.

4034M511AA

3. The paper moving through the


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

4034M512AA

4. The image of page 1 of the original is


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

4034M513AA

5. While the first sheet of paper is being


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

4034M514AA

Steps 2 through 5 are repeated.

6
bizhub_162_210_TO.book 7

Theory of Operation Ver. 1.0 Apr. 2005 2. Duplex Unit (AD-504)

2.6 2-sided Copying with Two Sheets of Paper Resident in the


Unit

AD-504
2.6.1 Operation

1. The first sheet of paper is taken up


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

4034M510AA

2. Immediately before the first sheet of


paper leaves the Paper Exit Roller,
the direction of rotation of the Paper
Exit Roller is reversed and the first

Composition/Operation
sheet of paper is transported toward
and into the Duplex Unit.
3. At the same time, the second sheet
4034M511AA
of paper is taken up and fed in.

4. The image of page 4 of the original is


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

4034M512AA

6. The image of page 1 of the original is


printed on the other side of the first
sheet of paper that has been fed into
the copier again.
7. At the same time, the second sheet
of paper is subjected to a switchback
sequence at the exit section.
4034M513AA
8. It is then fed through the Duplex Unit
without.

9. While the first sheet of paper is being


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

4034M514AA

7
bizhub_162_210_TO.book 8

2. Duplex Unit (AD-504) Theory of Operation Ver. 1.0 Apr. 2005

10. While the second sheet of paper is


being fed out of the copier, the third
sheet of paper is taken up and the
AD-504

image of page 6 of the original is


printed.

4034M514AA

Steps 2 through 10 are repeated.


Composition/Operation

8
bizhub_162_210_TO.book 1

SERVICE MANUAL THEORY OF OPERATION

PF-502

2005.04
Ver. 1.0
bizhub_162_210_TO.book 2
bizhub_162_210_TO.book 1

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.

2005/04 1.0 Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision
bizhub_162_210_TO.book 2
bizhub_162_210_TO.book i

Theory of Operation Ver. 1.0 Apr. 2005

CONTENTS

PF-502
Outline
1. Product specification ............................................................................................... 1

Composition/Operation
2. Paper Feed Unit (PF-502) ....................................................................................... 3
2.1 Construction ......................................................................................................... 3

Outline
2.2 Operation .............................................................................................................. 3
2.3 Edge Guide and Trailing Edge Stop...................................................................... 4
2.4 Paper Lifting Plate ................................................................................................ 4
2.5 Tray-in-Position Detection ..................................................................................... 5
2.6 Paper Empty Detection ......................................................................................... 5

Composition/Operation
2.7 Paper Size Detecting Mechanism......................................................................... 6
2.8 Paper Separating Mechanism .............................................................................. 7
2.9 Paper Take-Up Control ......................................................................................... 8
2.10 Paper Take-Up Retry Control................................................................................ 8

i
bizhub_162_210_TO.book ii

Theory of Operation Ver. 1.0 Apr. 2005


PF-502
Outline
Composition/Operation

Blank page

ii
bizhub_162_210_TO.book 1

Theory of Operation Ver. 1.0 Apr. 2005 1. Product specification

Outline
1. Product specification

PF-502
Name Add-on paper feed unit
Installation Installed on the underside of the copier

Types and Sizes of Paper

Plain paper (60 to 90 g/m2)


Type 250 sheets

Outline
Recycled paper (60 to 90 g/m2)
Metric areas: A3, A4 R, A4, A5, B4, B5 R, and B5
Sizes Inch areas: Ledger (11 x 17), 11 x 14, Legal (8-1/2 x 14), Letter/R (8-1/2 x 11/R), and
Invoice (5-1/2 x 8-1/2)

Paper Alignment Center


Capacity 250 sheets
Power Requirements DC24 V, DC5 V (supplied from the copier)
Power Consumption 9 W or less
Dimensions Width = 590 mm
Depth = 558 mm
Height = 108 mm
Mass 5.5 kg
Operating Environment Conforms to that of the copier

1
bizhub_162_210_TO.book 2

1. Product specification Theory of Operation Ver. 1.0 Apr. 2005


PF-502
Outline

Blank page

2
bizhub_162_210_TO.book 3

Theory of Operation Ver. 1.0 Apr. 2005 2. Paper Feed Unit (PF-502)

Composition/Operation
2. Paper Feed Unit (PF-502)

PF-502
2.1 Construction

Composition/Operation
2

4 3
4686M004AA

[1] Trailing Edge Stop [3] Paper Lifting Plate


[2] Side Door [4] Edge Guide

2.2 Operation
Drive from the Main Motor (M1) is transmitted via a gear train to the paper take-up mech-
anism for the Paper Feed Unit.

Vertical Transport Roller

Paper Take-Up Drive


Mechanism

Feed Roller

4686M003AA

3
bizhub_162_210_TO.book 4

2. Paper Feed Unit (PF-502) Theory of Operation Ver. 1.0 Apr. 2005

2.3 Edge Guide and Trailing Edge Stop


The Edge Guide and Trailing Edge Stop can be slid into any desired position.
PF-502

Trailing Edge Stop Edge Guide

4686M005AA 4686M009AA
Composition/Operation

2.4 Paper Lifting Plate


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

Paper Lifting Spring

Paper Lifting Plate


4686M006AA

4
bizhub_162_210_TO.book 5

Theory of Operation Ver. 1.0 Apr. 2005 2. Paper Feed Unit (PF-502)

2.5 Tray-in-Position Detection


When a tray is slid into the cabinet, the Drawer Set Sensor is blocked and the copier

PF-502
determines that the tray has been slid in position.

Light Blocking Plate

Composition/Operation
Drawer Set Sensor (PC13/PF)
4686M007AA

2.6 Paper Empty Detection


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

Paper Empty Sensor (PC11/PF) 4686M008AA

5
bizhub_162_210_TO.book 6

2. Paper Feed Unit (PF-502) Theory of Operation Ver. 1.0 Apr. 2005

2.7 Paper Size Detecting Mechanism


Both the width (in the crosswise direction) and length (in the feeding direction) of the
PF-502

paper are detected and the copier CPU determines the paper size based on the combi-
nation of the two readings.
The width (CD) of the paper is detected when the lever that is operatively connected to
the Edge Guide activates or deactivates the Paper Size (CD) Detection Sensor.
The length (FD) of the paper is detected when the lever that is operatively connected to
the Trailing Edge Stop actuates or deactuates the switches on the Paper Size (FD)
Detection Board.

Paper Size (FD) Detection Board


(PWB-I/PF)

SW4 SW3 SW2 SW1


Composition/Operation

Paper Size (CD) Detection Sensor


(S11/PF)

4686M511AA

Trailing Edge Stop Edge Guide

Paper Size (FD) Detection Board


(PWB-I/PF) Paper Size (CD) Detection Sensor
Paper Size
(S11/PF)
SW4 SW3 SW2 SW1
A3 ON ON
B4
A4 R ON ON ON
A4 ON ON ON
B5 R ON ON ON ON
B5 ON ON
A5 ON

6
bizhub_162_210_TO.book 7

Theory of Operation Ver. 1.0 Apr. 2005 2. Paper Feed Unit (PF-502)

2.8 Paper Separating Mechanism


A loop is formed in the paper between the Separator Fingers and the Feed Roller. The

PF-502
turning force of the Feed Roller overcomes the block of the Separator Fingers, causing
the top sheet of paper to ride over the fingers and be fed out of the tray into the copier.
When there are only two sheets of left in the tray and if the friction force of the Paper Lift-
ing Plate is low, the bottom sheet of paper is taken up and fed into the copier with the top
sheet of paper. To prevent this situation from occurring, there is a Friction Plate provided
on top of the Paper Lifting Plate.
Before the Feed Roller contacts the paper, the Feed Roller holds the paper down so that
the paper remains stationary before its being taken up by the Feed Roller.

Feed Roller

Paper

Composition/Operation
Separator Finger
Roll

4686M010AA
Friction Plate
Paper Lifting Plate

7
bizhub_162_210_TO.book 8

2. Paper Feed Unit (PF-502) Theory of Operation Ver. 1.0 Apr. 2005

2.9 Paper Take-Up Control


The operation of the Paper Take-Up Solenoid is controlled by the signal output from
PF-502

PJ3A-1 and 2 of the Control Board.

For the 2nd Tray


Composition/Operation

4686M514CA

2.10 Paper Take-Up Retry Control


To minimize the occurrence of paper misfeed, the Paper Take-Up Solenoid is energized a
second time to carry out a paper take-up retry sequence if a sheet of paper fails to reach
the Synchronizing Roller Sensor (for the 2nd Tray) or the Paper Take-Up Sensor (for the
3rd to 5th Tray) within a given period of time after a paper take-up sequence has been
initiated. This sequence is repeated a predetermined number of times.

For the 2nd Tray

No. of Paper Take-Up Retry Sequences


Paper Take-Up Retry 1

4686M515CA

8
bizhub_162_210_TO.book 1

SERVICE MANUAL THEORY OF OPERATION

MB-501

2005.04
Ver. 1.0
bizhub_162_210_TO.book 2
bizhub_162_210_TO.book 1

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.

2005/04 1.0 Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision
bizhub_162_210_TO.book 2
bizhub_162_210_TO.book i

Theory of Operation Ver. 1.0 Apr. 2005

CONTENTS

MB-501
Outline
1. Product specification ............................................................................................... 1

Composition/Operation
2. Multiple Bypass (MB-501) ....................................................................................... 3
2.1 Construction ......................................................................................................... 3

Outline
2.2 Operation .............................................................................................................. 4
2.3 Paper Take-Up Mechanism................................................................................... 5
2.4 Paper Empty Detection Mechanism ..................................................................... 6
2.5 Paper Take Up Control.......................................................................................... 6
2.6 Paper Take Up Retry Control ................................................................................ 7

Composition/Operation

i
bizhub_162_210_TO.book ii

Theory of Operation Ver. 1.0 Apr. 2005


MB-501
Outline
Composition/Operation

Blank page

ii
bizhub_162_210_TO.book 1

Theory of Operation Ver. 1.0 Apr. 2005 1. Product specification

Outline
1. Product specification

MB-501
Name Multiple Bypass Tray
Installation Screwed to the copier

Copy Medium

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

Outline
OHP film
Thick Paper (91 to 157 g/m2) 20 sheets
Type
Postcards and Labels
Envelopes 10 sheets
Recycled Paper (60 to 90 g/m2) 100 sheets
Width 90 X 297 mm
Size
Length 140 X 432 mm
A3, A4 R, A4, A5, A5 R, B4, B5 R, B5, FLS, Ledger, 11 x 14, Legal,
Sizes
Letter R, Letter, Invoice R, Invoice, 8K, 16K R, and 16K

Registration Center
Capacity 100 sheets (80 g/m2)
Power Requirements DC24 V, DC5 V (supplied from the copier)
Power Consumption 9 W or less
Dimensions Width = 439 mm, Depth = 435 mm, Height = 137 m
Mass 3.1 kg
Operating Environment Conforms to that of the copier

1
bizhub_162_210_TO.book 2

1. Product specification Theory of Operation Ver. 1.0 Apr. 2005


MB-501
Outline

Blank page

2
bizhub_162_210_TO.book 3

Theory of Operation Ver. 1.0 Apr. 2005 2. Multiple Bypass (MB-501)

Composition/Operation
2. Multiple Bypass (MB-501)

MB-501
2.1 Construction

1
2

Composition/Operation
3 4021M031AA

[1] Take-up Roller [3] Paper Empty Sensor (PC21/MB)


[2] Paper Take-up Solenoid (SL21/MB)

3
bizhub_162_210_TO.book 4

2. Multiple Bypass (MB-501) Theory of Operation Ver. 1.0 Apr. 2005

2.2 Operation
Drive for bypass paper take-up is provided by the Main Motor (M1).
MB-501

The drive is transmitted through the Paper Take-up Solenoid.

Main Motor (M1)

Feed Roller
Composition/Operation

Paper Take-up Solenoid


(SL21/MB)

Paper Empty Sensor (PC21/MB)

4021M032AA

4
bizhub_162_210_TO.book 5

Theory of Operation Ver. 1.0 Apr. 2005 2. Multiple Bypass (MB-501)

2.3 Paper Take-Up Mechanism


The Paper Lifting Plate is raised to press the paper stack on the tray up against the Feed

MB-501
Roller.
The Paper Lifting Plate is raised and lowered in time with a paper take-up sequence.
The ascent and descent motion of the Paper Lifting Plate is accomplished when the drive
from the motor is transmitted to the cam through a solenoid to rotate the cam.

Paper Take-up Solenoid (SL21/MB)


Drive from Main Motor

Feed Roller

Composition/Operation
Cam 4021M033AA

<Ascent/Descent Motion>
Main Motor (M1) is energized.
Feed Roller is turned. Feed Roller
Paper
Paper Take-up Solenoid (SL21/MB): Energized Cam

Cam: Rotates

Tray: Raised

Paper Take-up Solenoid (SL21/MB): Deenergized

Paper take-up

Paper Take-up Solenoid (SL21/MB): Energized

Cam: Rotates

Tray: Lowered
4021M059AA

Paper Take-up Solenoid (SL21/MB): Deenergized

5
bizhub_162_210_TO.book 6

2. Multiple Bypass (MB-501) Theory of Operation Ver. 1.0 Apr. 2005

2.4 Paper Empty Detection Mechanism


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

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

Paper Take-up Solenoid (SL21/MB)

Paper

4021M034AA 4021M035AA
Composition/Operation

2.5 Paper Take Up Control

4034M542CA

6
bizhub_162_210_TO.book 7

Theory of Operation Ver. 1.0 Apr. 2005 2. Multiple Bypass (MB-501)

2.6 Paper Take Up Retry Control


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

MB-501
rarily halted if the paper fails to reach the Synchronizing Roller Sensor within a given
period of time after the sequence has been started. The paper take-up sequence is then
performed again. These paper take-up sequences are repeated a given number of times.

No. of Paper Take-Up Retry Sequences


Paper Take-Up Retry 2

Composition/Operation
4034M543CA

7
bizhub_162_210_TO.book 8

2. Multiple Bypass (MB-501) Theory of Operation Ver. 1.0 Apr. 2005


MB-501
Composition/Operation

Blank page

8
bizhub_162_210_TO.book 1

SERVICE MANUAL THEORY OF OPERATION

JS-503

2005.04
Ver. 1.0
bizhub_162_210_TO.book 2
bizhub_162_210_TO.book 1

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.

2005/04 1.0 Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision
bizhub_162_210_TO.book 2
bizhub_162_210_TO.book i

Theory of Operation Ver. 1.0 Apr. 2005

CONTENTS

JS-503
Outline
1. Product specification ............................................................................................... 1

Composition/Operation
2. Job Separator (JS-503) ........................................................................................... 3
2.1 Construction ......................................................................................................... 3

Outline
2.2 Operation .............................................................................................................. 4
2.3 Tray Selecting Mechanism .................................................................................... 5
2.4 Tray-Full Detecting Mechanism ............................................................................ 6
2.5 Job Tray Paper Detecting Mechanism .................................................................. 6

Composition/Operation

i
bizhub_162_210_TO.book ii

Theory of Operation Ver. 1.0 Apr. 2005


JS-503
Outline
Composition/Operation

Blank page

ii
bizhub_162_210_TO.book 1

Theory of Operation Ver. 1.0 Apr. 2005 1. Product specification

Outline
1. Product specification

JS-503
Type Add-on drawer
Installation Built into the exit section of the copier
Paper Storage System Moving drawer system

Capacities

Upper Drawer Lower Drawer

Outline
100 sheets (A4/R),
150 sheets (A4/R),
Plain paper (60 to 90 g/m2) 50 sheets (other than A4/R)
75 sheets (other than A4/R)
Load height up to 22 mm
OHP film
Paper Thick paper (91 to 157 g/m2)
10 sheets 20 sheets
Type
Postcards, labels, and enve-
lopes
100 sheets (A4/R),
150 sheets (A4/R),
Recycled Paper (60 to 90 g/m2) 50 sheets (other than A4/R)
75 sheets (other than A4/R)
Load height up to 22 mm

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


Power Consumption 24 W or less
Operating Environment Conforms to that of the copier

1
bizhub_162_210_TO.book 2

1. Product specification Theory of Operation Ver. 1.0 Apr. 2005


JS-503
Outline

Blank page

2
bizhub_162_210_TO.book 3

Theory of Operation Ver. 1.0 Apr. 2005 2. Job Separator (JS-503)

Composition/Operation
2. Job Separator (JS-503)

JS-503
2.1 Construction

3
2 4

5
1 6

Composition/Operation
4021M045AC

[1] Job Tray [5] Upper Home Position Sensor (PC32/JOB)


[2] Control Board (PWB-B/JOB) [6] Lower Home Position Sensor (PC33/JOB)
[3] Paper Empty Sensor (PC35/JOB) [7] Paper Detecting Board (PWB-B/JOB)
[4] Paper Full Sensor (PC34/JOB) [8] Bin Switching Motor (M1/JOB)

3
bizhub_162_210_TO.book 4

2. Job Separator (JS-503) Theory of Operation Ver. 1.0 Apr. 2005

2.2 Operation
The Main Motor (M1) provides drive for the Job Separator.
JS-503

2
Composition/Operation

4689M501AA

1 Bin Switching Motor (M1/JOB) 2 Job Tray

4
bizhub_162_210_TO.book 5

Theory of Operation Ver. 1.0 Apr. 2005 2. Job Separator (JS-503)

2.3 Tray Selecting Mechanism


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

JS-503
is selected according to the operating mode (either the fax, copier, or printer mode).
The Exit Tray of the copier is for the copier. The Job Tray is, on the other hand, for the fax
and printer.
The corresponding tray is selected through the operation of the motor and sensor as
shown below.

<When feeding paper into the Exit Tray: Copier>

Upper Home Position Sensor (PC32/JOB): Activated


Bin Switching Motor (M1/JOB)

Composition/Operation
4021M046AB
Paper

(M1/JOB: Backward Rotation)

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

Lower Home Position Sensor (PC33/JOB): Activated

Paper

4021M047AB
Job Tray

5
bizhub_162_210_TO.book 6

2. Job Separator (JS-503) Theory of Operation Ver. 1.0 Apr. 2005

2.4 Tray-Full Detecting Mechanism


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

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

Paper Paper Full Sensor (PC34/JOB)

Job Tray

Exit Roller

4021M049AA
Composition/Operation

2.5 Job Tray Paper Detecting Mechanism


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

<When Paper is Present>


Paper Empty Sensor (PC35/JOB)
Paper

Paper Detecting Board


(PWB-B/JOB)

Job Tray 4021M051AA

<When Paper is not Present>

4021M050AA
4021M052AA

6
bizhub_162_210_TO.book 1

SERVICE MANUAL THEORY OF OPERATION

SF-501

2005.04
Ver. 1.0
bizhub_162_210_TO.book 2
bizhub_162_210_TO.book 1

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.

2005/04 1.0 Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision
bizhub_162_210_TO.book 2
bizhub_162_210_TO.book i

Theory of Operation Ver. 1.0 Apr. 2005

CONTENTS

SF-501
Outline
1. Product specification ............................................................................................... 1

Composition/Operation
2. SHIFTING UNIT (SF-501) ....................................................................................... 3
2.1 Construction ......................................................................................................... 3

Outline
2.2 Exit Position Shifting Mechanism.......................................................................... 4

Composition/Operation

i
bizhub_162_210_TO.book ii

Theory of Operation Ver. 1.0 Apr. 2005


SF-501
Outline
Composition/Operation

Blank page

ii
bizhub_162_210_TO.book 1

Theory of Operation Ver. 1.0 Apr. 2005 1. Product specification

Outline
1. Product specification

SF-501
Shifting amount 28 mm
Paper capacity 250 sheets
Power consumption Less than 63 W

Outline

1
bizhub_162_210_TO.book 2

1. Product specification Theory of Operation Ver. 1.0 Apr. 2005


SF-501
Outline

Blank page

2
bizhub_162_210_TO.book 3

Theory of Operation Ver. 1.0 Apr. 2005 2. SHIFTING UNIT (SF-501)

Composition/Operation
2. SHIFTING UNIT (SF-501)

SF-501
2.1 Construction

1
2

Composition/Operation
4021M053AB

[1] Main Board (PWB-A) [3] Shift Motor (M1)


[2] Home Sensor (S31)

3
bizhub_162_210_TO.book 4

2. SHIFTING UNIT (SF-501) Theory of Operation Ver. 1.0 Apr. 2005

2.2 Exit Position Shifting Mechanism


Paper is fed into the Shifting Unit along a straight path or shifted from the reference
SF-501

straight path position. This exit position shifting mechanism allows different finishing
functions offered by the machine (Non-Sort, Sort, and Group) to be effected.
<Straight Feeding>
The paper that travels along a straight path is fed straight into the Shifting Unit without
being shifted sideways as the Exit Roller turns.

Exit Roller

Paper
Composition/Operation

4021M054AA

<Shifted Feeding>
When the trailing edge of the paper transported to the exit section moves past the Fusing
Roller, the Shift Motor is energized to move the Transport Roller sideways.
The paper is fed into the Shifting Unit as it is shifted sideways.
The Exit Roller is moved sideways by turning the motor forward or backward.
The Exit Roller is detected at its home position by a sensor.

Shift Motor M1 Paper

4021M055AA
Home Sensor S31

Exit Roller

4021M056AB

4
SERVICE MANUAL THEORY OF OPERATION

THEORY OF OPERATION
2005.04 Ver.1.0

2005 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.


Printed in Japan
Use of this manual should be strictly supervised to
DD4035CE1-1000
2005.04
avoid disclosure of confidential information.
Ver. 1.0

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