BizHub C452, C552, C652 and Options Theory of Operation

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SERVICE MANUAL THEORY OF OPERATION
This service manual is designed for machine with

firmware card ver. 47 and onward.
2009.07
Ver. 2.0
WWW.SERVICE-MANUAL.NET
THEORY OF OPERATION TOTAL CONTENTS
SAFETY AND IMPORTANT WARNING ITEMS ..............................................................S-1

IMPORTANT NOTICE ................................................................................................S-1
DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION .........................S-1
SAFETY WARNINGS .................................................................................................S-2
WARNING INDICATIONS ON THE MACHINE ........................................................S-18
MEASURES TO TAKE IN CASE OF AN ACCIDENT ....................................................S-21
Composition of the service manual ................................................................................. C-1
Notation of the service manual ....................................................................................... C-2
bizhub C652/C552/C452 Main body

OUTLINE ........................................................................................................................ 1
CONFIGURATION/OPERATION .................................................................................. 21
DF-618
OUTLINE ........................................................................................................................ 1
CONFIGURATION/OPERATION .................................................................................... 6
LU-301
OUTLINE ........................................................................................................................ 1
LU-204
OUTLINE ........................................................................................................................ 1
JS-504
OUTLINE ........................................................................................................................ 1
ZU-606
OUTLINE ........................................................................................................................ 1
FS-526
OUTLINE ........................................................................................................................ 1
i
SD-508
OUTLINE ........................................................................................................................ 1
PK-516
OUTLINE ........................................................................................................................ 1
JS-602
OUTLINE ........................................................................................................................ 1
PI-505
OUTLINE ........................................................................................................................ 1
FS-527
OUTLINE ........................................................................................................................ 1
PK-517
OUTLINE ........................................................................................................................ 1
SD-509
OUTLINE ........................................................................................................................ 1
JS-603
OUTLINE ........................................................................................................................ 1
AU-101/AU-102/AU-201/OT-503
AU-101/AU-102............................................................................................................... 1
AU-201............................................................................................................................ 2
OT-503 ............................................................................................................................ 3
EK-604/605/SC-507
EK-604............................................................................................................................ 1
EK-605............................................................................................................................ 2
SC-507 ........................................................................................................................... 4
ii
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
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
[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
[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
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
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
Ventilation
CAUTION
• The product generates ozone gas during operation, but it
will not be harmful to the human body.
If a bad smell of ozone is present in the following cases,
ventilate the room.
a. When the product is used in a poorly ventilated room
b. When taking a lot of copies
c. When using multiple products at the same time
Stability
CAUTION
• Be sure to lock the caster stoppers.
In the case of an earthquake and so on, the product may
slide, leading to a injury.
Inspection before Servicing
CAUTION
• Before conducting an inspection, read all relevant docu-
mentation (service manual, technical notices, etc.) and
proceed with the inspection following the prescribed pro-
cedure in safety clothes, using only the prescribed tools.
Do not make any adjustment not described in the docu-
mentation.
If the prescribed procedure or tool is not used, the prod-
uct may break and a risk of injury or fire exists.
• Before conducting an inspection, be sure to disconnect

the power plugs from the product and options.
When the power plug is inserted in the wall outlet, some
units are still powered even if the POWER switch is
turned OFF. A risk of electric shock exists.
• The area around the fixing unit is hot.
You may get burnt.
S-7
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.

fire.
S-8
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.
• 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.
fire.
S-9
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.
S-10
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.
• When using any solvent, ventilate the room well.

Breathing large quantities of organic solvents can lead to
discomfort.
S-11
[4] Used Batteries Precautions

ALL Areas
CAUTION
Danger of explosion if battery is incorrectly replaced.
Replace only with the same or equivalent type recommended by the manufacturer.
Dispose of used batteries according to the manufacturer’s instructions.
Germany
VORSICHT!
Explosionsgefahr bei unsachgemäßem Austausch der Batterie.
Ersatz nur durch denselben oder einen vom Hersteller empfohlenen gleichwertigen Typ.
Entsorgung gebrauchter Batterien nach Angaben des Herstellers.
France
ATTENTION
Il y a danger d’explosion s’il y a remplacement incorrect de la batterie.
Remplacer uniquement avec une batterie du même type ou d’un type équivalent recom-
mandé par le constructeur.
Mettre au rebut les batteries usagées conformément aux instructions du fabricant.
Denmark
ADVARSEL!
Lithiumbatteri - Eksplosionsfare ved fejlagtig håndtering.
Udskiftning må kun ske med batteri af samme fabrikat og type.
Levér det brugte batteri tilbage til leverandøren.
Finland, Sweden
VAROlTUS
Paristo voi räjähtää, jos se on virheellisesti asennettu.
Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin.
Hävitä käytetty paristo valmistajan ohjeiden mukaisesti.
VARNING
Explosionsfara vid felaktigt batteribyte.
Använd samma batterityp eller en ekvivalent typ som rekommenderas av apparat-
tillverkaren.
Kassera använt batteri enligt fabrikantens instruktion.
Norway
ADVARSEL
Eksplosjonsfare ved feilaktig skifte av batteri.
Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten.
Brukte batterier kasseres i henhold til fabrikantens instruksjoner.
S-12
[5] Laser Safety

• This is a digital machine certified as a Class 1 laser product. There is no possibility of
danger from a laser, provided the machine is serviced according to the instruction in this
manual.
5.1 Internal Laser Radiation
semiconductor laser
Maximum power of the laser diode 30 mW
bizhub C652 19.2 µW
Maximum average radiation power (*) bizhub C552 16.3 µW
bizhub C452 16.3 µW
Wavelength 775-800 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
Print Head Unit
A0P0P0C501DA
S-13
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
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
Denmark
ADVARSEL
• Usynlig laserstråling ved åbning, når sikkerhedsafbrydere er ude af funktion.
Undgå udsættelse for stråling. Klasse 1 laser produkt der opfylder IEC60825-1
sikkerheds kravene.
halvlederlaser
Laserdiodens højeste styrke 30 mW
bølgelængden 775-800 nm
S-14
Finland, Sweden
LUOKAN 1 LASERLAITE
KLASS 1 LASER APPARAT
VAROITUS!
• Laitteen käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saat-
taa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle laser-
säteilylle.
puolijohdelaser
Laserdiodin suurin teho 30 mW
aallonpituus 775-800 nm
VARNING!
• Om apparaten används på annat sätt än i denna bruksanvisning specificerats,
kan användaren utsättas för osynlig laserstrålning, som överskrider gränsen
för laserklass 1.
halvledarlaser
Den maximala effekten för laserdioden 30 mW
våglängden 775-800 nm
VARO!
• Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättomälle laser-
säteilylle. Älä katso säteeseen.
VARNING!
• Osynlig laserstråining när denna del är öppnad och spärren är urkopplad.
Betrakta ej stråien.
Norway
ADVERSEL
• Dersom apparatet brukes på annen måte enn spesifisert i denne bruksanvisn-
ing, kan brukeren utsettes för unsynlig laserstrålning, som overskrider grensen
for laser klass 1.
halvleder laser
Maksimal effekt till laserdiode 30 mW
bølgelengde 775-800 nm
S-15
5.2 Laser Safety Label

• A laser safety label is attached to the inside of the machine as shown below.
* Only for the U.S.A.
A0P0P0E507DA
5.3 Laser Caution Label

• A laser caution label is attached to the outside of the machine as shown below.
A0P0P0C503DA
S-16
5.4 PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT

• When laser protective goggles are to be used, select ones with a lens conforming to the
above specifications.
• When a disassembly job needs to be performed in the laser beam path, such as when
working around the printerhead and PC drum, be sure first to turn the printer OFF.
• If the job requires that the printer be left ON, take off your watch and ring and wear laser
protective goggles.
• A highly reflective tool can be dangerous if it is brought into the laser beam path. Use
utmost care when handling tools on the user’s premises.
• The Print head is not to be disassembled or adjusted in the field. Replace the unit or
Assembly including the control board. Therefore, remove the laser diode, and do not per-
form control board trimmer adjustment.
S-17
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.
WARNING
Do not burn used toner cartridges.
Toner expelled from the fire is CAUTION
dangerous.
The area around the fusing unit is
extremely hot.
Touching any part other than those
indicated may result in burns.
WARNING
Do not burn the used waste toner
box. Toner expelld from the fire is
dangerous.
WARNING
Do not burn used Imaging Units.
Toner expelled from the fire is dangerous.
A0P0P0E508DC
S-18
High voltage
This area generates high voltage.
Be careful not to touch here when the power is turned
ON to avoid getting an electric shock.
High voltage
A0P0P0E509DA
S-19
High voltage
High voltage
A0P0P0E510DA
CAUTION:
• You may be burned or injured if you touch any area that you are advised not to
touch by any caution label. Do not remove caution labels. If any caution label has
come off or soiled and therefore the caution cannot be read, contact our service
office.
S-20
MEASURES TO TAKE IN CASE OF AN ACCIDENT
MEASURES TO TAKE IN CASE OF AN

ACCIDENT
1. If an accident has occurred, the distributor who has been notified first must immediately
take emergency measures to provide relief to affected persons and to prevent further
damage.
2. If a report of a serious accident has been received from a customer, an on-site evalua-
tion must be carried out quickly and KMBT must be notified.
3. To determine the cause of the accident, conditions and materials must be recorded
through direct on-site checks, in accordance with instructions issued by KMBT.
4. For reports and measures concerning serious accidents, follow the regulations speci-
fied by every distributor.
S-21
MEASURES TO TAKE IN CASE OF AN ACCIDENT
Blank Page
S-22
Composition of the service manual
This service manual consists of Theory of Operation section and Field Service section to
explain the main machine and its corresponding options.
Theory of Operation section gives, as information for the CE to get a full understanding of
the product, a rough outline of the object and role of each function, the relationship
between the electrical system and the mechanical system, and the timing of operation of
each part.
Field Service section gives, as information required by the CE at the site (or at the cus-
tomer’s premise), a rough outline of the service schedule and its details, maintenance
steps, the object and role of each adjustment, error codes and supplementary information.
The basic configuration of each section is as follows. However some options may not be
applied to the following configuration.
<Theory of Operation section>
OUTLINE: Explanation of system configuration,

product specifications, unit configuration, and paper path
CONFIGURATION/ Explanation of configuration of each unit,
OPERATION: operating system, and control system
<Field service section>
OUTLINE: Explanation of system configuration, and product

specifications
MAINTENANCE: Explanation of service schedule, maintenance steps, ser-
vice tools, removal/reinstallation methods of major parts,
and firmware version up method etc.
ADJUSTMENT/SETTING: Explanation of utility mode, service mode, and mechanical
adjustment etc.
TROUBLESHOOTING: Explanation of lists of jam codes and error codes, and
their countermeasures etc.
APPENDIX: Parts layout drawings, connector layout drawings, timing
chart, overall layout drawing are attached.
C-1
Notation of the service manual
A. Product name
In this manual, each of the products is described as follows:
(1) bizhub C652/C552/C452: Main body

(2) Microsoft Windows 98: Windows 98
Microsoft Windows Me: Windows Me
Microsoft Windows NT 4.0: Windows NT 4.0 or Windows NT
Microsoft Windows 2000: Windows 2000
Microsoft Windows XP: Windows XP
Microsoft Windows Vista: Windows Vista
When the description is made in combination of the OS’s mentioned above:
Windows 98/Me
Windows NT 4.0/2000
Windows NT/2000/XP/Vista
Windows 98/Me/ NT/2000/XP/Vista
B. Brand name
The company names and product names mentioned in this manual are the brand name or
the registered trademark of each company.
C. Feeding direction
• When the long side of the paper is parallel with the feeding direction, it is called short
edge feeding. The feeding direction which is perpendicular to the short edge feeding is
called the long edge feeding.
• Short edge feeding will be identified with [S (abbreviation for Short edge feeding)] on the
paper size. No specific notation is added for the long edge feeding.
When the size has only the short edge feeding with no long edge feeding, [S] will not be
added to the paper size.
<Sample notation>
Paper size Feeding direction Notation

Long edge feeding A4
A4
Short edge feeding A4S
A3 Short edge feeding A3
C-2
2009.07
Ver. 2.0
Revision history
After publication of this service manual, the parts and mechanism may be subject to change for
improvement of their performance.
Therefore, the descriptions given in this service manual may not coincide with the actual machine.
When any change has been made to the descriptions in the service manual, a revised version will be
issued with a revision mark added as required.
Revision mark:
• To indicate clearly a section revised, 1 is shown at the left margin of the revised section.
The number inside 1 represents the number of times the revision has been made.
• To indicate clearly a page that contains the revision, 1 is shown near the page number of the
corresponding page.
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.
Description addition of bizhub C452 and the

2009/07 2.0 1 function version 2 (card ver. 47) firmaware/
Error corrections
2009/01 1.0 — Issue of the first edition
Date Service manual Ver. Revision mark Descriptions of revision
Theory of Operation Ver. 2.0 Jul. 2009
bizhub C652/C552/C452
CONTENTS
bizhub C652/C552/C452 Main body
OUTLINE
1. SYSTEM CONFIGURATION................................................................................... 1
1.1 bizhub C652/C552 ................................................................................................ 1
1.2 bizhub C452 ......................................................................................................... 3
OUTLINE
2. PRODUCT SPECIFICATIONS ................................................................................ 5
2.1 Type ...................................................................................................................... 5
2.2 Functions .............................................................................................................. 6
2.3 Paper .................................................................................................................... 8
2.4 Materials ............................................................................................................... 9
2.5 Print volume........................................................................................................ 10
CONFIGURATION/
OPERATION
2.6 Machine specifications........................................................................................ 11
2.7 Operating environment ....................................................................................... 12
2.8 Print functions ..................................................................................................... 13
2.9 Scan functions .................................................................................................... 15
3. SECTION CONFIGURATION................................................................................ 17
4. PAPER PATH......................................................................................................... 18
4.1 C652/C552 ......................................................................................................... 18
4.2 C452 ................................................................................................................... 19
CONFIGURATION/OPERATION
5. OVERALL CONFIGURATION ............................................................................... 21
5.1 Control block diagram ......................................................................................... 21
5.2 Image creation process ...................................................................................... 22
5.3 Image forming control ......................................................................................... 24
5.4 Process speed .................................................................................................... 24
6. INTERFACE SECTION ......................................................................................... 25
6.1 Configuration ...................................................................................................... 25
6.1.1 Front side ................................................................................................... 25
6.1.2 Rear side..................................................................................................... 26
6.1.3 Right side .................................................................................................... 28
7. SCANNER SECTION............................................................................................ 33
7.1 Configuration ...................................................................................................... 33
7.2 Drive ................................................................................................................... 34
7.3 Operation ............................................................................................................ 35
7.3.1 When the power is ON ................................................................................ 35
i
7.3.2 Control when the Start key is pressed ........................................................ 36

7.3.3 DF original glass cleaning control............................................................... 38
7.3.4 Original scanning area................................................................................ 40
7.3.5 Original size detection control..................................................................... 41
7.3.6 Image processing ....................................................................................... 43
8. WRITE SECTION (PH SECTION) ........................................................................ 44
8.1 Configuration ...................................................................................................... 44
8.2 Operation............................................................................................................ 45
OUTLINE
8.2.1 Outline ........................................................................................................ 45

8.2.2 Laser exposure process.............................................................................. 46
8.2.3 Laser emission timing ................................................................................. 47
8.2.4 Laser emission stop.................................................................................... 48
8.2.5 Laser emission area ................................................................................... 49
8.2.6 Color registration control (color shift correction) system............................. 50
CONFIGURATION/
OPERATION
8.2.7 Color skew correction control...................................................................... 52

8.2.8 Skew adjustment/skew adjustment reset .................................................... 53
8.2.9 PH unit temperature detection control ........................................................ 53
8.2.10 Image processing ....................................................................................... 54
9. IMAGING UNIT ..................................................................................................... 55
9.1 Configuration ...................................................................................................... 55
9.2 Drive ................................................................................................................... 56
9.3 Operation............................................................................................................ 57
9.3.1 Detection of imaging unit ............................................................................ 57
9.3.2 Detection of drum unit/K ............................................................................. 59
9.3.3 Detection of developing unit/K .................................................................... 60
9.3.4 Image stabilization control .......................................................................... 61
10. PHOTO CONDUCTOR SECTION ........................................................................ 62
10.1 Configuration ...................................................................................................... 62
10.2 Drive ................................................................................................................... 62
10.3 Operation............................................................................................................ 63
10.3.1 Photo conductor drive mechanism ............................................................. 63
10.3.2 Main erase lamp control ............................................................................. 66
10.3.3 Photo conductor cleaning ........................................................................... 67
11. CHARGE CORONA SECTION ............................................................................. 68
11.1 Configuration ...................................................................................................... 68
11.2 Operation............................................................................................................ 69
11.2.1 Photo conductor charge control.................................................................. 69
11.2.2 Charge corona cleaning control.................................................................. 69
ii
12. DEVELOPING SECTION ...................................................................................... 71
12.1 Configuration ...................................................................................................... 71
12.2 Drive ................................................................................................................... 72
12.3 Operation ............................................................................................................ 73
12.3.1 Developer flow............................................................................................. 73
12.3.2 Auto refining developing system ................................................................. 75
12.3.3 Developing bias........................................................................................... 76
12.3.4 Toner scattering prevention......................................................................... 77
OUTLINE
12.3.5 Developing cooling control .......................................................................... 78
12.3.6 Toner density control ................................................................................... 79
13. TONER SUPPLY SECTION .................................................................................. 80
13.1 Configuration ...................................................................................................... 80
13.2 Drive ................................................................................................................... 81
13.3 Operation ............................................................................................................ 82
CONFIGURATION/
13.3.1 Replenishing the toner hopper with toner ................................................... 82
OPERATION
13.3.2 Replenishing the developing unit with toner................................................ 84
13.3.3 Toner cartridge detection ............................................................................ 85
13.3.4 Toner cartridge life control........................................................................... 85
13.3.5 Toner spill prevention shutter ...................................................................... 87
14. 1st IMAGE TRANSFER SECTION........................................................................ 88
14.1 Configuration ...................................................................................................... 88
14.2 Drive ................................................................................................................... 89
14.3 Operation ............................................................................................................ 90
14.3.1 1st image transfer roller control................................................................... 90
14.3.2 Pressure/retraction control by print mode ................................................... 93
14.3.3 ACS............................................................................................................. 94
14.3.4 Transfer belt cleaning .................................................................................. 98
14.3.5 Image stabilization control .......................................................................... 98
15. 2nd IMAGE TRANSFER SECTION ...................................................................... 99
15.1 Configuration ...................................................................................................... 99
15.2 Drive ................................................................................................................. 100
15.3 Operation .......................................................................................................... 101
15.3.1 2nd image transfer roller control ............................................................... 101
15.3.2 2nd image transfer control ........................................................................ 102
15.3.3 2nd image transfer roller cleaning............................................................. 103
15.3.4 Paper separation control ........................................................................... 104
15.3.5 Sensor protection ...................................................................................... 105
16. TONER COLLECTING SECTION....................................................................... 106
16.1 Configuration .................................................................................................... 106
iii
16.2 Drive ................................................................................................................. 107

16.3 Operation.......................................................................................................... 108
16.3.1 Toner collecting path................................................................................. 108
16.3.2 Agitation control in waste toner box .......................................................... 109
16.3.3 Detection of waste toner box loaded in position ....................................... 109
16.3.4 Waste Toner full detection......................................................................... 110
17. PAPER FEED SECTION (TRAY1, TRAY2)......................................................... 112
17.1 Configuration .................................................................................................... 112
OUTLINE
17.1.1 Major components .................................................................................... 112

17.1.2 Layout of sensors and rollers.................................................................... 113
17.2 Drive ................................................................................................................. 114
17.3 Operation.......................................................................................................... 115
17.3.1 Up/down control........................................................................................ 115
17.3.2 Paper feed control..................................................................................... 117
CONFIGURATION/
OPERATION
17.3.3 Paper size detection control...................................................................... 124

17.3.4 Remaining paper detection control ........................................................... 126
17.3.5 Paper temperature detection control......................................................... 127
18. PAPER FEED SECTION (TRAY3, TRAY4)......................................................... 128
18.1 Configuration .................................................................................................... 128
18.1.1 Major components (tray3) ......................................................................... 128
18.1.2 Major components (tray3 horizontal transport section)............................. 129
18.1.3 Major components (tray4) ......................................................................... 130
18.1.4 Layout of sensors and rollers.................................................................... 131
18.2 Drive ................................................................................................................. 132
18.2.1 Tray3 ......................................................................................................... 132
18.2.2 Tray3 horizontal transport ......................................................................... 132
18.2.3 Tray4 ......................................................................................................... 133
18.3 Operation.......................................................................................................... 134
18.3.1 Up/down control........................................................................................ 134
18.3.2 Paper Feed control ................................................................................... 137
18.3.5 Dehumidification heater control ................................................................ 147
18.3.6 Detection of tray3/4 slid out/in................................................................... 148
18.3.7 Detection of horizontal transport unit slid out/in........................................ 149
19. PAPER FEED SECTION (BYPASS TRAY) ......................................................... 150
19.1 Configuration .................................................................................................... 150
19.2 Drive ................................................................................................................. 151
iv
19.3 Operation .......................................................................................................... 152
19.3.1 Bypass paper lifting motion control ........................................................... 152
19.3.2 paper feed control ..................................................................................... 153
19.3.5 Detection of bypass unit opened/closed ................................................... 159
19.3.6 Detection of bypass sub tray extended/retracted ...................................... 160
20. VERTICAL TRANSPORT SECTION................................................................... 161
OUTLINE
20.1 Configuration .................................................................................................... 161
20.2 Drive ................................................................................................................. 162
20.3 Operation .......................................................................................................... 163
20.3.1 Vertical transport control ........................................................................... 163
20.3.2 Transport motor control ............................................................................. 163
20.3.3 Operation timing........................................................................................ 163
CONFIGURATION/
OPERATION
21. REGISTRATION SECTION................................................................................. 165
21.1 Configuration .................................................................................................... 165
21.2 Drive ................................................................................................................. 165
21.3 Operation .......................................................................................................... 166
21.3.1 Registration control ................................................................................... 166
21.3.2 OHP detection........................................................................................... 167
21.3.3 Paper transport speed control................................................................... 168
22. FUSING SECTION.............................................................................................. 169
22.1 Configuration .................................................................................................... 169
22.2 Drive ................................................................................................................. 171
22.3 Operation .......................................................................................................... 172
22.3.1 Fusing speed correction............................................................................ 172
22.3.2 Fusing pressure/retraction control............................................................. 174
22.3.3 Heating roller heating control .................................................................... 175
22.3.4 Heating control of the fusing pressure roller ............................................. 178
22.3.5 Fusing temperature control ....................................................................... 179
22.3.6 Heating roller temperature sensor............................................................. 183
22.3.7 Heating roller temperature sensor condensation detection....................... 184
22.3.8 Heating roller temperature sensor contamination detection control.......... 184
22.3.9 Heating roller alternative temperature control ........................................... 185
22.3.10 Protection against abnormal temperature................................................. 186
22.3.11 Sensor disconnection detection control .................................................... 188
22.3.12 Brandnew detection .................................................................................. 188
22.3.13 Fusing cooling control ............................................................................... 189
v
23. DUPLEX SECTION............................................................................................. 192

23.1 Configuration .................................................................................................... 192
23.2 Drive ................................................................................................................. 193
23.3 Operation.......................................................................................................... 194
23.3.1 Paper conveyance control......................................................................... 194
23.3.2 Duplex circulation control.......................................................................... 196
24. PAPER EXIT SECTION ...................................................................................... 202
24.1 Configuration .................................................................................................... 202
24.2 Drive ................................................................................................................. 203
OUTLINE
24.3 Operation.......................................................................................................... 204

24.3.1 Transport control ....................................................................................... 204
25. IMAGE STABILIZATION CONTROL ................................................................... 207
25.1 Overview .......................................................................................................... 207
25.2 Description of control........................................................................................ 208
CONFIGURATION/
25.2.1 IDC registration sensor adjustment control............................................... 208

OPERATION
25.2.2 Max. density adjustment control ............................................................... 208

25.2.3 LD (laser diode) intensity adjustment control............................................ 208
25.2.4 Gamma correction control ........................................................................ 208
25.3 Operation sequence ......................................................................................... 209
25.4 Operation timing ............................................................................................... 210
26. IMAGE PROCESSING........................................................................................ 215
26.1 Scanner section image processing block diagram ........................................... 215
26.2 Write section image processing block diagram ................................................ 216
27. POWER SUPPLY SECTION............................................................................... 219
27.1 Parts energized when the main power switch is turned ON ............................. 219
27.1.1 Configuration ............................................................................................ 219
27.1.2 Operation .................................................................................................. 219
27.2 Parts energized when the sub power switch is turned ON ............................... 220
27.2.1 Configuration ............................................................................................ 220
27.2.2 Operation .................................................................................................. 220
27.3 Power cables .................................................................................................... 221
27.3.1 Configuration ............................................................................................ 221
27.3.2 Operation .................................................................................................. 221
28. FAN CONTROL................................................................................................... 222
28.1 Configuration .................................................................................................... 222
28.2 Operation.......................................................................................................... 223
28.2.1 Function .................................................................................................... 223
28.2.2 Control conditions ..................................................................................... 224
vi
29. COUNTER CONTROL ........................................................................................ 227
29.1 Configuration .................................................................................................... 227
29.2 Operation .......................................................................................................... 227
OUTLINE
CONFIGURATION/
OPERATION
vii
OUTLINE
CONFIGURATION/
OPERATION
Blank Page
viii
Theory of Operation Ver. 2.0 Jul. 2009 1. SYSTEM CONFIGURATION
OUTLINE
1. SYSTEM CONFIGURATION
1.1 bizhub C652/C552
1/2 System front view
[15] [16] [17] [18]

[2] [3] [4]
OUTLINE
[1]
[5]
[6]
[7]
[8]
[14] [9]
[10]
[11]
[13] [12]
A0P0F1E503DB
[1] bizhub C652/552 [9] Mount kit MK-715 *2

[2] Authentication unit: Biometric type [10] Large capacity unit LU-301
AU-101 [11] Large capacity unit LU-204
1 [3] Authentication unit: Biometric type [12] Z folding unit ZU-606

AU-102 [13] Saddle sticher SD-508
[4] Authentication unit: IC card type [14] Finisher FS-526
AU-201 [15] Punch kit PK-516
1 [5] Working table WT-506 [16] Post inserter PI-505
1 [6] Keyboard holder KH-101 [17] Job separator JS-602

[7] Local interface kit EK-604 [18] Output tray OT-503
1 [8] Local interface kit EK-605 *1
*1: Except for China.

*2: Except for the North America and Europe area.
1 1
1. SYSTEM CONFIGURATION Theory of Operation Ver. 2.0 Jul. 2009
2/2 System rear view
1
[10] [11] [2]
[1]
[9]
[8]
[7]
OUTLINE
[6] [3]
[5]
[4]
A0P0F1C502DB
[1] bizhub C652/552 [7] Mount kit MK-720

[2] Stamp unit SP-501 [8] Key counter kit KIT-1
[3] Fax kit FK-502 [9] Key counter kit KIT-CF *2
[4] Image controller IC-412 [10] i-Option LK-101 v2/102/103 v2
1 /105 *3
1 [5] Security kit SC-507 [11] Upgrade kit UK-203

[6] Video interface kit VI-505
*1: Europe only

*2: Except for North America area.
1 2
Theory of Operation Ver. 2.0 Jul. 2009 1. SYSTEM CONFIGURATION
1
1.2 bizhub C452
1/2 System front view
[14] [15] [16] [17] [2] [3] [4]
[1]
OUTLINE
[5]
[6]
[7]
[8]
[13] [9]
[10]
[11]
[12]
A0P0F1C506DA
[1] bizhub C452 [8] Local interface kit EK-605 *1

[2] Authentication unit: Biometric type [9] Mount kit MK-715 *2
AU-101 [10] Large capacity unit LU-301
[3] Authentication unit: Biometric type [11] Large capacity unit LU-204
AU-102 [12] Saddle sticher SD-509
[4] Authentication unit: IC card type [13] Finisher FS-527
AU-201 [14] Punch kit PK-517
[5] Working table WT-506 [15] Job separator JS-603
[6] Keyboard holder KH-101 [16] Output tray OT-503
[7] Local interface kit EK-604 [17] Job separator JS-504
*1: Except for China.

*2: Except for the North America and Europe area.
3 1
1. SYSTEM CONFIGURATION Theory of Operation Ver. 2.0 Jul. 2009
2/2 System rear view

1
[10] [11] [2]
[1]
[9]
[8]
[7]
OUTLINE
[6] [3]
[5]
[4]
A0P0F1C502DB
[1] bizhub C452 [7] Mount kit MK-720

[2] Stamp unit SP-501 [8] Key counter kit KIT-1
[3] Fax kit FK-502 [9] Key counter kit KIT-CF *1
[4] Image controller IC-412 [10] i-Option LK-101 v2/102/103 v2
/105 *2
[5] Security kit SC-507 [11] Upgrade kit UK-203
[6] Video interface kit VI-505
*1: Europe only

*2: Except for North America area.
1 4
Theory of Operation Ver. 2.0 Jul. 2009 2. PRODUCT SPECIFICATIONS
2. PRODUCT SPECIFICATIONS
2.1 Type
Type Combination scanner and printer console type

Copying system Electrostatic dry-powdered image transfer to plain paper
Printing process Laser electrostatic printing system
PC drum type OPC drum: KM-12 (OPC with high mold releasability)
Scanning density Main scan direction: 600 dpi, Sub scan direction: 600 dpi
Exposure lamp White rare-gas fluorescent lamp 30 W
OUTLINE
Platen Stationary (mirror scan)
Mirror scanning CCD optical system
Original scanning
* Sheet through system when ADF is used
Registration Rear left edge
Manual bypass : Roller separation system with pick-up mechanism
Tray 1 : Roller separation system with pick-up mechanism
Paper feeding
separation system
Exposure system 1 polygon 2 beam x 4 LD exposure and polygon mirror scan system
Equivalent to 1800 dpi in main scanning direction ×
Exposure density
600 dpi in sub scanning direction
Developing system Dry 2 components developing method, HMT developing system
Charging system DC comb electrode scorotron system with electrode cleaning function
Neutralizing system Red LED system
Image transfer system Belt image transfer system (1st)/roller image transfer system (2nd)
Paper separating Combination of curvature, separating claws, and bias system
system
Fusing system Belt IH fusing system
Heating system Heating: IH heating, Soaking: Halogen lamp
5
2. PRODUCT SPECIFICATIONS Theory of Operation Ver. 2.0 Jul. 2009
2.2 Functions
Types of original Sheets, books, and three-dimensional objects

Max. original size A3 or 11 x 17
Max. original weight 2 kg
Multiple copies 1 to 9999
Warm-up time When the sub power switch is turned ON at any timing while the main power
(at ambient tempera- switch remains ON for a predetermined period of time or more
ture of 23° C/73.4° F (room temperature is 23° C/73.4° F)
and rated source volt- bizhub 30 sec. or less (Black print, Color print)
OUTLINE
age) C652/C552/C452
1
bizhub C552: 60 sec. or less (Black print, Color print)
Taiwan only
1 bizhub C452: 30 sec. or less (Black print)

Taiwan only 60 sec. or less (Color print)
When the main power switch is turned ON during the sub power switch being
ON (room temperature is 23° C/73.4° F)
bizhub 45 sec. or less (Black print, Color print)
1 C652/C552/C452
bizhub C552: 60 sec. or less (Black print, Color print)
Taiwan only
1 bizhub C452: 45 sec. or less (Black print)
Taiwan only 60 sec. or less (Color print)
Image loss Leading edge: 4.2 mm (3/16 inch),
Trailing edge: 3 mm (1/8 inch),
Rear edge: 3 mm (1/8 inch),
Front edge: 3 mm (1/8 inch)
First copy time (Tray1/2 A4 or 8 1/2 x 11, full size)
bizhub C652 3.8 sec. or less (Black print)
5.5 sec. or less (Color print)
bizhub C552 4.3 sec. or less (Black print)
1 bizhub C452 4.8 sec. or less (Black print)

Processing speed Plain paper bizhub C652: 310.00 mm/s
black bizhub C552: 264.00 mm/s
1 bizhub C452: 216.00 mm/s

Plain paper/full color bizhub C652: 240.00 mm/s
bizhub C552: 216.00 mm/s
1 bizhub C452: 216.00 mm/s

Thick 1, Thick 1+ bizhub C652: 155.00 mm/s
bizhub C552: 132.00 mm/s
1 bizhub C452: 132.00 mm/s
Thick 2, Thick 3, bizhub C652: 120.00 mm/s

Thick 4, OHP, Post
card, Envelope, Label bizhub C552: 108.00 mm/s
sheet, glossy mode bizhub C452: 108.00 mm/s
1
1 6
Copying speed for Black bizhub C652: 1-sided: 65 copies/min,
multi-copy cycle 2-sided: 65 copies/min
(A4 or 8 1/2 x 11, plain (8 1/2 x 11: 64 copies/min)
paper, tray 1) bizhub C552: 1-sided: 55 copies/min,
2-sided: 55 copies/min
1 bizhub C452: 1-sided: 45 copies/min,

Full color bizhub C652: 1-sided: 50 copies/min,
bizhub C552: 1-sided: 45 copies/min,
OUTLINE
1 bizhub C452: 1-sided: 45 copies/min,
Fixed zoom ratios Full size x1.000
Reduction Metric area x0.500, x0.707, x0.816, x0.866
Inch area x0.500, x0.647, x0.733, x0.785
Enlargement Metric area x1.154, x1.224, x1.414, x2.000
Inch area x1.214, x1.294, x1.545, x2.000
Zoom ratios memory Metric area 3 memories
Variable zoom ratios x0.250 to x4.000 Inch area in 0.001 increments
Paper size Tray 1/Tray 2 Metric area A3 Wide, A3 to A5S, A6S, post card
11 x 17 to 8 1/2 x 11, 8 x 13 *1, 16K, 8K,
Inch area
12 1/4 x 18
Tray 3/Tray 4 A4, B5, A5, 8 1/2 x 11, 5 1/2 x 8 1/2, 16K, postcard
Bypass tray A3 wide, A3 to B6S, A6S, postcard,
Metric area long size paper (210 to 297 mm x 457 to
1,200 mm)
11 x 17 to 5 1/2 x 8 1/2, 8 x 13 *1, 16K, 8K,
Inch area 12 1/4 x 18, long size paper (8 1/4 to 11
11
/16 x 18 to 47 1/4)
Copy exit tray capacity Plain paper 250 sheets
(When OT-503 is Thick paper 10 sheets
mounted)
OHP transparencies 1 sheet
1 External memory Supported external USB flash memory device that supports the USB
function memory devices (1.1/2.0) interface
FAT32-formatted memory device
7 1
2.3 Paper
Paper source (maximum tray capacity)

Type
Tray 1 Tray 2 Tray 3 Tray 4 Bypass tray
Plain paper
❍ ❍ ❍ ❍ ❍
(64 to 90 g/m2 / 17
(500 sheets) (500 sheets) (1500 sheets) (1000 sheets) (150 sheets)
to 24 lb)
Translucent paper – – – – –
OHP ❍
– – – –
transparencies (20 sheets)*3
OUTLINE
Thick paper 1 *1
❍ ❍ ❍ ❍ ❍
(91 to 120 g/m2
/ 24.25 to 32 lb)
Thick paper 1+ *1
❍ ❍ ❍ ❍ ❍
(121 to 157 g/m2
/ 32 to 41.75 lb)
Paper type
Thick paper 2 *1
❍ ❍ ❍ ❍ ❍
(158 to 209 g/m2
/ 42 to 55.5 lb)
Thick paper 3 *1,2
❍ ❍ ❍ ❍ ❍
(210 to 256 g/m2
/ 55.75 to 68 lb)
Thick paper 4 *1,2
❍
(257 to 300 g/m2 – – – –
(50 sheets)
/ 68.25 to 80 lb)
❍ ❍ ❍
Postcards – –
(200 sheets) (200 sheets) (50 sheets)
Envelopes – – – – ❍ (10 sheets)
Labels – – – – ❍ (50 sheets)
Long size paper *4 – – – – ❍ (1 sheet)
139.7 to 311.1 mm 90 to 311.1 mm
Long size paper *4 Copy paper dimensions
Width
5 1/2 to 12 1/2 inch 3 1/2 to 12 1/4 inch
A4, B5, A5, 8 1/2 x 11,

5 1/2 x 8 1/2, 16K, postcard 139.7 to 457.2
182.0 to 457.2 mm
Length mm
7 1/4 to 18 inch
5 1/2 to 18 inch
210 to 297 mm
Width – – – –
8 1/4 to 11 3/4 inch
457 to 1200 mm
Length – – – –
18 to 47 1/4 inch
*1: Excluding damp paper, curled paper, and recycled paper.

*2: Image is not guaranteed when thick paper 3/4 is used.
*3: Black print only.
*4: 127 to 210 g/m2 / 33.75 to 55.75 lb
Automatic duplex unit : Only the plain paper weighing 64 to 90 g/m2 (17 to 24 lb) or
thick paper weighing 91 to 256 g/m2 (24.25 to 68 lb) are
reliably fed.
8
2.4 Materials
Parts name Field standard yield *1 Type name

Toner cartridge/C 30,000 prints TN613C
Toner cartridge/M 30,000 prints TN613M
Toner cartridge/Y 30,000 prints TN613Y
Toner cartridge/K 45,000 prints TN613K
Imaging unit/C bizhub C652 135,000 prints IU612C
bizhub C552 120,000 prints
OUTLINE
Imaging unit/M bizhub C652 135,000 prints IU612M
Imaging unit/Y bizhub C652 135,000 prints IU612Y
Developing unit/K 1,140,000 prints DV612K
Drum unit/K 285,000 prints DR612K
Waste toner box 48,000 prints Waste toner box
*1: Field standard yield

• This machine has the field standard yield which indicates the available print numbers
estimated by the quantities and usage of the unit in the market standard job mode.
Yields for each preventative maintenance unit will differ depending on actual usage.
• The market standard job modes for this unit are as follows.
1 Market standard job modes

bizhub C652 bizhub C552 bizhub C452
Printing B/W 7 P/J 6 P/J 5 P/J
Color 4 P/J 3 P/J 3 P/J
Color mode [Full Color] or [Black] (apart from [Auto Color])
Paper size A4: 93 %, A4S: 7 %
Color ratio 25 %
Total print volume/month US: 21,900 US: 15,700 US: 10,500
EU: 29,600 EU: 21,200 EU: 14,300
No. of No. of times power
20 times/month
image turned on
stabilization No. of returns from
operations None
sleep mode
Changes in sur-
rounding environ- None
ment
9 1
2.5 Print volume

• bizhub C652
US Average Color print 5,500 prints/month
Black print 16,400 prints/month
Maximum Color print 63,000 prints/month
EU Average Color print 7,400 prints/month
OUTLINE
• bizhub C552
1 • bizhub C452
1 10
2.6 Machine specifications
• bizhub C652
Power requirements Voltage: AC 100 V, 120 V, 127 V, 220-240 V
Current: 100 V 15 A + 7A
110 V 15 A + 7A
120 V 16 A
127 V 16 A
1 220-240 V 10 A
Frequency: 50 to 60 Hz ± 3 Hz
OUTLINE
Max power consumption 100 V 2,000 W or less
110 V 2,000 W or less
120 V 2,100 W or less
127 V 2,100 W or less
1 220-240 V 2,100 W or less
Dimensions 650 *1 (W) x 879 *2 (H) x 1,155 mm (H)
25.5 *1 (W) x 34.5 *2 (D) x 45.5 inch (H)
1 Space requirements 2,554 (W) x 1,525 mm (D) x 1,650 mm (H)*3
100.5 (W) x 60.0 inch (D) x 65.0 inch (H) *3
Weight Machine Approx. 207.0 kg / 456.25 lb (without IU and TC)
IU and TC Approx. 14.0 kg / 32.0 lb
*1: Width when the bypass tray is closed.
1 *2: Including the control panel.
*3: Space requirements are the values when the finisher tray extension, paper trays and
LCU are pulled out, and the ADF is open.
• bizhub C552

Current: 100 V 15 A
110 V 15 A
120 V 16 A
127 V 16 A
1 220-240 V 10 A
110 V 1,500 W or less
120 V 2,000 W or less
127 V 2,000 W or less
1 220-240 V 2,000 W or less
25.5 *1 (W) x 34.5 *2 (D) x 45.5 inch (H)
1 Space requirements 2,554 (W) x 1,525 mm (D) x 1,650 mm (H)*3
100.5 (W) x 60.0 inch (D) x 65.0 inch (H) *3
1 *2: Including the control panel.
11 1
1 • bizhub C452

Current: 100 V 15 A
110 V 15 A
120 V 16 A
127 V 16 A
OUTLINE
220-240 V 10 A
110 V 1,500 W or less
120 V 2,000 W or less
127 V 2,000 W or less
220-240 V 2,000 W or less
25.5 *1 (W) x 34.5 *2 (D) x 45.5 inch (H)
Space requirements 2,148 (W) x 1,525 mm (D) x 1,650 mm (H) *3
84.5 (W) x 60.0 inch (D) x 65.0 inch (H) *3
*2: Including the control panel.
2.7 Operating environment
Temperature 10 to 30° C / 50 to 86° F (with a fluctuation of 10° C / 18° F or less per hour)
Humidity 15 to 85% (Relative humidity with a fluctuation of 10%/h)
Levelness Difference between front and back, right and left should be 1 degree or under.
1 12
2.8 Print functions
Type Built-in printer controller

RAM 2 GB (shared with the main body)
HDD 250 GB (shared with the main body)
Interface Standard Ethernet (1000Base-T/100Base-TX/10Base-T)
USB2.0/1.1
Option USB 2.0
Frame type Ethernet 802.2, Ethernet 802.3, Ethernet II, Ethernet SNAP
Supported protocols TCP/IP (IPv4/IPv6), BOOTP, ARP, ICMP, DHCP, DHCPv6, AutoIP, SLP, SNMP,
OUTLINE
FTP, LPR/LPD, RAW Socket, SMB over TCP/IP, IPP, HTTP, POP, SMTP, LDAP,
NTP, SSL, IPX/SPX, AppleTalk, Bonjour, NetBEUI, WebDAV, DPWS, S/MIME,
IPsec, DNS, DynamicDNS, LLMNR, LLTD
Print speed Black print C652: 1-sided: 65 ppm, 2-sided: 65 ppm (64 ppm
(A4 or 8 1/2 x 11, plain for 8 1/2 x 11)
paper) C552: 1-sided: 55 ppm, 2-sided: 55 ppm
1 C452: 1-sided: 45 ppm, 2-sided: 45 ppm
Color print C652: 1-sided: 50 ppm, 2-sided: 50 ppm
1 C552/C452: 1-sided: 45 ppm, 2-sided: 45 ppm
Printer language PCL5c/6 Emulation
PCL XL ver. 2.1 Emulation
PostScript 3 Emulation (3016)
XPS ver.1.0
Print resolution Equivalent to 1,800 dpi in main scanning direction ×
600 dpi in sub scanning direction
Printer fonts PCL Latin 80 Fonts Postscript 3 Emulation Latin 137 Fonts
Supported computer IBM PC/AT compatible machine,
Macintosh
(PowerPC/Intel processor : Only MacOS X 10.4/10.5 for Intel processor)
1 Printer driver PCL KONICAMINOLTA Windows NT Workstation Version 4.0 (SP6 or later)
driver (PCL driver) Windows NT Server Version 4.0 (SP6 or later)
Windows 2000 Professional (SP4 or later)
Windows 2000 Server (SP3 or later)
Windows XP Home Edition (SP1 or later)
Windows XP Professional (SP1 or later)
Windows Server 2003, Standard Edition (SP1 or later)
Windows Server 2003, Enterprise Edition (SP1 or later)
Windows Server 2003 R2, Standard Edition
Windows Server 2003 R2, Enterprise Edition
Windows XP Professional x64 Edition
Windows Server 2003, Standard x64 Edition
Windows Server 2003, Enterprise x64 Edition
Windows Server 2003 R2, Standard x64 Edition
Windows Server 2003 R2, Enterprise x64 Edition
Windows Vista Business *
Windows Vista Enterprise *
Windows Vista Home Basic *
Windows Vista Home Premium *
Windows Vista Ultimate *
Windows Server 2008 Standard *
Windows Server 2008 Enterprise *
* 32 bits (x86)/64 bits (x64) environment are sup-
ported
13 1
1 Printer driver PostScript KONICAMI- Windows 2000 Professional (SP4 or later)

NOLTA driver (PS driver) Windows 2000 Server (SP3 or later)
OUTLINE

ported
XPS KONICAMINOLTA Windows Vista Business *
driver (XPS driver) Windows Vista Enterprise *
ported
PostScript PPD driver Mac OS 9.2 or later
(PS-PPD) Mac OS X 10.2.8/10.3/10.4/10.5
1 14
1 Printer driver Fax driver Windows NT Workstation Version 4.0 (SP6 or later)
Windows NT Server Version 4.0 (SP6 or later)
Windows 2000 Professional (SP4 or later)
Windows 2000 Server (SP3 or later)
OUTLINE
ported
1 2.9 Scan functions
Scanner Scannable range Same as the copier

(Max. 11 x 17: inch area, A3: metric area)
Scan speed 78 pages/min
(A4 or 8 1/2 x 11,
Resolution 300 dpi)
Functions Scan to E-mail, Scan to FTP, Scan to SMB, Scan to
WebDAV, Scan to BOX
Scanning resolution 200/300/400/600 dpi
TWAIN Driver TWAIN Driver, HDD TWAIN Driver
Supported operating Windows 2000 Professional (SP4)
systems Windows XP Home Edition (SP3)
Windows XP Professional (SP3)
Windows NT 4.0 (SP6a)
Windows Vista Home Basic (SP1)
Windows Vista Home Premium (SP1)
Windows Vista Business (SP1)
Windows Vista Enterprise (SP1)
Windows Vista Ultimate (SP1)
PC Conform to the specification of operating system
Required memory Conform to the specification of operating system
Network Computer to which TCP/IP protocol is correctly set
Hard disk Required 20 MB or more disk space
15 1
SMB Supported Windows Windows NT4.0 Server/Workstation

operating Windows 2000 Server/Professional
systems Windows XP Home/Professional
Windows Server 2003 each edition
Windows Vista each edition
Windows Server 2008
DFS function is supported only in the environment

that structured with the following Windows server
operating systems.
• Windows 2000 Server each edition
• Windows Server 2003 each edition
OUTLINE
• Windows Server 2008
Direct hosting function apply to the following oper-

ating systems.
• Windows 2000
• Windows XP
• Windows Vista
(IPv6 function is available only when the Windows
Vista is installed.)
Samba 2.2.x
3.x
Novell Netware 6.5 (SP6 or later)
Netware
NOTE
• These specifications are subject to change without notice.
1 16
Theory of Operation Ver. 2.0 Jul. 2009 3. SECTION CONFIGURATION
3. SECTION CONFIGURATION
Auto document feed section

* Standard
Scanner section
(IR section)
Paper exit section
OUTLINE
Fusing section
Toner supply section
Duplex section
Transfer corona section (standard)
Imaging unit section Paper feed section

(IU section) (Bypass tray)
Write section (PH section)
Paper feed section (Tray1)

Toner collecting section
In front door (dotted line
section)
A00JT1C201AA
17
4. PAPER PATH Theory of Operation Ver. 2.0 Jul. 2009
4. PAPER PATH
1 4.1 C652/C552
OUTLINE
A0P0JT1C599AA
1 18
Theory of Operation Ver. 2.0 Jul. 2009 4. PAPER PATH
1
4.2 C452
OUTLINE
A0P0T1C001DA
19 1
OUTLINE
Blank Page
20
Theory of Operation Ver. 2.0 Jul. 2009 5. OVERALL CONFIGURATION
5. OVERALL CONFIGURATION
5.1 Control block diagram
1
Scanner Inverter board
section Original glass
position control
board
CCD board Scanner
Vendor
R G B relay board
Control panel
Key counter
HDD R G B
Total
USB board counter
CONFIGURATION/
OPERATION
Authentic Fusing unit
-ation unit
MFP board Printer control DC power supply unit
board
Fax board
Service EEPROM
Video PC motor
interface kit Y M C K
Developing motor
Main High voltage unit

PH relay board body
Paper feed
section
Polygon motor
Laser drive Paper
board Index board transport Duplex unit
drive board
Skew correction motor
PH section Bypass tray
section
Image controller Finisher Paper feed unit

A0P0T5E095DB
21 1
5. OVERALL CONFIGURATION Theory of Operation Ver. 2.0 Jul. 2009
5.2 Image creation process
[10] Transfer belt cleaning [15] Paper exit [13] Fusing
[7] 1st transfer [9] Separation
[1] Photoelectric
conversion [8] 2nd transfer
Y M C K
[2] Printer image
processing
[3] Photo
conductor (K)
[4] Photo conductor
[3] Photo conductor
charging (K)
[4] Charging Y M C [14] Duplex

K
CONFIGURATION/
[12] Main erase

OPERATION
[5] Exposure [6] Developing [11] Photo conductor cleaning
A00JT1C203AA
• The light reflected off the surface of the original is separated into dif-
Photoelectric ferent colors using the color filters (R, G, and B); CCD then converts
[1]
conversion it into a corresponding electric signal and outputs the signal to the
printer image processing section (MFP board).
• The electric signal is converted to 8-bit digital image signals. After
going through some corrections, the digital image signals are con-
Printer image verted to video signals (C, M, Y, and K).
[2]
processing • D/A conversion will be performed after the VIDEO signals (Y, M, C,
Bk) are corrected. This data will control the emission of the laser
diode.
• The image of the original projected onto the surface of the photo con-
[3] Photo conductor
ductor is changed to a corresponding electrostatic latent image.
[4] Charging • Supply DC ( - ) charge on the photo conductor.
• Expose photo conductor to a laser beam to develop electrostatic
[5] Exposure
latent image.
• The toner, agitated and negatively charged in the developer mixing
chamber, is attracted onto the electrostatic latent image formed on
the surface of the photo conductor. It is thereby changed to a visible,
[6] Developing developed image.
• AC and DC negative bias voltages are applied to the developing
roller, thereby preventing toner from sticking to the background image
portion.
• A DC positive voltage is applied to the backside of the transfer belt,
thereby allowing the visible, developed image on the surface of each
[7] 1st transfer
of the photo conductors (Y, M, C, and K) to be transferred onto the
transfer belt.
22
Theory of Operation Ver. 2.0 Jul. 2009 5. OVERALL CONFIGURATION
• A DC positive voltage is applied to the backside of the paper, thereby
[8] 2nd transfer allowing the visible, developed image on the surface of the transfer
belt to be transferred onto the paper.
• The paper, which has undergone the 2nd image transfer process, is
[9] Separation neutralized so that it can be properly separated from the transfer belt
by the paper separator claws.
• Residual toner on the surface of the transfer belt is collected for
[10] Transfer belt cleaning
cleaning by cleaning brush.
Photo conductor • The residual toner left on the surface of the photo conductor is
[11]
cleaning scraped off.
• The surface of the photo conductor is irradiated with light, which neu-
[12] Main erase tralizes any surface potential remaining on the surface of the photo
conductor.
• The visible toner image transferred onto the surface of the paper is
[13] Fusing melted by the heat of the fusing roller and fixed to the paper by pres-
sure.
• The 1-sided printed paper, on which the image of the first page of the
[14] Duplex original is printed, is turned over and fed back into the main body for
CONFIGURATION/
the print cycle of the second page of the original.
OPERATION
• The paper, for which the toner image has been properly fixed, is fed
out onto the exit tray.
[15] Paper exit
• For two-sided printing, the 1-sided printed paper is transported onto
the duplex unit.
23
5. OVERALL CONFIGURATION Theory of Operation Ver. 2.0 Jul. 2009
5.3 Image forming control
Developing bias DC Y/M/C

Developing bias DC K
Main erase lampY/M/C
Main erase lamp/K
Color PC drum motor (M16)
K PC drum motor (M18)
Charge Y/M/C
Charge K
Color developing motor (M17)
K developing motor (M19)
BCL (+)
BCL (-)
Cleaner motor (M38)
Transfer belt motor (M1)
2nd transfer roller pressure retraction
1st transfer pressure retraction
Image write start signal
Developing bias AC Y
Developing bias AC M
Developing bias AC C
Developing bias AC K
1st transfer Y
1st transfer M
CONFIGURATION/
1st transfer C
1st transfer K
OPERATION
2nd transfer
Neutralization
Registration motor (M2)
Take-up motor (M22)
Tray 1 paper feed clutch (CL1)
Tray1 vertical transport motor (M5)
Gate switch solenoid (SD1)
Exit motor (M4)
Power supply cooling fan motor (FM8)
Ozone ventilation fan motor (FM6)
Paper cooling fan motor (FM12)
Toner suction fan motor (FM7)
Fusing cooling fan motor/1 (FM2)
Suction fan motor (FM1)
Cooling fan motor (FM3)
IU cooling fan motor (FM14)
㪩㪼㪸㫉㩷side cooling fan motor (FM15)
IH cooling fan motor/1 (FM9)
PH cooling fan motor (FM13)
Tucking fan motor/1 (FM17)
Tucking fan motor/2 (FM18)
Polygon motor (M34)
LD
Waste toner agitating motor (M20)
Dehumidification heater
Fusing motor (M30)
A0P0T5E105DA
5.4 Process speed
Paper
Plain paper (mm/s) Thick
type Thick Thick Thick Thick Enve-
paper3 OHP
Monochrome paper1 paper1+ paper2 paper4 lopes
Gloss (mm/s) (mm/s) (mm/s) (postcards) (mm/s)
Mode High Medium Color (mm/s) (mm/s)
mode (mm/s)
speed speed
C652 310 240 240 120 155 120 120
C552 264 216 216 108 132 108 108
1 C452 216 216 108 132 108 108
1 24
Theory of Operation Ver. 2.0 Jul. 2009 6. INTERFACE SECTION
6. INTERFACE SECTION
6.1 Configuration
6.1.1 Front side
Main power switch (SW1)
CONFIGURATION/
OPERATION
Total counter
A0P0T5C050DA
Main power switch (SW1)
Total counter
A0P0T5C051DA
25
6. INTERFACE SECTION Theory of Operation Ver. 2.0 Jul. 2009
6.1.2 Rear side
Upper side
CONFIGURATION/
OPERATION
Lower side
A0P0T5C053DA
A. Upper side
Toner filter Optional finishing connection connector
A0P0T5C054DA
26
B. Lower side
Notes
• For the dehumidification heater, see “18.3.5 Dehumidification heater control”.
• The power cables are constructed differently according to the model and destina-
tion.
Main body only
AC 100V AC 110V AC 127V AC 120V AC 130V

Two (directly Two (directly One (directly One (directly
C652 One (inlet)
mounted / inlet) mounted / inlet) mounted) mounted)
1 C552/ One (directly One (directly One (directly One (directly

One (inlet)
C452 mounted) mounted) mounted) mounted)
Main body + image controller
AC 100V AC 110V AC 127V AC 120V AC 130V

Two (directly Two (directly One (directly One (directly
C652 One (inlet)
CONFIGURATION/
mounted / inlet) mounted / inlet) mounted) mounted)
OPERATION
1 C552/ Two (directly Two (directly One (directly Two (directly
One (inlet)
C452 mounted / inlet) mounted / inlet) mounted) mounted / inlet)
Power cable leader port for

image controller
A0P0T5C055DA
Power cable 2 (C652 Japan

Not used
and Taiwan only)
Dehumidification heater switch Power cable 1
(SW2)
Note: This photo is for 120V

version
A0P0T5C056DA
27 1
6.1.3 Right side
Front side
Rear side (upper)
Rear side (lower)

CONFIGURATION/
OPERATION
A0P0T5C057DA
28
A. Front side
1
Note
• Use utmost care when unplugging or plugging the cable. If the USB cable
extended from the USB port at the rear (upper) portion is unplugged, the USB port
at the front side is no longer operational.
USB port (optional) USB port (standard)
Audio output terminal

(optional)
CONFIGURATION/
OPERATION
Sub power switch
A0P0T5C059DA
A0P0T5C060DA
29 1
B. Rear side (upper)

1
Notes
• The USB cable is extended up to the USB port at the front side. If the cable is
unplugged from the USB port, therefore, the USB port at the front side is no longer
operational. Use utmost care when unplugging or plugging the cable.
• Sliding the USB port cover will reveal the USB port dedicated to firmware upgrad-
ing.
• The USB port cover is provided with a USB cover sensor that detects that the
cover is opened or closed.
• When the USB cover sensor is blocked, the machine determines that the cover is
closed.
Notes
• For details of “firmware upgrading”, see Field Service.
• Be sure to close the USB port cover after the firmware upgrading is completed.
CONFIGURATION/
Network port (standard:

OPERATION
dedicated to network print)
USB port (standard:

dedicated to local print)
Serial port (standard:

not used)
USB port for service
USB port cover (with (standard: dedicated to
open/close detection firmware upgrading)
system)
USB port cover fixing
screw
A0P0T5C061DA
USB extension cable (standard:

USB extension cable to the USB USB port (standard)
board at the front side)
USB port cover
A0P0T5C062DA
USB extension cable USB port for service (dedicated to firmware upgrading)
1 30
1
USB port cover
USB cover sensor

(PS60)
A0P0T5C063DB
CONFIGURATION/
OPERATION
31 1
C. Rear side (lower)
Fax kit (optional) Line extension kit

(optional)
* The second line is on
the outside.
TEL terminal (optional)
TEL terminal (optional)
LINE terminal (optional)
LINE terminal (optional)

CONFIGURATION/
OPERATION
A0P0T5C064DA
Security kit Fax kit (optional)

(optional)
Scanner section connection

connector (standard)
A0P0T5C065DA
Scanner section connection Image controller connection connector

connector (standard) (optional: when video interface kit is
mounted)
Note: This photo shows a system mounted with a fax kit, a video interface kit
and a security kit.
1 32
Theory of Operation Ver. 2.0 Jul. 2009 7. SCANNER SECTION
7. SCANNER SECTION
7.1 Configuration
A0P0T5C058DA
CONFIGURATION/
OPERATION
Original glass moving Original glass position
Lens CCD unit control board (OGPCB)
motor (M202)
Inverter board (INVB)

Glass moving unit
Exposure unit Scanner relay board

(REYB/SCAN)
Scanner home Optical cooling fan

sensor (PS201) motor (FM201)
Status display
board (MCMB)
15 degree sensor
Mirror unit (PS202)
Scanner motor (M201)

Fax speaker (SP) Original size detection
sensor 2 (PS205)
Original size detection
sensor 1 (PS204)
USB board (UB) A0P0T5C090DA
Original cover sensor
(RS201)
33 1
7. SCANNER SECTION Theory of Operation Ver. 2.0 Jul. 2009
7.2 Drive
Scanner motor (M201)
Scanner drive
Exposure unit cable/R
Mirror unit
Glass moving unit
Original glass moving
motor (M202)
CONFIGURATION/
Scanner drive cable/F

OPERATION
Scanner home sensor (PS201)

A00JT2C003DA
34
7.3 Operation
7.3.1 When the power is ON
1. The exposure unit moves from the scanner standby position to the home position.
2. Exposure unit moves from the home position to the shading position (under the
shading correction sheet) and stops (in scanning direction).
1 3. The exposure lamp turns ON and the gain value of the CCD sensor output voltage
to R, G, and B is adjusted.
1 4. After adjusting the gain value, a shading correction is performed. The exposure
lamp goes out when the correction is completed.
5. The exposure unit moves in the return direction and stops at the home position.
6. The exposure unit moves in the scan direction and stops at the standby position.
Shading position
Home position Standby position Scanning direction

Returning direction
CONFIGURATION/
OPERATION
A00JT2C004DA
Home position
Shading position
Standby position
Scanner movement
The exposure lamp (FL201) turns ON

and a gain adjustment and shading
correction are made.
A0P0T2C001AA
35 1
7.3.2 Control when the Start key is pressed

A. Original scanning mode
Original scanning mode has two types: Original cover mode and DF mode.
(1) Original cover mode

1. Turning the Start key ON will turn the exposure lamp ON (at the standby position)
2. The exposure unit moves in the return direction and stops at the shading position.
At the shading position, the gain adjustment is made.
3. The exposure unit moves in the return direction and stops at the scan start posi-
tion.
4. To start a scan, the exposure unit moves from the scan start position to the leading
edge of an original while performing shading correction. The exposure unit will start
reading the original image from the leading edge. The unit will finish reading the
image at the back edge of the image.
5. The exposure lamp will be OFF when the reading is complete.
6. The exposure unit moves in the return direction and stops at the home position.
Then the exposure unit moves in the scan direction and stops at the standby posi-
tion. It scans only once even for the color-copies, since R, G, and B data will all be
CONFIGURATION/
memorized in one scanning.

OPERATION
Shading position
Leading edge of the image
Home
position Standby position
Back edge of the image
Original
Scan start
position
Scan
Return
A00JT2C005DA
Home position Scanner

movement
Scan start position Exposure lamp

(FL201) ON
Shading position
Back edge of the image
Leading edge of the image
Standby position
A0P0T2C002AA
36
(2) DF mode
• The original fed by the document feeder will be read at the original DF glass for. The
Exposure unit will move to the reading position and stops. The document will be read as
the paper is transferred.
DF original glass
A0P0T5C109DA
Reading position
CONFIGURATION/
OPERATION
(3) Original scanning control
• The light reflected off the exposed original reaches the CCD sensor via the lens.
• The CCD sensor outputs an electric signal (analog) that varies according to the intensity
of the light.
• One CCD sensor has a photoreceiver that individually responds to each of the three pri-
mary colors of R, G, and B.
• The electric signal is converted to digital data for each of R, G, and B by the board
(CCDB), becoming individual digital signals.
• Analog-to-digital conversion is made according to an instruction given by the MFP board
(MFPB).
Scanning direction CCD sensor

Sub scanning
R
direction
G
37.3 µm
B 37.3 µm
Main scanning
direction
9.325 µm
9.325 µm
4036ma2602c0
(4) Calibration
The following adjustment and correction (calibration) are made before the original is
scanned, so that the image of the original can be adequately read. For details, see “26.
Image processing”. (See: P.215)
• Gain adjustment
• Shading correction
37
7.3.3 DF original glass cleaning control

A. DF original glass cleaning
• The reading lines will occur when DF original glass has stain. Shift mechanism for the DF
original glass is provided to avoid this trouble.
• The stand-by position for the DF original glass will be detected by the glass home sen-
sor.
• DF original glass will move back and forth by the original glass moving motor.
Original glass moving motor (M202)
Glass home sensor

(PS203)
CONFIGURATION/
OPERATION
A00JT2C007DA
B. Details of DF original glass cleaning

• The DF original glass makes three different movements. Each mode has different move-
ment.
• The following explains different movements and different modes.
(1) Normal movement performed each time after reading a sheet of original
• The DF original glass moves slightly back or forth every time after reading a sheet of
multiple originals. This changes the image reading position on the DF original glass and
prevents the repeated occurrence of lines in the sub scan direction due to the same stain
on the glass.
The first original The second original
A00JT2C538DA
A00JT2C539DA
DF original glass
Image reading position Image reading position
NOTE
This cleaning operation is not performed when the setting is made in the service mode as fol-
lows. [System 2] - [Split Line Detect. Setting] - [Prior Detection] - [Not Set]
38
(2) DF original glass cleaning movement performed each time after reading a sheet
of original
• While reading multiple originals consecutively, the DF original glass moves widely back
and forth between each original reading.
• Due to the effect of the step sheet that makes contact with the DF original glass, stain on
the DF original glass can be removed from the reading position and reduce image
streaks in the sub scan direction.
Step sheet A00JT2C540DA
DF original glass Image reading position
• Stain collected on the DF original glass is removed from the reading section by the trail-
ing edge of an original that is passing by.
CONFIGURATION/
OPERATION
Original
DF original glass Stain
Image reading position
A00JT2C544DA
(3) DF original glass cleaning movement performed after completing a job

• After the completion of a job, the DF original glass moves widely back and forth to
remove stain remaining on the surface. This reduces the occurrence of lines in the sub
scan direction.
39
C. Step sheet
• The step sheet is provided in order to reduce the stain on the DF original glass.
• It is installed to the operator side of the DF original glass in order to reduce the area orig-
inal touches the glass.
Original
Step sheet
DF original glass
9J07T2C007DA
CONFIGURATION/
7.3.4 Original scanning area

OPERATION
Original scanning areas vary depending on a scanning mode.
A. Original cover mode

• Main scanning direction: Max. 297.0 mm
• Sub scanning direction: Max. 431.8 mm
B. DF mode
• Main scanning direction: Max. 297.0 mm
• Sub scanning direction: Max. 1,000.0 mm
40
7.3.5 Original size detection control
A. Detection method
• For detection of the original size, the reflective size sensors detect the length of the orig-
inal while the CCD detects the width of the original.
1
Automatic document feeder
15 degrees
15 degrees sensor (PS202)

346.1 mm
313.5 mm
Original read
position
CONFIGURATION/
OPERATION
A0P0T5C058DA
Original size
detection
sensor 1 (PS204)
Exposure unit CCD unit
Original standard Original size
position detection
sensor 2 (PS205) *
Exposure unit
4037T2E597AA
Original size detection sensor 1 (PS204)
A0P0T5C074DA
Original size detection sensor 2 (PS205) * *: Option
1 • For the original of an irregular size, the nearest standard size on the large side is applied
to it.
41 1
B. Original size judgement
NOTE
• Table 1 or 2 can be selected in the service mode.
Criterion
Metric area & china areas
Table 1
1 Original Main scanning width (mm)

size
detection 0~130.0 ~153.0 ~187.0 ~200.0 ~215.0 ~225.0 ~261.5 ~275.0 275.1~
sensor 1
OFF No original A5S B5S 16KS A4S B5 B5 16K A4
ON A3 - - - - FLS B4 8K A3
Table 2
1 Original
CONFIGURATION/
size
OPERATION
Main scanning width (mm)

detection
sensor
1 2* 0~130 ~143.9 ~153 ~187 ~200 ~213 ~220.9 ~225 ~261.5 ~274.7 ~284.4 284.5~
No
51/2 × 16K 81/2 × 81/2 ×
OFF OFF origi- A5S B5S A4S - B5 16K A4
8 1/ 2 S S 11 S 11
nal
ON OFF A3 - - - - FLS FLS FLS - - - -
81/2 ×
- ON A3 - - - - - - B4 8K 11 × 17 A3
14
*: Option
Inch areas
Table 1
1 Original size Main scanning width (mm)

detection
sensor 1 0~130.0 ~144.7 ~220.9 ~221.0
OFF No original 51/2 × 81/2 S 81/2 × 11 S 81/2 × 11

ON 11 × 17 - 81/2 × 14 11 × 17
Table 2
1 Original size
detection Main scanning width (mm)
sensor
1 2* 0~130 ~143.9 ~153 ~187 ~213 ~220.9 ~225 ~262 ~284.4 284.5~
No
OFF OFF 5 /2 × 8 /2 S A5S
1 1
B5S A4S 8 /2 × 11 S
1
- B5 81/2 × 11 A4
original
ON OFF A3 - - - FLS FLS FLS - - -
- ON A3 - - - - 81/2 × 14 - B4 11 × 17 A3
*: Option
1 42
C. Detection timing
Validates the original length Validates the original size
Original size detection sensor 1 (PS204)

15 degree sensor (PS202)
Exposure lamp (FL201)
Original cover sensor (RS201)
A0P0T5E107DA
7.3.6 Image processing

The image processing has following items. For details, see “26. Image processing”. (See:
P.215)
Scanner section image processing block diagram

• Photoelectric conversion
• Analog-to-digital conversion
CONFIGURATION/
OPERATION
43
8. WRITE SECTION (PH SECTION) Theory of Operation Ver. 2.0 Jul. 2009
8. WRITE SECTION (PH SECTION)

8.1 Configuration
PH unit A00JT2C030AA
CONFIGURATION/
OPERATION
Index board (INDEXB) Index mirror

Index lens G3 lens
Return mirror (light source)
Synthetic mirror (Y,C,M)
Laser drive board/C

(LDDB/C)
Laser drive
board/M
(LDDB/M)
Laser drive board/Y

(LDDB/Y)
Laser drive board/K

(LDDB/K) Skew correction motor/
Y,M,C (M35,M36,M37)
Cylindrical lens A00JT2C001DA
G1 lens
Polygon mirror G2 lens
44
Theory of Operation Ver. 2.0 Jul. 2009 8. WRITE SECTION (PH SECTION)
8.2 Operation
8.2.1 Outline
• The surface of the photo conductor is irradiated with a laser light and an electrostatic
latent image is thereby formed.
• The PH unit has a single-piece configuration. The PH unit has four semiconductor lasers
with one laser for each four different color. A single polygon motor is used to make a
scan.
• To be compatible with the high speed printing system, a seven sided polygon mirror is
used. The two beam array LD is used to control the growth of the polygon motor rotation
speed.
• The two-beam array LD consists of two LD elements arranged vertically. Two lines are
scanned with two laser beams emitted from these two LD elements through a single face
of the polygon mirror.
Transfer belt
CONFIGURATION/
OPERATION
Y M C K
Photo conductor Y
Beam A
Beam A Photo Photo conductor surface
Beam B conduc- Beam B
tor 2 line
Return mirror/2 One scan
Laser diode
G3 lens
rotatory direction
Photo conductor
polygon G1 lens G2 lens

mirror Return mirror/1
A0P0T2C004AA
45
8.2.2 Laser exposure process

A. Operation
1. The K laser light enters the cylindrical lens via the return mirror (light source). The
Y, M, and C laser light enter the cylindrical lens via the synthetic mirror and return
mirror (light source).
2. At the cylindrical lens, each laser light is condensed in the vicinity of the polygon
mirror.
3. Since the angle of incidence for each color of laser light varies, the laser light
reflected by the polygon mirror is reflected in a different angle for each color.
4. The condensing angle of each color of laser light is corrected by the G1 and G2
lenses and then reaches each return mirror.
5. The K laser light is condensed on the photo conductor surface via the G3 lens and
return mirror/1. The Y and M laser light is condensed on the photo conductor sur-
face via the return mirror/1, G3 lens, and return mirror/2. The C laser light is con-
densed on the photo conductor surface via the return mirror/1, return mirror/2, G3
lens, and return mirror/3.
Laser drive board/C Cylindrical lens
Return mirror (light Index lens
(LDDB/C)
CONFIGURATION/
source) Index board (INDEXB)

OPERATION
Laser drive
board/M
(LDDB/M)
Laser drive board/Y

(LDDB/Y)
Laser drive board/K

(LDDB/K)
Synthetic mirror
(Y,C,M)
Polygon mirror
G1
G2
Y M C K
G3 lens G3 lens G3 lens
Return mirror
Return mirror/1 G3 lens

G1 lens G2 lens A00JT2E510DA
46
8.2.3 Laser emission timing
• After a print cycle has been started, when the stable rotation signals of photo conductor
and polygon motor are detected, a laser ON signal is output from the printer control
board.
• The laser ON signal causes each laser diode to turn ON and emit a laser beam.
• After passing through the return mirror (light source), cylindrical lens, polygon mirror, G1
lens, G2 lens, index mirror, and index lens, the K laser light is applied to the index board.
This generates an index signal.
• This index signal has a function of keeping the same laser light emission timing per every
two lines in the main scanning direction.
• If the index signal is not detected within a predetermined period of time, the machine
determines that it is a laser emission fault, displaying “malfunction code: C4501 laser
fault”.
• The machine continuously monitors the index signal. If the index signal cannot be
detected at regular intervals, the machine determines that it is a laser emission fault, dis-
playing “malfunction code: C4501 laser fault”.
CONFIGURATION/
Laser drive
Laser drive board/C Index board (INDEXB)
OPERATION
board/M
(LDDB/M) (LDDB/C)
Index lens
Index mirror
Laser drive board/Y
(LDDB/Y)
Laser drive board/K

(LDDB/K)
Polygon mirror
G1 lens
G2 lens A00JT2C010DA
47
8.2.4 Laser emission stop

Emission of the laser beam is stopped if any of the following conditions is encountered dur-
ing printing:
• End of a print job
• Laser emission of Y, M, and C is stopped if the print mode is changed from color to
monochrome during printing.
• The front door or any other door is opened.
• A misfeed occurs.
• A malfunction occurs.
CONFIGURATION/
OPERATION
48
8.2.5 Laser emission area
A. Main scanning direction
• The print start position in the main scanning direction is determined by the main scan-
ning print start signal (/HSYNC) that is output from the printer control board and the
width of the paper.
• The laser emission area is determined by the paper size. The area of 3 mm/0.118 inch
on both edges of the paper is, however, the void image area.
B. Sub scanning direction

• The print start position in the sub scanning direction is determined by the image write
start signal (/TOD) that is output from the printer control board and the length of the
paper.
• The laser emission area is determined by paper size. However, there are void areas that
are 4.2 mm/0.165” from the leading edge and 3 mm/0.118” from the trailing edge of
paper.
CONFIGURATION/
OPERATION
Void width: 3 mm/0.118” Void width: 3 mm/0.118”
Void width: 4.2 mm/

0.165”
Void width: 3mm/

0.118”
4138to2595c0
49
8.2.6 Color registration control (color shift correction) system

• In a tandem engine, each four different color has an independent image reproduction
process. Color shift may occur because of variations in part accuracy. The color registra-
tion control system automatically detects color shift and correct color shift in the main
and sub scanning directions.
• The color shift detection sequence proceeds as follows. A detection pattern each in the
main scanning direction is produced at the front and rear on the transfer belt. Each of
IDC registration sensor F and R at the front and rear reads the corresponding pattern.
The amount of color shift in the sub scanning direction is then calculated and stored in
memory. A detection pattern each in the sub scanning direction is next produced at the
front and rear on the transfer belt. Each of IDC registration sensor F and R at the front
and rear reads the corresponding pattern. The amount of color shift in the main scanning
direction is then calculated and stored in memory. Based on the data representing the
amounts of color shift, the machine calculates how much each of the different colors
should be corrected. The correction data is further stored in memory. Based on the data
stored in memory, the machine controls each dot during production of image outputs,
thereby correcting the color shift.
CONFIGURATION/
OPERATION
Detection pattern for sub Detection pattern for main

scanning direction scanning direction
4038T2C007AA
IDC registration sensor/R

Transfer belt (IDCS/R)
IDC registration
sensor/F (IDCS/F)
A00JT2C034DA
50
A. Color shift correction method
• Black (K) is used as a standard of reference when other colors, yellow (Y), magenta (M),
and cyan (C), are individually corrected.
(1) Color shift in the main scanning direction

• The following two methods are available to correct color shift in the main scanning direc-
tion.
1. Adjustment in the main scanning direction: Change of image write start timing in
the main scanning direction.
2. Overall scaling: Change of writing clock frequency.
Color shift in the main scanning Color shift by inappropriate

direction scaling
K K
Y,M,C Y,M,C
The direction in The direction in
which the transfer which the transfer
belt moves belt moves
• For an easier explanation, the above illustration uses the relation between black toner (K)
CONFIGURATION/
and color toners (Y, M, C) that are transferred onto the transfer belt.
OPERATION
(2) Color shift in the sub scanning direction
1. Adjustment in the sub scanning direction: Change of image write start timing in the
sub scanning direction.
2. Color skew correction:
Adjustment of the PH unit G3 lens skew.
The G3 lens is driven by the skew correction motor.
Color shift in the sub scan- Color skew (Tilt)
ning direction
Y,M,C
K
Y,M,C K
The direction in The direction in
which the transfer which the transfer
belt moves belt moves
• For an easier explanation, the above illustration uses the relation between black toner (K)
and color toners (Y, M, C) that are transferred onto the transfer belt.
B. Color registration control operation timing

The color registration control and the image stabilization control operate at one time. For
detail, refer to the image stabilization control section.
51
8.2.7 Color skew correction control

• Temperature may change inside the PH unit and the components can change over time.
This may cause color skew problems. To prevent the problems, individual G3 lenses that
correspond to Y, M, and C respectively have a color skew auto adjustment mechanism.
• When the skew correction motor runs, the G3 lenses moves up and down to perform an
automatic color skew correction.
Skew correction motor/

Y,M,C (M35,M36,M37)
G3 lens holder A00JT2C011DA

CONFIGURATION/
OPERATION
A00JT2C026AA
Skew adjustment
Y M C
K
A00JT2C012DA
A. Operation timing
• The color registration control and the color skew control operate at one time.
• By using the sub scanning registration pattern detected, the color skew amount is calcu-
lated for each color. Each color skew is corrected using the previous correction data as a
standard of reference.
52
8.2.8 Skew adjustment/skew adjustment reset
• Certain specific conditions require that a skew adjustment be performed manually. There
may also be cases where the “color skew correction control” cannot be executed for
some reason.
The machine provides functions that allow you to make “skew adjustments” manually
and to reset the “skew adjustment data” against these situations.
• Instead of making an automatic adjustment using “color skew correction control”, the ref-
erence position of the skew correction motor can be manually set by entering “Skew
value” in “Skew adjustment” of the service mode. For details of the service mode, see
“Skew adjustment and skew adjustment data reset” of “Service mode” in “Field”.
A. Possible conditions and causes

• The print head unit is replaced with a new one.
• The alarm code “P-14: skew correction fault” is displayed.
• A door is opened or the main power switch is turned OFF during color skew correction
control, causing the skew correction sequence to be halted; as a result, the current posi-
tion of the skew correction motor is unknown.
• The skew correction motor position information set and backed up in the main body is
CONFIGURATION/
lost when, for example, the service EEPROM board is replaced with a new one.
OPERATION
8.2.9 PH unit temperature detection control
• Temperature change inside the PH unit may cause color shift. To prevent the problem,
temperature inside the PH unit is measured by the PH thermistor. The color registration
control and the color skew control start to operate when the machine detects a certain
amount of temperature change between the current temperature and the one measured
when the color registration was performed last time.
A00JT2C023AA
PH thermistor (TH7)
53
8.2.10 Image processing

The image processing has following items. For details, see “26. Image processing”. (See:
P.215)
Write section image processing block diagram

• Shading correction
• Line-to-line variation correction/color aberration correction
• Free erase
1 • Detection of security pattern
• ACS control
• AE processing
• Image data editing
• Image area discrimination
• Miscellaneous processing (improved reproduction of black text, edge emphasis, smooth-
ing and color balance)
• BTC compression
• Input buffer memory
• JBIG compression
CONFIGURATION/
• File (code) memory

OPERATION
DRAM:1024MB (standard)
HDD:60GB (standard)
• JBIG expansion
• Memory access coordinator
• Frame memory
• Output buffer memory
• BTC expansion
• Main scanning direction resolution conversion and movement
• Sub-scanning direction resolution conversion
• Color conversion processing
RGB to YMCK
1 • Embedment of security pattern
• Area discrimination FEET
• Interpolation
• Gamma correction
• Error diffusion (binary)
• Screening
• Delay control for the interval of photo conductors
• Main scanning position correction
Speed conversion
Modulation
1 54
Theory of Operation Ver. 2.0 Jul. 2009 9. IMAGING UNIT
9. IMAGING UNIT
9.1 Configuration
• The imaging unit/K is divided into two smaller units: the drum unit/K and the developing
unit/K.
• We call the drum unit/K and developing unit/K assembled together as the imaging unit/K.
Cleaning blade
Photo conductor
Imaging unit/Y, M, C
CONFIGURATION/
OPERATION
Imaging unit/Y, M, C Toner collecting screw
A0P0T2C001DA
A00JT2C014DA
Photo conductor charge corona
Imaging unit/K
Cleaning blade
Drum unit/K Toner collecting screw
Photo conductor
A0P0T2C002DA
Developing unit/K
A0P0T4C002DA
Photo conductor charge corona
55
9. IMAGING UNIT Theory of Operation Ver. 2.0 Jul. 2009
9.2 Drive
K developing motor (M19) K PC drum motor (M18)
Color PC drum motor

(M16)
CONFIGURATION/
Color developing
motor (M17)
OPERATION
A0P0T4C003DA
56
9.3 Operation
9.3.1 Detection of imaging unit
• Each of IU/Y, M, C has EEPROM board that detects a new IU and keeps track of the ser-
vice life of the IU.
A. New IU detection
• New IU/Y, M, C is detected when 24 V is turned ON after the main power switch is turned
OFF and ON or the front door is opened and closed.
• When a new IU is detected, the lift counter is automatically reset and a TCR adjustment
is carried out.
• An automatic TCR adjustment time is about 140 sec.
Operation when a new IU is detected
Transfer belt TCR automatic Image

is retracted adjustment stabilization
CONFIGURATION/
OPERATION
Operation when a new IU is not detected
Transfer belt Image

is retracted stabilization
4036ma2133c0
57
B. When life is reached

• The IU life counter is used to keep track of the life of the color IU.
• A warning screen appears when the life value is reached. Initiation of a new print cycle is
prohibited when a predetermined number of printed pages are produced after the life
value has been reached, at which time an IU replacement screen will appear.
• Warning screen and IU replacement screen is displayed differently by promoting expend-
able supplies choosing unit replacement in the service mode, and settings of IU life stop
in the security mode.
• If one of the color IUs reaches its life and a certain number of sheets are printed, the
machine stops printing. In this case, by pressing the Continue operation key on the
screen, monochrome print instead of color print can be made.
When an IU life value is reached When color IU life printing is pro-

hibited
CONFIGURATION/
OPERATION
A0P0T5E100DA A0P0T5E099DA
Continue operation key
A00JT2E504DA
58
9.3.2 Detection of drum unit/K
A. When life is reached

• The drum unit life counter is used to keep track of the life of the drum unit.
• A near-life condition is encountered when the consumption rate reaches about 87%, at
which time a lubrication mark appears.
value has been reached, at which time a drum unit replacement screen will appear.
When a near-life value is reached When a life value is reached
CONFIGURATION/
OPERATION

A0P0T5E101DA
A0P0T5E098DA
Lubrication mark
When printing is prohibited
A0P0T5E102DA
59
9.3.3 Detection of developing unit/K

• The developing unit/K has EEPROM board that detects a new unit and keeps track of the
service life of the unit.
A. New developing unit detection

• A new developing unit/K is detected when 24 V is turned ON after the main power switch
is turned OFF and ON or the front door is opened and closed.
• When a new developing unit is detected, the lift counter is automatically reset and a TCR
adjustment is carried out.
• An automatic TCR adjustment takes about 140 sec.
Operation when a new developing unit/K is detected
Transfer belt TCR automatic Image

is retracted adjustment stabilization
CONFIGURATION/
OPERATION
Operation when a new IU is not detected
Transfer belt Image

is retracted stabilization
4036ma2133c0
B. When life is reached

• The developing unit life counter is used to keep track of the life of the developing unit.
value has been reached, at which time a developing unit replacement screen will appear.
When a life value is reached When printing is prohibited
A0P0T5E096DA A0P0T5E097DA
60
9.3.4 Image stabilization control
• An image stabilization control is automatically performed when a new color IU, develop-
ing unit/K, or drum unit/K is detected.
• For details, see image stabilization control.
CONFIGURATION/
OPERATION
61
10. PHOTO CONDUCTOR SECTION Theory of Operation Ver. 2.0 Jul. 2009
10. PHOTO CONDUCTOR SECTION

10.1 Configuration
Charge generating
layer
Charge transport
layer Aluminum
cylinder
4036ma2338c0
Photo conductor
A0P0T2C003DA
CONFIGURATION/
OPERATION
10.2 Drive
Color PC drum motor (M16) K PC drum motor (M18)
Photo conductor/K
Photo conductor/C
Photo conductor/Y
Photo conductor/M
A00JT2C016DA
62
Theory of Operation Ver. 2.0 Jul. 2009 10. PHOTO CONDUCTOR SECTION
10.3 Operation
10.3.1 Photo conductor drive mechanism
• Two independent photo conductor motors, one for color and the other for monochrome,
are used for the drive mechanism to suppress incorrect color registration and uneven
pitch.
• The Color PC drum motor drives the photo conductors/Y, M, and C.
• The K PC drum motor drives the photo conductor/K.
• Drive is transmitted to each of the photo conductors when the triangular coupling is
engaged with the mating coupling that also has a triangular shape.
• CPM is different between color and monochrome printing. The K photo conductor drive
gear is designed to be larger than the color photo conductor drive gear.
Color PC drum motor (M16) K PC drum motor (M18)
CONFIGURATION/
OPERATION
Large-diameter Gear Coupling
A00JT2C017DA
Shaft
Coupling 4036ma2051c0
A0P0T2C004DA
63
A. Photo conductor speed control

• The K photo conductor drive gear has a diameter larger than that of the color photo con-
ductor drive gears to enable the high-speed monochrome printing.
• The K photo conductor diameter is also larger than that of the color photo conductors. (K
ø60/YMC ø30)
• Conventional phase control is not applicable to the photo conductors having different
diameters from each other. By controlling the K PC drum motor speed, the machine
reduces irregular rotation (color shift) caused by eccentricity of the K photo conductor
drive gear.
Encoder
K PC encoder sensor/2
K PC encoder sensor/1 (PS46)
(PS45)
CONFIGURATION/
OPERATION
A0P0T4C004DA
K photo conductor drive gear
64
B. Photo conductor small amount rotation control
• Humidity around the IU can produce a difference in sensitivity among different photo con-
ductors.
This could lead to drum memory, allowing black bands to occur in the image.
• Ozone stagnant in areas near the photo conductor charge corona reduces sensitivity of
the photo conductors, causing white bands to occur in the image.
• To prevent these image problems, that the photo conductor is turned at regular intervals
to keep the surface sensitivity uniform as temperature and humidity change.
• The time interval between small amount rotations is set different depending on how long
the photo conductor has been used and what the humidity and the temperature are
inside the machine.
• During the standby state after the end of a print cycle, the photo conductor small amount
rotation is made under the following timings.
The machine continues to print for more than a predetermined period of time. (The photo
conductor continues to run for more than a predetermined period of time.)
The machine prints intermittently for a given period of time with an intermission of less
than 10 minutes between print jobs. (The machine detects that the cumulative rotation
time of the photo conductor exceeds a given period of time.)
CONFIGURATION/
Photo conductor cumulative rotation time is calculated based on cumulative drive dis-
OPERATION
tance of the photo conductor.
Photo conductor/K Photo conductor/Y,M,C
A0P0T4C005DA A00JT2C014DA
65
10.3.2 Main erase lamp control

A. Main erase lamp/K control
• The Drum unit/K has a main erase lamp/K located on the upstream side of the cleaning
blade to improve cleaning performance.
• Main erase lamp/K radiation onto the surface of the photo conductor removes electric
charge remaining on the surface and makes the cleaning operation by the cleaning
blade.
< Drum unit/K >

Main erase lamp/K
CONFIGURATION/
OPERATION
A0P0T4C005DA
Cleaning blade
B. Main erase lamp/Y,M,C control

• The main erase lamp/Y, M, C radiation onto the photo conductor surface neutralizes
potential left on the surface of the photo conductor.
< IU/Y,M,C >

Cleaning blade
A00JT2C014DA
Main erase lamp/Y, M, C (EL/Y, M, C)

(Machine side)
66
10.3.3 Photo conductor cleaning
• The cleaning blade is pressed up against the surface of the photo conductor, scraping
residual toner off the surface (Blade abutting photo conductor in a counter direction).
• Toner, which has been scraped off the surface of the photo conductor, is conveyed to the
front side of the machine by the toner collecting screw. It is collected into the waste toner
collecting box.
< Drum unit/K > < IU/Y,M,C >
CONFIGURATION/
OPERATION
Cleaning blade
A00JT2C036AA
Cleaning blade
67
11. CHARGE CORONA SECTION Theory of Operation Ver. 2.0 Jul. 2009
11. CHARGE CORONA SECTION

11.1 Configuration
Serrate
electrode
4038T2C027AA
Photo conductor charge control plate (grid mesh)
CONFIGURATION/
OPERATION
Developing unit/K, Drum unit/K IU/Y,M,C

Photo conductor
charge corona Photo conductor
charge corona
Corona Wire Cleaning Lever
A00JT2C018DA
Cleaning blade
Photo conductor Photo conductor

charge corona charge corona
68
Theory of Operation Ver. 2.0 Jul. 2009 11. CHARGE CORONA SECTION
11.2 Operation
11.2.1 Photo conductor charge control
A. Serrate electrode
• The charge corona incorporates a serrate electrode, capable of conducting charging
operation centrally on the charge control plate (grid mesh), which reduces the amount of
ozone produced.
B. Charge control plate

• Discharge occurs via the charge control plate (grid mesh), so that the photo conductor
surface can be uniformly charged.
• The grid voltage (Vg) applied to the charge control plate (grid mesh) is controlled through
the image stabilization control.
Color PC drum motor (M16)
CONFIGURATION/
Drum charge corona bias/
OPERATION
Y,M,C
Drum charge corona bias/K
K PC developing motor (M19) Charge corona

(Mounted separately
Color developing motor (M17) for each of Y, M,
C, and K)
A00JT2E512DA
11.2.2 Charge corona cleaning control

• A dirtied charge corona may cause bands and uneven image problems and the increase
of the electric potential on the surface of the photo conductor. To prevent these problems,
the charge corona has a cleaning mechanism that periodically cleans the serrate elec-
trode and the charge control plate (grid mesh).
• Only the drum unit/K frequently used in printing has the charge corona cleaning control.
• The cleaner is driven by the charge cleaning motor/K.
• When the power switch is turned ON or the front door is opened/closed, the charge
corona cleaner home position is detected.
• The charging cleaner home sensor detects the position (rear) of the charge corona
cleaner. The charging cleaner return sensor (this side) detects the return position.
• When the count goes over 2,700 during a print job, the cleaning operation starts after the
completion of the print job. However, when the remaining number of pages of the job is
50 sheets or more, the job is stopped and the cleaning operation is performed.
• The count method is shown below.
Paper length in the sub scanning direction Count

216 mm or less 1
Over 216 mm and up to 432 mm 2
Over 1080 mm 6
69
11. CHARGE CORONA SECTION Theory of Operation Ver. 2.0 Jul. 2009
• With the IU/Y, M, C, the charge corona is cleaned manually using the photo conductor
charge corona cleaning lever incorporated in the IU.
1 • Perform cleaning upon maintenance call.
IU/Y,M,C
Photo conductor charge corona cleaning lever

A00JT2C018DA
CONFIGURATION/
OPERATION
1 70
Theory of Operation Ver. 2.0 Jul. 2009 12. DEVELOPING SECTION
12. DEVELOPING SECTION
12.1 Configuration
< K developing section > < Color developing section >
Developing roller Doctor blade
Doctor blade
Developing roller
A0P0T4C007DA
CONFIGURATION/
4037T2C513AA
OPERATION
Supply/agitating/ Supply/agitating/
conveying screws conveying screws
K developing motor (M19)
Color PC drum motor

(M16)
Photo conductor/K
Developing roller
Color developing
motor (M17)
Photo conductor/Y
A0P0T4C008DA
Supply/agitating/
conveying screws
71
12. DEVELOPING SECTION Theory of Operation Ver. 2.0 Jul. 2009
12.2 Drive
K developing motor (M19) K PC drum motor (M18)
Color PC drum motor

(M16)
Photo conductor/K
Developing roller
Color developing
motor (M17)
Photo conductor/Y
CONFIGURATION/
OPERATION
A0P0T4C008DA
Supply/agitating/
conveying screws
72
12.3 Operation
12.3.1 Developer flow
A. Developing unit/K
1. Toner supplied from the front end of the developing unit is fed to the lower screw. It
is then fed to the rear of the unit, while being mixed with developer and electrically
charged by the Supply/Agitating/Conveying Screws.
2. The TCR sensor installed on the underside of the developing unit detects toner to
carrier ratio during this time.
3. The developer conveyed to the rear of the unit is carried to the screw on the right.
4. The developer is conveyed onto the developing roller. The doctor blade then con-
trols the height of the developer brush to ensure that the developer on the develop-
ing roller levels out.
5. Toner sticks to the electrostatic latent image on the surface of the photo conductor.
The developer that is left on the developing roller is returned to the screw on the
right by the magnetic pole positioning of the developing roller. It is then conveyed to
the front of the unit.
CONFIGURATION/
Photo conductor/K
OPERATION
Doctor blade
Toner supplied
from toner hopper
Developing roller
A0P0T4C010DA
A0P0T4C009DA
TCR sensor (TCRS/K) Supply/agitating/

conveying screws
73
B. Imaging unit/Y, M, C
1. Toner supplied from the front end of the developing unit is fed to the lower screw. It
is then fed to the rear of the unit, while being mixed with developer and electrically
charged by the Supply/Agitating/Conveying Screws.
2. The TCR Sensor installed on the underside of the developing unit detects toner to
carrier ratio during this time.
3. The developer, fed to the rear of the developing unit, is conveyed further to the
upper screw.
4. The developer is conveyed onto the developing roller. The doctor blade then con-
trols the height of the developer brush to ensure that the developer on the develop-
ing roller levels out.
5. The Toner sticks to the electrostatic latent image on the surface of the photo con-
ductor. The developer that is left on the developing roller is returned to the upper
screw by the magnetic pole positioning of the developing roller. It is then conveyed
to the front side of the developing unit.
Photo conductor/
Y,M,C Developing roller
CONFIGURATION/
Doctor blade
OPERATION
Toner supplied
from toner hopper Supply/agitating/ 4036ma2605c0
conveying screws
74
12.3.2 Auto refining developing system
• The machine incorporates the auto refining developing system for maintaining the devel-
oper at a predetermined charge state.
• Carrier is mixed with toner in the toner cartridge and the developing unit is supplied with
the carrier together with the toner.
• Deteriorated carrier (developer) is collected from the developing unit into the waste toner
box. This reduces the degree of deterioration of the carrier in the developing unit, which
allows a stable image to be maintained for a long time.
• The auto refining system is incorporated only in the developing unit/K.
Toner bottle
Toner
New carrier
Low degree of deterio-

ration of entire carrier
CONFIGURATION/
OPERATION
Developing unit Circulation
and agitation
Waste toner box
A0P0T2J609AA
Waste toner box

A0P0T2J609AA
75
12.3.3 Developing bias

• The developing bias voltage (Vb) is applied to the developing roller so that an adequate
amount of toner is attracted onto the surface of the photo conductor can be controlled.
• To help toner to be attracted more easily to the surface of the photo conductor, the devel-
oping bias Voltage (Vb) of Vdc+Vac is applied during development. AC component is
applied only while development is taking place. At any other timing, only Vdc is applied.
• The developing bias (Vb) is supplied from high voltage unit /1.
Developing unit/K
Developing roller
CONFIGURATION/
Developing bias A0P0T2C005DA

OPERATION
Developing bias
Developing roller
4036ma2507c0
76
12.3.4 Toner scattering prevention
• To prevent the image and machine interior from being dirtied, a toner filter is installed at
the rear of the machine, and the toner suction fan motor that work together sucks toner
particles rising up during development.
• The toner filter comes together with the drum unit/K.
Toner filter
Drum unit/K
Toner suction fan

motor (FM7)
CONFIGURATION/
OPERATION
A0P0T4C012DA
77
12.3.5 Developing cooling control

• Removes ozone produced by the drum charge corona.
• Only air drawn by the ozone ventilation fan motor is discharged out of the machine after
the ozone filter removes ozone from it.

CONFIGURATION/
OPERATION
A0P0T4C013DA
78
12.3.6 Toner density control
A. Toner density detection
• The magnetic TCR sensor is mounted on the underside of each of the developing sec-
tions. Each of these TCR sensors detects toner-to-carrier ratio (T/C) of the developer.
The reading is used for determining the amount of toner supplied.
• The target T/C ratio is 7% for both color and K.
• When a new imaging unit/Y, M, C or developing unit/K is mounted in the machine, the
TCR sensor is automatically adjusted, and it cannot be adjusted manually.
TCR sensor/Y,M.C TCR sensor/K
CONFIGURATION/
OPERATION
A0P0T2C007DA A0P0T2C006DA
TCR sensor/Y,M,C
(TCRS/Y,M,C)
A0P0T2C655AA
A0P0T4C007DA
TCR sensor/K
(TCRS/K)
79
13. TONER SUPPLY SECTION Theory of Operation Ver. 2.0 Jul. 2009
13. TONER SUPPLY SECTION

13.1 Configuration
Toner cartridge/Y,M,C
Toner cartridge/K A0P0T2C008DA

CONFIGURATION/
OPERATION
Conveyance screw /K
Conveyance screw /Y, M, C

Toner cartridge/K
Toner hopper/K
Toner cartridge/Y, M, C
Toner hopper/Y, M, C
A0P0T4C014DA
80
Theory of Operation Ver. 2.0 Jul. 2009 13. TONER SUPPLY SECTION
13.2 Drive
Toner cartridge motor C/K (M14)
Toner cartridge motor

Y/M (M13)
CONFIGURATION/
OPERATION
A0P0T4C015DA
81
13.3 Operation
13.3.1 Replenishing the toner hopper with toner
A. Toner replenishing control
• In the toner replenishing step from the toner cartridge to the toner hopper, a single toner
supply motor is turned either forward or backward to supply toner of two different colors.
(A toner cartridge motor for K/C and a toner cartridge motor for Y/M)
• The toner empty sensor located in the toner hopper detects the remaining toner amount
and controls toner replenishment from the toner cartridge to the toner hopper.
Toner cartridge Toner cartridge

K toner C toner Y toner M toner
motor C/K motor Y/M
Turned forward Replenished Deenergized Turned forward Replenished Deenergized
Turned backward Deenergized Replenished Turned backward Deenergized Replenished
One-way clutch
CONFIGURATION/
OPERATION
Toner cartridge
motor C/K (M14)
Toner cartridge
motor Y/M (M13)
A00JT2C032DA
82
• A reed switch is used as the toner empty sensor/Y, M, C, while a piezo sensor is used as
the toner empty sensor/K.
Toner empty sensor/K (PZS/K)

Toner empty sensor/Y,M,C
(RS/Y,RS/M,RS/C)
CONFIGURATION/
OPERATION
Toner supply motors
(M9,10,11,12) Toner hopper
A0P0T4C016DA
B. Replenishing speed selection control

• Depending on the toner efficiency, the toner cartridge motor selects a rotation speed of
either low or high.
• When much toner remains in the toner cartridge, the toner cartridge motor rotates at the
low speed.
• Due to the toner efficiency decrease after detecting a toner cartridge near empty, speed
of toner cartridge motor is changed from high speed to low speed in order to supply toner
to the toner hopper.
83
13.3.2 Replenishing the developing unit with toner

A. Toner replenishing control
• Toner, which has been supplied from the toner cartridge to the toner hopper, is replen-
ished to the developing unit by the toner supply motors that independently operate for Y,
M, C, and K
• T/C is detected when the K developing motor is energized for K or when the color devel-
oping motor is energized for C, M, and Y.
• Based on T/C ratio detected by the TRC sensor and amount of consumption calculated
by the dot counter, toner replenishing time (amount) is determined.
• When the machine determines the toner replenishing, sometime it detects the toner
amount that surpasses the maximum volume for one replenishing control. If it is not pos-
sible to replenish the supply of the required amount of toner within this maximum replen-
ishing time, the reminder time is stored in memory and added to the replenishing time for
the next replenishing sequence. (For printing an image highly concentrated)
Toner supply motors/K (M12) Toner empty sensor K (PZS/K)

CONFIGURATION/
OPERATION
Conveying screws
Agitating seat
A00JT2C097DA
Toner supply motors/ Y,M,C,K Toner empty sensor/Y,M,C

(M9,10,11,12) (RS/Y,RS/M,RS/C)
Conveying screws
Agitating seat
A0P0T4C017DA
84
13.3.3 Toner cartridge detection
• Individual cartridge detection is controlled by means of accessing the toner cartridge set
board when the front upper door is closed or the main power switch is turned ON to
determine whether a specific toner cartridge is loaded or not.
• After detecting the presence of the cartridge, the machine determines whether the car-
tridge is new or not.
Toner cartridge set board
CONFIGURATION/
OPERATION
A0P0T2C010DA
13.3.4 Toner cartridge life control

• The amount of toner remaining in the cartridge is displayed as the four states, normal,
toner cartridge near empty, toner cartridge empty, and toner hopper empty.
Remaining toner amount Description

Enough toner remains in the toner cartridge and the toner hopper.
Normal
(Low speed replenishment)
Toner cartridge near Low speed replenishment cannot supply the required amount of toner to the
empty toner hopper within a certain time. (Switch to the high speed replenishment)
Even high speed replenishment cannot supply the required amount of toner
Toner cartridge empty
to the toner hopper within a certain time.
Toner inside the toner hopper is running out and a printing cannot be contin-
toner hopper empty
ued.
• Normal: The number of pages that can be printed is 7,500 or more for black and 7,000 or
more for color.
• Toner cartridge near empty: The number of pages that can be printed is less than 5,000-
7,500 for black and less than 5,000-7,000 for color.
• Toner cartridge empty: No toner remains in the toner cartridge.
The number of pages that can be printed is less than 1,000. (Both for black and color)
• Toner hopper empty: The machine stops printing.
A. Toner cartridge near empty detection control

• A toner cartridge near empty warning is displayed, if the toner empty sensor of the toner
hopper detects no toner while the toner cartridge motor runs at low speed.
B. Toner cartridge empty control

• After the toner cartridge empty condition is detected, if the toner hopper toner empty
sensor detects toner empty, the toner cartridge empty warning is displayed.
85
C. Toner hopper empty detection

• Toner amount more than the given level is supplied to the developing section after detect-
ing a toner cartridge empty, toner hopper empty warning is displayed.
Toner cartridge near-empty Toner cartridge empty
A00HT2E307AA A00JT2E506DA
CONFIGURATION/
Toner hopper empty

OPERATION
A0P0T5E103DA
• A different toner hopper empty screen is displayed if “User” is selected for “Unit change”
available from the Service Mode.
86
13.3.5 Toner spill prevention shutter
• To prevent toner from being spilled when the toner cartridge is removed from the
machine, there is a shutter mechanism provided. When the toner cartridge is installed in
the machine, the shutter opens.
• Put the replacement port face down to keep the cover close.
Before toner cartridge is installed When toner cartridge is installed

Shutter
CONFIGURATION/
OPERATION
87
14. 1st IMAGE TRANSFER SECTION Theory of Operation Ver. 2.0 Jul. 2009
14. 1st IMAGE TRANSFER SECTION

14.1 Configuration
A0P0T2C013DA
CONFIGURATION/
1st Image transfer roller/Y 1st Image transfer roller/C

OPERATION
Cleaning brush 1 1st Image transfer roller/M 1st Image transfer roller/K
Cleaning brush 2
Transfer belt drive roller
A0P0T5C037DA
1st Image transfer pressure/

retraction motor (M21) Pressure cam
Pressure welding alienation

sensor/K (PS51)
sensor color (PS52) A00JT2C037DA
88
Theory of Operation Ver. 2.0 Jul. 2009 14. 1st IMAGE TRANSFER SECTION
14.2 Drive
Cleaner motor (M38)
CONFIGURATION/
Transfer belt
OPERATION
A0P0T5C092DA
1st Image transfer roller/K
1st Image transfer roller/C
1st Image transfer roller/Y
1st image transfer

pressure retraction
motor (M21)
1st Image transfer roller/M
A00JT2C041DA
89
14.3 Operation
14.3.1 1st image transfer roller control
• The machine is provided with a mechanism that presses the 1st image transfer rollers up
against the inside of the transfer belt during the 1st image transfer stage. The 1st image
transfer pressure retraction motor provides the drive for this operation.
• Three different types of cams are mounted on one shaft. The K cam causes the 1st
Image transfer roller/K and the K retraction roller to perform pressure/retraction opera-
tion.
• The color cam causes the 1st Image transfer roller/Y, M, C and color retraction roller to
perform pressure/retraction operation.
• The retraction roller cam causes the color retraction roller to perform pressure/retraction
operation.
• The retraction position sensor/K detects the retraction position of the 1st image transfer
roller/K and retraction position sensor/color detects the retraction position of the 1st
image transfer rollers/Y, M, C.
• To detect pressure and retraction positions, the K and color sliding plate positions are
detected respectively.
CONFIGURATION/
• In the pressure operation, a predetermined pulse controls the stop position.

OPERATION
• In order to reduce the first print time, the machine uses the cam that can turn both for-
ward and backward. With the least rotation of the cam, the 1st transfer roller position can
be changed.
K sliding plate Color sliding plate K cam
Color cam
Retraction roller cam
Pressure welding
alienation sensor/K
(PS51)
Pressure welding 1st image transfer

alienation sensor/color pressure retraction
(PS52) motor (M21)
A0P0T5C106DA
When retracted Spring When pressed
A00JT2C045DA A00JT2C046DA
1st Image Transfer Roller
90
• The pressure operation starts when a print cycle starts, and the retraction operation
starts when the print cycle completes.
Start key ON Paper Moves Past 2nd Image transfer roller

1st Image transfer pressure
retraction motor (M21)
Pressure welding alienatioin
sensor/color (PS52)
sensor/K (PS51)
A0P0T5E092DA
CONFIGURATION/
OPERATION
91
A. Retraction roller control

• In addition to the change of the pressure position of the 1st image transfer roller, the
machine moves the color retraction roller or the K retraction roller up and down to change
the position of the image transfer on the surface of the transfer belt depending on the
print mode of each job.
• Changing the cam stop position moves the retraction lever, which results in the retraction
roller moving up or down.
• The color retraction roller is driven by the color cam.
Retraction position
Cam position
Retraction lever
Driven roller Color retraction roller
CONFIGURATION/
OPERATION
Monochrome Mode Color Mode
A00JT2C048DA
• The K retraction roller is driven by the K cam.
Retraction position Monochrome Mode

Color Mode
1st image transfer

roller/K
K Retraction roller
A00JT2C049DA
92
14.3.2 Pressure/retraction control by print mode
(1) Black
• The pressure position of the image transfer roller/Y, M, C in the monochrome mode is
where the photo conductor/Y, M, C leaves the transfer belt, while that of the image trans-
fer roller/K is where the photo conductor/K is in contact with the transfer belt. This allows
the photo conductor/Y, M, C to remain stationary in this mode.
(2) Color
• The pressure position of the image transfer roller in the color mode is where the photo
conductor is in contact with the transfer belt for all four colors of toner.
Cam position
Retraction
position
Y M C K
CONFIGURATION/
OPERATION
Cam position (K)
Monochrome
Y M C K Retraction roller
Cam
K Sliding plate
Color
Cam position (Color)
1st Image Transfer roller
Y M C K
Transfer belt Photo conductor

Color sliding plate
A00JT2C047DA
93
14.3.3 ACS
• For monochrome printing in the ACS mode, the pressure/retraction operation of the 1st
image transfer roller is controlled according to the number of monochrome originals that
continue during multiple copies. It promotes high productivity and extends consumables
life.
* ACS: Auto color selection
A. Operation
• ACS control starts counting the number of multi-copies of the monochrome original when
switched from the color original to the monochrome original.
• When the number of multi-copies is as specified or under.
: The monochrome printing will start with color mode. (with the 1st image transfer roller /
Y/M/C being pressed)
The transfer belt being pressed saves time since the 1st image transfer roller does not
need to be retracted.
• When the number of multi-copies is as specified or over.
: The monochrome printing will start when the color mode is complete and the 1st image
transfer roller /Y/M/C is retracted to be switched to the monochrome mode.
CONFIGURATION/
The transfer belt being retracted prevents IU to be wasted by useless rotation.

OPERATION
(1) C652
• Number of multiple copies of monochrome originals when the paper feed speed is 240
mm/s (Plain paper).
Paper length in the sub Monochrome printing after switched

Monochrome printing in color mode
scanning direction to monochrome mode
216 mm or less 4 sheets or less 5 sheets or more
Over 216 mm and up to
3 sheets or less 4 sheets or more
297 mm
381 mm
1 sheet or less 2 sheets or more
432 mm
Over 432 mm 1 sheet or less 2 sheets or more
mm/s (Thick stock 1, Thick stock 1+, Thick stock 2, Thick stock 3, Thick stock 4, Special
paper).

297 mm
381 mm
432 mm
94
paper).

297 mm
381 mm
432 mm
1 (2) C552/C452
mm/s (Plain paper).
CONFIGURATION/
OPERATION
297 mm
381 mm
432 mm
paper).

297 mm
381 mm
432 mm
95 1
paper).

297 mm
381 mm
432 mm
CONFIGURATION/
OPERATION
96
• ACS control operates only after the number of multi-copies for monochrome original is
counted.
“The pressure/retraction control for ACS mode” will not be properly executed with only
one sheet of print job, since on the first copy, the control can be performed only for where
the original is read and counted.
The ACS control performs effectively for the print jobs as listed below.
For the 2nd set of prints onward in electronic sorting
printing using job programs
When printing in monochrome with color mode

(effecting monochrome printing with the four photo conductors rotating)
First sheet of color mode First sheet of monochrome mode First sheet of color mode
Y M C K Y M C K Y M C K
CONFIGURATION/
OPERATION
A00JT2C052DA
Switching to monochrome mode
First sheet of color mode First sheet of Second sheet of

monochrome mode monochrome mode
Third sheet of Fourth sheet of Fifth sheet of

monochrome mode monochrome mode monochrome mode
A00JT2C053DA
97
14.3.4 Transfer belt cleaning

• To scrape residual toner off the surface of the transfer belt, the transfer belt is provided
with cleaning brushes 1 and 2.
• Cleaning brush 1/2 is a rotary brush. To enhance its ability to scrape residual toner off
the surface of the transfer belt, the brush is turned in a direction opposite to that of the
transfer belt. The cleaner motor provides the drive for this system.
Cleaning brush 1
Transfer belt
Toner collecting
roller 1
Toner collecting
CONFIGURATION/
roller 2
OPERATION
Driven roller
Cleaning brush 2
A0P0T4C018DA
A0P0T2C013DA
• During a print cycle, an image stabilization operation, the 2nd transfer roller cleaning,
and other states whenever the transfer belt operates.
Cleaning start signal
Cleaner motor (M38)
A0P0T5E117DA
14.3.5 Image stabilization control

• An image stabilization control sequence is automatically performed when a new image
transfer belt unit is mounted in the machine and the retraction of new transfer belt unit is
carried out from the service mode.
• For detail, refer to the image stabilization control section.
98
Theory of Operation Ver. 2.0 Jul. 2009 15. 2nd IMAGE TRANSFER SECTION
15. 2nd IMAGE TRANSFER SECTION
15.1 Configuration
2nd Image transfer roller
A0P0T4C019DA
A0P0T2C015DA
CONFIGURATION/
OPERATION
Temperature/humidity sensor
(TEM/HUMS) A0P0T2C016DA

sensor (PS50)
2nd image transfer pressure

(IDCS/R)
Shutter
IDC registration sensor/F (IDCS/F) A00JT2C038DA
99
15. 2nd IMAGE TRANSFER SECTION Theory of Operation Ver. 2.0 Jul. 2009
15.2 Drive
Pressure welding alienation sensor (PS50)

Cam 2nd image transfer pressure

(IDCS/R)
Shutter
Pressure lever
CONFIGURATION/
IDC registration sensor/F (IDCS/F)

A00JT2C043DA
OPERATION
100
15.3 Operation
15.3.1 2nd image transfer roller control
A. 2nd image transfer roller pressure/retraction
• The 2nd image transfer roller has a pressure/retraction mechanism which presses to and
retracts from the transfer belt so the patterns made on the transfer belt except by copy-
ing, such as detection pattern during image stabilization operation, will not affect the 2nd
image transfer roller.
• Pressure/retraction operation
1. Drive from the 2nd image transfer pressure/retraction motor is transmitted to the
drive gear.
2. The drive gear rotates to rotate the cam. Pressing down the pressure lever will
press the 2nd image transfer roller against the transfer belt.
3. At this time, the 2nd image transfer pressure position sensor detects that the 2nd
image transfer roller reaches the pressure position. The 2nd image transfer pres-
sure retraction motor is stopped.
4. The cam rotates further when the motor turns ON again. Releasing the pressure
lever will move the 2nd image transfer roller to the retraction position. At this time,
CONFIGURATION/
the 2nd image transfer pressure position sensor detects that the roller reaches the
OPERATION
retraction position. The 2nd image transfer pressure retraction motor is stopped.

sensor (PS50)
2nd Image transfer

roller
Cam A0P0T2C017DA
When retracted When pressed
Drive roller
2nd Image
transfer roller
Cam 4036ma2168c0 4036ma2023c1
101
• The pressure operation starts when a print cycle starts, and the retraction operation
starts when the print cycle completes.
Start key ON Paper moves past 2nd Image transfer roller

2nd Image transfer pressure
sensor (PS50)
A0P0T5E093DA
15.3.2 2nd image transfer control

• The toner on the transfer belt is transferred onto the paper when the paper is transported
between the transfer belt and the 2nd image transfer roller.
CONFIGURATION/
2nd image transfer remote signal

OPERATION
1st sheet of paper 2nd sheet of paper

2nd image transfer output
A0P0T2C606AA
• To adjust the 2nd image transfer output to the correct voltage, ATVC system is installed.
A constant current is output to the 2nd image transfer roller to measure voltage. The
measured voltage is corrected to be used for automatic adjustment of the 2nd image
transfer output voltage.
• The ATVC operation is performed after the power switch is turned ON. (Mainly just before
image stabilization operation) Or, it is performed before the machine starts a print cycle
for the first time after the temperature change inside the machine went over the thresh-
old.
• Overview of ATVC operation
Printer control board (PRCB)

Output a constant current to the 2nd
image transfer roller. Measures the voltage
Calculate the resistance value of the HV2

2nd image transfer roller. Constant current
Determine the 2nd image transfer

output voltage. 2nd image transfer roller
Transfer belt
Transfer belt drive roller
102
15.3.3 2nd image transfer roller cleaning
• To remove residual toner off the surface of the 2nd Image transfer roller, a +/- DC bias is
applied alternately to the roller, thereby moving the residual toner to the surface of the
transfer belt.
• The cleaning brush then scrapes off the toner on the surface of the transfer belt.
Cleaning brush 1
- - -
- - -
-
- +
H V2
Cleaning brush 2 Transfer belt 2nd Image A0P0T5C036DA
transfer roller
• The sequence is carried when the power switch are turned ON or each door is opened
and closed when a print cycle has been abnormally terminated due to a misfeed or mal-
CONFIGURATION/
function.
OPERATION
• The sequence is also carried out at the end of a print cycle that is run after the cumula-
tive number of printed pages produced has exceeded 300, or during a print cycle that is
run after the cumulative number of printed pages produced has exceeded 3000, since
the previous cleaning operation.
Paper length in the

sub scanning Print mode Count
direction
Color 3
216 mm or less
Monochrome 1
Color 6
Over 216 mm
Monochrome 2
2nd image transfer roller cleaning after the completion of a print cycle
Start the 2nd image transfer roller cleaning operation
2nd Image Transfer reverse bias

Retracted
retraction motor (M3) Pressure Retracted
A00JT2E517DA
103
15.3.4 Paper separation control

• To neutralize any charge potential left in the paper which has undergone the 2nd image
transfer stage, a charge neutralizing needle is installed to the guide plate after the 2nd
Image Transfer Roller.
• The output of the charge neutralizing needle is switched automatically using the high
voltage unit according to the paper type and the environmental conditions, and whether
the print cycle is for printing the 1st side or 2nd.
• In order to separate thin paper or curled paper caused by 2-sided printing from the trans-
fer belt without fail after the 2nd image transfer, transfer belt separator claws are
mounted at 3 places.
Paper Separator Claws

Charge neutralizing needle
CONFIGURATION/
HV2
OPERATION
Transfer Belt 2nd Image

Transfer Roller A00JT2C022AA
A0P0T2C014DA
• Switching of output of the charge neutralizing needle
Paper Type Ambience Control Detailed description

Low humidity Bias applied • A negative charge, which is the reverse polarity to
the positive output from the 2nd Transfer Roller, is
1-sided applied to prevent the paper from being wound
Normal Bias applied
printing on the around the Transfer Belt.
plain paper
GND through • To prevent separation noise, grounded through
High humidity
resistors resistors regardless of the ambient conditions.
• Bias is applied regardless of the ambient condi-
2nd side of
tions, since the paper to go to the 2nd side print
2-sided
– Bias applied cycle, which has undergone the fusing process, has
printing on the
the condition equivalent to paper under low humid-
plain paper
ity ambience.
• Paper is stiff enough to present no separation prob-
Special paper
GND through lems.
other than –
resistors • To prevent separation noise, grounded through
plain paper
resistors regardless of the ambient conditions.
104
15.3.5 Sensor protection
• The IDC sensor can be contaminated with toner since it is located under the transfer belt.
There is a shutter mechanism provided for the sensor to prevent it from being contami-
nated.
• The shutter is closed and opened in time with the 2nd image transfer roller being pressed
and retracted. When the 2nd image transfer roller is retracted, the pressure pin presses
the shutter holder, causing the shutter at the IDC sensor section to move to the front
side.
• When the 2nd image transfer roller is pressed, on the other hand, the shutter at the IDC
sensor section is moved to the rear by the spring force and closed.
2nd image transfer roller Shutter

Retracted Open
pressed Closed
CONFIGURATION/
OPERATION
IDC registration
sensor/R (IDCS/R)
Shutter Pressure
Shutter holder pin
IDC registration A00JT2C050DA
sensor/F (IDCS/F) 4036ma2171c0
When Sensor Shutter is Closed When Sensor Shutter is Open
105
16. TONER COLLECTING SECTION Theory of Operation Ver. 2.0 Jul. 2009
16. TONER COLLECTING SECTION

16.1 Configuration
A0P0T2C020DA
Transfer belt
CONFIGURATION/
toner collecting screw

OPERATION
Drum unit/K
Waste toner
box
Developing unit/K Agitating screw
developer collecting section
A0P0T4C020DA
106
Theory of Operation Ver. 2.0 Jul. 2009 16. TONER COLLECTING SECTION
16.2 Drive
Transfer belt toner collecting screw

Cleaner motor (M38)
Toner collecting roller
CONFIGURATION/
OPERATION
Color PC drum
motor (M16)
A0P0T4C021DA
107
16.3 Operation
16.3.1 Toner collecting path
• Toner collected by the cleaning brush of the transfer belt and waste toner on each of the
photo conductors are conveyed by the corresponding toner collecting screws to the
waste toner box. The deteriorated developer is also conveyed from the developing unit/K
to the waste toner box by the collecting screw.
Transfer belt toner

collecting screw
Drum unit/K
IU toner collecting screw

CONFIGURATION/
OPERATION
Waste toner box
Developing unit/K A0P0T4C022DA

developer collecting section
• The waste toner box consists of the waste toner collecting section and the developer col-
lecting section.
• When waste toner accumulates in the waste toner collection section, it is dropped into
the developer collection section through the pipe and mixed with the developer, so that
the near-full detection window is packed with the mixture.
Developer collecting section
Waste toner collecting section
Pipe
Developer collecting port (K)
Near-full detection window A0P0T4C023DA
108
16.3.2 Agitation control in waste toner box
• In order to avoid detecting an incorrect waste toner amount, two agitating screws are
installed in the waste toner box so that waste toner and developer can build up evenly in
the box.
• The agitating screws are driven and rotated by the waste toner agitating motor.
• The waste toner agitating motor lock sensor detects the waste toner agitating motor lock.
• The waste toner agitating motor operates when the TCR sensor performs an automatic
adjustment, toner is forcefully replenished, and the transfer belt is driven.
Agitating screw
CONFIGURATION/
Agitating screw
OPERATION
Waste toner agitating motor lock sensor
(PS23)
A0P0T4C024DA
16.3.3 Detection of waste toner box loaded in position

• The waste toner box set sensor is provided to detect a waste toner box loaded in posi-
tion. Timing for this detection is when the power switch is turned ON, and the front door is
closed. If the waste toner box is found to be out of position, the machine inhibits the initi-
ation of a new print cycle.
Waste toner box
Waste toner box set

sensor (PS53)
A0P0T4C025DA
109
16.3.4 Waste Toner full detection

• An interrupter-type photosensor is used to detect waste toner. When the sensor is
blocked for a given period of time, the machine determines that the waste toner box is
nearly full of waste toner.
• At this time, a corresponding warning (near-full warning) is given on the control panel.
• The machine detects a waste toner full condition after a predetermined number of
printed pages are produced after the detection of the waste toner near full condition.
• Upon the waste toner near full detection, the counter exclusive for waste toner inside the
machine starts counting. When the number of printed pages, regardless of whether they
are color or monochrome, reaches around 3,000 counts, the machine detects a waste
toner full condition and stops printing.
• Counting method of the counter exclusive for the waste toner is carried out based on the
paper length in the sub scanning direction shown in the below table. For A4, the machine
will stop at 3,000 sheets.
Paper length in the sub scanning direction Print mode Count

216 mm or less Color/Monochrome 1
Over 216 mm and up to 432 mm Color/Monochrome 2
CONFIGURATION/

OPERATION

Over 1080 mm Color/Monochrome 6
110
• After the waste toner box has been replaced and the waste toner full sensor has been
unblocked for a given period of time, the machine cancels the copying-disabled condi-
tion, while at the same time automatically clearing the counter exclusive.
Waste toner full sensor (PS54)
Before near-full Near-full condition Waste toner box

A0P0T2C020DA
condition is detected detected
CONFIGURATION/
Waste toner
OPERATION
A0P0T4C026DA
Near-Full Condition Warning Display Full Condition Warning Display
A00JT2E508DA A0P0T5E104DA
A different toner full warning screen is displayed if “User” is selected for “Unit Change”
available from the Service Mode.
111
17. PAPER FEED SECTION (TRAY1, TRAY2) Theory of Operation Ver. 2.0 Jul. 2009
17. PAPER FEED SECTION (TRAY1, TRAY2)

17.1 Configuration
17.1.1 Major components
• Tray1 and 2 have same sensor position.
CONFIGURATION/
A00JT2C277AA
OPERATION
Tray1 upper limit sensor (PS6)
Tray1 near empty sensor (PS3) Tray1 vertical transport sensor (PS4)
Tray1 paper feed sensor (PS5)

Tray1 device detection sensor (PS1)
Tray1 paper empty
sensor (PS2)
A00JT2C286AA
Paper size detect board/1 (PSDTB/1)

Tray1 CD paper size sensor/1 (PS7)
Tray1 CD paper size sensor/2 (PS8)
Tray2 sensor identification
Tray2 upper limit sensor (PS14) Tray2 paper feed sensor (PS13)
Tray2 near empty sensor (PS11) Tray2 paper empty sensor (PS11)
Tray2 device detection sensor (PS9) Tray2 CD paper size sensor/1 (PS15)
Paper size detect board/2 (PSDTB/2) Tray2 CD paper size sensor/2 (PS16)
Tray2 vertical transport sensor (PS12) Tray2 paper empty display board (PEIB/2)
112
Theory of Operation Ver. 2.0 Jul. 2009 17. PAPER FEED SECTION (TRAY1, TRAY2)
17.1.2 Layout of sensors and rollers
Timing roller
Timing roller sensor (PS38)
Tray1 vertical transport

sensor (PS4)
Tray1 vertical transport roller
Tray1 paper feed roller

First sheet of paper
Second sheet of paper
Tray2 vertical transport sensor

(PS12)
CONFIGURATION/
OPERATION
A00JT2C213AA
113
17.2 Drive
• Drive parts are arranged in the same way in tray1 and 2.
• Take-up motor drives the tray1 and 2 paper feed rollers.
• Each paper feed roller has a clutch that is turned ON when it needs to be driven.
Tray1
Tray1 paper feed clutch (CL1)

Take-up motor (M22)
Tray1 lift-up motor (M6) Tray1 vertical transport roller

CONFIGURATION/
OPERATION
A00JT2C286AA
Tray 2
Take-up motor (M22) Tray2 vertical transport roller
Tray2 lift-up motor (M8)
A0P0T5C031DA
114
17.3 Operation
17.3.1 Up/down control
A. Up operation
• Paper lifting plate B is located under paper lifting plate A.
• The lifting plate drive shaft of the tray1(2) lift-up motor is connected to paper lifting plate
2.
• When the drive shaft of the tray1(2) lift-up motor rotates, paper lifting plate B raises paper
lifting plate A.
Paper lifting plate B
Paper lifting plate A
CONFIGURATION/
OPERATION
A00JT2C315AA
Lifting plate drive shaft

A00JT2C314AA
B. Down operation
• When the tray is slid out of the machine, the coupling and the lifting plate drive shaft of
the tray1(2) lift-up motor are disconnected from each other.
• When the driving force of the tray1(2) lift-up motor is released from the lifting plate drive
shaft, the paper lifting plate starts lowering by its own weight.
115
C. Operation timing
(1) When the tray is slid in
• When the tray is slid into the machine, the tray1(2) device detection sensor is blocked.
The machine then determines that the tray is slid into position.
• The paper lifting plate is lowering when the tray is slid out, so that the tray1(2) upper limit
sensor is unblocked.
• Determining that the tray1(2) upper limit sensor is unblocked, the machine lets the
tray1(2) lift-up motor rotate to start the up operation of the paper lifting plate.
• When the paper stack is raised to a predetermined height after the up operation of the
paper lifting plate has been started, the actuator blocks the tray1(2) upper limit sensor.
• Determining that the tray1(2) upper limit sensor is blocked, the machine stops the lift-up
motor to complete the up operation of the paper lifting plate.
• Control is provided to make sure that only one tray performs the up operation at one
time.
• If the tray is slid out during the up operation of the paper lifting plate and accordingly the
tray1(2) device detection sensor is unblocked, the up operation of the paper lifting plate is
terminated.
Lifting completed
CONFIGURATION/
OPERATION
Tray set Paper consumption
Tray1 (Tray2) Set detection sensor
Tray1 (Tray2) Upper limit sensor

Tray1 (Tray2) Lift-up motor
A0P0T5E108DA
(2) During a print cycle

• When the amount of paper decreases as the unit keeps printing, the pick-up roller will
gradually come down to unblock the upper limit sensor. The lift-up motor will rotate again
to lift up the paper lifting plate.
• When the upper limit sensor is blocked, the lift-up motor will stop to stop lifting the paper
lifting plate.
• The sequence of these operations is repeated to keep constant the pressure between
the pick-up roller and paper stack (paper take-up pressure) regardless of the amount of
paper still available for use.
116
17.3.2 Paper feed control
• Tray1 and Tray2 are controlled in the same control procedure.
A. Pick-up control
• The take-up motor is energized by the print start signal.
• The tray1(2) paper feed clutch is energized after the lapse of a predetermined period of
time after the print start signal.
• As the tray1(2) paper feed clutch is energized, the driving force of the take-up motor is
transmitted to the pick-up roller and the paper feed roller. As a result, the pick-up roller
picks up a sheet of paper and transports it onto the paper feed roller.
• The paper feed roller transports the paper onto the tray1(2) vertical transport roller.
• The take-up motor and the tray1(2) paper feed clutch are deenergized when the tray1(2)
vertical transport sensor located downstream of the tray1(2) vertical transport roller
along the paper path detects the leading edge of the paper fed off from the tray1(2) verti-
cal transport roller.
• The pick-up roller and the paper feed roller are driven by the moving paper, continuing to
rotate.
• The pick-up roller and the paper feed roller stop rotating as the paper moves past them.
CONFIGURATION/
OPERATION
Take-up motor (M22)
Pick-up roller
Paper feed roller
Paper separator roller
tray1 paper feed

clutch (CL1)
Torque limiter A0P0T5C032DA
117
B. Separation control
• The paper separator roller is driven via a torque limiter in the direction opposite the paper
transport direction.
• The paper separator roller is pressed against the paper feed roller by the operating pres-
sure generated by pressure of the spring and torque of the torque limiter.
• The operating pressure of the paper feed roller, paper separator roller, and the torque
limiter serves as the limit torque for double feed prevention.
• If there is no sheet of paper or only one sheet of paper between the paper separator
roller and paper feed roller, the limit torque is exceeded, so that the paper separator roller
follows the rotation of the paper feed roller.
• If there are two or more sheets of paper between the paper separator roller and paper
feed roller, the limit torque is greater than the friction force of the paper, so that the paper
separator roller rotates backward.
• The backward rotation of the paper separator roller allows the lower sheet of paper in
contact with the paper separator roller to be returned back into the tray. This properly
separates the sheets of paper.
Paper feed roller

CONFIGURATION/
OPERATION
Pick-up roller Paper Paper separator roller
A0P0T5C033DA
118
C. Paper transport control
• The tray1(2) vertical transport motor is energized after the lapse of a predetermined
period of time after the print start signal.
• The driving force of the tray1(2) vertical transport motor is transmitted to the tray1(2) ver-
tical transport roller. Rotation of the tray1(2) vertical transport roller transports the paper
onto the timing roller (registration roller).
• The tray1(2) vertical transport sensor located downstream of the tray1(2) vertical trans-
port roller along the paper path detects the leading edge of the paper fed off from the
tray1(2) vertical transport roller.
• If the tray1(2) vertical transport sensor is unable to detect the leading edge of the paper
even after the lapse of a predetermined period of time, the machine determines that a
paper misfeed occurs at the vertical transport section.
• If the paper reaches earlier than the predetermined time, the tray1(2) vertical transport
motor is decelerated to correct the timing at which the paper reaches the timing roller
(registration roller).
(1) Operation timing

• Tray1 and Tray2 are controlled in the same operation timing.
CONFIGURATION/
OPERATION
*Tray1 paper feed control timing
Timing sensor ON (OHP sensor ON for 264m/s or more)
Start key ON Timing roller drive
Take-up motor (M22)
Tray 1 paper feed clutch (CL1)
Tray1 vertical transport sensor (PS4)
A0P0T5E114DA
119
D. Paper feed speed reduction control

• When paper reaches the tray1(2) paper feed sensor, if the interval between the paper
and the preceding paper is short, the take-up motor speed is reduced temporarily to
adjust the paper interval to the proper one.
• When paper reaches the tray1(2) vertical transport sensor, if the interval between the
paper and the preceding paper is short, the tray1(2) vertical transport motor reduces its
speed or stops in order to adjust the paper interval to the proper one.
• Paper from the tray1 and tray2 is transported at the same speed with the system speed.
Preceding paper
Paper interval
Sensor
Paper to be controlled
CONFIGURATION/
OPERATION
A00JT2C317AA
1 E. Paper feed retry control

• If the second sheet of paper reaches the paper feed sensor during the paper take-up
sequence for the first sheet of paper, the system determines that there is a double feed
occurring and the speed of the paper feed roller (take-up motor) is reduced during the
take-up of the second sheet of paper to ensure that there is a good distance between the
two sheets of paper.
1 120
F. Downstream exit control during multi-print cycle
• The following terms are used for convenience’ sake throughout this chapter.
Upstream: Refers to the source side of paper supply relative to the paper feeding direc-
tion
Downstream: Refers to the destination side of paper transport relative to the paper feed-
ing direction
• If a paper misfeed occurs at the paper feed section which is upstream in paper transport,
the print cycle is not brought to an immediate stop; rather, the machine allows a sheet of
paper, for which the print cycle is to be completed at a downstream side, to continue
undergoing the current print cycle and feeds the printed page out after completion of the
current print cycle.
(1) Types of paper misfeed governed by downstream exit control
Misfeed at tray1 Misfeed at bypass paper feed section

Misfeed at tray2 Misfeed at LCT paper feed section
Misfeed at tray3 Misfeed at vertical transport section
Misfeed at tray4
CONFIGURATION/
(2) Paper pass
OPERATION
Paper exit section
ADU transport roller 1

Switchback roller
ADU transport sensor/1 (PS47)
Fusing section
Transfer section
Duplex section
Registration
section
Timing roller
Transport sensor/2 (PS48)
Paper feed section A00JT2C245AA
121
(3) 1-sided printing

Operation 1
• In consecutive 1-sided printing, 4th sheet causes a jam-
ming at the paper feed tray section. Sheet before a 1-sided
image transfer
• 1st sheet after an image transfer is remained at the fusing Sheet after a 1-sided
section and the paper exit section. image transfer
• 2nd sheet before an image transfer is remained at the ver-

tical conveyance section and the registration section.
• 3rd sheet before an image transfer is remained at the
paper feed section and the vertical conveyance section. Jamming
A0P0T5E110DA
Operation 2
• Feed and convey 4th sheet is stopped.
• Exit 1st sheet.
• Transfer/fuse images on 2nd sheet.
• Convey 3rd sheet to transfer images.
CONFIGURATION/
OPERATION
A0P0T5C078DA
Operation 2
• Exit 2nd sheet.
• Fuse 3rd sheet to exit paper.
A0P0T5C079DA
122
(4) 2-sided printing
Operation 1
• In consecutive 2-sided printing, 5th sheet causes a jam- Sheet before a 1-sided
image transfer
ming at the paper feed tray section. Sheet after a 1-sided
image transfer
• 1st sheet after a 2-sided image transfer is remained at the
Sheet after a 2-sided
paper exit section. image transfer
• 2nd sheet before a 1-sided image fusing is remained at the

duplex section.
• 3rd sheet before a 1-sided image fusing is remained at the
paper exit section. Jamming
A0P0T5E111DA
• 4th sheet before an image transfer is remained at the verti-

cal conveyance section and the registration section.
Operation 2
• Feed and convey 5th sheet is stopped.
• Exit 1st sheet.
• Transfer/fuse 2-sided images on 2nd sheet.
• Convey 3rd sheet to the duplex section.
CONFIGURATION/
• Transfer/fuse 1-sided images on 4th sheet to convey to the
OPERATION
paper exit section.
A0P0T5C081DA
Operation 3
• Exit 2nd sheet.
• Convey 3rd sheet to the duplex section to stop.
• Stop 4th sheet at the duplex section.
A0P0T5C082DA
Operation 4
• Open a cover over the duplex section to remove 3rd and 4th sheet remained in the
duplex section.
NOTE
• 3rd and 4th sheets are conveyed to the duplex section which allowed removing a
jamming easily. 2-sided images are not printed on a sheet conveyed to the duplex
section.
123
17.3.3 Paper size detection control

• The size in the main scanning direction is detected based on the combination of tray1(2)
CD paper size sensor/1 and tray1(2) CD paper size sensor/2 being unblocked or
blocked.
• Tray1(2) CD paper size sensor/1 and tray1(2) CD paper size sensor/2 are unblocked or
blocked by the paper width detection plate provided in the paper width guide plate.
• The size in the sub scanning direction is detected based on the combination of ON or
OFF position of switches 1 to 4 mounted on paper size detect board/1,/2.
• Each of switches 1 to 4 is turned ON or OFF by the paper length detection plate con-
nected to the paper length guide plate.
4 3 2 1

CONFIGURATION/
OPERATION
Guide
A0P0T5C007DA
124
C. Sheet size determination
• Combination of the width of the main scanning and the length of the sub scanning will
decide a sheet size.
Detection switch/ Paper size detect board/1 (PSDTB/1) Tray1 CD paper size Tray1 CD paper size
Detection sensor Paper size detect board/2 (PSDTB/2) sensor/1 (PS7) sensor/2 (PS8)
Tray2 CD paper size Tray2 CD paper size
Paper size Switch 1 Switch 2 Switch 3 Switch 4 sensor/1 (PS15) sensor/2 (PS16)
A3 H H/L H H H L
B4 H H H L H L
A4S L H/L H H L H
A4 L L L L H L
B5S L L H L L L
B5 H H L L H L
A5S L L L L L L
12 × 18 L H H L H L
11 × 17 H L H H H H
CONFIGURATION/
81/2 × 14 H H H L L H
OPERATION
81/2 × 11S H L L H L H
81/2 × 11 L L L L H H
FLS *1 H H H H L H
8K (8 Open) S
(270 mm × 390 H H L H H H
mm)
16K (16 Open)
(270 mm × 195 H L L L H H
mm)
*: One of the following paper sizes can be selected to be set for FLS.
220 x 330 mm, 8 × 13, 81/8 × 131/4, 81/4 × 13, 81/2 × 13
Switch/sensor states
Physical state
Switch/sensor
HIGH signal LOW signal
Paper size detect board/1, 2 : Switches 1 to 4 ON OFF
Tray1 CD paper size sensor/1, 2
Blocked Unblocked
Tray1 CD paper size sensor/1, 2
125
17.3.4 Remaining paper detection control

A. Paper near-empty detection
• The tray1(2) near empty sensor detects a paper near-empty condition of the tray.
• As paper is consumed, the position of the near empty detection actuator provided at the
lifting plate drive shaft of the lift-up motor is raised.
• When the near empty detection actuator is raised to a position at which the tray1(2) near
empty sensor is blocked, the machine detects a near-empty condition.
• A near-empty condition is detected when the amount of paper still available for use
becomes about 50 ± 30 sheets (about 50 sheets in terms of paper weighing 80 g/m2).
A near-empty condition
Tray1 near empty sensor (PS3)
CONFIGURATION/
OPERATION

Tray2 lift-up motor (M8) A00JT2C311AA
B. Paper empty detection

• The tray1(2) empty sensor detects a paper empty condition of the tray.
• As paper is consumed, the position of the empty detection actuator provided beside the
paper feed roller is raised.
• When the empty detection actuator is raised to a position at which the tray1(2) empty
sensor is blocked, the machine detects a paper empty condition.
An empty condition
Tray1 paper empty sensor (PS2)

A00JT2C312AA
126
C. Remaining paper level display
• The amount of remaining paper is indicated by the LED on the right side of each tray and
by the screen of the control panel.
• The following shows how the level is displayed.
Other statuses
Tray condition Empty Near empty
(Including during lift-up and no tray conditions)
LED ON Blinking *1 OFF
*1: LED turns OFF when Paper Remainder is set to Type 2: Service Mode − System 1 −
Machine State LED Setting − Paper Remainder.
Tray1 paper empty indicator board (PEIB/1)
CONFIGURATION/
OPERATION
A00JT2C269AA
17.3.5 Paper temperature detection control

• Paper temperature is detected as the machine interior temperature detected at the paper
feed section by the paper temperature thermistor located in the paper feed section.
• The machine interior temperature at the paper feed section is used as data for controlling
the fusing temperature during printing. For “temperature control during printing”, see the
fusing section.
Paper temperature thermistor (TH8)
A0P0T5C009DA
127
18. PAPER FEED SECTION (TRAY3, TRAY4)

18.1 Configuration
18.1.1 Major components (tray3)
Horizontal transport section (upper section)

CONFIGURATION/
A0P0T5C073DA
OPERATION
Tray3 paper feed section

Tray3 near empty sensor (PS22) Tray3 paper feed sensor (PS21)
A00JT2C300AA
128
18.1.2 Major components (tray3 horizontal transport section)
A0P0T5C072DA
Tray4 paper feed section Tray3 horizontal transport section
CONFIGURATION/
Horizontal transport
OPERATION
clutch/1 (CL3) Vertical transport motor (M26)
Horizontal
transport
roller 2
Transport motor (M25)
A0P0T5C011DA
Horizontal transport roller 1
Intermediate roller
129
18.1.3 Major components (tray4)
A00JT2C276AA
CONFIGURATION/
OPERATION
Tray4 near empty sensor (PS27) Tray4 paper empty sensor (PS24)
A00JT2C294AA
130
18.1.4 Layout of sensors and rollers
Timing roller
Timing roller sensor
(PS38)
OHP detect sensor
(PS40)
Tray1 vertical transport sensor (PS4) Tray1 vertical

transport roller
Tray2 vertical transport sensor (PS12) Tray2 vertical

transport roller
Horizontal transport sensor (PS29)
Horizontal transport roller 1 Intermediate roller
Tray3 paper feed roller Intermediate roller sensor

(PS28)
Tray3 transport roller
CONFIGURATION/
OPERATION
Tray3 paper feed sensor (PS21) Tray4 paper feed sensor (PS26)
A00JT2C227AA
131
18.2 Drive
18.2.1 Tray3
Tray3 transport clutch (CL6)

Tray3 take-up axis
Coupling
CONFIGURATION/
OPERATION
A00JT2C301AA

Tray3
18.2.2 Tray3 horizontal transport
Vertical transport motor (M26)
Horizontal transport clutch/1 (CL3)

A0P0T5C091DA
Horizontal transport roller 1 Intermediate roller
132
18.2.3 Tray4
Vertical transport motor (M26) Tray4 paper feed clutch (CL7)

CONFIGURATION/
OPERATION
Coupling

A00JT2C295AA
Tray4
Tray4 take-up axis
133
18.3 Operation
18.3.1 Up/down control
• The same control procedure applies to tray3 and tray4.
A. Up operation
• A lifting cable is connected to the paper lifting plate and the paper plate is held in the hor-
izontal position by the take-up axis.
• When the tray3(4) lift-up motor is energized, the take-up axis takes up the cable to
thereby raise the paper plate.
B. Down operation
• When the tray is slid out of the machine, the coupling of the tray3(4) lift-up motor and the
take-up axis are disconnected from each other.
• When the driving force of the tray3(4) lift-up motor is released from the hoisting axis, the
paper lifting plate starts lowering by its own weight.
Tray4 lift-up motor (M24) Coupling
Take-up axis
CONFIGURATION/
OPERATION
Paper lifting plate
A00JT2C305AA
134
C. Operation timing
(1) When the tray is slid in
• When the tray is slid in, the drawer connector of tray3(4) is connected. The machine then
determines that the tray is slid in position.
• The paper plate is lowering when the tray is slid out, so that the tray3(4) upper limit sen-
sor is unblocked.
tray3(4) lift-up motor rotate to start the up operation of the paper lifting plate.
• Control is provided to make sure that only one tray performs the up operation at one
time.
• If the tray is slid out during the up operation of the paper lifting plate and accordingly the
tray3(4) drawer connector is disconnected, the machine determines that the tray has
been slid out and terminates the up operation of the paper lifting plate.
Tray3 upper limit sensor (PS22) Tray4 upper limit sensor (PS27)
CONFIGURATION/
OPERATION
Actuator
Actuator A0P0T5C012DA
Drawer connector
A0P0T5C013DA
Lifting completed
Tray set Paper consumption
Tray3, Tray4 Drawer connector
Tray3, Tray4 upper limit sensor
Tray3, Tray4 Lift-up motor
4038T2C141AA
135
(2) During printing

• As paper is consumed, the pick-up roller gradually lowers and the tray3(4) upper limit
sensor is unblocked.
tray3(4) lift-up motor rotate to start the up operation of the paper plate.
• The above operations are repeated, so that the pressure (paper feed pressure) of the
pick-up roller and paper are kept at a constant value at all times without being affected by
the amount of paper still available for use.
Actuator
CONFIGURATION/
OPERATION
Actuator
A00JT2C296AA
136
18.3.2 Paper Feed control
A. Pick-up control (tray3)
• The transport motor is energized by the print start signal.
• The tray3 paper feed clutch is energized after the lapse of a predetermined period of
• As the tray3 paper feed clutch is energized, the driving force of the transport motor is
• The paper feed roller transports the paper onto the tray3 transport roller.
• The tray3 transport clutch is energized after the lapse of a predetermined period of time
after sending out the print start signal.
• As the tray3 transport clutch is energized, the driving force of the transport motor is
transmitted to the tray3 transport roller. As a result, the tray3 transport roller transports a
sheet of paper onto the horizontal transport roller.
• In consecutive printing, if the horizontal transport sensor has not detected the arrival of a
preceded paper, the tray3 transport roller will be stopped temporarily and the interval
between a preceded paper and a succeeding paper will be corrected.
• The tray3 paper feed clutch and tray3 transport clutch is deenergized after the lapse of a
CONFIGURATION/
predetermined period of time after the tray3 paper feed sensor detects the leading edge
OPERATION
of the paper.
rotate.
137
B. Pick-up control (tray4)

• The transport motor is energized by the print start signal.
• The tray4 paper feed clutch is energized after the lapse of a predetermined period of
• As the tray4 paper feed clutch is energized, the driving force of the transport motor is
• The paper feed roller transports the paper onto the tray4 vertical transport roller.
• The tray4 paper feed clutch is deenergized after the lapse of a predetermined period of
time after the tray4 paper feed sensor detects the leading edge of the paper.
rotate.
Vertical transport Horizontal transport clutch (CL3)

motor (M26)
Transport motor
(M25) Intermediate roller
CONFIGURATION/
OPERATION
Intermediate transport roller

sensor (PS28)
Tray3 paper feed
clutch (CL5)
sensor (PS29)
roller 2
Tray3
transport Paper feed roller (tray4)
clutch (CL6)
Pick-up roller Paper separator

(tay3) Tray3 transport roller roller (tray4)
Pick-up roller (tray4)
Paper separator roller Tray3 Paper feed sensor (PS21)
(tray3)
Paper feed roller (tray3) Horizontal transport roller1
A0P0T5C034DA
138
C. Separation control
Drive connecting gear Paper feed roller
CONFIGURATION/
OPERATION
Pick-up roller Paper
A0P0T5C033DA
139
D. Horizontal transport control (tray3)

• The transport motor is energized after the lapse of a predetermined period of time after
the print start signal.
• The horizontal transport clutch is energized after the lapse of a predetermined period of
time after the transport motor has been energized.
• When the horizontal transport clutch is energized, the driving force of the transport motor
is transmitted to horizontal transport roller 1 and horizontal transport roller 2. The hori-
zontal transport rollers 1 and 2 rotate to transport the paper onto the intermediate roller.
• The horizontal transport sensor located downstream of the horizontal transport roller
along the paper path detects the leading edge of the paper fed off from the tray3 trans-
port roller.
• The intermediate roller sensor located downstream of the intermediate roller along the
paper path detects the leading edge of the paper fed off from horizontal transport roller 2.
• The horizontal transport clutch is deenergized after the lapse of a predetermined period
of time after the intermediate roller sensor has detected the leading edge of the paper.
• If the horizontal transport sensor is unable to detect the leading edge of the paper even
after the lapse of a predetermined period of time, the machine determines that a paper
misfeed occurs at the horizontal transport section.
CONFIGURATION/
• If the intermediate roller sensor is unable to detect the leading edge of the paper even
OPERATION
misfeed occurs at the vertical transport section.
E. Paper feed deceleration control

• If the spacing between the current and preceding sheets of paper taken up from tray3 is
narrow, the tray3 transport clutch is temporarily deenergized, thereby achieving an ade-
quate spacing between the two sheets of paper.
• If there is only a narrow spacing from the preceding sheet of paper when the current one
reaches the intermediate roller, the vertical transport motor is temporarily deenergized to
achieve an adequate spacing between the two sheets of paper.
140
F. Operation timing
(1) The tray3
Plain paper: OHP detection sensor ON

* When there is no preceding paper
Thick paper: Timing roller sensor ON
Start key ON Timing motor ON
Tray3 transport clutch (CL6)
Horizontal Transport clutch 1 (CL3)
Horizontal transport sensor (PS29)
CONFIGURATION/
OPERATION
Intermediate roller sensor (PS28)
vertical transport motor (M26)
A00JT2E526DA
141
(2) The tray4

Plain paper: OHP detection sensor ON
* When there is no preceding paper Thick paper: Timing roller sensor ON
Start key ON Timing motor
ON
Intermediate roller sensor (PS28)
Vertical transport motor (M26)

CONFIGURATION/

OPERATION
A00JT2E527DA
G. Paper feed deceleration control

• If a paper fed from the tray 3 has a narrow spacing with a preceded paper, the tray3
paper feed clutch is stopped temporarily to control to have a proper spacing between
papers.
• If a paper has a narrow spacing with a preceded paper when the paper reached to the
intermediate roller, the vertical transport motor is stopped temporarily to control to have a
proper spacing between papers.
142
• Tray3 and 4 don’t have paper size detection function.
• To set a different paper size, press keys as follows.
[Service mode] − [System setting 2] − [LCC size setting]
• In accordance with the set paper size, change positions of the guide plates (end guide
plate, paper guide plate/front, and paper guide plate/rear).
CONFIGURATION/
OPERATION
A00JT2E533DA
Paper guide plate/ rear

End guide plate
Paper guide plate/ front
A00JT2C318AA
143

A. Paper near-empty detection
• The tray3(4) near empty sensor detects a paper near-empty condition of the tray.
• As the amount of paper becomes small during printing, the paper lifting plate is raised.
(See “A. Up operation” of “17.3.1 Up/down control”.)
• As the paper lifting plate is raised, the position of the near empty detection actuator pro-
vided at the paper lifting plate is raised.
• When the near empty detection actuator is raised to a position at which it blocks the
tray3(4) near empty sensor, the machine detects a near-empty condition.
• A near-empty condition is detected when the amount of paper still available for use
becomes about 50 ± 30 sheets (about 50 sheets in terms of paper weighing 80 g/m2).

CONFIGURATION/
OPERATION
A00JT2C306AA
B. Paper empty detection (tray3)

• The tray3 paper empty sensor detects a paper empty condition of the tray.
• When the empty detection actuator is raised to a position at which it unblocks the tray3
paper empty sensor, the machine detects a paper empty condition.
Actuator
Tray3 paper empty sensor

(PS19)
A0P0T5C017DA
144
C. Paper empty detection (tray4)
• The tray4 paper empty sensor detects a paper empty condition of the tray.
• When the empty detection actuator is raised to a position at which it blocks the tray4
paper empty sensor, the machine detects a paper empty condition.
Actuator
CONFIGURATION/
OPERATION
A0P0T5C018DA
D. Remaining paper detection

• Paper supply level is detected by calculation of the paper remaining level based on the
time when the tray is lifted.
• Plain paper is used as the reference of the calculation for the paper supply level.
• When the thick paper is set, off set value is used to calculate the paper supply level.
Ex: When thick paper 2 is set, paper supply level is calculated as a half of the plain paper
level.
• Lifting time is measured when the power is turned ON, save mode is released and a tray
is inserted.
Tray condition Paper full Paper near full Paper remained

Paper supply level 100 to 66% 65 to 33% 33% to 51 sheets
Tray3 paper supply level 1500 to 1000 sheets 999 to 501 sheets 500 to 51 sheets
Tray4 paper supply level 1000 to 666 sheets 665 to 334 sheets 333 to 51 sheets
145
E. Display of paper supply level

• The amount of remaining paper is indicated by the LED on the right side of each tray and
by the screen of the control panel.
• The following shows how the level is displayed.
Other statuses
Tray condition Empty Near empty
(Including during lift-up and no tray conditions)
LED ON Blinking *1 OFF
*1: LED turns OFF when Paper Remainder is set to Type 2: Service Mode − System 1 −
Machine State LED Setting − Paper Remainder.

CONFIGURATION/
OPERATION
A00JT2C269AA
146
18.3.5 Dehumidification heater control
• The machine has two dehumidification heaters mounted on its frame (heaters for tray3
and tray4 come as standard).
• When energized, the dehumidification heater generates heat to dehumidify the inside of
the tray and the machine. By dehumidifying, the dehumidification heater prevents the
paper stack loaded in the tray from becoming damp.
• The dehumidification heater is energized when the dehumidification heater switch
located on the lower part at the back of the main body is turned ON.
• When the dehumidification heater switch is ON, the dehumidification heater is energized
as long as the PC motor remains deenergized (in the standby state; for details, see the
table below).
• While the PC motor remains energized (during printing), the dehumidification heater is
deenergized to inhibit power consumption. (Photo conductor small amount rotation con-
trol is worked in standby. If the Color PC drum motor and the K PC drum motor are
rotated in short time, the dehumidification heater has no OFF/ON operation but hold ON
status.)
For the photo conductor

Dehumidification heater Color PC motor K PC motor
CONFIGURATION/
small amount rotation*
OPERATION
ON Halt Halt OFF
ON - - ON
OFF Running Halt OFF
OFF Halt Running OFF
OFF Running Running OFF
*: For details, see “Photo conductor section/Photo conductor small amount rotation control”
Tray4 dehumidification heater (DH2)
Tray3 dehumidification heater (DH1)
A0P0T5C019DA
Dehumidification heater transformer (T1)
Dehumidification heater switch

(SW2)
A00JT2C279AA
147
18.3.6 Detection of tray3/4 slid out/in

• The connection state of the drawer connection located in the rear of the tray determines
whether the tray3(4) is slid out or in.
• When the tray3(4) is slid in, the tray3(4) drawer connector is connected and the machine
determines that the tray3(4) is slid in position.
• When the tray3(4) is slid out, the tray3(4) drawer connector is disconnected and the
machine determines that the tray3(4) is slid out.
CONFIGURATION/
A0P0T5C013DA
OPERATION
Tray4 drawer connector Tray3 drawer connector
148
18.3.7 Detection of horizontal transport unit slid out/in
• The horizontal transport sensor detects the horizontal transport unit that is being slid out
or in.
• By sliding out the horizontal transport unit, the horizontal transport guide for clearing
paper misfeed from the horizontal transport unit can be opened.
• There is no open/close mechanism provided for the horizontal transport guide. The hori-
zontal transport unit cannot, however, be slid into the machine with the horizontal trans-
port guide left opened.
• Slide out tray4 and, holding onto the lever of the horizontal transport unit, withdraw the
horizontal transport unit. This moves the light blocking plate for unit position detection
provided for the horizontal transport unit to the front.
• When the light blocking plate for unit position detection is moved to a position at which it
unblocks the horizontal transport sensor, the machine detects that the horizontal trans-
port unit has been slid out.
• When the horizontal transport unit is slid in, the light blocking plate for unit position detec-
tion blocks the horizontal transport sensor. The machine then detects that the horizontal
transport unit has been slid in.
CONFIGURATION/
OPERATION
Horizontal transport set sensor (PS58)
Light blocking plate for

unit position detection
A0P0T5C020DA
149
19. PAPER FEED SECTION (BYPASS TRAY) Theory of Operation Ver. 2.0 Jul. 2009
19. PAPER FEED SECTION (BYPASS TRAY)

19.1 Configuration
Paper side guide plate

CONFIGURATION/
OPERATION
A00JT2C274AA
Bypass sub tray
Bypass paper width

Bypass paper empty detection resistor (VR)
sensor (PS34) Bypass sub tray set
sensor (PS37)
Bypass paper
feed roller
Bypass set sensor

(PS30)
Paper lifting plate

A00JT2C282AA
Multi FD size sensor/2 (PS32)
Multi FD size sensor/1 (PS31) Multi FD size sensor/3 (PS33)
150
Theory of Operation Ver. 2.0 Jul. 2009 19. PAPER FEED SECTION (BYPASS TRAY)
19.2 Drive
Bypass tray up down motor (M28)

Bypass paper lower sensor (PS36)
Bypass paper limit sensor (PS35)
Paper lifting plate
CONFIGURATION/
OPERATION
Bypass paper feed motor
(M27)
Bypass paper feed roller Bypass tray separator roller

A00JT2C283AA
151
19.3 Operation
19.3.1 Bypass paper lifting motion control
A. Up operation
• The bypass tray up down motor rotates forward to drive the lifting gear, which raises the
paper lifting plate to the paper feed position.
B. Down operation
• The bypass tray up down motor rotates backward to drive the lifting gear, which lowers
the paper lifting plate to the standby position.
C. Operation timing
(1) Move to paper feed position (up)
• When the bypass paper feeding starts, the bypass tray up and down motor makes a nor-
mal rotation to move the paper lifting plate up to the paper feeding position. When the
paper lifting plate is moved up, the bypass paper limit sensor turns ON to stops the
bypass tray up and down motor at the feeding position.
• When the paper supply level goes down during paper feeding and the bypass paper limit
CONFIGURATION/
sensor turns OFF, the bypass tray motor rotates positively to move it up to the paper
OPERATION
feeding position.
(2) Move to standby position (down)

• When there is no print request from the bypass tray and the paper fed from the bypass
tray turns OFF the exit sensor, the paper lifting plate is lowered.
• Though other jobs are being processed, if the above conditions are met, the paper lifting
plate is lowered.
• When the sensor detects the bypass paper empty at the feeding position, the paper lift-
ing plate is moved to the standby position.
• When paper jam occurs, the paper lifting plate stops at the paper feeding position. After
paper jam is resolved, the paper lifting plate moves to the standby position.
Bypass tray up down motor (M28)
Bypass paper lower limit sensor (PS36)
Bypass paper upper limit sensor (PS35)
Paper lifting plate
A00JT2C285AA
Bypass paper empty detection
152
Occurrence of the event that
Start key ON moves to standby position
Standby
Paper feeding position position
Normal rotation
Bypass tray up
down motor (M28)
Inverse rotation
Bypass paper lower limit sensor (PS36)

A0P0T5E115DA
19.3.2 paper feed control

A. Pick-up control
• The bypass tray up down motor is energized by the print start signal to raise the paper to
the paper feed position.
CONFIGURATION/
• The bypass paper feed motor is energized after the paper has been raised to the paper
OPERATION
feed position.
• As the bypass paper feed motor is energized, the driving force of the bypass paper feed
motor is transmitted to the pick-up roller and the paper feed roller. As a result, the pick-up
roller picks up a sheet of paper and transports it onto the paper feed roller.
• The paper feed roller transports the paper onto the registration roller (timing roller).
• The bypass paper feed motor is deenergized when the paper fed from the bypass tray is
fed out.
• The bypass tray up down motor is energized to lower the paper down to the standby
position.
153
B. Separation control
Bypass paper feed motor

(M27) Paper feed roller Drive connecting gear Pick-up roller
CONFIGURATION/
OPERATION
Paper
Pick-up roller
Drive connecting gear
Paper feed roller
Paper separator roller A0P0T5C021DA
Start key ON
Paper feeding position Finish the paper feeding
Bypass tray up Normal rotation

down motor (M28) Inverse rotation
Bypass paper feed motor (M27)
A0P0T5C035DA
154
• The paper size in the main scanning direction is detected with 10-bit digital data detected
by the bypass paper width detection resistor.
• Rotation of the gear provided for the paper side plate and the detection gear mounted on
the rotation shaft of the bypass paper width detection resistor results in the voltage
obtained from the bypass paper width detection resistor being varied.

• The size in the sub scanning direction is detected based on the combination of multi FD
size sensors 1 to 3 being unblocked and blocked.
• The specific position of the paper length detection actuator determines whether each of
multi FD size sensors 1 to 3 is unblocked or blocked.
CONFIGURATION/
OPERATION
A00JT2C264AA
Bypass paper width detection resistor (VR)
155
C. Sheet size determination

• Combination of the width of the main scanning and the length of the sub scanning will
decide a sheet size.
Metric area
Bypass paper width detection

Multi FD size Multi FD size Multi FD size resistor Paper detection size
sensor/1 sensor/2 sensor/3
Width (mm)
80 to less than 115 A6S
115 to 144 inclusive B6S
OFF OFF OFF
196 to 225 inclusive A5
242 to 268 inclusive B5
133 to 164 inclusive A5S
169 to less than 196 B5S
ON OFF OFF 196 to 225 inclusive A4S
255 to less than 288 11 × 81/2
CONFIGURATION/
ON ON OFF 188 to 235 inclusive FLS*

OPERATION
201 to 231 inclusive 81/2 × 14

242 to less than 268 B4
ON ON ON 268 to less than 288 11 × 17
288 to less than 301 A3
301 to 330 inclusive 12 × 18
*: One of the following paper sizes can be selected to be set for FLS.
220 x 330 mm, 8 × 13, 81/8 × 131/4, 81/4 × 13, 81/2 × 13
156
Inch area
Bypass paper width detection

Multi FD size Multi FD size Multi FD size resistor Paper detection size
sensor/1 sensor/2 sensor/3
Width (mm)
80 to less than 115 A6S
115 to 144 inclusive B6S
OFF OFF OFF
201 to 231 inclusive 51/2 × 81/2
242 to 282 inclusive 71/4 × 101/2
125 to 155 inclusive 51/2 × 81/2 S
169 to less than 201 71/4 × 101/2 S
ON OFF OFF 201 to 231 inclusive 81/2 × 11 S
225 to less than 288 81/2 × 11
ON ON OFF 188 to 235 inclusive Foolscap*
201 to 231 inclusive 81/2 × 14
CONFIGURATION/
242 to less than 268 B4
OPERATION
ON ON ON 268 to less than 288 11 × 17
288 to less than 301 A3
301 to 330 inclusive 12 × 18
*: One of the following paper sizes can be selected to be set for Foolscap.
8 × 13, 81/8 × 131/4, 81/4 × 13, 81/2 × 13, 81/2 × 13
157

A. Paper near-empty control
• The bypass tray is not mounted with any near-empty detection mechanism.
B. Paper empty control

• The bypass paper empty sensor detects a paper empty condition in the bypass tray.
• As the amount of paper in the bypass tray becomes small, the paper empty detection
actuator is raised.
• When the paper empty detection actuator is raised to a position at which it unblocks the
bypass paper empty sensor, the machine detects a paper empty condition in the bypass
tray.
• Paper empty is detected both at the standby and the paper feed positions.
When there is no paper

CONFIGURATION/
OPERATION
When there is paper A00JT2C217AA
Bypass paper empty sensor (PS34)
158
19.3.5 Detection of bypass unit opened/closed
• The bypass unit is equipped with an open/close mechanism that facilitates misfeed clear-
ing procedure and access to the tray1 paper feed part.
• The bypass tray set sensor detects whether or not the bypass unit is opened or closed.
• Pull the bypass unit release lever and open the bypass unit. This actuates the open/close
detection actuator provided at the bypass unit.
• When the bypass unit is opened, the open/close detection actuator provided at the
bypass unit is actuated.
• When the open/close detection actuator is moved to a position at which it unblocks the
bypass tray set sensor, the machine determines that the bypass unit has been opened.
Bypass unit
CONFIGURATION/
OPERATION
A00JT2C265AA
Tray1 paper feed section Lock tab
Bypass set sensor (PS30) Lock tab
Release lever
Open/close detection actuator
Bypass set sensor (PS30)
Open/close detection actuator
A0P0T5C086DA
159
19.3.6 Detection of bypass sub tray extended/retracted

• The bypass sub tray set sensor prevents erroneous detection by multi FD size sensors 2
and 3 when the bypass sub tray is retracted.
• The bypass tray set sensor detects whether or not the bypass sub tray is extended.
• When the bypass sub tray is extended until the light blocking plate mounted on the
bypass sub tray unblocks the bypass tray set sensor, the machine determines that the
bypass sub tray has been extended.
• When the bypass sub tray is in the fully retracted position, detection made by multi FD
size sensors 2 and 3 is not reflected.
Bypass sub tray set sensor

(PS37)
Bypass sub tray
Multi FD size sensor/3

(PS33)
CONFIGURATION/
OPERATION
Multi FD size sensor/2

(PS32)
A00JT2C264AA
160
Theory of Operation Ver. 2.0 Jul. 2009 20. VERTICAL TRANSPORT SECTION
20. VERTICAL TRANSPORT SECTION
20.1 Configuration
Timing roller Timing roller sensor (PS38)

Actuator
Registration motor
(M2) OHP detection sensor (PS40)
Tray1 vertical transport motor OHP detection sensor

(M5) (reflection unit) (PS40)
Tray1 paper
feed clutch Tray1 vertical
Paper feed motor
(CL1) transport sensor
(M22)
(PS4)
Tray2 paper
feed clutch Tray1 vertical
(CL2) transport roller
Tray2 vertical
CONFIGURATION/
transport motor
OPERATION
(M7)
Vertical transport
motor (M26)
Tray1 paper
feed roller
Tray1 paper
feed sensor
(PS5)
Tray2 vertical
transport
sensor (PS12)
Tray2 paper
feed sensor
(PS13)
Intermediate
roller
Intermediate
Horizontal transport transport roller
clutch (CL3) sensor (PS28)
Transport motor Horizontal
(M25) transport roller 2
Tray4 paper feed clutch A0P0T5C022DA
(CL7)
Tray4 paper feed
sensor (PS26)
Horizontal transport sensor Tray4 vertical
(PS29) transport roller
161
20. VERTICAL TRANSPORT SECTION Theory of Operation Ver. 2.0 Jul. 2009
20.2 Drive
Timing roller Registration motor (M2)

OHP detection sensor (PS40)

(PS38)

section Tray1 vertical transport roller
Tray1 paper feed sensor

(PS5)
CONFIGURATION/
OPERATION
Paper feed motor (M22)
Tray1 vertical transport motor

(M5)
Tray2 paper feed
section
sensor (PS12)
(PS13)
Vertical transport motor Tray2 vertical transport
(M26) motor (M7)
Intermediate roller
Horizontal transport sensor
(M29) Intermediate transport
roller sensor (M28)

Tray3 horizontal
transport section Tray4 vertical transport
roller

(PS26)
Tray4 paper feed
section
A0P0T5C023DA
162
Theory of Operation Ver. 2.0 Jul. 2009 20. VERTICAL TRANSPORT SECTION
20.3 Operation
20.3.1 Vertical transport control
• The vertical transport section transports paper fed from tray1, 2, 3, or 4 onto the registra-
tion section.
• The paper fed from tray1 is transported onto the registration section by the tray 1 vertical
transport roller.
• The paper fed from the bypass tray is transported onto the registration section by the tray
1 vertical transport roller.
• The paper fed from tray2 is transported onto the registration section by the tray2 vertical
transport roller and the tray 1 vertical transport roller.
• The paper fed from tray3 is transported onto the registration section by horizontal trans-
port roller 1, horizontal transport roller 2, the intermediate roller, the tray2 vertical trans-
port roller, and the tray 1 vertical transport roller.
• The paper fed from tray4 is transported onto the registration section by the intermediate
roller, tray2 vertical transport roller, and the tray 1 vertical transport roller.
20.3.2 Transport motor control
CONFIGURATION/
A. Tray1 vertical transport motor
OPERATION
• The tray1 vertical transport motor is connected to the tray1 vertical transport roller. When
the tray1 vertical transport motor is energized, the tray1 vertical transport roller is rotated.
B. Tray2 vertical transport motor

• The tray2 vertical transport motor is connected to the tray2 vertical transport roller. When
the tray2 vertical transport motor is energized, the tray2 vertical transport roller is rotated.
C. Vertical transport motor

• The vertical transport motor is connected to the intermediate roller and tray4 vertical
transport roller. When the vertical transport motor is energized, the intermediate roller
and tray4 vertical transport roller are rotated.
20.3.3 Operation timing

A. Tray1 vertical transport roller
• The tray1 vertical transport roller starts rotating after the lapse of a predetermined period
of time after the print start signal.
• The tray1 vertical transport sensor located downstream of the tray1 vertical transport
roller along the paper path detects the leading edge of the paper that has moved past the
tray1 vertical transport roller.
• If the tray1 vertical transport sensor is unable to detect the leading edge of the paper
even after the lapse of the predetermined period of time, the machine determines that a
• If the tray1 vertical transport sensor is unable to detect the trailing edge of the paper
• If the tray1 vertical transport sensor detects paper earlier than the predetermined time,
the vertical transport motor is decelerated to correct timing at which the paper reaches
the timing roller.
• If the OHP detect sensor located upstream of the timing roller detects paper earlier than
the predetermined time, the vertical transport motor is decelerated to correct timing at
which the paper reaches the timing roller.
163
20. VERTICAL TRANSPORT SECTION Theory of Operation Ver. 2.0 Jul. 2009
B. Tray2 vertical transport roller

• The tray2 vertical transport roller starts rotating after the lapse of a predetermined period
of time after the print start signal.
• The tray2 vertical transport sensor located downstream of the tray2 vertical transport
roller along the paper path detects the leading edge of the paper that has moved past the
tray2 vertical transport roller.
• If the tray2 vertical transport sensor is unable to detect the leading edge of the paper
even after the lapse of the predetermined period of time, the machine determines that a
• If the tray2 vertical transport sensor is unable to detect the trailing edge of the paper
• If the tray2 vertical transport sensor detects paper earlier than the predetermined time,
the tray2 vertical transport motor is decelerated to correct timing at which the paper
reaches the timing roller.
• If the OHP detect sensor located upstream of the timing roller detects paper earlier than
the predetermined time, the vertical transport motor is decelerated to correct timing at
which the paper reaches the timing roller.
CONFIGURATION/
OPERATION
C. Intermediate roller and tray4 vertical transport roller

• The intermediate roller and the tray4 vertical transport roller start rotating after the lapse
of a predetermined period of time after the print start signal.
• The tray4 paper feed sensor located upstream of the tray4 vertical transport roller along
the paper path detects the leading edge of the paper fed by the tray4 paper feed roller.
• The intermediate roller sensor located upstream of the intermediate roller along the
paper path detects the leading edge of the paper that is about to advance onto the inter-
mediate roller.
• If the intermediate roller sensor is unable to detect the leading edge of the paper fed off
from tray3 even after the lapse of a predetermined period of time, the machine deter-
mines that a paper misfeed occurs at the tray3/4 horizontal transport section.
• If the intermediate roller sensor is unable to detect the leading edge of the paper fed off
from tray4 even after the lapse of a predetermined period of time, the machine deter-
mines that a paper misfeed occurs at the tray3/4 intermediate roller section.
• If the intermediate roller sensor is unable to detect the trailing edge of the paper even
misfeed occurs at the tray3/4 intermediate roller section.
• If the intermediate roller sensor detects paper earlier than the predetermined time, the
vertical transport motor is deenergized to halt paper transport temporarily and thereby
correct timing at which the paper reaches the timing roller.
164
Theory of Operation Ver. 2.0 Jul. 2009 21. REGISTRATION SECTION
21. REGISTRATION SECTION
21.1 Configuration
2nd image transfer roller
Timing roller
CONFIGURATION/
OPERATION
A0P0T5C094DA
21.2 Drive
IDC registration sensor/R (IDCS/R)

Timing roller
OHP detection sensor

(PS40) (Reflection unit)
Tray1 vertical trans-

port motor (M5) IDC registration sensor/F
(IDCS/F)
Take-up motor (M22)

OHP detection
sensor (PS40)
Temperature/humidity sensor
A0P0T5C024DA
165
21. REGISTRATION SECTION Theory of Operation Ver. 2.0 Jul. 2009
21.3 Operation
21.3.1 Registration control
• The registration motor is connected to the timing roller. When the registration motor is
energized, therefore, the timing roller is rotated.
• The paper will create a loop between the tray 1 vertical transport roller (or ADU transport
roller 4) and the regist motor when the paper is being conveyed in order to correct the
skew.
• Timing roller is controlled in order to synchronize the timing the unit starts writing the
image and conveying paper.
A. Adjustment
• The amount of the loop of the paper can be adjusted in the “Service Mode - Machine
Adjustment - Printer Regist Loop Amount”. Changing the adjustment value will change
the OFF timing of the tray 1 vertical transport motor (or ADU transport motor 2).
Paper loop is created before the timing roller

Registration start
CONFIGURATION/

OPERATION
(PS38)
Timing roller rotation start

motor (M5)
A00JT2C223AA
Tray1 vertical transport roller rotation stop Tray1 vertical transport roller rotation start
Timing roller

OHP detect sensor
(PS40)
OHP detection sensor
(reflection unit)
Loop creating

Paper
A00JT2C222AA
166
Theory of Operation Ver. 2.0 Jul. 2009 21. REGISTRATION SECTION
21.3.2 OHP detection
• OHP detection sensor checks to prevent printing on the paper other than OHP.
• OHP detection will be performed after paper made the loop at the timing roller. When the
OHP detection shows the different result from the setting on the operation panel, printing
will stop to display “Error.”
Paper type set from Results of OHP detection

Operation
control panel sensor detection
OHP Other than OHP Stops printing promptly based on the detec-
Other than OHP OHP tion of paper type inconsistency
Timing roller
Reflection unit
OHP detect sensor (PS40)
CONFIGURATION/
OPERATION
LED remote
Sensor output
A0P0T5C110DA
167
21. REGISTRATION SECTION Theory of Operation Ver. 2.0 Jul. 2009
21.3.3 Paper transport speed control

• It controls the timing the paper reaches to the timing roller sensor.
A. Operation
• The tray1 vertical transport roller, the tray2 vertical transport roller and the intermediate
roller may speed up, slow down or stop temporarily during paper transportation in order
to adjust the paper interval.
Timing roller
Tray1 vertical transport roller (Speed increase, speed

reduction, halt)
CONFIGURATION/
OPERATION
Tray2 vertical transport roller (Speed increase, speed

reduction, halt)
Intermediate roller (Speed increase, halt)
A00JT2C228AA
168
Theory of Operation Ver. 2.0 Jul. 2009 22. FUSING SECTION
22. FUSING SECTION
22.1 Configuration
IH coil unit Heating roller Heating roller

temperature temperature
sensor/1 (TEMS1) sensor/2 (TEMS2)
Heating roller A0P0T5C075DA

A00JT2C271AA temperature
Fusing unit sensor/3 (TEMS3) Loop amount detection
CONFIGURATION/
sensor 1 (PS41),
OPERATION
Loop amount detection
Fusing unit (Periodically sensor 2 (PS42)
replaced parts)
Soaking roller thermistor/1 (TH2)
IH coil unit Separator claw Soaking roller thermistor/2 (TH3)
(Fixed at the main body side) Soaking roller thermostat (TS2)
Soaking roller heater

lamp (FH2)
Soaking roller
Brush roller
IH coil (FH1)
Heating roller Fusing pressure roller
A0P0T5C087DA
Heating roller sensor/1 (TEMS1)
Heating roller sensor/2 (TEMS2) Heating roller thermistor/1 (TH1)
Heating roller sensor/3 (TEMS3) Heating roller thermostat (TS1)
(Fixed to the main body)
169
22. FUSING SECTION Theory of Operation Ver. 2.0 Jul. 2009
(1) Configuration of the temperature detector element of fusing unit
Heating roller sensor/1 (TEMS1)
Heating roller Heating roller thermistor/1 (TH2)

rotation sensor
(PS56) Soaking roller thermistor/2 (TH3)
Soaking roller thermostat (TS2)

sensor/2 (PS42)
Heating roller sensor/2 sensor/1 (PS41)
(TEMS2)
IH coil/1st
demagnetization
Heating roller thermistor/1 coil (FH1)
(TH1)
CONFIGURATION/
Heating roller thermostat A0P0T5C025DA

(TS1)
OPERATION
Pressure home sensor

IH coil/Main coil
(PS55)
IH coil / 2nd demagnetization
coil (FH1):C652 only Heating roller
temperature
sensor/3 (TEMS1)
170
22.2 Drive
Fusing pressure retraction motor (M29)

Fusing retraction position sensor (PS59)
Fusing pressure roller
CONFIGURATION/
OPERATION
Pressure home
sensor (PS55)
Fusing motor (M30)
Front side
A00JT2C299AA
Heating roller
171
22.3 Operation
22.3.1 Fusing speed correction
A. Roller speed control
• In order to avoid fusing error, the rotation speed of heating roller/fusing pressure roller is
exchanged according to the paper type or the print mode.
• By selecting the gloss mode, fusing speed slows down by 50% from the normal speed.
• Fusing speed is set to 80 mm/s during standby mode.
(1) C652 fusing speed
Paper type Print mode Fusing speed (mm/second)

Monochrome 310
Plain paper (60 g/m2 to 90 g/m2)
Color 240
Monochrome
Thick paper 1/1+ (91g/m2 to 157 g/m2) 155
Color
Thick paper 2/3/4 (158g/m2 to 300 g/m2) Monochrome

Postcard, Envelopes, Label sheet Color 120
CONFIGURATION/
OHP Monochrome
OPERATION
(2) C552 fusing speed

Monochrome 264
Plain paper (60 g/m2 to 90 g/m2)
Color 216
Monochrome
Color

OHP Monochrome
1 (3) C452 fusing speed

Monochrome
Plain paper (60 g/m2 to 90 g/m2) 216
Color
Monochrome
Color

OHP Monochrome
1 172
B. Adjustment of paper loop amount
• By creating a paper loop, the speed difference between the fusing and paper convey-
ance at 2nd transfer section will be adjusted. It prevents the double transferred image or
brush effect.
• The fussing speed is controlled (speed up/speed down) according to the amount of
paper loop.
• The loop amount detection sensor/1, /2 turns ON in different timing according to the loop
amount so that the loop amount can be detected in three stages.
Loop amount detection Loop amount detection

Loop amount Fussing speed
sensor/1 sensor/2
Unblocking Unblocking large Speed-up (High speed)
Unblocking Blocking average Speed-up (Low speed)
Blocking Blocking small Slowdown
Loop amount: small Fusing pressure roller
CONFIGURATION/
Loop amount: large
OPERATION
Loop amount detection sensor/2
(PS42)
Actuator
Loop amount detection sensor/1

A0P0T5C026DA
(PS41)
2nd transfer roller

• It starts controlling when the front-edge of the paper reaches to the predetermined posi-
tion before the fusing pressure roller.
• If the loop amount is “large” or “average”, the fusing speed is increased to reduce the
paper loop amount to an appropriate value.
• If the loop amount is “small”, the fusing speed is decreased to increase the paper loop
amount to an appropriate value.
• The control will finish when the back-edge of the paper passes the predetermined posi-
tion on the back of the 2nd transfer roller.
C. PPM control
• PPM control, which allows for given paper transport intervals to reduce the number of
printed pages produced per minute, is performed to prevent fusing failure, faulty image,
or other related malfunctions from occurring due to decreased temperature at the center
of the heating roller and fusing pressure roller or increased temperature at edges of
these rollers.
• The PPM control can reduce productivity to about 40 to 90% against the ordinary 100%.
173
22.3.2 Fusing pressure/retraction control

• To ensure prolonged durability of the heating roller, the heating roller and fusing pressure
roller is retracted *1 from the fusing belt during any time other than printing. (The roller is,
however, retracted *1 during printing using envelopes.)
*1: The fusing pressure roller does not completely retract but is slightly pressed to the
pressure roller.
• The fusing pressure retraction motor is turned forward or backward to press the pressure
roller up against, and retract it from, the heating roller. When the motor rotates, the fan-
sector gear will rotate to move the pressure roller.
• Pressed position of the fusing pressure roller is detected by the roller pressure home
sensor. The alienation is detected by the fusing retraction position sensor.
• When there is no change in output of the fusing retraction position sensor even if the
given time has passed after the fusing pressure retraction motor started its rotation, it is
judged as abnormal spacing and “Trouble code C3101: abnormal in fusing pressure
roller pressure welding alienation” message appears.
Pressure operation Retraction operation

Pressed by the
heating roller
CONFIGURATION/
OPERATION
A00JT2C292AA
Fusing pressure A0P0T5C088DA

Sector gear Heating roller
roller
A. Pressure/retraction timing
Conditions Pressure/retraction operation

The fusing pressure roller is retracted from the
heating roller until the heating roller reaches Retraction
the predetermined temperature.
Warm-up
The fusing pressure roller is pressed against
the heating roller when the heating roller Pressure
reaches the predetermined temperature.
Standby Normal Retraction
For envelopes Retraction
Printing
For paper types other than envelopes Pressure
Power save mode ON – Retraction
Heater OFF – Retraction
174
22.3.3 Heating roller heating control
A. Heating control
• The inside surface of the heating roller is formed with Ni layer.
• The IH coil located beside the heating roller radiates magnetic flux to the heating roller
when energized.
• The IH coil consists of two different types of coil: main coil and demagnetization coil.
• The heating roller is heated by the main coil. The demagnetization coil controls the heat-
ing zone.
• Ni layer of the heating roller is the nonmagnetic conducting layer in which eddy current is
generated with magnetic flux.
• The eddy current generated in the conducting layer produces Joule heat to heat the
heating roller.
• The main coil is provided only on one side of the heating roller, so that the heating roller
generates heat from a local surface of the heating roller close to the main coil. The heat-
ing roller is therefore rotated to ensure that the entire periphery of the roller is heated to
an adequate temperature.
• The heating roller sensor/1, heating roller sensor/2, and the heating roller sensor/3 mea-
sure the temperature of the heating roller.
CONFIGURATION/
OPERATION
Surface section
Ni layer (coated back side)
Heating roller
A00JT2C230AA
B. Whole area heating control

• During printing, the whole area of the heating roller is heated by the main coil.
175
C. Center heating switch control

• The temperature on ends of the heating roller is measured with the heating roller sensor/
3.
• When the temperature of ends of the heating roller exceeds a predetermined value dur-
ing printing using paper of a small size or in the standby state, the demagnetization coil
comes into play in inhibiting heating of roller ends and only the center portion of the roller
is heated.
• When the demagnetization coil is energized, the demagnetization coil radiates magnetic
flux so as to cancel the magnetic flux radiated from the main coil. Canceling the magnetic
flux on the ends of the roller results in generation of heat on the roller ends being inhib-
ited.
1 • The heating roller of C552/C452 are provided with two first demagnetization coils, one on
either side of the heating roller.
• The heating roller of C652 is provided with two first demagnetization coils and two sec-
ond demagnetization coils, each provided on either side of the heating roller to achieve
even greater demagnetization effect.
• Control is performed to turn ON or OFF each of these demagnetization coils according to
the paper width (CD: main scanning length) and the heating roller end temperature.
CONFIGURATION/
1
OPERATION
C652
2nd demagnetization coil 2nd demagnetization coil

1st demagnetization coil Main coil 1st demagnetization coil
C552/C452
A00HT2C301AA
1 176
D. Detection of rotation of the heating roller
• The heating roller is rotated while it is being heated to ensure that the entire periphery of
the roller reaches an adequate temperature.
• If the heating roller does not rotate while the IH coil (main coil) is energized, the temper-
ature of the entire periphery of the roller cannot be measured and thus proper tempera-
ture control cannot be provided. At this time, only the half surface of the heating roller is
heated. If the main coil is energized with the heating roller remaining stationary, the roller
can be damaged.
• Rotation of the heating roller results in the cam gear being rotated. The rotation of the
cam gear, in turn, actuates the actuator of the heating roller rotation sensor periodically.
• As the heating roller rotation sensor alternates between unblocked and blocked states at
regular intervals, the machine determines that the heating roller is rotating.
• If the heating roller rotation sensor remains unblocked or blocked for a predetermined
period of time during printing, the machine determines that a paper misfeed occurs at the
exit, displaying a corresponding message on the control panel.
• If the heating roller rotation sensor remains unblocked or blocked for a predetermined
period of time during a warm-up cycle, standby state, or any other timing than a print
cycle, the machine displays the malfunction code “C3102 Heating roller’s failure to
CONFIGURATION/
rotate” on the control panel.
OPERATION
Heating roller rotation detection gear
Heating roller
Cam gear
Heating roller rotation sensor (PS56)
A0P0T5C027DA
177
22.3.4 Heating control of the fusing pressure roller

• The fusing pressure roller has the soaking roller for heating.
• The soaking roller is pressed constantly to the fusing pressure roller.
• The soaking roller has hollow structure. Inside of the roller has the soaking heater lamp.
• The soaking heater lamp generates a heat after turning on electricity to heat the soaking
roller.
• Heated soaking roller heats the fusing pressure roller.
• Temperature of the soaking roller is measured by the soaking roller thermistor/1 and 2.
Soaking roller
Fusing pressure roller
Soaking roller heater lamp

(FH2)
CONFIGURATION/
OPERATION
Heating roller
A0P0T5C028DA
178
22.3.5 Fusing temperature control
• The surface temperature of the heating roller and the soaking roller are detected to con-
trol the amount of the heat of the IH heater and the soaking pressure roller heater lamp in
the soaking roller in order to maintain the appropriate fusing temperature.
A. Temperature control chart
Print is available
Sleep mode
Sub-power
switch ON Start key ON Low power mode
Temp. [1] [2] [4]

[3] [5] [6]
Heating roller
Soaking roller
Fusing pressure
roller
CONFIGURATION/
OPERATION
0 Time A00JT2C233AA
[1] Warm-up [4] Standby (normal operation)

Controlled temperature at stand by
[2] [5] Low power mode *1
(normal operation)
[3] Printing (plain/color) [6] Sleep mode
*1: The heating roller does not control a temperature because IH heater is OFF.
179
B. IH heater temperature control

• The heater is controlled to allow the heating roller temperature to fall within a predeter-
mined range during warm-up, printing, and in the standby state.
• Temperature of the heating roller is measured with the NC sensor, and the temperature
change (up/down) is monitored by comparing the current temperature with the previous
value (before 133 msec.)
• When the temperature in the heating roller goes up beyond the upper limit, IH coil is
deenergized.
• When the temperature in the heating roller goes down under the upper limit, IH coil is re-
energized.
Temperature change of heating roller 133 msec. Temperature check
Temperature
Upper limit
Target
temperature
Lower limit
CONFIGURATION/
OPERATION
ON
IH coil
(FH1)
OFF
Time (sec.)
A0P0T5C112DA
180
C. Temperature control during warm-up
• The warm-up control is started as soon as the main power switch and the sub power
switch are turned ON.
• If the fusing pressure roller presses the heating roller, the fusing pressure retraction
motor is energized to let the fusing pressure roller retract from the heating roller.
• The fusing motor is energized and, using the driving force of the fusing motor, the heat-
ing roller, fusing pressure roller, and the soaking roller are rotated.
• The main coil is energized to heat the heating roller to the specified temperature value*1.
• The soaking roller heater lamp is energized to heat the soaking roller. Heat of the soak-
ing roller heater lamp is transferred onto the fusing pressure roller and heat it.
• The soaking roller is heated to the specified temperature value*1.
• When the temperature of the heating roller reaches the predetermined value, the fusing
pressure retraction motor is energized to let the fusing pressure roller press the heating
roller.
• When the temperatures of all rollers exceed the predetermined value, the print cycle can
now be started.
• A print cycle is started if so requested. If there is no print request, the machine enters the
“temperature control under standby”.
CONFIGURATION/
OPERATION
(1) Warm-up time
1 Model Warm-up time Conditions

C652/C552/
30 sec. or less • At room temperature 23°C and rated voltage
C452
• For the period from a stable condition of the main
Taiwan only
60 sec. or less power switch turned ON and sub power switch
C552
turned OFF to a condition of being ready to print fol-
Taiwan only Color: 60 sec. or less lowing turning ON of the sub power switch
C452 Monochrome: 30 sec. or less
*1: The temperature control is provided by varying the target temperature according to the
combination of the temperature of the soaking roller and the machine interior absolute
humidity*2 at the start of the warm-up cycle.
*2: Absolute humidity: water content contained as moisture in the air (1 m3) regardless of
the temperature
Condition at the start of warm-up

Mode
Soaking roller temperature Machine interior absolute humidity
Low
Specified value or less Don’t care
temperature
High humidity Specified value or more Specified value or more
Normal Specified value or more Less than specified value
181 1
D. Temperature control in standby state

• The machine enters the standby temperature control if no print requests are received
after the warm-up.
• The standby temperature control ensures that the temperature of each roller in the
standby state is not decreased.
• For a predetermined period of time after the machine has started to enter the standby
temperature control, control is provided with the target temperature of each of low tem-
perature, normal, and high humidity modes.
• The temperature is controlled by normal mode, after predetermined time from standby
control start.
* Counted period for standby control includes the printing time.
E. Temperature control during printing

• Temperature control is provided in order to keep optimum fusing performance with vari-
ous factors, such as the type of paper, print mode, paper temperature*1, use of paper of
small size, decreased temperature during paper passage, and warm-up carried out with
a cool fusing unit.
*1: For paper temperature, “the machine interior temperature at the paper feed section”
CONFIGURATION/
detected by the paper temperature thermistor located in the paper feed section is used
OPERATION
as a data for controlling a fusing temperature.
Paper temperature thermistor

(TH8)
A0P0T5C009DA
182
F. Temperature control under low power mode
• Temperature control is provided, in which the main coil and demagnetization coil are
deenergized to suspend heating of the heating roller in order to reduce power consump-
tion during the low power mode.
• The soaking roller heater is controlled by lowering the target temperature of the soaking
roller from the temperature under printing or standby.
• The fusing motor is deenergized to keep all rollers stationary.
• In the low power mode, the soaking roller remains stationary while the temperature con-
trol of the soaking roller heater lamp is being provided. If the soaking roller is left to stand
under the abovementioned condition for a long time, the brush roller in contact with the
soaking roller is deformed and noise may occur when the roller is restarted. After the
machine has entered the low power mode, therefore, the soaking roller and the fusing
pressure roller are rotated at predetermined intervals to change the position of contact of
the brush roller with the soaking roller. The brush roller is thereby prevented from being
deformed.
• The temperature control under the low power mode is performed so that the temperature
reaches the printable level within 30 sec. at most.
CONFIGURATION/
G. Temperature control in sleep mode
OPERATION
• The main coil, demagnetization coil, and the soaking roller heater lamp are deenergized
to stop heating the heating roller and the fusing pressure roller, thereby reducing power
consumption in the sleep mode.
• The fusing motor is also deenergized to keep all rollers stationary.
• The rollers are not heated in the sleep mode and, as a result, the roller temperature may
be reduced down to room temperature. The machine may therefore require the period of
time equivalent to the warm-up time until the rollers reach the printable temperatures.
22.3.6 Heating roller temperature sensor

• A non-contact type NC sensor is used for heating roller temperature sensor/1 (hereinaf-
ter referred to as “temperature sensor”). The temperature sensor detects the tempera-
ture of the heating roller through infrared rays and controls the roller temperature.
• The temperature sensor is provided with a lens. For its structural reason, therefore, the
temperature sensor can be dirtied by dew condensation formed or foreign matter depos-
ited on the lens.
• The temperature sensor, if contaminated with dew drops or dirt on the lens, becomes
unable to detect the temperature accurately, since the contaminants blocks the infrared
rays that are otherwise detected by the sensor.
• If temperature control is provided under such conditions, the temperature sensor detects
a temperature that is lower than the actual temperature of the heating roller. Then, the
heating roller temperature is controlled based on a temperature higher than the target
one.
183
22.3.7 Heating roller temperature sensor condensation detection

A. Detection of condensation on the heating roller temperature sensor
• The control of detection of condensation on the heating roller temperature sensor is to
determine degradation of detection accuracy of the temperature sensor caused by con-
densation or dirt.
• When condensation on the temperature sensor is detected and the control is switched to
“alternative temperature control”, the machine displays the corresponding P code “P-32
Heating roller temperature sensor/1 temperature detection failure” on the control panel.
B. Condensation detection conditions

When any of the following conditions is detected, the machine determines that the heating
roller temperature sensor/1 lens has condensation on it and starts the heating roller alter-
native temperature control. (For details, see P.185 Heating roller alternative temperature
control)
(1) During warm-up

• The difference in temperature between that detected by heating roller thermistor/1 and
that detected by heating roller temperature sensor/1 is equal to, or more than, a specified
CONFIGURATION/
value and that condition lasts for 1 sec. or more.

OPERATION
(2) In standby state

• Within 30 sec. after the completion of the warm-up, the difference in temperature
between that detected by heating roller thermistor/1 and that detected by heating roller
temperature sensor/1 is equal to, or more than, a specified value and that condition lasts
for 1 sec. or more.
(3) During printing

• During printing, the difference in temperature between that detected by heating roller
thermistor/1 and that detected by heating roller temperature sensor/1 is equal to, or more
than, a specified value and that condition lasts for 1 sec. or more.
22.3.8 Heating roller temperature sensor contamination detection control

A. Detection of contamination on the heating roller temperature sensor
• The control of detection of contamination on the heating roller temperature sensor (here
in after referred to as “contamination detection control”) is to determine degradation of
detection accuracy of the temperature sensor caused by contamination.
• The contamination detection control is performed only in the standby state. No control is
provided during the alternative temperature control initiated by condensation of the tem-
perature sensor.
• If contamination of the lens of the heating roller temperature sensor/1 is detected, the
machine displays the corresponding malfunction code “C-3924 Fusing sensor contami-
nation (NC sensor)” on the control panel. It then shuts down the circuit to the main coil
and soaking roller heater lamp and terminates fusing unit temperature control.
184
B. Contamination detection conditions
(1) Control start conditions
• The contamination detection control is started if, at any timing 30 sec. or more after the
completion of the warm-up, the difference in temperature between that detected by heat-
ing roller thermistor/1 and that detected by heating roller temperature sensor/1 is equal
to, or more than, a specified value and that condition lasts for 1 sec. or more.
(2) Control termination conditions

• The contamination detection control is terminated if, at any timing within 10 min. after the
contamination detection control has been started, the difference in temperature between
that detected by heating roller thermistor/1 and that detected by heating roller tempera-
ture sensor/1 is equal to, or less than, a specified value.
• The contamination detection control is terminated if the machine enters any mode other
than the current one, including the warm-up or the low power mode as initiated by the
start of a print cycle or restart.
(3) Criteria for contamination

• If, after the start of the contamination detection control, the difference in temperature
between that detected by heating roller thermistor/1 and that detected by heating roller
CONFIGURATION/
temperature sensor/1 is equal to, or more than, a specified value and that condition lasts
OPERATION
for 10 min. or more, the machine determines that the heating roller temperature sensor/1
lens is contaminated and displays the corresponding malfunction code.
22.3.9 Heating roller alternative temperature control

A. Control start conditions
• Temperature control for the heating roller is provided based on the temperature detected
by the heating roller temperature sensor/1.
• If condensation on the heating roller temperature sensor is detected, the heating roller
temperature control is provided based on the temperature detected by the heating roller
thermistor/1, instead of that detected by the heating roller temperature sensor/1. This
control is referred to as the heating roller alternative temperature control.
• When the control is switched to the alternative temperature control, the machine displays
the corresponding P code “P-32 Heating roller temperature sensor/1 temperature detec-
tion failure” on the control panel.
B. Control termination conditions

• If the difference in temperature between that detected by heating roller thermistor/1 and
that detected by heating roller temperature sensor/1 becomes less than a specified value
during the alternative temperature control, the machine determines that condensation on
the heating roller temperature sensor/1 has been eliminated and resumes the tempera-
ture control based on the temperature detected by the heating roller temperature sensor/
1.
• If the difference in temperature between that detected by heating roller thermistor/1 and
that detected by heating roller temperature sensor/1 is not improved even after the lapse
of 10 min. after the alternative temperature control has been initiated, the machine deter-
mines that the cause is not condensation, but contamination, on the lens and terminates
the heating roller alternative temperature control.
185
C. Print job during the alternative temperature control

• If a print job is received during the heating roller alternative temperature control, control
is performed according to the settings made in “Security setting” of “Service mode”.
Reference: Service mode – Security setting – Engine FW Dip S – Switch No. 4 – Fusing
unit alternative temperature control
• If “OFF” is selected, the machine disables any print job during the alternative tempera-
ture control.
• If “ON” is selected, the machine enables a print job during the alternative temperature
control.
• The print job during the alternative temperature control is processed at 50% productivity.
• The default setting is “OFF”.
22.3.10 Protection against abnormal temperature

• The machine provides protection against abnormally high temperature of the fusing unit
in the following three steps.
A. Soft protection
• When the temperature higher than the control range at each roller is detected more than
CONFIGURATION/
1 second, the temperature is judged to be abnormally high, and the trouble code
OPERATION
appears.
• When the trouble code is displayed, printing will be prohibited.
Detected
temperature
Roller name Sensor name Trouble code
(Degrees
centigrade)
Heating roller temperature Fusing high temperature
225 C3725
sensor/1: TEMS1 abnormality_NC sensor
Heating roller 260 C3721
sensor/2: TEMS2 abnormality_heating center
260 C3722
sensor/3: TEMS3 abnormality_heating edge
Soaking roller thermistor/1: Fusing high temperature
Soaking roller 200 C3724
TH2 abnormality_Soaking
186
B. Hard protection
• Next level is provided when the level 1 cannot detect due to CPU overrun.
• The heater relay, through the printer control board, is turned OFF in the second level
operation to block the power supply to the IH coil and soaking roller heater lamp.
• When the controlled temperature of each roller is detected higher than the predeter-
mined value, the temperature is judged to be abnormally high, and the trouble code
appears.
• Through these control procedures, the power supply to the IH coil and soaking roller
heater lamp can be shut down before the thermostat is activated in the third level. It
thereby suppresses damage to the fusing unit itself.
Controlled
temperature
Roller name Sensor name: code Trouble code
(Degrees
centigrade)
Heating roller thermistor/1:
195
TH1 Fusing high temperature
C3721
Heating roller temperature abnormality_heating center
Heating roller 260
sensor/2: TEMS2
CONFIGURATION/
OPERATION
260 C3722
sensor/3: TEMS3 abnormality_heating edge
Soaking Soaking roller thermistor/2: Fusing high temperature
165 C3724
roller TH3 abnormality_Soaking
C. Overheat protection
• If the abnormal high temperature of soft protection/hard protection cannot be detected
due to a faulty temperature sensor or thermistor, thermostat blocks the power supply to
each heater lamp.
• The thermostat rating is 210 degrees centigrade for both the heating roller thermostat
and the soaking roller thermostat.
The ratings do not, represent the actual surface temperature of the corresponding rollers,
since the thermostats are installed in a non-contact with respect to each of the rollers.
187
22.3.11 Sensor disconnection detection control

• If the temperature of the NC sensor/thermistor fails to reach the specified temperature in
the given period after the warm-up started, the sensor is judged to have disconnection,
and the trouble code will appear.
Roller name Sensor name: code Trouble code

Heating roller temperature sensor/1: Fusing sensor disconnection
C3925
TEMS1 abnormality_NC sensor
Heating roller C3921
TEMS2 abnormality_heating center
C3922
TEMS3 abnormality_heating edge
Soaking Fusing sensor disconnection
Soaking roller thermistor/1: TH2 C3924
roller abnormality_Soaking
22.3.12 Brandnew detection

• The fusing unit is not provided with a new unit detection function.
CONFIGURATION/
• When the fusing unit is replaced with a new one, the counter must be reset to zero using
OPERATION
the function of “counter reset” of the service mode.

Reference: Service mode – Counter – Data – Life – Counter reset
188
22.3.13 Fusing cooling control
A. Cooling of the IH coil unit
• The machine is provided with the cooling fan motor for cooling the IH coil that heats the
heating roller and heat accumulated in and around the K toner cartridge.
• Outside air is drawn into the inside of the machine through its backside and is blown
through a ventilation duct against the IH coil unit to let it cool down. The areas around the
K toner cartridge is also cooled as the air flows through the ventilation duct.
• Heated air flowing through the IH coil unit is discharged through the slit in the upper sur-
face of the unit. It is then discharged to the outside of the machine by way of the exit sec-
tion.
Cooling fan motor (FM3)

Outside air
CONFIGURATION/
OPERATION
Ventilation duct
IH coil (IH1)
A0P0T5C085DA
189
B. Cooling of the fusing unit 1

• The machine is provided with fusing cooling fan motor/1 for cooling the fusing unit and
the paper after the fusing process and drawing smell of the fusing section.
• Heated air in and around the fusing unit is drawn and discharged to the outside of the
machine through the ventilation duct.
Discharge air
CONFIGURATION/
OPERATION
Ventilation duct
A0P0T5C083DA
190
C. Cooling of the fusing unit 2
• The machine is provided with fusing cooling fan motor/2 and fusing cooling fan motor/3
for cooling the machine interior around the fusing unit and the paper that has been fed
out of the machine.
• Outside air is drawn into the inside of the machine through the upper surface of the exit
section and is blown against the paper being transported through the exit section to let it
cool down. It also cools the machine interior near the fusing section.
• The heated air is discharged to the outside of the machine through the exit section.

Outside air
CONFIGURATION/
OPERATION
A0P0T5C084DA
191
23. DUPLEX SECTION Theory of Operation Ver. 2.0 Jul. 2009
23. DUPLEX SECTION

23.1 Configuration
A00JT2C275AA A0P0T5C076DA
CONFIGURATION/
OPERATION
ADU transport roller 2 ADU transport roller 3
ADU paper passage sensor/1 (PS47)
ADU door sensor (PS49)
ADU paper passage sensor/2

(PS48)
A00JT2C291AA
192
Theory of Operation Ver. 2.0 Jul. 2009 23. DUPLEX SECTION
23.2 Drive
ADU transport motor/1 ADU transport roller 2

(M31)
CONFIGURATION/
OPERATION
ADU transport motor/2

(M32)
ADU transport roller 4 A00JT2C291AA
193
23.3 Operation
23.3.1 Paper conveyance control
• Paper transported from the paper exit section is conveyed to the internal duplex section
by the ADU transport roller 1 and 2.
• Paper is conveyed to the vertical conveyance section by the ADU transport roller 3 and 4
to re-transport the paper.
Paper exit section

Stop position 1

Switchback roller
ADU paper passage sensor/1

(PS47)
CONFIGURATION/
Fusing section
OPERATION
Stop position 2
Duplex section
Registration
section
Timing roller
Stop position 3
A00JT2C245AA
A. Transport roller control

• ADU transport roller 1 and ADU transport roller 2 are connected to ADU transport motor/
1. When ADU transport motor/1 is energized, these rollers start rotating to transport
paper.
• ADU transport roller 3 and ADU transport roller 4 are connected to ADU transport motor/
2. When ADU transport motor/2 is energized, these rollers start rotating to transport
paper.
194
B. Paper entrance control
• The switchback motor at the paper exit section is deenergized to stop transport of the
paper temporarily (stop position 1). The switchback motor thereafter rotates backward to
transport the paper into the duplex section.
• When the switchback motor is deenergized, ADU transport motor/1 is energized and
ADU transport roller 1 and ADU transport roller 2 start rotating.
• ADU transport roller 1 transports the paper transported from the paper exit section onto
ADU transport roller 2.
• ADU paper passage sensor/1 located downstream of ADU transport roller 2 along the
paper path detects the leading edge of the paper transported from ADU transport roller
1.
• If there is, before the current sheet of paper, another sheet of paper being transported
through the duplex part and if that particular sheet of paper is yet to reach the specified
position before the timing roller, ADU transport motor/1 is deenergized to stop the sheet
of paper temporarily (stop position 2).
• When the advanced sheet of paper moves past the specified position, ADU transport
motor/1 is energized to resume the transport of paper.
• The paper is transported from ADU transport roller 2 to ADU transport roller 3.
CONFIGURATION/
• If ADU paper passage sensor/1 is unable to detect the trailing edge of the paper even
OPERATION
after the lapse of a predetermined period of time after it has detected the leading edge of
the paper, the machine determines that a paper misfeed occurs at the duplex transport
part.
• If ADU paper passage sensor/2 is unable to detect the leading edge of the paper even
after the lapse of a predetermined period of time after ADU paper passage sensor/1 has
detected the leading edge of the paper, the machine determines that a paper misfeed
occurs at the duplex transport part.
C. Duplex paper feed control

• When the leading edge of the paper reaches the specified position, ADU transport
motor/2 is energized and ADU transport roller 3 and ADU transport roller 4 start rotating.
• ADU transport roller 3 transports paper transported from ADU transport roller 2 onto
ADU transport roller 4.
• ADU paper passage sensor/2 located downstream of ADU transport roller 4 along the
paper path detects the leading edge of the paper transported from ADU transport roller
3.
• When the paper moves past ADU transport roller 4 and reaches the specified position,
ADU transport motor/2 is deenergized to stop the transport of the paper temporarily (stop
position 3). If, in this case, the paper has a length of 217 mm or more in the sub scanning
direction, ADU transport motor/1 is also deenergized.
• At predetermined paper feed timing, ADU transport motor/2 is energized to resume the
transport of the paper. ADU transport motor/1 is also energized if it has been deener-
gized.
• The paper is fed from ADU transport roller 4 onto the timing roller at the vertical transport
part.
• If ADU paper passage sensor/2 is unable to detect the leading edge of the paper even
after the lapse of a predetermined period of time after ADU paper passage sensor/1 has
detected the leading edge of the paper, the machine determines that a paper misfeed
occurs at the duplex transport part.
195
23.3.2 Duplex circulation control

• The duplex circulation control is performed differently according to the sub scanning
direction length of the paper.
Sub scanning direction paper length

Duplex circulation control
Lower limit Upper limit
433 mm or more Less than 459 mm One-sheet circulation operation
217 mm or more Less than 433 mm Two-sheet circulation operation
- Less than 217 mm Three-sheet circulation operation
A. One-sheet circulation operation

Operation 1
• One sheet of paper is supplied and the image of the sec-
ond page is printed.
2
CONFIGURATION/
OPERATION
A00JT2C236AA
Operation 2
• After the paper transported to the paper exit part stops at
the stop position 1, the switchback roller turns around to 2
send the sheet to the duplex part (paper reversed).
Stop position 1
A00JT2C237AA
Operation 3
• The paper transported to the duplex part is transported to
the stop position 3 (ADU transport roller 4) faster than the
system speed.
• It stops at the stop position 3 (ADU transport roller 4).
Stop position 3 2
A00JT2C238AA
196
Operation 4
• The image of the first page is printed on the paper re-sup-
plied from the duplex section.
1 2
A00JT2C239AA
Operation 5
• The first sheet of the paper is fed out.
• The image of fourth page is printed on the second sheet. 2
1
4
CONFIGURATION/
OPERATION
A00JT2C240AA
• Steps 2 through 5 are repeated.
One A4-size original for 2-sided

Instruction form the Stop before re-supply
printing
optimal paper position of paper
Exhaust sensor (PS39)
Gate switch solenoid (SD)
Exit motor (M4)
Normal rotation
Switchback motor (M33)
Inverse rotation
ADU transport motor/1 (M31)
A0P0T5E116DA
197
B. Two-sheet circulation operation

Operation 1
• The first sheet of paper is supplied and the image of the
second page is printed.
A00JT2C236AA
Operation 2
• The first sheet of paper is reversed at the paper exit sec-
tion and transported onto the duplex section. 2
• The second sheet of paper is supplied.
CONFIGURATION/
OPERATION
A00JT2C242AA
Operation 3
• The first sheet of the paper is sent trough the duplex sec-
tion and stops at the stop position 3 (ADU transport roller
4).
4
• The image of the fourth page is printed on the second
sheet of paper.
2
A00JT2C243AA
Operation 4
• The first sheet of the paper is re-supplied and an image of
the first page is printed on.
• The second sheet of paper is reversed at the paper exit
1 2
part and transported onto the duplex section.
• The third sheet of paper is supplied. 4
6
A00JT2C244AA
198
Operation 5
• The first sheet of paper is fed out.
• The second sheet of paper waits at stop position3 (ADU 2
transport roller 4). 1
• The image of the sixth page is printed on the third sheet of
paper.
6 4
A00JT2C246AA
Operation 6
• The second sheet of the paper is re-supplied.
6
• The third sheet of paper is reversed at the paper exit sec-
tion and transported onto the duplex part. 2
1
CONFIGURATION/
OPERATION
4
A00JT2C247AA
Operation 7
• The image of the third page is printed on the second sheet
of paper.
• The third sheet of paper is transported in the duplex sec- 2
3 4
tion. 1
• The fourth sheet of paper is supplied. 6
A00JT2C248AA
Operation 8
• The second sheet of the paper is fed out.
• The third sheet of the paper waits at stop position 3 (ADU 4
transport roller 4). 3 2
• The image of eighth page is printed on the fourth sheet of
1
the paper. 8 6
A00JT2C249AA
199
C. Three-sheet circulation operation

Operation 1
• The first sheet of paper is supplied and the image of the
second page is printed.
A0P0T5C040DA
Operation 2
• The first sheet of paper is reversed at the paper exit section 2
and transported onto the duplex section.
• The second sheet of paper is supplied and the image of the
4
fourth page is printed.
• The third sheet of paper is supplied.
CONFIGURATION/
OPERATION
A0P0T5C041DA
Operation 3
• The first sheet of the paper is transported onto, and stopped 4
at, stop position 3 (ADU transport roller part).
• The second sheet of paper is reversed at the paper exit sec-
tion and transported onto the duplex part. 6
• The image of the sixth page is printed on the third sheet of
paper.
2
A0P0T5C042DA
Operation 4
• The first sheet of paper is transported onto the vertical
transport section.
4
• The second sheet of paper is transported into the duplex 6
section.
• The third sheet of paper is transported onto the paper exit 2
section.
A0P0T5C043DA
Operation 5
• The first sheet of paper is re-supplied and the image of the
first page is printed on it.
6
• The second sheet of the paper is transported onto, and
1 2
stopped at stop position 3 (ADU transport roller 4).
• The third sheet of paper is reversed at the paper exit part
and transported onto the duplex section. 4
• The fourth sheet of paper is supplied.
A0P0T5C044DA
200
Operation 6
• The first sheet of paper is fed out.
• The second sheet of paper waits at stop position 3. 6
2 8
• The third sheet of the paper is transported onto, and
stopped at, stop position 2 (ADU transport roller 2). 1
• The image of the eighth page is printed on the fourth sheet 4
of paper.
A00JT2C253AA
Operation 7
• The second sheet of paper is transported onto the vertical
transport section. 2 6
• The third sheet of paper is transported into the duplex sec-
1 8
tion.
• The fourth sheet of paper is transported onto the paper exit
4
section.
CONFIGURATION/
A0P0T5C045DA
OPERATION
Operation 8
• The image of the third page is printed on the second sheet
of paper. 6
2 8
• The third sheet of the paper is transported onto, and
stopped at, stop position 3 (ADU transport roller 4). 1
4
• The fourth sheet of paper is reversed at the paper exit sec-
tion and transported onto the duplex section.
• The fifth sheet of paper is supplied.
A0P0T5C046DA
Operation 9
• The second sheet of paper is fed out. 4
• The third sheet of paper waits at stop position 3 (ADU trans- 3 2 8
port roller 4). 10
1
• The fourth sheet of the paper is transported onto, and
stopped at stop position 2 (ADU transport roller 2). 6
• The image of the tenth page is printed on the fifth sheet of
paper.
A0P0T5C047DA
Operation 10
• The third sheet of paper is transported onto the vertical 4
transport section. 3 2 8
• The fourth sheet of paper is transported onto the duplex 10
1
section.
6
• The fifth sheet of paper is transported onto the paper exit
section.
A0P0T5C048DA
201
24. PAPER EXIT SECTION Theory of Operation Ver. 2.0 Jul. 2009
24. PAPER EXIT SECTION

24.1 Configuration
Switchback paper exit section
A00JT2C280AA
CONFIGURATION/
Paper exit section

OPERATION
Switchback roller
Paper exit sensor

(PS39)
Paper exit roller 2

A00JT2C309AA
Paper exit switch gate Paper exit roller 1
202
Theory of Operation Ver. 2.0 Jul. 2009 24. PAPER EXIT SECTION
24.2 Drive
• The paper exit and switchback roller are driven by the exclusive motor.
Switchback Motor (M33)
Paper exit motor (M4)
Switchback roller
CONFIGURATION/
A00JT2C310AA
OPERATION
Paper exit roller 2
203
24.3 Operation
24.3.1 Transport control
• The paper exit section feeds the paper transported from the fusing section out onto the
exit tray using paper exit roller 1 and paper exit roller 2.
• In the 2-sided print mode, the paper that has undergone the first print cycle is trans-
ported onto the switchback roller by changing the paper path after it has moved past
paper exit roller 1. The paper is transported onto the duplex section. The second print
cycle is thereafter completed and the paper is fed from the fusing section and out onto
the exit tray by paper exit roller 1 and paper exit roller 2.
• If the machine is equipped with a finisher or other optional unit, the paper fed from the
fusing section is transported onto the optional unit by paper exit roller 1 and paper exit
roller 2.
A. Paper transport path
Switchback roller Paper exit switch gate

When the exit part are
Paper exit section Switchback position transported
CONFIGURATION/
2-sided transport ADU transport roller 1

OPERATION
Paper exit
Duplex section
Paper exit roller 2
Fusing
When the switchback section
are transported
Paper exit sensor (PS39)

Paper exit roller 1
A00JT2C235AA
204
Theory of Operation Ver. 2.0 Jul. 2009 24. PAPER EXIT SECTION
B. Paper exit control
• The paper exit roller 1 is connected to the fusing motor. When the fusing motor is ener-
gized, the paper exit roller 1 is synchronized with the fusing roller and the roller 1 starts
rolling.
• The paper exit roller 2 is connected to the paper exit motor. When the paper exit motor is
energized, the paper exit roller 2 starts rolling.
• When the paper transported from the fusing section reaches a specified position, the exit
motor is energized and the paper exit roller 2 starts rotating.
• Paper exit roller 1 transports the paper onto the paper exit switch gate.
• The paper exit sensor located downstream of paper exit roller 1 along the paper path
detects the leading edge of the paper that has moved past paper exit roller 1.
• The paper is guided onto paper exit roller 2 by the paper exit switch gate in its upper
position (the paper exit switch gate is in its upper position in the initial state).
• Paper exit roller 2 feeds the paper out onto the exit tray outside the machine.
detects the trailing edge of the paper that has moved past paper exit roller 1.
• If the paper exit sensor is unable to detect the trailing edge of the paper even after the
lapse of a predetermined period of time, the machine determines that a paper misfeed
CONFIGURATION/
occurs at the fusing section.
OPERATION
C. Switchback control
• The switchback roller 1 is connected to the switchback motor. When the switchback
motor rotates forward, the switchback rollers rotate forward; when the switchback motor
rotates backward, the switchback rollers rotate backward.
• The paper exit switch gate is connected to the gate switch solenoid. When the gate
switch solenoid is energized, the paper exit switch gate is swung down to its lower posi-
tion (at which paper is transported toward the paper feed section).
• When the paper transported from the fusing section reaches a specified position, the
paper exit motor is energized and the paper exit roller 2 start rotating.
• When the paper reaches the specified position, the switchback motor rotates forward and
the paper exit rollers start rotating forward.
• Paper exit roller 1 transports the paper toward the paper exit switch gate.
detects the leading edge of the paper that has moved past paper exit roller 1.
• When the paper reaches a specified position, the gate switch solenoid is energized to
swing down the paper exit switch gate to the lower position (at which paper is transported
toward the paper feed section).
• The paper exit switch gate swung into its lower position guides the paper toward the
switchback roller.
detects the trailing edge of the paper that has moved past paper exit roller 1.
• If the exhaust sensor is unable to detect the trailing edge of the paper even after the
lapse of a predetermined period of time, the machine determines that a paper misfeed
occurs at the fusing section.
• When the paper reaches a specified position, the switchback motor is deenergized and
then the switchback rollers start rotating backward.
• The switchback rollers rotate backward to transport the paper into the duplex section.
205
Instruction form the Switchback motor

optimal paper position turns around
Fusing motor (M30)
Exhaust sensor (PS39)
Gate switch solenoid (SD)
Nomal rotation
Switchback motor (M33)
Inverse rotation

A00JT2E531DA
CONFIGURATION/
OPERATION
206
Theory of Operation Ver. 2.0 Jul. 2009 25. IMAGE STABILIZATION CONTROL
25. IMAGE STABILIZATION CONTROL
25.1 Overview
• The machine provides the following image stabilization control to ensure stabilized copy
image.
Purpose Control Control means

• IDC registration sensor adjust-
ment control
• Max. density adjustment control IDC registration sensor
To stabilize image density
• LD intensity adjustment control Temperature/humidity sensor
To stabilize gradation
• Registration control (color shift PH temperature sensor
correction)
• Gamma correction control
To stabilize toner density * TCR control (Y,M,C,K) TCR sensor
* Image transfer output control
To stabilize image transfer Temperature/humidity sensor
2nd image transfer ATVC
CONFIGURATION/
* An explanation is given of the control for each section.
OPERATION
Toner supply motor
Color skew
correction
PC PC PC PC
drum/ drum/ drum/ drum/
Y M C K
PH temperature
sensor
G3/Y G3/M G3/C
TCR sensor Developing bias Vdc Grid voltage Vg
Toner replenishing
control
Image density
Gradation control IDC sensor
Gamma correction data
Gradation correction table
Transfer ATVC control
OUT/IN
Temperature/
humidity sensor IN
· To be set on control panel
D MAX density OUT
Background voltage margin
ATDC toner supply
A00JT2E518DA
207
25. IMAGE STABILIZATION CONTROL Theory of Operation Ver. 2.0 Jul. 2009
25.2 Description of control

25.2.1 IDC registration sensor adjustment control
• Controls changes in characteristics due to change with time and contamination of the
transfer belt and IDC registration sensor, part-to-part variations in the sensors, and
change of environment.
• The intensity (current value) of the IDC registration sensor is adjusted on the surface of
the transfer belt, on which no toner sticks (background level).
25.2.2 Max. density adjustment control

• The developing bias (Vdc) is adjusted to control changes in the solid density resulting
from variations in developing characteristics and IDC registration sensor intensity, varia-
tions in sensitivity of the photo conductor, and changes in the environment, durability,
and the amount of charge in toner.
• Patterns are produced on the surface of the transfer belt and the IDC registration sensor
detects the amount of toner sticking to them.
• Referring to the detected data and the environment data taken by the temperature/
humidity sensors, the developing bias value that results in the appropriate maximum
CONFIGURATION/
density is calculated and stored in memory.

OPERATION
• Thereafter, the grid voltage (Vg) value, including the background margin adjustment
value, is calculated and stored in memory.
25.2.3 LD (laser diode) intensity adjustment control

• It adjusts the variation in reproducibility of the thin line and the reverse outline, which is
resulting from the variations in electrostatic characteristics of the photo conductor, devel-
oping characteristics and transfer characteristics in terms of individual difference, envi-
ronment and durability, to make it the target level.
• It produces detection patterns on the surface of the transfer belt with the given level of LD
intensity and detects the output value of IDC sensor.
• LD intensity is calculated from the detected IDC sensor data.
25.2.4 Gamma correction control

• The intensity of LD in all gradation levels is adjusted to correct changes in gradation
characteristics to a linear one. The changes in gradation characteristics are caused by
variations in the photo conductor sensitivity and developing characteristics and changes
with time and in environment.
• It produces gradation patterns on the transfer belt and calculates gradation characteris-
tics output by the current engine with the IDC registration sensor.
• The gamma correction data is calculated using the density measurements of different
gradation levels. The optimum LD intensity is set for each of the different gradation levels.
208
25.3 Operation sequence
Mode 1 Mode 3 Mode 4 Mode 5 Mode 6

Mode 2
Sequence (new, initial- (registration (registration (mono- (mono-
(ordinary)
ized) 1) 2) chrome 1) chrome 2)
IDC registra- IDC registra- IDC registra- IDC registra-
Simplified Simplified
1 tion sensor tion sensor tion sensor tion sensor
registration registration
adjustment adjustment adjustment adjustment
Dmax Simplified
Dmax density Dmax density Dmax density
2 density gamma -
adjustment 1 adjustment 3 adjustment 3
adjustment 2 correction
LD light LD light LD light
3 intensity intensity - - intensity -
adjustment 1 adjustment 2 adjustment 2
Simplified
Dmax density Ordinary
4 - - gamma -
adjustment 2 registration
correction
LD light inten-
Gamma
CONFIGURATION/
5 sity adjust- - - - -
correction 1
OPERATION
ment 2
Full registra-
6 - - - - -
tion
Gamma
7 - - - - -
correction 1
* Max. density adjustment control 1: Use default for characteristic tilted value and Vdc
value.
Max. density adjustment control 2: Use previous setting value for characteristic tilted value
and Vdc value.
Max. density adjustment control 3: Use previous setting value for the monochrome Vdc
value.
* LD (laser diode) intensity adjustment control 1: Use default for LD intensity for adjustment
pattern.
LD (laser diode) intensity adjustment control 2: Use previous setting value for LD intensity
for adjustment pattern.
209
25.4 Operation timing

A. Predrive operation
Mode Operation condition * Stabilization mode

• A new transfer belt is detected
• IU units are removed and installed.
• A new IU is detected (Image stabilization in the initial
value is executed only for a new IU that has been
Mode 1 installed) Stabilization performed for
(new, initialized) • A new drum unit/K or a new developing unit/K is all modes
detected
• Skew adjustment is reset (Service mode)
• After initialization and image stabilization (Service
mode)
• The main and sub power switches are turned ON Stabilization performed
(only in color priority mode) only in color priority mode
• Information is provided indicating that the last stabili-
zation control was discontinued.
• While a warning code is being displayed, the front
CONFIGURATION/
door is opened and closed. Stabilization performed for

OPERATION
Mode 2 • A change in environment is detected (the threshold all modes

(normal) value in changes in absolute humidity is exceeded
relative to the absolute humidity during the last stabili-
zation sequence).
Stabilization performed in
• In case of lapsing of a predetermined period of time
the standard mode and
after stopping the photo conductor
color priority mode
• Image stabilization (Service mode) -
1 • A change in environment is detected (the threshold

value in changes in humidity is exceeded relative to
Mode 5 (mono- the absolute humidity during the last stabilization Stabilization performed
chrome 1) sequence). only in black priority mode
• In case of lapsing of a predetermined period of time
after stopping the photo conductor
* Stabilization mode setting

• The following three different modes are provided to select the optimum stabilization con-
trol according to utilization condition of the user. The mode can be selected via the
administrator mode or the service mode.
1. Standard (default setting)
2. Black Priority
3. Color Priority
1 210
• These modes are provided to maintain image quality and achieve the following purposes.
1. To reduce frequency at which the stabilization control is performed in order to
reduce cost per print for users who have a low print volume and low color ratio
2. To shorten time between when the machine is turned ON and when it is ready for
printing
3. To maintain convenience for users having a high color frequency
Mode Control
• The ordinary stabilization sequence is performed regardless of whether there
is a print job or not if a change in absolute humidity is detected during a
warm-up cycle.
1.Standard • Registration adjustment is made before a color print if there is a PH tempera-
ture change.
• No registration adjustment is made in monochrome printing even with a PH
temperature change.
• Monochrome stabilization sequence is performed and the ordinary stabiliza-
tion sequence is performed before a color print regardless of whether there is
a print job or not if a change in absolute humidity is detected during a warm-
up cycle.
2.Black Priority
CONFIGURATION/
• Registration adjustment is made before a color print if there is a PH tempera-
OPERATION
ture change.
• No registration adjustment is made in monochrome printing even with a PH
temperature change.
• Stabilization sequence is performed unconditionally when the main power
3.Color Priority switch and the sub power switch are turned ON. It takes 70 sec. for a warm-
up cycle after the main power switch is turned ON.
211
B. Before, during, and after a print cycle
Operating conditions
Change in
Change in PH
absolute
temperature of
Pressure Count of humidity of a The number
a predeter-
Mode condition of printed pages predeter- of pages yet Execution
mined value or
1st image produced mined value or to be printed timing *1
more relative
transfer since last sta- more relative of the current
to that during
roller bilization *5 to that during print job
the last stabili-
the last stabili-
zation
zation
50 sheets or
0
more
Change
500 or less 50 sheets or
2
less
Mode 2 Change - 2
500 or more - 2
Not change
1000 or more - 1
CONFIGURATION/
All in
OPERATION
pressed 2000 or more - 0

condition 50 sheets or
0 *4
more
Mode 4 500 or less Not change Change
50 sheets or
2 *4
less
500 or more - 2 *4
Mode 3
1000 or more Not change Not change - 1 *4
*2
2000 or more - 0 *4
2000 or less - - 2
Mode 5 Change
2000 or more - - 0
K in pressed
Mode 4 2000 or less - 3
condition Change
Mode 6 Not change - 0
2000 or more
*3 Not change - 0
*1: Details of execution timing
0 Executed by interrupting the print cycle

Before or after a print cycle, when the print mode changes from monochrome to color, or
1
between each print set
2 Before or after a print cycle, or when the print mode changes from monochrome to color
3 Before a print cycle, or when the print mode changes from monochrome to color
*2: Image stabilization of mode 2 is performed if gamma correction data does not fall within
a predetermined range when P-5, 6, 7, 8, 9,14, or 29 is detected or in the last image sta-
bilization.
*3: Image stabilization of mode 5 is performed if gamma correction data does not fall within
a predetermined range when P-5, 6, 7, 8, 9, 14, or 29 is detected or in the last image
stabilization.
*4: Image stabilization of mode 2 is performed when P-21 or 22 is detected.
*5: A copy of A4 size or equivalent is counted as one.
212
Paper length in the sub scanning direction Count
216 mm or less 1
Over 216 mm and up to 432 mm or less 2
Over 1080 mm 6
1 C. Service Mode
• Image Stabilization within the Service Mode
Service Mode – Image Process Adjustment – Stabilizer menu

Mode 1 Initialize + Image Stabilization
Mode 2 Stabilization Only
Service Mode – Image Process Adjustment – Gradation Adjust menu
CONFIGURATION/
Mode 2 Stabilizer
OPERATION
1 D. Expert Adjustment
• Image Stabilization within the Expert Adjustment
Utility – Administrator Settings – System Settings – Expert Adjustment – Image Stabilization

– Image Stabilization Only menu
Mode 1 Initialize + Image Stabilization
Mode 2 Image Stabilization Only
Utility – Counter – Administrator Settings – System Settings – Expert Adjustment

– Gradation Adjustment menu
Mode 2 Image Stabilization Only
E. Stabilization time
• C652
States Time
Mode 1 (new, initialized) 33 sec
Mode 2 (normal) 23 sec
Mode 3 (registration 1) 7 sec
Mode 5 (monochrome 1) 9 sec
213 1
• C552
States Time
1 • C452
States Time
CONFIGURATION/

OPERATION
1 214
Theory of Operation Ver. 2.0 Jul. 2009 26. IMAGE PROCESSING
26. IMAGE PROCESSING
26.1 Scanner section image processing block diagram
1. Photoelectric conversion
CCD sensor board
2. Analog-to-digital conversion
To the MFP board
• The following detail the image processing operations performed by the scanner section.
1. A reduction type CCD sensor is used to read the light reflected off the original and
convert the optical data to a corresponding electric signal. To make data process-
ing faster, data transfer and output are done through two channels, one for even-
numbered pixels and the other for odd-numbered pixels.
CONFIGURATION/
2. The odd and even analog signals output from the CCD sensor chips are synthe-
OPERATION
sized to form a single string of signal data which is in turn converted to 10-bit digital
signals (1024 gradation levels).
• The image data is transmitted to MFP board on the write section through the interface
cable.
215
26. IMAGE PROCESSING Theory of Operation Ver. 2.0 Jul. 2009
26.2 Write section image processing block diagram
1 From scanner section
1. Shading correction MFP board
2. Line-to-line variation
correction/color
aberration correction
17. Output buffer memory
3. Detection of security pattern
18. BTC expansion
4. Free erase
19. Resolution conversion
processing in the main
5. ACS control scanning direction/move
ment processing
CONFIGURATION/
6. AE processing
OPERATION
20. Resolution conversion

processing in the sub
7. Image data editing scanning direction
8. Image area discrimination 21. Color conversion

processing
RGB to YMCK
9. Miscellaneous processing Mode other than
(improved reproduction of photo
22. Embedment of security
black text, edge emphasis,
pattern
smoothing and color balance)
23. Area discrimination FEET

10. BTC compression
24. Interpolation
11. Input buffer memory
Gamma correction 25. Gamma correction

12. JBIG compression
13. File (code) memory 26. Error diffusion

DRAM:2GB (standard) (binary)
HDD:250GB (standard)
27. Screening
14. JBIG expansion
28. Delay control for the
interval of photo conductors
15. Memory access coordinator
29. Main scanning position

16. Frame memory correction
Speed conversion
Modulation
To PH unit
1 216
Theory of Operation Ver. 2.0 Jul. 2009 26. IMAGE PROCESSING
• The following detail the image processing operations performed by MFP board on the
Write section.
1. Correct variations in reading caused by pixel-to-pixel variations in sensitivity of the
CCD sensor and uneven light distribution by the exposure lamp. A peak-hold-type
shading correction is performed, in which the maximum value of two or more read-
ings of two or more lines is taken to prevent effect due to dust or dirt on the shading
sheet.
2. To correct differences in the position of each chip of CCD sensors R, G, and B,
FIFO memory is adopted to match the output timing. Also correct color aberration
of the lens.
1 3. The security pattern created during printing on this machine is detected and copy-
ing is enabled or disabled through a password (when the security kit SC-507 is
mounted).
4. If outer document elimination is selected from the control panel, document area
determination processing is performed for each line within the document area data
acquired during prescan. Then, the START and END positions of the document
area in the main scanning direction are detected and the area outside the START
and END positions is erased as the outside-the-document area.
CONFIGURATION/
5. The scanning area is divided into multiple blocks. The ratio of color or monochrome
OPERATION
is calculated for each of these blocks. The machine then determines whether the
entire original is colored or monochrome.
6. A histogram of lightness for AE processing is generated. The AE level of the docu-
ment is determined based on this histogram and AE processing is performed.
7. R, G, and B data are then converted to value and color component data for adjust-
ments of saturation, lightness, and hue.
8. Each image area, whether it is a color edge area, black edge area, dot area, or a
continuous gradation area, is discriminated.
9. Other types of processing performed are the improved reproduction of black text,
edge emphasis, smoothing and color balance.
10. Each Image data of R, G, and B is compressed to reduce the consumption of data
capacity.
11. Temporarily stores the BTC-compressed image data.
12. The stored image data is compressed in the JBIG (Joint bi-level image experts
group) format.
13. Each Image data of R, G, and B in the copy, print, scan, and fax mode is stored. In
PS printing, multi-valued data of Y, M, C, and K is stored.
14. The image data read from the file memory is uncompressed through a method in a
reverse way of JBIG compression. At this time, image rotating or sorting processing
is conducted.
15. JBIG image data are expanded in the frame memory.
16. Each Image data of R, G, and B is stored in frame memory.
17. Temporarily stores the image data output from the frame memory.
18. The image data is expanded through a method opposite to that used in the BTC
compression.
19. FIFO memory is used to enlarge or reduce images in the main scanning direction.
The image is enlarged by increasing the number of data readings and reduced by
decreasing the number of data readings.
20. Reduction processing is conducted in sub scanning direction. No processing is
done at same size or zoom, but at reduction, the lines are thinned out.
217 1
26. IMAGE PROCESSING Theory of Operation Ver. 2.0 Jul. 2009
21. When copying in a photo mode or making PC print, the R, G, and B data is con-
verted to the Y, M, C, and K density data. Also, the masking processing, which
compensates for the deviation in the spectral reflection characteristics of the toner,
and UCR/BP processing are performed on the image data.
For PS printing, multi-valued data of Y, M, C, and K are stored and there is no need
of converting or processing those data.
1 22. The security pattern is embedded in the image data. Either enabling copying
through a password or unconditionally prohibiting copying can be selected from the
control panel for the security pattern to be embedded (when the security kit SC-507
is mounted).
23. Edge of letter and lineal drawing gets area discrimination and FEET processing is
conducted according to the discrimination result.
24. When FEET processing is conducted, interpolation is done so that no influence is
given to continuous gradation portion.
25. Makes the necessary corrections so that the printed gradations have linear charac-
teristics, since the image density of the input image data is not directly proportional
to that of the printed image because of the changing developing and photo conduc-
tor characteristics.
CONFIGURATION/
26. In photo mode during copying and PC print, the image is processed as multi-valued
OPERATION
data (8-bit data). In any mode other than photo, the error diffusion method is
employed to process the image as binary (1-bit) data.
27. Creates the density distribution of a predetermined pattern to enable outstanding
gradation reproduction.
28. Image data of the file memory is developed to the frame memory and output delay
control for the interval of photo conductors, Y, M, C, K is conducted.
29. Correct the shear in printing start position in the main scanning direction, which
occurs when each PH unit of Y, M, C, K is exposed on the photo conductor. Adjust
the processing speed in the board (main scanning) to conform to the input process-
ing speed. The laser is emitted according to the laser intensity information.
1 218
Theory of Operation Ver. 2.0 Jul. 2009 27. POWER SUPPLY SECTION
27. POWER SUPPLY SECTION
27.1 Parts energized when the main power switch is turned ON
27.1.1 Configuration
CONFIGURATION/
OPERATION
Main power switch A0P0T2J613AA
27.1.2 Operation
• When the main power switch is turned ON, power is supplied from the DC power supply
unit to the following components.
Voltage Power supplied to

12V Fax board, control panel
5V MFP board, HDD, Fax board, Scanner section
3.3V Control panel
219
27. POWER SUPPLY SECTION Theory of Operation Ver. 2.0 Jul. 2009
27.2 Parts energized when the sub power switch is turned ON

Sub power switch

CONFIGURATION/
OPERATION
A0P0T2E614AA
27.2.2 Operation
• When the sub power switch is turned ON, MFP board detects it and sends a control sig-
nal to the DC power supply through the printer control board.
• The DC power supply then supplies 3.3 VDC, 5VDC, 12VDC, 15VDC, and 24VDC to all
PWBs and options. It also turns ON the relays in the PWBs and power can be supplied to
the IH heater and the heater lamp.
NOTE
• To turn OFF and ON the main power switch, first turn OFF the main power switch
and wait for 10 sec. or more before turning it ON again. If a setting value or values
in the tech. rep. mode are changed, it takes 10 sec. or more to incorporate the set-
ting changes properly in the machine.
220
Theory of Operation Ver. 2.0 Jul. 2009 27. POWER SUPPLY SECTION
27.3 Power cables
1 • C652/C552/C452
Power supply:15A
CONFIGURATION/
OPERATION
A00HT2C304AA
• C652 (Only Taiwan)
Power supply 1:15A
A00HT2C303AA
Power supply 2:7A
27.3.2 Operation
1 • C652/C552/C452
The main body uses a single outlet.
• C652 (Only Taiwan)
The main body uses two outlets (15 A + 7 A) to achieve an even higher printing speed
and a shorter warm-up time.
221 1
28. FAN CONTROL Theory of Operation Ver. 2.0 Jul. 2009
28. FAN CONTROL

28.1 Configuration
Optical cooling fan motor (FM201)

Rear side cooling fan motor (FM16)
Toner suction fan
motor (FM7)
Paper cooling fan motor (FM13)
CONFIGURATION/
OPERATION
CPU cooling fan

motor (built into
MFP board)
IH cooling fan motor/2
(FM12)
MFP control
board cooling
fan motor
(FM17)

(FM10)
Power supply cooling

fan motor (FM9) Suction fan motor (FM1)
IU cooling fan motor
(FM15) Cooling fan motor (FM3)
Intake air Writing cooling fan motor (M14)
Discharge air
A0P0T4C027DA
222
Theory of Operation Ver. 2.0 Jul. 2009 28. FAN CONTROL
28.2 Operation
28.2.1 Function
Motor name Control conditions

• Paper will be sucked between transfer part and fusing part, so it will have
Suction fan motor (FM1) a stable behavior and go smoothly into the fusing roller.
• The air inside will be exhausted outside the unit.
• Odor accumulated in the fusing part is absorbed by the odor filter to be
Fusing cooling fan motor/ removed.
1 (FM2) • Heat accumulated inside the unit will be discharged outside in order to
avoid temperature increase at the fusing part.
• Heat accumulated inside the unit will be discharged outside in order to
Cooling fan motor/1 (FM3)
avoid temperature increase at the transfer part or the fusing part.
Fusing cooling fan motor/ • Toner with paper heated at the fusing part may adhere to another paper
2 (FM4) on the paper exit tray when it will exit on the tray with remaining heat. In
Fusing cooling fan motor/ order to avoid toner adhesion to other things, outside air is sent to
3 (FM5) ejected paper and toner to cool it down.
• A white belt may occur on the image because of the lower sensitivity of
CONFIGURATION/
the photo conductor due to ozone accumulated around the photo con-
OPERATION
ductor charge corona. In order to avoid this trouble, ozone filter removes
Ozone ventilation fan
the ozone inside the photo conductor charge corona to keep the sensitiv-
motor (FM6)
ity of the photo conductor.
• Ozone accumulated around photo conductor charge corona will be
absorbed by ozone filter and be removed.
Toner suction fan motor • Toner easily scattered around a developing roller is sucked. Sucked air
(FM7) will be filtered and toner will be discharged outside.
Power supply cooling fan • Heat accumulated inside the unit will be discharged outside in order to
motor (FM9) avoid temperature increase at the power part.
IH cooling fan motor/1 • Heat accumulated inside the unit will be discharged outside in order to
(FM10) avoid temperature increase at the IH power used for fusing part.
IH cooling fan motor/2 • In order to avoid the temperature increase around IH power used for the
(FM12) fusing part, the outside air is sucked into the unit to cool it.
Paper cooling fan motor • In order to avoid toner adhesion to other things, outside air is sent to
(FM13) ejected paper to cool it down.
PH cooling fan motor • In order to avoid the temperature increase around PH, the outside air is
(FM14) sucked into the unit to cool it.
IU cooling fan motor • In order to avoid the temperature increase around TC part, IU part, trans-
(FM15) fer unit, etc., the outside air is sucked into the unit to cool it.
• Heat accumulated inside the unit will be discharged outside in order to
Rear side cooling fan
avoid temperature increase at rear side of the unit, such as the board
motor (FM16)
box.
1 MFP control board cooling • Heat accumulated inside the unit will be discharged in order to avoid tem-
fan motor (FM17) perature increase at the MFP board.
Scanner cooling fan motor • Heat accumulated inside the IR part will be discharged in order to avoid
(FM201) temperature increase at the scanner motor.
Exit cooling fan motor/1, / • In order to avoid toner attachment while the exit plate kit is used, outside
2, /3 (FM101, FM102, air is applied to the paper to cool it.
FM103) • Fan motor for the exit plate kit (0T-503)
1 CPU cooling fan motor • Blows outside air against the CPU to cool it down, thereby preventing the
(built into MFP board) temperature of the CPU from rising.
223 1
28.2.2 Control conditions
Motor name Control Control conditions (outline)

Stop • Any timing other than below
• During print cycle
Suction fan motor (FM1) • During image stabilization performed during print cycle
Full speed • During transfer belt cleaning performed during print cycle
• Function for putting through papers is diagnosed as adjust-
ment.
Power supply cooling • During print cycle
fan motor/1 (FM2) Full speed • Function for putting through papers is diagnosed as adjust-
ment.
• During warm-up cycle (in case that warm-up cycle is within
60 sec.)
Stop
• For 60 sec. after the start of warm-up cycle (in case that
warm-up cycle is within 60 sec. or more)
Cooling fan motor (FM3) Half speed
• Other than stop and full speed
CONFIGURATION/
*1
OPERATION

Full speed • Function for putting through papers is diagnosed as adjust-
ment.
• During predrive
Stop
• During fusing warm-up
Half speed • In standby state
Fusing cooling fan
*1 • During image stabilization performed during print cycle
motor/2 (FM4)
Fusing cooling fan • During print cycle
motor/3 (FM5) • Function for putting through papers is diagnosed as adjust-
Full speed ment.
• During transfer belt cleaning performed during print cycle
• Full speed rotation for 30 sec. after the above operations
• Half speed rotation for a predetermined period of time follow-
Half speed ing full speed rotation for 30 sec. after stop of the photo con-
ductor
Ozone ventilation fan • During print cycle
motor (FM6) • During image stabilization
• During TCR automatic adjustment
Full speed
• During auxiliary toner supply
• Full speed rotation for 30 sec. after the completion of above
operations and stop of the photo conductor
Stop • When the K developing motor is deenergized
Color toner suction fan
motor (FM7) • While the developing motor remains energized at such timing
Full speed
as during print cycle or stabilization
Stop • In power OFF state
Half speed
• Any timing other than below
*1
Power supply cooling
fan motor (FM9) • During print cycle
Full speed
ment.
• During image stabilization
224
Theory of Operation Ver. 2.0 Jul. 2009 28. FAN CONTROL
• Half speed rotation for 30 sec. after the end of following con-
Half speed
ditions
(FM10) • During print cycle
Full speed
ment.
IH cooling fan motor/2 • During print cycle

(FM12) • Function for putting through papers is diagnosed as adjust-
Full speed
ment.
• Half speed rotation for 110 sec. after the end of following
Half speed
conditions
Paper cooling fan motor • During print cycle
(FM13)
CONFIGURATION/
Full speed ment.
OPERATION
• Full speed rotation for 10 sec. after the end of above opera-
tion
Half speed
• In standby
*1
Writing cooling fan
motor (FM14) • During print cycle
• During image stabilization
Full speed
• Full speed rotation for 10 sec. after print cycle or image stabi-
lization
IU cooling fan motor
(FM15) • While the K PC motor remains energized at such timing as
Full speed
during print cycle or stabilization
• During image stabilization performed during print cycle
Rear side cooling fan • During transfer belt cleaning performed during print cycle
motor (FM16) Full speed • Function for putting through papers is diagnosed as adjust-
ment.
• Full speed rotation for 10 sec. after the end of above opera-
tion
• When sub power switch is turned OFF
Stop • In sleep state
MFP control board cool- • In low power state
1
ing fan motor (FM17)
Half speed • In standby state
Full speed • Any timing other than above
Optical cooling fan
Full speed • While the exposure lamp (FL201) is ON
motor (FM201)
Exit cooling fan motor/1
(FM101) • Full speed rotation for 30 sec. after paper exit following the
Full speed
end of print cycle
225 1

• For printing a paper which size is B5 or less. Or other than
Stop
following.
Exit cooling fan motor2/
3 (FM102,FM103) • Full speed rotation for 30 sec. after paper exit following the
Full speed end of print cycle. (For printing a paper which size is larger
that B5.
• ON/OFF control is performed using the temperature sensor
inside the CPU.
Stop
CPU cooling fan motor • When the CPU internal temperature is less than a predeter-
1
(built into MFP board) mined value.
• When the CPU internal temperature is equal to, or more
Full speed
than, a predetermined value.
*1: Half speed control: When switching from stop to half speed control, the fan will rotate at
full speed and then will rotate at half speed.
CONFIGURATION/
OPERATION
1 226
Theory of Operation Ver. 2.0 Jul. 2009 29. COUNTER CONTROL
29. COUNTER CONTROL
29.1 Configuration
Printer control board Total counter

(PRCB)
Key counter (option)
MFP board (MFPB) Electronic counter
A0P0T2C612AA
CONFIGURATION/
29.2 Operation
OPERATION
Name Function/system
• Displays the cumulative number of copies and prints of all jobs.
Total counter • A mechanical counter driven by an electric signal
• Counts one when an exit signal is applied to it
• Number of total in copy/printer/fax/scan mode will be displayed on
the screen as described below.
• Black, full color, single color, and 2 color
1 Electronic counter • Total counter, large size counter, color total (copy + printer), scan
counter, fax TX counter, fax RX counter, No. of originals counter, No.
of prints counter, total duplex counter
• Counts one when an exit signal is applied to it
• When charging prints by using the key counter, copies cannot be
made with out the key counter. However PC prints and fax TX/RX
service are available without the key counter.
• Displays the cumulative number of copies while the key counter is
Key counter (option)
being mounted.
• A mechanical counter driven by an electric signal
• Counts one when a paper take-up start signal or image forming start
signal, whichever occurs earlier, is applied to it
NOTE
• The counting modes can be selected at [billing setting] of service mode.
For details, see [Field service/adjustment/setting/billing setting].
227 1
29. COUNTER CONTROL Theory of Operation Ver. 2.0 Jul. 2009
CONFIGURATION/
OPERATION
Blank Page
228
2009.01
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

Theory of Operation Ver. 1.0 Jan 2009
CONTENTS
DF-618
DF-618
OUTLINE
2. SECTION CONFIGURATION.................................................................................. 5
3. PAPER PATH........................................................................................................... 5
OUTLINE
4. CONFIGURATION .................................................................................................. 6
5. DRIVE ..................................................................................................................... 7
6. OPERATION ........................................................................................................... 8
CONFIGURATION/
6.1 Paper feed section ................................................................................................ 8
OPERATION
6.1.1 Document feed tray ascent/descent mechanism .......................................... 8
6.1.2 Feeding the original....................................................................................... 9
6.1.3 Document set detection ................................................................................ 9
6.1.4 Original size detection................................................................................. 10
6.2 Transport section ................................................................................................ 11
6.2.1 Transfer mechanism.................................................................................... 11
6.2.2 Reading roller pressure/retraction control ................................................... 11
6.3 Turnover/paper exit section................................................................................. 12
6.3.1 Transferring the original............................................................................... 12
6.3.2 Switching mechanism for turnover/paper exit ............................................. 12
6.3.3 Switch back roller pressure/retraction control ............................................. 14
6.4 Paper path .......................................................................................................... 15
6.4.1 1-sided mode .............................................................................................. 15
6.4.2 2-sided mode .............................................................................................. 16
6.4.3 Mixed original/AMS mode (2-sided) ............................................................ 17
6.5 Open/close detecting section.............................................................................. 19
6.5.1 DF 15 degree open/close detection ............................................................ 19
6.5.2 DF open/close detection ............................................................................. 19
6.6 Cooling inside the unit ........................................................................................ 20
i
DF-618
OUTLINE
CONFIGURATION/
OPERATION
Blank Page
ii
Theory of Operation Ver. 1.0 Jan 2009 1. PRODUCT SPECIFICATIONS
OUTLINE
DF-618
A. Type
Name Reverse automatic document feeder

Paper feed section Paper feed from top of stack
Image reading section Sheet-through system
Type
Turnover section Switchback system
Exit section Straight exit system
OUTLINE
Installation Screw cramp to the main body
Document alignment Center
Document loading Face up
B. Functions
Modes Standard mode / Mixed original detection mode / FAX mode
C. Paper type
1-sided mode
35 to 210 g/m2 (9.25 to 55.75 lb)
Standard mode
2-sided mode
50 to 128 g/m2 (13.25 to 34 lb)
1-sided / 2-sided mode
Type of document Mixed original detection mode
50 to 128 g/m2 (13.25 to 34 lb)
1-sided mode
35 to 210 g/m2 (9.25 to 55.75 lb)
FAX mode
2-Sided Mode
50 to 128 g/m2 (13.25 to 34 lb)
Detectable document Metric area: B6S to A3
Standard mode/FAX mode
size*1 Inch area: 5 1/2 x 8 1/2 to 11 x 17
Capacity 100 sheets (80 g/m2) or stack of 14 mm and below
*1: For the combined original detection mode, refer to the mixed original feed chart.
1
1. PRODUCT SPECIFICATIONS Theory of Operation Ver. 1.0 Jan 2009
D. Paper feed prohibited originals

• If fed, trouble occurrence will be highly possible.
DF-618
Type of original Possible trouble

Paper feed failure, damaged sheet, defective drive
Sheets stapled or clipped together
mechanism due to jammed staples or clips
Sheets glued together Paper feed failure, damaged sheet
Book original Paper feed failure, damaged sheet
Original weighing less than 35 g/m2 (9.25 lb) or
Paper feed failure, transport failure
210 g/m2 (55.75 lb) or more
Paper feed failure, damaged sheet,
OUTLINE
Sheets folded, torn or wrinkled

transport failure
Sheets misfed due to being dog-eared or fed in
Sheets severely curled
askew
OHP film (Transparency film) Paper feed failure, transport failure
Label paper Paper feed failure, transport failure
Offset master paper Paper feed failure, transport failure
Glossy photographic paper or glossy enamel
Transport failure, damaged sheet
paper
Sheets clipped or notched Damaged sheet, transport failure
Sheets patched Patched part folded or torn sheet
E. Paper feed not guaranteed originals

• If fed, paper feed will be possible to some extent but trouble occurrence will be possible.
Type of Original Possible Trouble

Sheets lightly curled (Curled amount: 10 to 15 mm) Dog-eared, exit failure, transport failure
Heat sensitive paper Edge folded, exit failure, transport failure
Ink jet paper Paper feed failure, transport failure
Sheets with smooth surface (Coated paper) Paper feed failure, transport failure
Intermediate paper Paper feed failure, transport failure
Paper immediately after paper exit from the main unit Paper feed failure, transport failure
Paper with many punched holes (e.g., loose leaf) limited
Multi-page feed due to flashes from holes
to vertical feeding
Sheets with 2 to 4 holes Transport failure
Sheets two-folded or Z-folded Transport failure, image deformation
Sheets with rough surface (e.g., letterhead) Paper feed failure
2
Theory of Operation Ver. 1.0 Jan 2009 1. PRODUCT SPECIFICATIONS
F. Mixed original feed chart

For metric
DF-618
Max. original
297 mm 257 mm 210 mm 182 mm 148 mm 128 mm
size
Mixed original size A3 A4 B4 B5 A4S A5 B5S A5S B6S
A3 OK OK - - - - - - -
297 mm
A4 OK OK - - - - - - -
B4 OK OK OK OK - - - - -
257 mm
B5 OK OK OK OK - - - - -
OUTLINE
A4S OK OK OK OK OK OK - - -
210 mm
A5 NG NG OK OK OK OK - - -
182 mm B5S NG NG OK OK OK OK OK - -
148 mm A5S NG NG NG NG NG NG NG OK -
128 mm B6S NG NG NG NG NG NG NG OK OK
For inch
Max. original size 11 8 1/2 5 1/2

Mixed original size 11 x 17 8 /2 x 11
1 8 /2 x 14
1 8 /2 x 11S
1 5 /2 x 8 /2 5 /2 x 8 1/2S
1 1 1
11 x 17 OK OK - - - -
11
8 1/2 x 11 OK OK - - - -
8 1/2 x 14 OK OK OK OK OK -
8 1/ 2 8 1/2 x 11S OK OK OK OK OK -
5 1/2 x 8 1/2 NG NG OK OK OK -
5 1/ 2 5 1/2 x 8 1/2S NG NG NG NG NG OK
OK Mixed original feed available (Tilted with in 1.5% or less)

NG No. mixed original feed
- Can not set original
3
1. PRODUCT SPECIFICATIONS Theory of Operation Ver. 1.0 Jan 2009
G. Machine specifications
DC 24 V (supplied from the main unit)

DF-618
Power requirements
DC 5 V
Max. power
60 W or less
consumption
618 mm (W) x 575 mm (D) x 130 mm (H)
Dimensions
24.33 inch (W) x 22.64 inch (D) x 5.12 inch (H)
Weight 16.0 kg (35.27 lb)
OUTLINE
H. Operating environment
Conforms to the operating environment of the main body.
NOTE
4
Theory of Operation Ver. 1.0 Jan 2009 2. SECTION CONFIGURATION
DF-618
Transport section Paper feed section Paper exit section
OUTLINE
9J07T2C203c0
Turnover section Paper exit turnover section
3. PAPER PATH
Feed tray Exit tray
A0HTT2C001DA
Document read position
5
4. CONFIGURATION Theory of Operation Ver. 1.0 Jan 2009
4. CONFIGURATION
DF-618
[1] [2]
A0P0T5C052DA A01HT2C002AA
CONFIGURATION/
[4] [3] [5] [6]

OPERATION
[1] Transportation cover [5] Original read section

[2] Document feed tray [6] Magnet
[3] Turnover cover
[4] Document guide
Feed roller Pick-up roller
Registration roller Separation roller Switch back roller
A0HTT4C001DA
Reading roller 2 Exit roller
Reading roller 1
Switch back registration roller Exit switch back roller
6
Theory of Operation Ver. 1.0 Jan 2009 5. DRIVE
5. DRIVE
DF-618
Take-up motor (M2) Exit motor (M3)
Lift-up motor (M6)
Switch back roller

Regist motor (M7) pressure/retraction
motor (M5)
CONFIGURATION/
Reading motor (M1)
OPERATION
Reading roller pressure/
A0HTT5C001DA
7
6. OPERATION Theory of Operation Ver. 1.0 Jan 2009
6. OPERATION
6.1 Paper feed section
DF-618
6.1.1 Document feed tray ascent/descent mechanism

• The document feed tray will move up to feed the original.
• Ascent/descent of the document feed tray will be performed by the lift-up motor.
A. Document feed tray ascent

• The document feed tray will stay in the stand-by position when in stand-by status.
• Setting the original and pressing the start key will move the document feed tray up.
• The lift-up motor will rotate the drive cam through the gear. The lift up lever will move
above the cam, and the document feed tray will move up.
• The document feed tray will stop moving up when the lift up upper sensor is transmitted.
Descent position
CONFIGURATION/
Drive cam
OPERATION
Ascent position
Lift up lever
Lift up upper
sensor (PS16)
Lift-up motor (M6)
Lift up lower 9J07T2C202c0
sensor (PS15)
Empty sensor (PS14)
B. Document feed tray descent

• When all the originals are fed and the empty sensor is interrupted, the lift-up motor will
reverse.
• The lift-up motor will rotate the drive cam through the gear. The lift up lever will move
above the cam, and the document feed tray will move down.
• The document feed tray will stop moving down when the lift up lower sensor is inter-
rupted.
8
Theory of Operation Ver. 1.0 Jan 2009 6. OPERATION
6.1.2 Feeding the original

• The paper feed section consists of the pick-up roller, feed roller as well as the separation
DF-618
roller, and is directly driven by the take-up motor.
• Pressing the start key will transfer the original to the registration roller by the pick-up
roller and the feed roller.
Pick-up roller
Take-up motor (M2)
CONFIGURATION/
OPERATION
Feed roller
A07HT2C002DB
Separation roller
6.1.3 Document set detection

• To prevent a document set mistake, the document set sensor detects a document loaded
in the document feed tray.
Document feed tray
Document set
sensor (PS20)
A0HTT6C001DA
9
6.1.4 Original size detection
Length sensor 3
DF-618
Length sensor 1
(PS10) (PS12)
Length sensor 2
(PS11)
CONFIGURATION/
OPERATION
Before read Document width detection

sensor (PS9) variable resistor (VR1)
A0HTT6C002DA
Mixed sensor 1
(PS19) Mixed sensor 3
Mixed sensor 2 (PS17)
(PS18)
A. Detecting the width of the original 1

• The width of the original will be detected by the document width detection variable resis-
tor under the document feed tray.
• Reference for setting the original on the document feed tray is its center.
B. Detecting the width of the original 2

• Three mixed sensors are mounted to where the paper passes immediately after it is fed.
It is for detecting the width of the original for mixed original/AMS.
C. Detecting the length of the original 1

• The length of the original will be detected by the length sensor 1/2/3.
• Length sensors 1 and 3 are mounted in this order with the length sensor 2 being closest
to the feed roller.
D. Detecting the length of the original 2

• Length of the mixed original/AMS will be calculated by the time before read sensor is
interrupted.
10
6.2 Transport section

6.2.1 Transfer mechanism
DF-618
• The original transferred from the paper feed section will be transferred to the paper exit
section or turnover section by the registration roller, the reading roller 1 and 2, and the
switch back roller.
• The registration roller and the switch back roller are driven by the regist motor.
• Reading roller 1 and 2 are driven by the reading motor.
Regist motor (M7) Switch back roller Registration roller
CONFIGURATION/
OPERATION
Reading motor (M1)
Reading roller 1
Registration
sensor (PS3)
Reading roller 2
A07HT2C003DB
6.2.2 Reading roller pressure/retraction control

• Document speed fluctuates as the trailing edge of the document moves past reading
roller 1. To inhibit these speed fluctuations, the reading roller pressure/retraction motor is
employed to retract reading roller 1.
Retract reading
roller 1
Reading roller pressure/

A0HTT6C003DA
Lever
11
6.3 Turnover/paper exit section

6.3.1 Transferring the original
DF-618
• The original transferred from the transport section will switch back or exit by the exit
roller, the switch back roller, and the exit switch back roller.
• The exit roller and the exit switch back roller are driven by the exit motor.
• The switch back roller is driven by the regist motor.
Switch back roller Exit motor (M3)

Exit switch back roller
Exit roller
CONFIGURATION/
OPERATION
Regist motor (M7)
A0HTT6C004DA
6.3.2 Switching mechanism for turnover/paper exit

A. Turnover section
• Pathway of the original will be switched and the original will turnover by the switch back
lever.
• Switch back lever is switched by ON/OFF of the switch back solenoid.
When in 1-sided mode: When in 2-sided/

Switch back solenoid will be OFF mixed original/AMS (1-sided, 2-sided) mode:
Switch back solenoid will be ON
Switch back solenoid (SD1)
Exit roller Switch back roller

9J07T2C013DA
9J07T2C012DA
Switch back lever
12
B. Paper exit section

• The exit lever will switch the pathway of the original to exit.
• The exit lever will be switched by ON/OFF of the exit switch back solenoid.
DF-618
When in 1-sided mode: Exit switch back solenoid will be OFF
When in 2-sided/mixed original/AMS (1-sided, 2-sided) mode: Exit switch back solenoid will be ON
Exit switch back solenoid (SD2)
Exit switch back roller
CONFIGURATION/
OPERATION
Exit lever
9J07T2C014DA
13
6.3.3 Switch back roller pressure/retraction control

• To enhance productivity in document scanning, control is performed at the turnover sec-
DF-618
tion by narrowing the gap between two originals so that they pass each other properly at
the switch back roller. The switch back roller pressure/retraction motor provides the drive
for the pressure/retraction operations of the switch back roller.
• This control is performed during the mixed original AMS mode only.
A0HTT6C005DA
Switch back
CONFIGURATION/
roller
OPERATION
Switch back
roller pressure/
retraction
motor (M5)
A0P0T5C114DA
14
6.4 Paper path

6.4.1 1-sided mode
DF-618
A0HTT6C007DA
1. Pressing the start key will lift up the feed tray and press the reading roller 1.
2. After the feed tray is lifted up, the feed motor is started and the pick-up roller and
the feed roller will start rotating to start feeding the first sheet of paper.
3. When the paper reaches the registration roller, a loop is formed in the paper. Then,
CONFIGURATION/
the regist motor is started, so that the registration roller transfers the paper.
OPERATION
4. The take-up motor is deenergized when a predetermined period of time elapses
after the registration motor has been activated. The reading motor and the exit
motor will start running.
5. It starts reading from the front edge of the original when the before read sensor
turned ON and the specified period of time has passed.
6. Reading roller 1 will be retracted right before the back edge of the original passes
through the reading roller 1. The retracted reading roller 1 will be pressed again to
prepare for the next original.
7. The original will be exit by the reading roller 2 and the exit roller.
8. All motors will turn OFF after the back edge of the original turns OFF the exit sen-
sor and the specified period of time is passed.
15
6.4.2 2-sided mode

1. The first side of the original will be read.
DF-618
2. The original will be transferred to the turnover section. (Switch back solenoid will be
ON)
3. In order to read the second side of the original which is transferred to the turnover
section, the switch back roller will reverse by the switch pack operation of the regist
motor, and transfer the original to the switch back registration roller.
A0HTT6C008DA
CONFIGURATION/
4. The switch back registration sensor will turn ON and the switch back registration
OPERATION
roller will rotate by the exit motor to transfer the original to the original read section.
5. It starts reading from the front edge of the original when the before read sensor
turned ON and the specified period of time has passed.
6. The original will be transferred to the paper exit turnover section after it is read.
(switch back solenoid will be ON)
Exit switch back roller will reverse by the exit motor’s reverse operation.
A0HTT6C009DA
7. In order to keep the proper order of the original, exit switch back roller will rotate for-
ward by the exit motor’s forward operation. The original will be turned over and be
discharged.
A0HTT6C010DA
16
6.4.3 Mixed original/AMS mode (2-sided)

• Paper path control will be the same as the 2-sided mode.
DF-618
1. The original will be fed to detect the paper length. (It will not read the original)
The length of the original will be judged by the before read sensor ON time, and the
width of the original will be judged by the mixed sensor 1, 2, and 3.
A0HTT6C011DA
2. The original will be fed without the 2nd side being read.
CONFIGURATION/
OPERATION
A0HTT6C012DA
3. After reading the first side, the original will be transferred again to the switch back
part to read the second side.
A0HTT6C013DA
17
4. The original will be transferred to the paper exit turnover section after second side
is read. (Switch back solenoid will be ON)
Exit switch back roller will reverse by the exit motor’s reverse operation.
DF-618
A0HTT6C014DA
5. In order to keep the proper order of the original, exit switch back roller will rotate for-
ward by the exit motor’s forward operation. The original will be turned over and be
discharged.
CONFIGURATION/
OPERATION
A0HTT6C015DA
18
6.5 Open/close detecting section

6.5.1 DF 15 degree open/close detection
DF-618
• The lever actuator is provided to detect the original size when using the auto document
feeder as the original cover.
• When lowering the auto document feeder to 15 degree angle or lower, the angle detec-
tion lever for the original cover on the copier will be pressed to turn ON the 15 degree
sensor.
6.5.2 DF open/close detection

• The magnet is installed to detect the open/close of the auto document feeder on the
copier side.
• The original cover/DF open sensor on the copier will turn ON by the magnet when lower-
ing DF.
Lever Magnet
CONFIGURATION/
OPERATION
A0HTT2C501AA
Original cover/DF open sensor (RS201)
19
6.6 Cooling inside the unit

• The air will be blown inside the unit by the cooling fan in order to avoid the temperature
DF-618
increase of the driving motor and the board.
Cooling
fan motor
(FM1)
CONFIGURATION/
OPERATION
A01HT2C004AA
20
2009.01
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
LU-301
LU-301
OUTLINE
1. PRODUCT SPECIFICATION .................................................................................. 1
3. PAPER FEED PATH ................................................................................................ 2
OUTLINE
4. CONFIGURATION .................................................................................................. 3
5. DRIVE ..................................................................................................................... 4
6. OPERATIONS ......................................................................................................... 5
CONFIGURATION/
6.1 Paper Feed and Transport Control ....................................................................... 5
OPERATION
6.2 Paper level detection ............................................................................................ 7
6.3 Paper empty detection.......................................................................................... 8
6.4 Paper level indicator ............................................................................................. 8
6.5 Tray lift-up control ................................................................................................. 9
6.5.1 Tray ascend/descend mechanism................................................................. 9
6.5.2 Paper size detection.................................................................................... 11
6.6 Dehumidification heater control .......................................................................... 11
i
LU-301
OUTLINE
CONFIGURATION/
OPERATION
Blank Page
ii
Theory of Operation Ver. 1.0 Jan 2009 1. PRODUCT SPECIFICATION
OUTLINE
1. PRODUCT SPECIFICATION
LU-301
A. Type
Name 3,000 sheets Large Capacity Unit

Type External option attached to the right side of the main body
B. Paper type
OUTLINE
Type Size Weight Capacity
Plain paper 64 g/m2 to 90 g/m2 3,000 sheets
Thick paper 1 91 g/m2 to 120 g/m2 2,500 sheets *2
Thick paper 1+ A4, 8 1/2 x 11 121 g/m2 to 157 g/m2 1,750 sheets *2
Thick paper 2 158 g/m to 209 g/m
2 2
1,550 sheets *2
Thick paper 3 210 g/m2 to 256 g/m2 1,300 sheets *1 *2
*1: Images are out of guarantee.

C. Machine specifications
Power requirements DC 24 V, DC 5 V, DC 3.3 V (supplied from the main body)

Max. power
23 W or less
consumption
367 mm (W) x 528 mm (D) x 405 mm (H)
Dimensions
14.5 inch (W) x 20.75 inch (D) x 16 inch (H)
D. Operating environment
• Conforms to the operating environment of the main body.
NOTE
1
2. SECTION CONFIGURATION Theory of Operation Ver. 1.0 Jan 2009
LU-301
Paper transport section Paper storage section

Paper feed section
OUTLINE
A03NT1C002AA
3. PAPER FEED PATH
Transportation to main body
Paper feed from the tray
A03NT1C001AA
Main body LU-301
2
Theory of Operation Ver. 1.0 Jan 2009 4. CONFIGURATION
4. CONFIGURATION
LU-301
A03NT2C204AA
LU drive board (LUDB)
CONFIGURATION/
Near empty sensor /1 (PS5)
OPERATION
LU door switch (MS1) Upper limit sensor (PS2)
Tray LED (LED)
A03NT2C213AA
(DH)
Lift-up motor (M1)
Paper empty sensor (PS4)
Tray set sensor (PS1) Paper feed sensor (PS3)
3
5. DRIVE Theory of Operation Ver. 1.0 Jan 2009
5. DRIVE
LU-301
Transport motor (M3) Feed roller

CONFIGURATION/

OPERATION
Transport roller
A03NT2C214AA
4
Theory of Operation Ver. 1.0 Jan 2009 6. OPERATIONS
6. OPERATIONS
6.1 Paper Feed and Transport Control
LU-301
• The feed roller rotates and feeds paper at a predetermined timing.
• The LCT transport rollers rotate and convey paper at a predetermined timing.
• In consecutive print, when the interval between the preceding and following sheets is
below the specified value, the LCT transport rollers temporarily stop to ensure a prede-
termined interval.
• The paper transport speed is faster than the system speed.
System speed (mm/s) Paper transport speed (mm/s)

310 to 240 420
264 to 216 350
155 to 108 216
Start key ON
CONFIGURATION/
OPERATION
Paper feed sensor (PS3)
A03NT2C001AA
5
6. OPERATIONS Theory of Operation Ver. 1.0 Jan 2009
• Layout of sensors and rollers

LU-301
Transfer roller
Feed roller
(PS12)

roller
A03NT2C002AA
Main body LU-301

CONFIGURATION/
OPERATION
6
6.2 Paper level detection

• The level of the paper still available for use is determined based on the outputs from near
LU-301
empty sensor/1 and sensor/2.
• A near empty condition is detected when the amount of paper left still available for use is
about 50 sheets ± 30 sheets.
Reference data:
Paper full Paper near full Paper available Near empty
plain paper
Paper level 3000 to 2000 sheets 2000 to 1000 sheets 1000 to 51 sheets 50 to 1 sheets
Near empty sensor /1 blocking blocking unblocking unblocking
Near empty sensor /2 unblocking blocking blocking unblocking
Paper level detection plate
CONFIGURATION/
OPERATION
Notch
Notch

A03NT2C203AA
7
6.3 Paper empty detection

• The paper empty sensor detects a paper empty condition.
LU-301
Paper empty sensor (PS4) Upper limit sensor (PS2) Paper still available
A03NT2C205AA
Paper empty condition

CONFIGURATION/
A03NT2C205AA
OPERATION
6.4 Paper level indicator

• The amount of paper still available for use, or the paper level, is indicated by the LED
provided on the right-hand side of the unit as viewed from the front.
• Following describe different paper level conditions.
Other than empty and near empty conditions,

Paper condition Empty Near empty
during lift-up
LED display ON blinking OFF
Tray LED
A03NT2C204AA
8
6.5 Tray lift-up control

6.5.1 Tray ascend/descend mechanism
LU-301
• The tray is suspended by the wires at the front and rear.
• Rotation of the lift-up motor winds the wires, which causes the tray to go up.
• Opening the LU door disconnects the lift-up motor from the tray ascend/descend mecha-
nism, causing the tray to lower by its own weight.
• There is a drive assist spring used for bringing the tray to a stop at an appropriate height.
LU door
Paper tray
Coupling
CONFIGURATION/
OPERATION
Lift-up motor (M1) A03NT2C215AA
Wire
Drive assist spring
Lift-up axis
9
A. Closing the LU door

• The condition of the upper limit sensor signal is checked when the LU door is closed. If
the upper limit sensor is unblocked, the lift-up motor is energized so that lifting of the tray
LU-301
is started.
• When the upper limit sensor is blocked after the lifting of the tray has been started, the
lift-up motor is deenergized to complete the lifting of the tray.
Upper limit sensor (PS2)
Paper tray
CONFIGURATION/
A03NT2C216AA
OPERATION
LU door closed Lifting completed
LU door switch (MS1)

Lift-up motor (M1)
A03NT2C207AA
B. During a print cycle

• As the paper is consumed for a number of print cycles carried out, the pickup roller grad-
ually lowers and eventually unblocks the upper limit sensor. The lift-up motor is then
energized again and the lifting of the tray is started.
• When the upper limit sensor is blocked, the lift-up motor is deenergized to complete the
lifting of the tray.
• The sequence of these operations is repeated. This maintains the pressure (paper take-
up pressure) between the pickup roller and the paper stack at a constant level regardless
of the level of the paper stack left.
Pick-up Roller Upper limit sensor (PS2)
A03NT2C209AA
A03NT2C208AA
10
6.5.2 Paper size detection

• The LCT is not capable of detecting the paper size.
• The paper size is set by Service Mode → System 2 → LCT Paper Size Setting.
LU-301
A03NT2E500DA
6.6 Dehumidification heater control
CONFIGURATION/
OPERATION
• The LCT is equipped with a dehumidification heater as standard.
• ON/OFF control of the dehumidification heater is operatively associated with turning on
or off of the dehumidifier heater of the machine.
Right side
surface
Dehumidification
heater (DH)
A03NT2C212AA
11
LU-301
CONFIGURATION/
OPERATION
Blank Page
12
2009.01
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

Theory of Operation Ver. 1.0 Jan. 2009
CONTENTS
LU-204
LU-204
OUTLINE
3. PAPER FEED PATH ................................................................................................ 2
OUTLINE
4. CONFIGURATION .................................................................................................. 3
5. DRIVE ..................................................................................................................... 4
6. OPERATIONS ......................................................................................................... 5
CONFIGURATION/
6.1 Paper feed and transport control .......................................................................... 5
OPERATION
6.2 Paper level detection ............................................................................................ 6
6.3 Paper empty detection.......................................................................................... 7
6.4 Paper level indicator ............................................................................................. 8
6.5 Tray lift-up control ................................................................................................. 9
6.5.1 Tray ascend/descend mechanism................................................................. 9
6.5.2 Paper size detection.................................................................................... 12
6.6 Dehumidification heater control .......................................................................... 12
i
LU-204
OUTLINE
CONFIGURATION/
OPERATION
Blank Page
ii
Theory of Operation Ver. 1.0 Jan. 2009 1. PRODUCT SPECIFICATION
OUTLINE
LU-204
A. Type
Name 2,500 sheets Large Capacity Unit

Type External option attached to the right side of the main body
B. Paper type
OUTLINE
Type Size Weight Capacity
Plain paper A3, B4, A4, A4S 64 g/m2 to 90 g/m2 2,500 sheets
Thick paper 1 A3W (12 x 18) *3 91 g/m2 to 120 g/m2 2,000 sheets *2
11 x 17 *4
Thick paper 1+ 121 g/m to 157 g/m
2 2
1,450 sheets *2
8 1/2 x 14 *4
Thick paper 2 8 1/2 x 11S *4 158 g/m2 to 209 g/m2 1,250 sheets *2
*4
8 /2 x 11
1
Thick paper 3 210 g/m2 to 256 g/m2 1,000 sheets *1 *2
12 x 18 *4
*1: Images are out of guarantee.

*3: Fixed size for European market
*4: Fixed size for North American market
Power requirements DC 24 V, DC 5 V, DC 3.3 V (supplied from the main body)

Max. power
23 W or less
consumption
629 mm (W) x 556 mm (D) x 405 mm (H)
Dimensions
NOTE
1
2. SECTION CONFIGURATION Theory of Operation Ver. 1.0 Jan. 2009
LU-204
Paper transport section Paper feed section Paper storage section

OUTLINE
A0TJT1C001DA
3. PAPER FEED PATH
Transportation to main body
Paper feed from the tray
Main body LU-204 A0TJT1C002DA
2
Theory of Operation Ver. 1.0 Jan. 2009 4. CONFIGURATION
4. CONFIGURATION
LU-204
A0TJT2C001DA
LU drive board (LUDB)
CONFIGURATION/
OPERATION
Paper feed Tray LED (LED)

sensor (PS3)
Paper empty sensor (PS4)
Lift-up motor (M1) Upper limit sensor (PS2)
Tray set sensor/2 (PS7)

Tray set sensor (PS1) A0TJT2C002DA
Dehumidification heater (DH)
3
5. DRIVE Theory of Operation Ver. 1.0 Jan. 2009
5. DRIVE
LU-204
Transport motor (M3) Feed roller

CONFIGURATION/

OPERATION
Transport roller
A0TJT2C003DA
4
Theory of Operation Ver. 1.0 Jan. 2009 6. OPERATIONS
6. OPERATIONS
6.1 Paper feed and transport control
LU-204
• The feed roller rotates and feeds paper at a predetermined timing.
• The LCT transport rollers rotate and convey paper at a predetermined timing.
• In consecutive print, when the interval between the preceding and following sheets is
below the specified value, the LCT transport rollers temporarily stop to ensure a prede-
termined interval.
• The paper transport speed is faster than the system speed.
System speed (mm/s) Paper transport speed (mm/s)

310 to 240 420
264 to 216 350
155 to 108 216
Start key ON
CONFIGURATION/
OPERATION

A03NT2C001AA
• Layout of sensors and rollers

(PS12) Paper feed sensor (PS3)
Transport roller
Feed roller

roller
Main body LU-204

A0TJT2C004DA
5
6. OPERATIONS Theory of Operation Ver. 1.0 Jan. 2009
6.2 Paper level detection

• The level of the paper still available for use is determined based on the outputs from near
LU-204
empty sensor/1 and sensor/2.

• The estimate amount of paper for near empty is around 50.
Reference data:
Paper full Paper near full Paper available Near empty
plain paper
Paper level 2500 to 2000 sheets 2000 to 1000 sheets 1000 to 50 sheets 50 to 1 sheets
Near empty sensor /1 blocking blocking unblocking unblocking
Near empty sensor /2 unblocking blocking blocking unblocking
Paper level detection plate

CONFIGURATION/
OPERATION
Notch
Notch
A0TJT2C005DA
6
6.3 Paper empty detection

• The paper empty sensor detects a paper empty condition.
LU-204
Paper empty sensor (PS4) Upper limit sensor (PS2)
Paper still available
CONFIGURATION/
OPERATION
Paper empty condition
A0TJT2C006DA
7
6.4 Paper level indicator

• The level of the paper still available for use is indicated by the LED provided on the right-
LU-204
hand side of the unit as viewed from the front, and displayed on the control panel.
• Following describe different paper level conditions.
Other than empty and near empty conditions,

Paper condition Empty Near empty
during lift-up
LED display ON blinking OFF
Tray LED Displayed on the Control panel

CONFIGURATION/
OPERATION
A0TJT2E014DA
8
6.5 Tray lift-up control

6.5.1 Tray ascend/descend mechanism
LU-204
• The tray is suspended by the wires at the front and rear.
• Rotation of the lift-up motor winds the wires, which causes the tray to go up.
• Opening the LU door disconnects the lift-up motor from the tray ascend/descend mecha-
nism, causing the tray to lower by its own weight.
• There is a drive assist spring used for bringing the tray to a stop at an appropriate height.
LU door
Coupling
CONFIGURATION/
Paper tray
OPERATION
Wire
Lift-up motor (M1)

Drive assist spring A0TJT2C008DA
Lift-up axis
9
A. Closing the LU door

• The condition of the upper limit sensor signal is checked when the LU door is closed. If
the upper limit sensor is unblocked, the lift-up motor is energized so that lifting of the tray
LU-204
is started.
• When the upper limit sensor is blocked after the lifting of the tray has been started, the
lift-up motor is deenergized to complete the lifting of the tray.
Paper tray
CONFIGURATION/
OPERATION
A0TJT2C013DA
LU door closed Lifting completed
Lift-up motor (M1)
A03NT2C207AA
10
B. During a print cycle

• As the paper is consumed for a number of print cycles carried out, the pickup roller grad-
ually lowers and eventually unblocks the upper limit sensor. The lift-up motor is then
LU-204
energized again and the lifting of the tray is started.
• When the upper limit sensor is blocked, the lift-up motor is deenergized to complete the
lifting of the tray.
• The sequence of these operations is repeated. This maintains the pressure (paper take-
up pressure) between the pickup roller and the paper stack at a constant level regardless
of the level of the paper stack left.
Pick-up Roller Upper limit sensor (PS2)
CONFIGURATION/
A0TJT2C010DA
OPERATION
11
6.5.2 Paper size detection

• The LCT is not capable of detecting the paper size.
• The paper size is set by Service Mode → System 2 → LCT Paper Size Setting.
LU-204
A0TJT2E015DA
6.6 Dehumidification heater control

CONFIGURATION/
OPERATION
• The LCT is equipped with a dehumidification heater as standard.

• ON/OFF control of the dehumidification heater is operatively associated with turning on
or off of the dehumidifier heater of the machine. See “18. PAPER FEED SECTION
(TRAY3, TRAY4)/18. 3. 5. Dehumidification heater control” in the main body manual.
Dehumidification
heater (DH)
A0TJT2C012DA
12
2009.07
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
JS-504
JS-504
OUTLINE
2. PAPER PATH........................................................................................................... 3
2.1 Exit to the upper tray............................................................................................. 3
OUTLINE
2.2 Exit to the lower tray ............................................................................................. 3
3. CONFIGURATION .................................................................................................. 5
4. DRIVE ..................................................................................................................... 6
CONFIGURATION/
5. OPERATION ........................................................................................................... 7
OPERATION
5.1 Transport/exit section............................................................................................ 7
5.1.1 Paper transport ............................................................................................. 7
5.1.2 Transport path switching ............................................................................... 8
5.1.3 Full-of-paper detecting mechanism............................................................. 12
5.2 Paper shift section .............................................................................................. 13
5.2.1 Paper shift mechanism................................................................................ 13
5.2.2 Shift operation overview.............................................................................. 14
i
JS-504
OUTLINE
CONFIGURATION/
OPERATION
Blank Page
ii
OUTLINE
JS-504
A. Type
Type Built-in type 2-bin stacker

Installation Installed in main body
Document align-
Center
ment
OUTLINE
B. Functions
Modes Sort, group, sort offset, group offset
C. Paper
Exit tray Size Type Capacity

A5S, B5S/B5, A4S/A4, B4, A3
8-1/2 X 11S/8-1/2 X 11, 8-1/2 X
14, 11 X 17
Plain paper (64 to 90 g/m2)
Upper tray Max.: 297 mm X 431.8 mm 50 sheets
(17 to 24 lb)
11.75 inch X 17 inch
Min.: 148 mm X 210 mm
5.75 inch X 8.25 inch
150 sheets
(17 to 24 lb)
Thick paper 1
(91 to 120 g/m2)
(24.25 to 32 lb)
Thick paper 1 +
(121 to 157 g/m2)
A6S, A5S/A5, B6S, B5S/B5, (32.25 to 41.75 lb)
A4S/A4, B4, A3, A3 Wide, Post Thick paper 2
card S (158 to 209 g/m2)
5-1/2 X 8-1/2S/5-1/2 X 8-1/2, (42 to 55.5 lb)
8-1/2 X 11S/8-1/2 X 11, 20 sheets
Lower tray Thick paper 3
8-1/2 X 14, 11 X 17, 12-1/4 X 18 Special
Max.: 311.1 mm X 1200 mm (210 to 256 g/m2)
paper
12.25 inch X 47.25 inch (55.75 to 68 lb)
Min.: 90 mm X 139.7 mm Thick paper 4
3.5 inch X 5.5 inch (257 to 300 g/m2)
(68.25 to 72.75 lb)
OHP film
Post card
Label
Envelope 10 sheets
Long size paper 1 sheet
1
D. Offset function
Exit tray Lower tray

JS-504
Shift amount 30 mm
Types of paper to
Plain paper, Thick paper 1/1+/2/3/4
be used
B5S/B5, A4S/A4, B4, A3
Size
8-1/2 X 11S/8-1/2 X 11, 8-1/2 X 14, 11 X 17
E. Machine specifications
DC 24 V ± 10 % (supplied from the main body)

OUTLINE
Power require-
ments DC5 V ± 5 %
Max. power con-
40 W or less
sumption
431 mm (W) X 540 mm (D) X 131 mm (H)
17 inch (W) X 21.25 inch (D) X 5.15 inch (H)
Dimensions
558 mm (W) X 540 mm (D) X 131 mm (H) *1
21.97 inch (W) X 21.26 inch (D) X 5.16 inch (H) *1
Weight 5.0 kg (11 lb)
*1: Size when the paper exit tray is pulled out
F. Operating environment
NOTE
2
2. PAPER PATH
2.1 Exit to the upper tray
JS-504
OUTLINE
A0D5T1C101AA
2.2 Exit to the lower tray
A0D5T1C102AA
3
JS-504
OUTLINE
Blank Page
4
Theory of Operation Ver. 1.0 Jul. 2009 3. CONFIGURATION
3. CONFIGURATION
JS-504
A0D5T2C112AA
CONFIGURATION/
Upper tray
OPERATION
Transport path switching mechanism
Lower tray Paper shift mechanism
A0D5T2C101AA
Upper tray exit sensor (PS2)
Lower tray exit sensor (PS1)
Route change home sensor

(PS4)
Shift home sensor (PS6)

A0D5T2C113AA
Front door sensor (PS3)
5
4. DRIVE Theory of Operation Ver. 1.0 Jul. 2009
4. DRIVE
JS-504
JS control board (JSCB)
Upper tray exit roller
Lower tray exit roller

CONFIGURATION/
OPERATION
Retraction motor (M3)
A0D5T2C102AA
Shift motor (M2)
6
Theory of Operation Ver. 1.0 Jul. 2009 5. OPERATION
5. OPERATION
5.1 Transport/exit section
JS-504
5.1.1 Paper transport
• The transport motor is energized a predetermined period of time after the paper has acti-
vated the paper exit sensor of the main body.
• Drive of the transport motor rotates the exit roller, so that paper is transported into the
corresponding tray.

Upper tray exit roller
CONFIGURATION/
OPERATION
Lower tray exit roller
A0D5T2C103AA
7
5. OPERATION Theory of Operation Ver. 1.0 Jul. 2009
5.1.2 Transport path switching

A. Overview
• The paper path switching guide adequately switches the paper transport path to ensure
JS-504
that the paper is transported properly into the upper or lower tray as necessary.
• The output tray is determined according to the setting made in Output Tray Setting of
Administrator Setting and options of finishing, paper type, and paper size as selected for
copy job setup.
Output tray Output Tray Setting Finishing Paper type Paper size
Plain paper,
Upper tray Set to upper tray – –
Recycled paper
Plain paper,
A3 wide, A5
Lower tray Set to lower tray Sort Recycled paper,
A6S, B6S
Special paper
Upper tray Paper path switching guide

CONFIGURATION/
OPERATION
Feeding from main body
Lower tray
A0D5T2C106AA
8
B. Operation
• Drive from the route change motor moves the paper path switching guide up or down to
select the output tray for the paper.
JS-504
• The route change home sensor detects the position of the paper path switching guide.
Output tray Guide moving direction Route change home sensor

Upper tray Guide swung down Unblocked
Lower tray Guide swung up Blocked
CONFIGURATION/
OPERATION
Route change motor (M3)
Paper path switching guide Cam A0D5T2C104AA
Route change home sensor (PS4)
Paper path switching guide
Guide swung down Guide swung up

(to feed paper into upper tray) (to feed paper into lower tray)
A0D5T2C105AA
9
(1) Predrive
• The route change motor is energized to move the paper path switching guide into a posi-
tion for feeding paper into the lower tray when the main body is turned ON or released
JS-504
from the sleep mode, or a malfunction is reset.

(2) Paper exit into the upper tray
• The route change home sensor is used to determine the position, at which the paper
path switching guide is stopped, so that the motion of the switching guide can be con-
trolled as necessary.
Route change Paper path switching guide

Control details
home sensor stop position
Unblocked Paper fed into upper tray Not applicable
The route change motor is energized to move the
Blocked Paper fed into lower tray paper path switching guide into the position, at which
paper is fed into the upper tray.

CONFIGURATION/
OPERATION
Before switching After switching

A0D5T2C108AA
• Control for feeding paper into upper tray - paper path switching guide moved, feeding out
two sheets of paper
1st sheet of paper activating 2nd sheet of paper fed out,
paper exit sensor of main body transport motor deenergized
Paper exit sensor at main body

Route change home sensor(PS4)

Lower exit sensor (PS1)
Upper exit sensor (PS2)
Shift motor (M2)
Drive of route change motor started 2nd sheet of paper reaching upper tray
Drive of transport motor started 2nd sheet of paper activating
1st sheet of paper reaching upper tray paper exit sensor of main body
A0D5T2E004DA
10
(3) Paper exit into the lower tray

• The route change home sensor is used to determine the position, at which the paper
path switching guide is stopped, so that the motion of the switching guide can be con-
JS-504
trolled as necessary.
Route change Paper path switching guide

Control details
home sensor stop position
The route change motor is energized to move the
Unblocked Paper fed into upper tray paper path switching guide into the position, at which
paper is fed into the lower tray.
Blocked Paper fed into lower tray Not applicable
CONFIGURATION/
OPERATION
Before switching After switching A0D5T2C107AA
• Control for feeding paper into lower tray - paper path switching guide not moved, feeding
out two sheets of paper
1st sheet of paper activating 2nd sheet of paper fed out,

paper exit sensor of main body transport motor deenergized


Shift motor (M2)
Drive of route change motor started 2nd sheet of paper reaching lower tray
1st sheet of paper reaching lower tray 2nd sheet of paper activating
paper exit sensor of main body
A0D5T2E005DA
11
5.1.3 Full-of-paper detecting mechanism

• Each tray is mounted with a tray paper full detect board that detects a full-of-paper condi-
tion of the tray.
JS-504
• The tray paper full detect board consists of a light emitter (LED) and a photoreceiver that
are paired up to serve for each tray. The system determines that the tray is in a full-of-
paper condition when paper blocks the LED light.
• When a full-of-paper condition is detected, the copier feeds paper being printed out and
then stops, with a corresponding message shown on the control panel.
• A stack of 150 sheets of plain paper (lower tray) is detected as a full-of-paper condition,
excluding curled paper.
Upper tray paper full detect board/PR (T2FDTB/PR)
Upper tray paper full detect board/LED (T2FDTB/LED)

CONFIGURATION/
OPERATION
Lower tray paper full detect board/PR (T1FDTB/PR)

Lower tray paper full detect board/LED (T1FDTB/LED)
A083T2C514AA
12
5.2 Paper shift section

5.2.1 Paper shift mechanism
JS-504
• The shift section is shifted forward during paper exit so that print jobs can be offset, one
job from another.
• The shift section is moved by drive supplied from the shift motor.
• The shift operation is executed when the sort function is used by the user.
Front Shift section Lower tray exit roller Rear
CONFIGURATION/
OPERATION
Shift direction
A083T2C513AA
Shift home sensor (PS6) Shift motor (M2)
13
5.2.2 Shift operation overview

• The shift motor is energized to slide the shift section in a forward direction at a predeter-
mined timing during paper exit into the lower tray after the trailing edge of the paper has
JS-504
moved past the exit roller of the main body.

• The position of the shift section is controlled as detailed below.
Shift section position Position control Shift home sensor

Home position – rearward Shift home sensor output Blocked
Shift position – forward Shift motor speed (number of pulses) (Unblocked)
• After the current sheet of paper has been fed out at the shift position, the shift section is
returned to its home position before the next sheet of paper reaches the lower tray exit
roller.
Paper Shift section

CONFIGURATION/
OPERATION
Home position Shift motor (M2) Shift position

A083T2C520AA
14
• 1st sheet of paper fed out normally with the 2nd sheet of paper fed out at shift position
1st sheet of paper reaching lower tray 1st sheet of paper fed out at normally position
JS-504
1st sheet of paper activating 2nd sheet of paper reaching
paper exit sensor of main body lower tray

Forward rotation
Shift motor (M2) Backward rotation
CONFIGURATION/
Drive of transport motor started
Shift operation for 2nd sheet of paper started
OPERATION
2nd sheet of paper fed out at shift position
Shift section returned to its home position
A0D5T2E006DA
15
JS-504
CONFIGURATION/
OPERATION
Blank Page
16
2009.07
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
ZU-606
ZU-606
OUTLINE
3. PAPER PATH........................................................................................................... 7
OUTLINE
4. CONVEYANCE SECTION ...................................................................................... 9
4.1 Configuration ........................................................................................................ 9
4.2 Drive ................................................................................................................... 10
CONFIGURATION/
4.3 Operation ............................................................................................................ 12
OPERATION
4.3.1 Conveyance path switching......................................................................... 12
4.3.2 Conveyance line speed switching ............................................................... 14
4.3.3 Registration control ..................................................................................... 17
5. PUNCH SECTION ................................................................................................ 18
5.1 Configuration ...................................................................................................... 18
5.2 Drive ................................................................................................................... 18
5.3 Operation ............................................................................................................ 19
5.3.1 Punch control .............................................................................................. 19
5.3.2 Punch position movement control ............................................................... 21
5.3.3 Punch hole switching control....................................................................... 24
6. PUNCH SCRAPS CONVEYANCE SECTION ....................................................... 25
6.1 Configuration ...................................................................................................... 25
6.2 Drive ................................................................................................................... 26
6.3 Operation ............................................................................................................ 27
6.3.1 Punch scraps conveyance control............................................................... 27
6.3.2 Punch scraps control .................................................................................. 28
7. Z-FOLDING SECTION .......................................................................................... 29
7.1 Configuration ...................................................................................................... 29
7.2 Drive ................................................................................................................... 30
7.3 Operation ............................................................................................................ 31
7.3.1 1st folding control ........................................................................................ 31
7.3.2 2nd folding control....................................................................................... 33
i
ZU-606
OUTLINE
CONFIGURATION/
OPERATION
Blank Page
ii
OUTLINE
ZU-606
A. Type
Type Z-folding multi punching device
B. Functions
Punch Punching method Reciprocal punching method (punching each paper)
OUTLINE
No. of holes Metric area : 2 holes/4 holes (switched automatically)
Inch area : 2 holes/3 holes (switched automatically)
Hole diameter Metric area : 6.5 ± 0.5 mm
Inch area : 8.0 ± 0.5 mm
Hole position
Metric area : 11.0 ± 5 mm
Inch area : 9.5 ± 5 mm
Hole pitch
Metric area : 80 ± 0.5 mm Center of the
Inch area : 70 ± 0.5 mm paper
Inch area : 9.5 ± 5 mm
Hole pitch 108 ± 0.5 mm

Center of the
Hole pitch 108 ± 0.5 mm paper

Center of the
Hole pitch 80 ± 0.5 mm paper
Hole pitch 70 ± 0.5 mm Center of the

paper
A109T1C001DA
Folding method Buckle folding method with the roller pair
1
Z-folding Folding length

a
ZU-606
A07TT1C010AA
Paper size L (mm) a (mm)

A3 209 or less
OUTLINE
B4 181 or less
4±2
11 x 17 215 or less
8K *1 194 or less
Folding precision
2 mm or less 2 mm or less
1st folding 2nd folding
A07TT1C011AA
Folding Folding length
A07TT1C003AA
Paper size L (mm)

8-1/2 x 14 263 or less
Folding precision
2 mm or less
A07TT1C004AA
2
Maximum tray capacity (80 g/m2) The maximum number of sheets for the FS main tray at
the Z-folding operation
• Z-folding continuous: Max. 30 sheets
ZU-606
• Z-folding/stapling: See the table below
No. of sheets per staple

No. of set on
No. of unfold the main tray
No. of fold sheets
sheets
1 to 40 sheets 20 set
1 sheet
41 to 90 sheets 10 set
2 sheets 1 to 80 sheets 10 set
OUTLINE
6 sheets or greater Not guaranteed
*1: Only for the Taiwan market
3
C. Type of paper
No punch mode Same as the main body.

ZU-606
Punch mode Paper size

• Combination with the folding/saddle stitching mode is not available.
Metric area 2holes:
A3, B4, A4, A4S, B5, B5S, A5, A5S,
8K *1, 16K *1, 16KS *1,
8 x 13, 8-1/2 x 13, 8-1/4 x 13, 8-1/8 x 13-1/4
4holes:
A3, B4, A4, 8K *1, 16K *1
OUTLINE
Inch area 2holes:

11 x 17, 8-1/2 x 14, 8-1/2 x 11, 8-1/2 x 11S,
5-1/2 x 8-1/2, 5-1/2 x 8-1/2S, 7-1/4 x 10-1/2, 7-1/4 x 10-1/2S
3holes:
11 x 17, 8-1/2 x 11
Type of paper 64 to 90 g/m2 of the high-quality paper and the plain paper
• Special paper is not guaranteed. The punching of label
paper, tab paper, OHP paper, blueprint master and bind-
ing-holed paper are not allowed.
Z-folding mode Paper size A3, B4, 11 x 17, 8-1/2 x 14, 8K
• For B4 paper (including the mix of the paper), the com-
bination with the stapling mode is not available.
• Special paper is not supported. Label paper, tab paper,
transparency film, paper, holed paper, and low stiffness
paper are not supported in Z-folding mode.
Folding mode Paper size 8-1/2 x 14
• Special paper is not supported. Label paper, tab paper,
transparency film, paper, holed paper, and low stiffness
paper are not supported in folding mode.
Paper curling
a 5 sheets of paper immediately after the printing
A07TT1C006AA
a : Excluding the OHP paper : Amount of curl: 15 mm or less

OHP paper : Amount of curl: 10 mm or less
*1: Only for the Taiwan market
4
D. Maintenance
Maintenance Same as the main body.
ZU-606
Machine service life Same as the main body.
Power requirements 100 to 240 VAC (automatic switching)

DC5 V (supplied from the main body)
Max. power 120 W or less
consumption
OUTLINE
Dimensions 169 mm (W) x 660 mm (D) x 1027.5 mm (H)
Weight 45 kg (99.21 lb)
Temperature 10 to 30 °C
Humidity 15 to 85 % RH (with no condensation)
NOTE
5
2. SECTION CONFIGURATION Theory of Operation Ver. 1.0 Jul. 2009
ZU-606
Z-folding section Conveyance section
Punch section
OUTLINE
Punch scraps conveyance section
Finisher ZU-606 Main body
A07TT1C009AA
6
3. PAPER PATH
A. Straight mode/punch mode (for the small size paper : A5, 5-1/2 x 8-1/2)
ZU-606
OUTLINE
A07TT1C005AA
B. Punch mode (excluding the small size paper)
A07TT1C007AA
7
C. Z-folding mode/punch + Z-folding mode

ZU-606
From the main body to the 1st folding

OUTLINE
A07TT1C013AA
From the 1st folding to the 2nd folding
From the 2nd folding to the paper exit
8
Theory of Operation Ver. 1.0 Jul. 2009 4. CONVEYANCE SECTION
4. CONVEYANCE SECTION
ZU-606
4.1 Configuration
Conveyance sensor (PS601)
Gate solenoid/Up (SD602) Conveyance encoder sensor (PS610)
Gate solenoid/Lw (SD601)
CONFIGURATION/
OPERATION
A07TT2C001AA
Exit sensor (PS609)
9
4. CONVEYANCE SECTION Theory of Operation Ver. 1.0 Jul. 2009
4.2 Drive
A. Conveyance drive
ZU-606
Main motor (M606)
2nd folding roller
Gate/Up
1st folding roller
Gate/Lw
Conveyance roller
CONFIGURATION/
OPERATION
Exit roller
A07TT2C002AA
Registration motor (M601) Registration roller
10
B. Gate drive
ZU-606
Gate solenoid/Up (SD602)
Gate/Up
CONFIGURATION/
OPERATION
A07TT2C003AA
Gate/Lw
11
4.3 Operation
4.3.1 Conveyance path switching
ZU-606
• The gates/Lw and /Up switch the conveyance path.

• The gate solenoid/Lw and the gate solenoid/Up drive the gate/Lw and the gate/Up
respectively.
A. Gate/Lw
• The gate/Lw switches the paper path between the straight conveyance path and the
upper conveyance path.
• The gate/Lw is set to the straight conveyance path when the gate solenoid/Lw turns OFF.
• The gate/Lw is set to the upper conveyance path when gate solenoid/Lw turns ON.
<Gate solenoid/Lw : OFF> <Gate solenoid/Lw : ON>

CONFIGURATION/
OPERATION
A07TT2C004AA
Gate/Lw
Straight conveyance path Upper conveyance path
12
B. Gate/Up
• The gate/Up switches the paper path of the paper that was conveyed to the upper con-
veyance path by the gate/Lw.
ZU-606
• The gate/Up is set to the paper path to the exit side when the gate solenoid/Up turns
OFF.
• The gate/Up is set to the paper path to the 1st folding stopper when gate solenoid/Up
turns ON.
<Gate solenoid/Up : OFF> <Gate solenoid/Up : ON>
Gate solenoid/Up (SD602) 1st folding stopper

Gate/Up
CONFIGURATION/
OPERATION
A07TT2C006AA
Conveyance path to the exit side Conveyance path to the 1st folding stopper
C. Operation timing
(1) Z-folding mode
1. In the Z-folding mode for the all paper size, the gate solenoid/Lw and the gate sole-
noid/Up turn ON when the paper size detect board detects the leading edge of the
paper.
2. The gate/Lw is set to the upper conveyance path and the gate/Up is set to the con-
veyance path to the 1st folding stopper.
3. The gate solenoid/Lw and the gate solenoid/Up turn OFF a specified period of time
after the last paper turns OFF the exit sensor.
Leading edge of the paper detected Gate solenoid/Lw and gate

by the paper size detect board solenoid/Up turned OFF
Paper size detect board (PSDTB)
Exit sensor (PS609)
Gate solenoid/Up (SD602)

A07TT2E035AA
13
(2) Punch mode for the small size paper (A5, 5-1/2 x 8-1/2)
• Gate solenoids/Lw and gate solenoids/Up always remain OFF, and never turn ON.
• The gate/Lw remains being set to the straight conveyance path.
ZU-606
(3) Punch mode for the large size paper (other than the small size paper)
• The gate solenoid/Lw turns ON when the paper size detect board detects the leading
edge of the paper, and then the gate/Lw is set to the upper conveyance path. The gate
solenoid/Up remains OFF and the gate/Up remains being set to the paper path to the exit
side.
• The gate solenoid/Lw turns OFF a specified period of time after the last paper turns OFF
the exit sensor.
(4) Straight exit mode

• Gate solenoid/Lw and gate solenoid/Up always remain OFF, and never turn ON.
• The gate/Lw remains being set to the straight conveyance path.
4.3.2 Conveyance line speed switching

• The main motor drives the conveyance drive roller, the 1st folding roller, and the 2nd fold-
ing roller, which perform the folding operation, as well as the conveyance roller and the
CONFIGURATION/
exit roller.
OPERATION
• The paper size detect board, the conveyance sensor, and the exit sensor detect the
paper.
Conveyance drive roller
1st folding roller

2nd folding roller

Conveyance roller
Paper size detect board

Exit roller
(PSDTB)
Exit sensor (PS609)
A07TT2C007AA
Registration roller
14
A. Operation timing
(1) Z-folding
1. Transmitting the paper pass signal from the horizontal transfer, the main motor
ZU-606
turns ON and rotates in high speed.
2. The main motor rotates in low speed and perform the 1st and 2nd folding opera-
tions a specified period of time after the paper size detect board detects the leading
edge of the paper.
3. The main motor rotates in high speed to perform the paper exit operation of the 1st
paper and to convey the 2nd paper in sync with the paper exit speed of the main
body when the conveyance sensor detects the leading edge of the paper and turns
ON after the 2nd folding operation.
4. The main motor turns OFF when the exit sensor detects the trailing edge of the last
paper.
Paper pass signal from

the horizontal transfer 1st paper 2nd paper 3rd (last) paper
CONFIGURATION/
OPERATION
Exit sensor (PS609)
High speed
Main motor (M606)
Low speed
Main motor driven in low speed Paper exit operation
1st and 2nd folding operations Main motor driven in high speed
Main motor turned OFF when the trailing
edge of the last paper is detected
A109T2C001DA
15
(2) Punch + Z-folding

1. Transmitting the paper pass signal from the horizontal transfer, the main motor
turns ON and rotates in high speed.
ZU-606
2. The main motor rotates in low speed and perform the 1st folding operation a speci-
fied period of time after the paper size detect board detects the leading edge of the
paper.
3. The main motor turns OFF for the punching operation a specified period of time
after paper size detect board detects the trailing edge of the paper.
4. After the punching operation, the main motor turns ON and perform the 2nd folding
operation.
5. The main motor rotates in high speed to perform the paper exit operation of the 1st
paper and to convey the 2nd paper in sync with the paper exit speed of the main
body when the conveyance sensor detects the leading edge of the paper and turns
ON after the 2nd folding operation.
6. The main motor turns OFF when the exit sensor detects the trailing edge of the last
paper.
Paper pass signal from

CONFIGURATION/
the horizontal transfer 1st paper 2nd paper 3rd (last) paper
OPERATION
Exit sensor (PS609)
High speed
Main motor (M606)
Low speed
Main motor driven in low speed Paper exit operation

Main motor stopped for the punching operation Main motor driven in high speed
2nd folding operation Main motor turned OFF when the trailing
edge of the last paper is detected
A109T2C002DA
16

• The registration control corrects paper skew in the Z-folding mode and the punch mode.
ZU-606
• The paper exited from the main body is pressed against the stopped registration roller
and forms a loop to correct skew of the paper, and then the paper is conveyed with its
leading edge nipped.
• The registration motor drives the registration roller.
Leading edge of the paper
Loop
Registration roller
CONFIGURATION/
OPERATION
A07TT2C009AA
A. Operation timing
(1) Punch + Z-folding
1. Transmitting the paper pass signal from the horizontal transfer, the registration
motor turns ON.
2. The registration motor stops a specified period of time after the paper size detect
board detects the leading edge of the paper conveyed from the main body.
3. The paper is pressed against the registration roller and forms a loop to correct
paper skew.
4. The registration motor turns ON and the conveyance is restarted a specified period
of time after the paper contacts with the registration roller.
5. The registration motor turns OFF a specified period of time after the paper is
exited.
• No registration control is conducted in the straight mode.
Paper pass signal from the horizontal transfer
Registration motor High speed

(M601)
Low speed
Registration motor stopped Conveyance restarted
A loop formed
A109T2C003DA
17
5. PUNCH SECTION Theory of Operation Ver. 1.0 Jul. 2009
5. PUNCH SECTION
5.1 Configuration
ZU-606
Punch home sensor (PS606)
A07TT2C014AA
Punch switchover switch (MS601) Paper size detect board (PSDTB)
5.2 Drive
CONFIGURATION/
OPERATION
<Top side view> <Rear side view>

Cam holder Eccentric cam
Punch motor (M604)
Cam cover
Punch switchover motor (M608)

Punch clutch (CL601)
Punch switchover cam
Eccentric cam (Metric type: 4 piece)

(Inch type : 5 piece)
Cam cover Punch motor (M604)
Punch edges Rack

Front direction
Belt
Punch switchover motor (M608) Punch shift motor (M605)

Punch switchover cam A07TT2C013AA
<Right side view>
18
Theory of Operation Ver. 1.0 Jul. 2009 5. PUNCH SECTION
5.3 Operation
• The punch operation is conducted for every paper.
ZU-606
• The controls related to the punch operation is the punch control, the punch position
movement control, and the punch hole switching control.
5.3.1 Punch control

• The punch operation is conducted by transmitting the rotation of the punch motor to the
eccentric cam by the punch clutch and reciprocating the punch edges connected to the
cam holder once.
• The punch motor drives the eccentric cam and performs the punch operation when
punch clutch turns ON.
• The punch motor rotates clockwise from the view of the rear.
• The punch motor keeps rotating during the punch operation.
• The punch home sensor detects the home position of the punch edges.
Punch clutch (CL601) Eccentric cam
CONFIGURATION/
OPERATION
Punch motor (M604)
Cam holder
Front direction
Punch home sensor (PS606)
Upper position
Cam holder Lower position
Eccentric cam
Punch edges
Paper
<Home position> <Punching position>
A07TT2C015AA
19
A. Operation timing
• The registration motor and the main motor turn OFF to stop the conveyance during the
punch operation.
ZU-606
1. The punch motor turns ON when the paper size detect board detects the leading
edge of the paper.
2. The punch clutch turns ON and performs the punch operation a specified period of
time after the paper size detect board detects the trailing edge of the paper.
3. The punch clutch turns OFF after a specified period of time.
4. The punch motor turns OFF a specified period of time after the punch clutch turns
OFF.
5. After the punch operation, the registration motor and the main motor turn ON to exit
the paper.
Punch motor (M604)

CONFIGURATION/
OPERATION
Leading edge of the paper detected Punch clutch turned ON Punch clutch turned OFF
A109T2C004DA
20
5.3.2 Punch position movement control

• The punch shift motor moves the punch unit to move the punch hole position in the main
ZU-606
scan direction.
• The registration motor controls the punch position in the sub scan direction by its stop
position.
• 5 sensors of the paper size detect board detects the punch hole position.
• The front side sensor among 5 sensors detects the leading/trailing/side edge of the
paper and the other 4 sensors detect the side edge of the paper. The different sensor is
used depending on the paper size.
• The punch shift home sensor detects the home position.
Side edge sensors
CONFIGURATION/
OPERATION
Leading/trailing/side edge sensor Belt
Punch unit
Front direction Punch shift home sensor (PS605)
Punch shift motor (M605)

A07TT2C017AA
21
A. Standby position movement of the punch unit

• In the punch mode, the punch unit is set to the standby position in accordance with the
paper size before the paper is conveyed.
ZU-606
• The punch shift motor moves the punch unit so that the sensor corresponding to the
paper size among 5 sensors of the paper size detect board (in case of A4 paper, the sen-
sor is used) is positioned 5 mm inward from the side edge of the paper.
• This operation is not conducted in the no punch mode.
Standby position Ex. : The sensor used at A4 paper
Side edge of the paper

5 mm
Punch blade
CONFIGURATION/
OPERATION
Paper conveyance direction

Punch unit
Punch shift motor (M605)
Paper
A07TT2C018AA
22
B. Punch position correction

• The punch unit positioned 5 mm inward from the side edge of the paper conducts the
punch position correction operation by moving the punch unit back and forth while con-
ZU-606
veying the paper to correct the misalignment between the conveyed paper and the punch
position.
1. Move the punch unit backward until the certain side edge sensor (in case of A4
paper) detects the side edge of the paper.
2. Then, move the punch unit forward until the side edge sensor detects the side edge
of the paper (the side edge reference position detection).
3. Move the punch unit forward further so that the center of the punch edges is posi-
tioned to the center of the paper.
Standby position Side edge of the paper

Punch unit
Punch edges Center of the punch Ex. : The sensor used at A4 paper
CONFIGURATION/
OPERATION
Moves backward
Moves forward
Paper
Paper conveyance direction

Center of the paper
A07TT2C019AA
23
5.3.3 Punch hole switching control

1. Transmitting the paper pass signal from the horizontal transfer, the punch switcho-
ZU-606
ver motor switches the number of holes in the punch mode.

2. The punch switchover motor rotates the punch switchover cam clockwise and
moves the eccentric cams and back and forth via the cam cover.
3. When switching between the 2 holes punching and the 4 holes punching in Metric
Type, 2 eccentric cams in the middle remain being held in the cam holders because
they are shared in both cases.
4. When the cam cover moves forward, the eccentric cams at the outside for the 4
holes punching are held in the cam holder so that the total of 4 eccentric cams are
driven.
5. When the cam cover move backward, 2 outside eccentric cams are disengaged.
6. For the switchover between the 2 holes punching and the 3 holes punching in Inch
Type, the 2 holes eccentric cams and the 3 holes eccentric cams work exclusively.
7. When the cam cover moves forward, the 3 holes eccentric cams are held in the
cam holder and the 2 holes eccentric cams are disengaged.
8. This operation is not conducted if the number of holes is same with the previous
printing.
CONFIGURATION/
OPERATION
<Upper side view>

Eccentric cam (4 holes) Eccentric cam (2 holes/4 holes)
Cam cover Cam holder
Moves backward
Moves forward
Punch switchover motor (M608)
Front side direction Punch switchover switch (MS601)
<Right side view> Eccentric cam (4 holes)

Eccentric cam (2 holes/4 holes)
Front side direction
Punch switchover motor (M608) A07TT2E034AA

Punch switchover cam
Punch switchover switch (MS601)
24
Theory of Operation Ver. 1.0 Jul. 2009 6. PUNCH SCRAPS CONVEYANCE SECTION
6. PUNCH SCRAPS CONVEYANCE SECTION

6.1 Configuration
ZU-606
Punch scraps conveyance motor (M607)
CONFIGURATION/
OPERATION
Punch scraps full sensor
(PS608)
Punch scraps box set sensor (PS607)
A07TT2C001DA
25
6. PUNCH SCRAPS CONVEYANCE SECTION Theory of Operation Ver. 1.0 Jul. 2009
6.2 Drive
ZU-606
Punch scraps conveyance screw gear

CONFIGURATION/
A07TT2C021AA
OPERATION
Punch scraps conveyance motor (M607)
26
Theory of Operation Ver. 1.0 Jul. 2009 6. PUNCH SCRAPS CONVEYANCE SECTION
6.3 Operation
6.3.1 Punch scraps conveyance control
ZU-606
• The punch scraps are conveyed by the punch scraps conveyance screw driven by the
punch scraps conveyance motor.
• They are conveyed to the punch scraps box via the punch scraps collective duct.
• The punch scraps conveyance motor turns ON to rotate the punch scraps conveyance
screw a specified period of time after the paper edge sensor detects the trailing edge of
the paper in the punch mode.
• The punch scraps are sent to the forward by the rotation of the screw and collected in the
punch scraps box via the punch scraps collective duct.
Punch scraps conveyance screw Punch scraps conveyance motor (M607)
CONFIGURATION/
OPERATION
Punch scraps collective duct
Punch scraps box
A07TT2C022AA
27
6. PUNCH SCRAPS CONVEYANCE SECTION Theory of Operation Ver. 1.0 Jul. 2009
6.3.2 Punch scraps control

• The punch scraps box set sensor and the punch scraps full sensor monitor the punch
ZU-606
scraps box.
Punch scraps full sensor (PS608)
Punch scraps box

CONFIGURATION/
OPERATION
A07TT2C023AA
Punch scraps box set sensor (PS607)
A. Punch scraps full detection

• The punch scraps full sensor detects whether the punch scraps box is full or not.
• The punch scraps full sensor turns ON and transmits the punch scraps full signal to the
main body when the punch scraps box becomes full of punch scraps, and then the main
body displays the message on its operation panel.
B. Punch scraps box detection

• The punch scraps box set sensor detects whether the punch scraps box is housed or
not.
• The punch scraps box set sensor turns ON and transmits the “no punch scraps box” sig-
nal to the main body when the punch scraps box is not set, and then the main body dis-
plays the message on its operation panel.
28
Theory of Operation Ver. 1.0 Jul. 2009 7. Z-FOLDING SECTION
7. Z-FOLDING SECTION
7.1 Configuration
ZU-606
1st folding stopper home sensor (PS603)
CONFIGURATION/
OPERATION
Exit sensor (PS609)
A07TT2C024AA
2nd folding stopper home sensor (PS604)
29
7. Z-FOLDING SECTION Theory of Operation Ver. 1.0 Jul. 2009
7.2 Drive
ZU-606
<1st folding stopper drive>

1st folding stopper

CONFIGURATION/
OPERATION
1st folding stopper motor (M602)

A07TT2C025AA
<2nd folding stopper drive>

2nd folding stopper motor (M603)
A07TT2C026AA
2nd folding stopper
30
7.3 Operation
7.3.1 1st folding control
ZU-606
1. The registration roller, the conveyance roller, and the 1st folding roller convey the
paper to the 1st folding stopper section via the gate/Up.
2. A loop is formed between the 1st folding roller and the conveyance drive roller
when the leading edge of the paper is pressed against the 1st folding stopper.
3. The loop grows, and then it is caught by these rollers and the 1st folding is con-
ducted.
4. The paper is then conveyed to the 2nd folding stopper section.
5. The position of the 1st folding depends on the position of the 1st folding stopper.
6. The 1st folding stopper motor sets the position in accordance with the number of
steps from the 1st folding stopper home sensor.
7. In the Z-folding mode with the punch mode, the registration motor and the main
motor stops to conduct the punch operation after the 1st folding operation, and then
the registration motor and the main motor turns ON to conduct the 2nd folding
operation.
CONFIGURATION/
OPERATION
1st folding stopper Gate/Up

1st folding
2nd folding
Loop direction
Front side
1st folding roller
Conveyance roller
Registration roller
A07TT2C027AA
31
A. Operation timing
1. The 1st folding stopper motor turns ON to drive the 1st folding stopper to the appro-
priate position in accordance with the paper size a specified period of time after
ZU-606
transmitting the paper pass signal from the horizontal transfer.

2. Transmitting the termination signal from the main body, the 1st folding stopper
motor replaces the 1st folding stopper to the home position.
Termination signal
1st folding stopper home sensor

(PS603)
1st folding stopper motor (M602)
Exit sensor (PS609)
Paper pass signal from the horizontal transfer 1st folding stopper returning to the home position
1st folding stopper moving to the paper size
A109T2C005DA
CONFIGURATION/
OPERATION
32
7.3.2 2nd folding control

1. The paper conveyed from the 1st folding section to the 2nd folding section is
ZU-606
stopped by the 2nd folding stopper and forms a loop between conveyance drive
roller and the 2nd folding roller.
2. The loop grows, and then it is caught by these rollers and the 2nd folding is con-
ducted.
3. The 2nd folding stopper motor turns ON to move the 2nd folding stopper to the
evacuation position for the paper conveyance when the leading edge of the paper
(2nd folding) conveyed to the paper exit direction passes the conveyance sensor.
4. The 2nd folding is not conducted for 8.5 x 14 paper.

Paper exit direction
Paper exit direction
Loop
CONFIGURATION/
OPERATION
2nd folding roller

Front side
2nd folding
2nd folding stopper home sensor
(PS604)
1st folding roller
2nd folding stopper
*Folding position
A07TT2C029AA
2nd folding stopper

Exit sensor (PS609) *Home position
33
A. Operation timing
1. The 2nd folding stopper motor turns ON to drive the 2nd folding stopper to the
appropriate position in accordance with the paper size when the paper size detect
ZU-606
board detects the leading edge of the paper.

2. The 2nd folding stopper motor rotates in the reverse direction to move the 2nd fold-
ing stopper to the home position when the conveyance sensor detects the leading
edge of the paper after the 2nd folding. It opens the paper exit path.
3. The 2nd folding stopper motor turns ON to replace the stopper to the original posi-
tion for the subsequent Z-folding when the exit sensor detects the trailing edge of
the paper.
2nd folding stopper motor (M603)
Exit sensor (PS609)

CONFIGURATION/
OPERATION
Paper pass signal from the horizontal transfer Moving to the home position
Moving to the 2nd folding position Moving to the 2nd folding position
for the subsequent paper
A109T2C006DA
34
2009.01
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
FS-526
FS-526
OUTLINE
2. PAPER FEED PATH ................................................................................................ 4
2.1 Main tray ............................................................................................................... 4
OUTLINE
2.2 Sub tray ................................................................................................................ 5
2.3 Stapling................................................................................................................. 6
3. CONFIGURATION .................................................................................................. 7
CONFIGURATION/
4. HORIZONTAL TRANSPORT SECTION ................................................................. 8
OPERATION
4.1 Configuration ........................................................................................................ 8
4.2 Horizontal transport mechanism........................................................................... 9
4.2.1 Paper transport ............................................................................................. 9
4.2.2 Fan motor.................................................................................................... 10
5. TRANSPORT SECTION ....................................................................................... 11
5.1 Drive ................................................................................................................... 11
5.2 Operation ............................................................................................................ 12
5.2.1 Route change gate...................................................................................... 12
5.2.2 Bypass gate ................................................................................................ 13
6. EXIT TRAY SECTION ........................................................................................... 15
6.1 Drive ................................................................................................................... 15
6.2 Operation ............................................................................................................ 16
6.2.1 Tray lift......................................................................................................... 16
6.2.2 Exit roller motor ........................................................................................... 17
6.2.3 Main tray transport ...................................................................................... 18
6.2.4 Sub tray exit ................................................................................................ 19
7. ALIGNMENT SECTION ........................................................................................ 20
7.1 Drive ................................................................................................................... 20
7.2 Operation ............................................................................................................ 21
7.2.1 Alignment plate ........................................................................................... 21
7.2.2 Shift control ................................................................................................. 22
7.2.3 Alignment section transport mechanism ..................................................... 24
i
8. STAPLER .............................................................................................................. 25
8.1 Drive ................................................................................................................... 25
FS-526
8.2 Operation............................................................................................................ 26
8.2.1 Stapler movement....................................................................................... 26
8.2.2 Stapler control............................................................................................. 27
OUTLINE
CONFIGURATION/
OPERATION
ii
Theory of Operation Ver. 1.0 Jan. 2009 1. PRODUCT SPECIFICATIONS
OUTLINE
FS-526
A. Type
Name Flat-stapling finisher: 100 sheets staple

Type Staple finisher attached to the side of the main body
Including horizontal transport unit (Built-in finisher that is mounted from the left of
Installation
the main body)
Document
Center
OUTLINE
alignment
Consumables Staples
B. Functions
Modes Non-sort, sort, offset, group offset, sort staple
C. Stapling
64 to 80 g/m2: 100 sheets or 94 sheets + 2 sheets (209 g/m2) *2

Max. flat-stapling
81 to 90 g/m2: 30 sheets or 28 sheets + 2 sheets (209 g/m2) *1
capacity
91 g/m2 or more: 2 sheets of thick paper or more not guaranteed
100 sheets B5 to A4S, 8 1/2 x 11S (Paper length: 150 to 300 mm)
Max. stapling 70 sheets B5 recycled paper 1-sided mode
capacity for differ- 65 sheets B4S/8 1/2 x 14S (Paper length: 389 mm or less)
ent paper sizes
Paper sizes other than the above (Paper length: 150 mm or less,
50 sheets
390 mm or more) *1, *2
Stapling position Back of the corner (0 to 45 degrees)
Front of the corner (0 to 45 degrees)
Center staple two points (Staple interval is fixed to 145 mm.)
Stapling method Bypass flat clinch
*1: The stapling capacity for colored paper and enamel paper is 35 sheets (recommended
paper).
*2: And the stapling thickness is 10 mm or less and the stack thickness including curl is 25
mm or less.
1
1. PRODUCT SPECIFICATIONS Theory of Operation Ver. 1.0 Jan. 2009
D. Max. paper capacity
3,000 sheets :A4/A4S, B5/B5S, 8 1/2 x 11/

FS-526
8 1/2 x 11S, 16K/16KS,

7 1/4 x 10 1/2 /7 1/4 x 10 1/2 S
1,500 sheets :A3, B4, 8 x 13, 8 1/4 x 13,
8 1/2 x 13, 8 1/2 x 13 1/4,
8 1/2 x 13 1/2, 12 x 8, 11 x 17,
8 1/2 x 14, 8K
Wide size paper (Max. : 320 mm X 450 mm)
Main tray Non-sort, sort, offset, 500 sheets :A5/A5S, B6S, A6S, 5 1/2 x 8 1/2 /
(80 g/m2) group offset, 5 1/2 x 8 1/2 S
OUTLINE
Size in the sub The others

No. of sheets in scan direction is
offset mode 150 to 417 mm
or longer
Set of 2 to 9
100 copies 50 copies
sheets
Set of 10 sheets 50 copies 50 copies
No. of sheets Size in the sub The others
per stapling scan direction is
150 to 417 mm
or longer
2 to 9 100 copies 100 copies
Main tray sort staple
51 to 60 15 copies -
61 to 100 10 copies -
Sub tray (80 g/m2) 100 sheets
E. Type of paper
Size A3, B4, A4/A4S, B5/B5S, A5/A5S, B6S, A6S, postcardS, 5 1/2 x 8 1/2, 5 1/2 x 8 1/2 S,
8 x 13, 8 1/4 x 13, 8 1/2 x 13, 8 1/8 x 13 1/4, 11 x 17, 8 1/2 x 14, 8 1/2 x 11, /8 1/2 x 11S,
7 1/4 x 10 1/2, 7 1/4 x 10 1/2 S, 8K, 16K/16KS
Custom size paper, wide size paper, standard size index paper (Upon paper exit,
only the leading edge side but not the trailing edge side is guaranteed.)
Min. : 100 mm x 139 mm (4 inch x 5.5 inch)
Max. : 311 mm x 488 mm (12.2 inch x 19.2 inch)
Type Plain paper, bond paper, colored paper, coated paper, speciality paper defined in
the main body specifications, and recommended paper are guaranteed.
Weight 60 to 300 g/m2
2
Theory of Operation Ver. 1.0 Jan. 2009 1. PRODUCT SPECIFICATIONS
F. Machine specifications
Power DC 24 V (supplied from the main body)
FS-526
requirements DC 5 V (supplied from the main body)
Max. power
85 W or less
consumption
723.8 (W) x 709.5 (D) x 1025 (H) mm
28.45 (W) x 27.88 (D) x 40.28 (H) inch
Dimensions
848.8 (W) x 709.5 (D) x 1025 (H) mm *
33.35 (W) x 27.88 (D) x 40.28 (H) inch *
OUTLINE
*: Size when the paper output tray is pulled out
G. Operating environment
3
2. PAPER FEED PATH Theory of Operation Ver. 1.0 Jan. 2009
2. PAPER FEED PATH

2.1 Main tray
FS-526
Paper output roller Alignment plate Bypass gate

OUTLINE
Main tray
Paper path from the horizontal

transport unit
A11PT1C001DA
4
Theory of Operation Ver. 1.0 Jan. 2009 2. PAPER FEED PATH
2.2 Sub tray
FS-526
Sub tray Sub tray change gate Bypass gate
OUTLINE
transport unit
A11PT1C002DA
5
2. PAPER FEED PATH Theory of Operation Ver. 1.0 Jan. 2009
2.3 Stapling
FS-526
Paper output roller Sub tray change gate Bypass gate

OUTLINE
Main tray

Stapler transport unit
Alignment
section
A11PT1C003DA
6
3. CONFIGURATION
FS-526
• The following sections are combined in a single unit: the horizontal transport section,
transport section, alignment section, exit tray section (main tray), and stapler section.
Alignment section Transport section Horizontal transport section
CONFIGURATION/
OPERATION
Exit tray section
(Main tray)
Stapler section
A11PT2C001DA
7
4. HORIZONTAL TRANSPORT SECTION Theory of Operation Ver. 1.0 Jan. 2009
4. HORIZONTAL TRANSPORT SECTION

4.1 Configuration
FS-526
• The horizontal transport section is composed of the transport control board, transport
motor, fan motor, door open/close sensor, and paper pass sensor.
Door open/close sensor (PS201)

Transport control board (TRCB)
Fan motor/2 (FM2)
Fan motor/1 (FM1)

CONFIGURATION/
OPERATION
Paper pass sensor (PS202)
A11PT2C002DA
8
Theory of Operation Ver. 1.0 Jan. 2009 4. HORIZONTAL TRANSPORT SECTION
4.2 Horizontal transport mechanism

4.2.1 Paper transport
FS-526
• The horizontal transport section transfers paper fed out from the main body to the fin-
isher.
• The transport motor provides drive for the transport rollers.
• On the finisher side, drive from the transport motor transfers the paper into the finisher.
Horizontal transport section
Finisher side Main body side
CONFIGURATION/
OPERATION
Transport roller
Transport roller
A11PT2C003DA
9
4. HORIZONTAL TRANSPORT SECTION Theory of Operation Ver. 1.0 Jan. 2009
4.2.2 Fan motor

• The fan motor cools the paper fed out from the main body.
FS-526
Fan motor/2 (FM2)
Fan motor/1 (FM1)

CONFIGURATION/
OPERATION
A11PT2C002DA
(1) Function
Motor name Function

Fan motor/1 (FM1) • In order to avoid toner attachment while the finisher is used, outside air is
Fan motor/2 (FM2) applied to the paper to cool it.
(2) Fan control

• The interior temperature of the main body is 18 °C or more dur-
Fan motor/1 (FM1) ing paper exit.
Full speed
Fan motor/2 (FM2) • Continues rotating for a 30-sec. period following the stop of a
print cycle.
10
Theory of Operation Ver. 1.0 Jan. 2009 5. TRANSPORT SECTION
5. TRANSPORT SECTION
5.1 Drive
FS-526
Sub tray exit roller/2 Bypass roller Bypass gate
Transport motor/2 (M2) Transport motor/1 (M1)
Sub tray exit roller/1

Stacker entrance
motor (M10)
Sub tray gate
solenoid (SD3) Z-fold punch
regist sensor
(PS2)
Bypass transport motor (M3) PF transport
CONFIGURATION/
roller
OPERATION
Bypass gate solenoid (SD2)
Saddle gate Entrance roller
Switch back solenoid (SD4)
Route change gate solenoid (SD1) Transport roller/1
A11PT2C005DA
11
5. TRANSPORT SECTION Theory of Operation Ver. 1.0 Jan. 2009
5.2 Operation
5.2.1 Route change gate
FS-526
• The route change gate switches paper to different routes that go to individual trays and
SD-508.
• The FS control board controls the route change gate solenoid.
• The FS operation signal from the main body makes the route change gate move up or
down.
A. Route change gate operation

• The route change gate solenoid drives the route change gate.
CONFIGURATION/
OPERATION
Route change gate
Route change gate solenoid (SD1)
A11PT2C006DA
12
Theory of Operation Ver. 1.0 Jan. 2009 5. TRANSPORT SECTION
5.2.2 Bypass gate

• The bypass route is provided to eliminate loss of time spent for the subsequent paper
FS-526
and to increase productivity during stapling.
• The bypass gate is provided at the place where the regular route and the bypass route
join.
A. Bypass gate operation

• The bypass gate solenoid drives the bypass gate.
• Paper sizes subject to this operation are 8 1/2 x 11, A4, 16K, Executive, and ISO-B5.
The bypass gate operates only for the 1st page of the 2nd and following copies to trans-
fer paper to the bypass route.
• The 2nd page of the 2nd and following copies is transferred to the regular route and then
the transferred to the alignment section.
CONFIGURATION/
Regular route
OPERATION
Bypass gate Bypass gate
Bypass route
Bypass gate solenoid (SD2) Bypass gate solenoid (SD2)

A11PT2C007DA
13
5. TRANSPORT SECTION Theory of Operation Ver. 1.0 Jan. 2009
B. Bypass gate control

• The bypass gate only operates for the paper (8 1/2 x 11, A4, 16K, Executive, B5, and ISO-
B5).
FS-526
• The FS control board controls the bypass gate solenoid.

• When stapling two sheets of paper for three copies, the bypass gate solenoid operates
as follows.
(1) For the 1st copy

• When the paper for the 1st copy is transferred, the bypass gate solenoid does not oper-
ate.
(2) For the 2nd copy

• At the moment when the z-fold punch regist sensor detects the leading edge of the 1st
paper of the 2nd copy, the bypass gate solenoid is turned ON to transfer the 1st paper of
the 2nd copy to the bypass route.
• The bypass gate solenoid turns OFF after a specified period of time since the z-fold
punch regist sensor detects the trailing edge of the 1st paper of the 2nd copy.
CONFIGURATION/
(3) For the 3rd and following copies

OPERATION
• The same operation as the one for the 2nd copy is repeated.
The 1st copy The 2nd copy The 3rd copy
Transport motor/1 (M1)
Z-fold punch regist sensor (PS2)
Bypass gate solenoid (SD2)
Transport motor/2 (M2)

Leading edge of Trailing edge of Trailing edge of
the 1st paper of the 1st paper of the 1st paper of
the 2nd copy the 2nd copy the 3rd copy
Transferring 1st paper of Leading edge of the 1st paper
the 2nd copy to the bypass of the 3rd copy A11PT2E004DA
14
Theory of Operation Ver. 1.0 Jan. 2009 6. EXIT TRAY SECTION
6. EXIT TRAY SECTION

6.1 Drive
FS-526
Main tray
Lift pulley /Up
CONFIGURATION/
Lift wire
OPERATION
Lift pulley /Lw
Main tray lift motor (M5)
A11PT2C009DA
15
6. EXIT TRAY SECTION Theory of Operation Ver. 1.0 Jan. 2009
6.2 Operation
6.2.1 Tray lift
FS-526
A. Tray lift operation

• The worm gear installed in the shaft of the main tray lift motor winds up the lift wire.
• It lifts up or down the main tray depending on the winding direction.
• Rotating the lift pulley /Lw clockwise and counterclockwise in view of front, the main tray
is lifted up and down respectively.
Main tray top surface sensor (PS4)
Main tray
Main tray empty

sensor (PS6)
CONFIGURATION/
OPERATION
Lift pulley /Up
Main tray lower limit

sensor (PS5)
Staple paper exit top surface

sensor (PS7)
Main tray lift motor (M5)

Lift pulley /Lw A11PT2C010DA
B. Paper detection
• The main tray top surface sensor and the staple paper exit top surface sensor keep the
specified distance between the upper surface of the paper exited to the main tray and the
paper exit opening to eliminate the misalignment of the exited paper.
• During the consecutive printing operation, FS counts the number of exited paper and
stops the printing when it reaches the maximum capacity.
• If the exited paper is ejected during the printing operation, the tray moves up and the
main tray empty sensor turns ON and resets the counter. It makes possible to exit paper
with no limitation.
• The main tray lower limit sensor detects the lower limit of the tray.
• During the intermittent printing operation, the main tray lower limit sensor controls the
capacity of the paper exit because the counter does not integrate the total number of
exited paper.
16
6.2.2 Exit roller motor

• The exit roller motor is driven by the signal from the FS control board.
FS-526
• The main tray exit roller is driven by the exit roller motor.
<Store paper into alignment section>

Paper
Exit roller motor (M4)
2 staples stacker
sensor (PS3)
Main tray exit roller
CONFIGURATION/
<Exit paper into main tray>
OPERATION

A11PT2C011DA
A. Exit roller motor operation

• When the 2 staples stacker sensor detects the leading edge of paper, the exit roller
motor rotates.
• After a specified period of time since the 2 staples stacker sensor detected the trailing
edge of paper, the exit roller motor rotates in the reverse direction.
• At the moment when the paper output roller motor is turned OFF, i.e. it finishes moving
down, the exit roller motor starts rotating at high speed. After a specified period of time,
the exit roller motor switches to low speed. After a specified period of time, the exit roller
motor stops.
17
6. EXIT TRAY SECTION Theory of Operation Ver. 1.0 Jan. 2009
6.2.3 Main tray transport

• After the process in the alignment section, the exit roller motor and paper output roller
FS-526
motor are driven to transfer paper to the main tray.
A. Transport operation
• When the paper output roller motor is driven, the paper output roller assy moves down to
be pressed against the main tray exit roller and the paper output roller rotates.
• After paper is transferred to the main tray, the paper output roller assy moves up.
Paper output roller motor (M6)

CONFIGURATION/
OPERATION
Exit roller motor (M4) Paper output roller

A11PT2C022DA
18
6.2.4 Sub tray exit

• The sub tray change gate is provided to transfer paper conveyed from the horizontal
FS-526
transport section to the sub tray.
• The sub tray change gate transfers the paper to the sub tray by moving up and down.
• The sub tray gate solenoid drives the sub tray change gate.
Sub tray Sub tray exit roller/2
Bypass transport
motor (M3)
Sub tray exit

roller/1 Transport motor/2
(M2)
CONFIGURATION/
OPERATION
Sub tray full
sensor (PS9)
Sub tray exit sensor

(PS8)
Sub tray change gate Sub tray gate solenoid (SD3)

A11PT2C026DA
A. Sub tray exit roller/1 drive

• The sub tray exit roller/1 is driven by the bypass transport motor.
B. Sub tray exit roller/2 drive

• The sub tray exit roller/2 is driven by the transport motor/2.
• The transport motor/2 rotates in high speed when the sub tray exit sensor detects the
leading edge of the paper.
• The sub tray exit roller/2 rotates in low speed after a specified period of time since the
FNS pass sensor detects the trailing edge of the paper.
• The transport motor/2 stops after a specified period of time since the sub tray exit sensor
detects the trailing edge of the paper.
C. Sub tray full detection

• When the exited paper on the sub tray reached to a specified thickness, the sub tray full
sensor turns ON and the sub tray full information is sent to the main body. Then, the main
body displays the message on its display panel.
19
7. ALIGNMENT SECTION Theory of Operation Ver. 1.0 Jan. 2009
7. ALIGNMENT SECTION
7.1 Drive
FS-526
Alignment plate/F
Trail edge stopper
Alignment plate/R Alignment plate belt/F
Alignment plate motor/F (M11)

CONFIGURATION/
OPERATION
Alignment plate motor/R (M12)

Alignment plate belt/R
2 staples trail edge stopper motor (M19)

A11PT2C015DA
20
Theory of Operation Ver. 1.0 Jan. 2009 7. ALIGNMENT SECTION
7.2 Operation
7.2.1 Alignment plate
FS-526
• After sheets of paper are aligned and stapled inside the finisher, they are transferred to
the main tray. With the exit roller separated, each copy set is stored in the alignment sec-
tion at a time.
• The alignment plate motor/F and /R rotate in the forward/reverse direction to open/close
the alignment plate/F and /R to perform the alignment of the paper transferred to the
alignment section.
Alignment plate/F
2 staples alignment motor
CONFIGURATION/
home sensor/F (PS17)
Alignment plate/R
OPERATION
2 staples alignment motor home sensor/R (PS18) A11PT2C016DA
A. Alignment plate operation

• The alignment plate motor/F rotates to open/close the alignment plate/F via the align-
ment plate belt/F.
• The 2 staples alignment motor home sensor/F detects the home position of the align-
ment plate/F.
• The alignment plate motor/R rotates to open/close the alignment plate/R via the align-
ment plate belt/R.
• The 2 staples alignment motor home sensor/R detects the home position of the align-
ment plate/R.
21
7.2.2 Shift control

• In normal print and staple mode, the paper is fed into the tray at its center position. If no
FS-526
stapling is involved in the sort or group copy mode, the alignment plate shifts 15 mm to
the front or rear from the center. This stacks copy sets/stacks in a saw tooth manner,
each being offset by about 30 mm with respect to the others.
Alignment <Normal/Staple> <Shift operation>

plate/R
30 mm
CONFIGURATION/
OPERATION
Alignment
plate/F
A11PT2C027DA
22
Theory of Operation Ver. 1.0 Jan. 2009 7. ALIGNMENT SECTION
A. Shift operation
• Under sort/group copy mode, after a specified period of time the 2 staples stacker sensor
detected the trailing edge of paper, the alignment plate motor/R and /F are turned ON to
FS-526
shift the alignment plate/R and /F.
• At the moment when the paper output roller motor is turned OFF, i.e. it finishes moving
down, the alignment motor/F is turned ON. After a specified period of time, the alignment
motor/R is turned ON to open the alignment plate/F and alignment plate/R.
• These operations are repeated for every paper to shift it.
To the main tray
Alignment plate/F Alignment plate/R
CONFIGURATION/
OPERATION
Alignment plate/F
To the main tray

Alignment plate/R
A11PT2C018DA
23
7.2.3 Alignment section transport mechanism

• When the paddle motor is driven, it makes the rewind paddle and paddle 1/2 rotate to
FS-526
transfer paper conveyed from the main body to the alignment section.
• The paper conveyed from the main body drops under its own weight and the paper is
transferred to the alignment section. However, as the paper conveyance performance is
incomplete, the rewind paddle motor is driven to push the rewind paddle downward and
transfer the paper to the alignment section.
Rewind paddle
Paddle motor (M16)
Paddle 2
CONFIGURATION/
OPERATION
Rewind paddle motor

(M18)
Paddle 2 Paddle 1
A11PT2C021DA
24
Theory of Operation Ver. 1.0 Jan. 2009 8. STAPLER
8. STAPLER
8.1 Drive
FS-526
Stapler position sensor/3 (PS52) Stapler position sensor/2 (PS51)
CONFIGURATION/
OPERATION
2 staples stapler movement motor (M13) Stapler drive rack
A11PT2C023DA
25
8. STAPLER Theory of Operation Ver. 1.0 Jan. 2009
8.2 Operation
8.2.1 Stapler movement
FS-526
A. Stapler movement operation

• The 2 staples stapler movement motor moves the stapler.
• The rotation of the 2 staples stapler movement motor makes the belt rotate the gear,
causing the stapler drive rack to operate with the stapler.
• The stapler position sensor/4 becomes the stapler’s home position. In 2 staples mode,
the stapler stops at the stapler position sensor/3 and stapler position sensor/2 to staple
sheets. In the one-corner stapling mode, the stapler stops at the stapler position sensor/
1 to staple sheets.

CONFIGURATION/
OPERATION
2 staples stapler movement motor (M13) Stapler drive rack

A11PT2C024DA
B. Stapler movement control

• With the FS start signal from the main body, the 2 staples stapler movement motor is
turned ON and the stapler moves to the standby position and stops.
26
Theory of Operation Ver. 1.0 Jan. 2009 8. STAPLER
8.2.2 Stapler control

• The stapling operation is performed by the 2 staples stapler motor.
FS-526
A. Stapling operation
• In the stapling operation, the 2 staples stapler motor drives the clincher side to press the
paper. Then, the staple is pushed out from the stapler side and bent at the clincher side.
Stapler (clincher side)
Paper
2 staples stapler
motor (M14)
CONFIGURATION/
OPERATION
Stapler (stapler side)
A11PT2C025DA
27
8. STAPLER Theory of Operation Ver. 1.0 Jan. 2009
B. Staple control
(1) Stapling
• After completing the alignment operation of the alignment plate, the 2 staples stapler
FS-526
motor performs the stapling operation.

• The stapling operation is completed when the stapler position sensor/4 in the stapler
detects the home position and turn ON.
(2) Clogged staple detection

• During the stapling operation, it is determined that the staple has been clogged and the 2
staples stapler motor turns OFF if the stapler position sensor/4 does not turn ON after a
specified period of time since they turn OFF.
(3) Cartridge detection

• The cartridge set switch detects the presence of a cartridge or the incorrect setting of a
cartridge.
• When no cartridge is set or it is set incorrectly, the main body displays the error message
on its display panel.
CONFIGURATION/
(4) Staple detection control

OPERATION
• When the staples run out, the staple empty switch turns ON and the main body displays
the error message on its display panel.
28
2009.07
Ver. 2.0
Revision history
Revision mark:
corresponding page.
NOTE
2009/07 2.0 1 Error corrections

CONTENTS
SD-508
SD-508
OUTLINE
2. PAPER FEED PATH ................................................................................................ 3
2.1 Folding/saddle stitching ........................................................................................ 3
OUTLINE
2.2 Tri-folding .............................................................................................................. 4
3. CONFIGURATION .................................................................................................. 5
4. ALIGNMENT SECTION .......................................................................................... 6
CONFIGURATION/
4.1 Drive ..................................................................................................................... 6
OPERATION
4.2 Operation .............................................................................................................. 7
4.2.1 Alignment ...................................................................................................... 7
4.2.2 Stopper ......................................................................................................... 9
5. STAPLER .............................................................................................................. 13
5.1 Drive ................................................................................................................... 13
5.2 Operation ............................................................................................................ 14
5.2.1 Stapler movement ....................................................................................... 14
5.2.2 Stapling ....................................................................................................... 16
6. FOLDING/SADDLE STITCHING/TRI-FOLDING .................................................. 18
6.1 Drive ................................................................................................................... 18
6.2 Operation ............................................................................................................ 19
6.2.1 Folding knife ................................................................................................ 19
6.2.2 Folding transfer ........................................................................................... 20
6.2.3 Tri-folding gate............................................................................................. 21
7. EXIT SECTION ..................................................................................................... 22
7.1 Drive ................................................................................................................... 22
7.2 Operation ............................................................................................................ 23
7.2.1 Exit .............................................................................................................. 23
i
SD-508
OUTLINE
CONFIGURATION/
OPERATION
Blank Page
ii
Theory of Operation Ver. 2.0 Jul. 2009 1. PRODUCT SPECIFICATION
OUTLINE
SD-508
A. Type
Name Saddle sticher SD-508

Type Built into the finisher
Installation Screwed to the finisher
Stapling function Center parallel two points
OUTLINE
B. Paper
(1) Saddle stitching
Type Plain paper, Thick paper 1, Thick paper 2

A3, B4, A4S, 12 x 18, 11 x 17, 8-1/2 x 14, 8-1/2 x 11S, 8KS
Size Min: 210 mm x 279 mm , 8-1/4 x 11
Max: 314 mm x 458 mm, 12-1/4 x 18
20 sheets (64 g/m2 to 80 g/m2 ,17 to 21.25 lb)
Max. saddle stitching capacity 16 sheets (81 g/m2 to 90 g/m2 ,21.5 to 24 lb)
19 sheets 80 g/m2 ,21.25 lb) + 1 sheet (209 g/m2 , 55.5 lb)
(2) Folding
Type Plain paper

A3, B4, A4S, 12 x 18, 11 x 17, 8-1/2 x 14, 8-1/2 x 11S, 8KS
Size Min: 210 mm x 279 mm , 8-1/4 x 11
Max: 314 mm x 458 mm, 12-1/4 x 18
1 Max. number of sheets folded together 3 sheets (64 g/m2 to 90 g/m2 ,17 to 24 lb)
(3) Tri-folding
Type Plain paper

Size A4S, 8-1/2 x 11S, 16KS
1 Max. number of sheets folded together 3 sheets (64 g/m2 to 90 g/m2 ,17 to 24 lb) *
1 *: It is not guaranteed when folding together more than 2 sheets.
DC 24 V (supplied from the finisher)

Power requirements
DC 5 V
Max. power consumption 40 W or less
281.3 mm (W) x 596.4 mm (D) x 529.8 mm (H)
Dimensions
Approx. 22.6 kg + 3.8 kg (Exit tray)
Weight
Approx. 49.75 lb + 8.5 lb (Exit tray)
1 1
1. PRODUCT SPECIFICATION Theory of Operation Ver. 2.0 Jul. 2009
SD-508
E. Consumables
• Staples 5000 (MS-5C)
NOTE
OUTLINE
2
Theory of Operation Ver. 2.0 Jul. 2009 2. PAPER FEED PATH
2. PAPER FEED PATH

2.1 Folding/saddle stitching
SD-508
OUTLINE
A11RT1C001DA
3
2. PAPER FEED PATH Theory of Operation Ver. 2.0 Jul. 2009
2.2 Tri-folding
SD-508
OUTLINE
A11RT1C002DA
4
3. CONFIGURATION
SD-508
Alignment section
Stapler
Exit section
CONFIGURATION/
OPERATION
A11RT2C001DA
5
4. ALIGNMENT SECTION Theory of Operation Ver. 2.0 Jul. 2009
4.1 Drive
SD-508
Alignment plate/R Alignment plate/F
Center staple alignment Center staple alignment

Leading edge motor/R (M21) motor/F (M20)
stopper
Leading edge stopper motor (M22)
CONFIGURATION/
Leading edge stopper

OPERATION
A11RT2C002DA
6
Theory of Operation Ver. 2.0 Jul. 2009 4. ALIGNMENT SECTION
4.2 Operation
4.2.1 Alignment
SD-508
• In the folding/saddle stitching/tri-folding mode, the center staple alignment motor/F and
/R aligns paper.
• The center staple alignment motor rotates in the forward/reverse direction to move the
alignment plates and align paper.
• The leading edge stopper motor rotates in the forward/reverse direction to make the
leading edge stopper oscillate and align paper in the sub scanning direction.
Alignment plate/F
Alignment plate/R
Center staple alignment

motor home sensor/F
(PS30)
CONFIGURATION/
OPERATION
motor home sensor/R Center staple alignment motor/F (M20)
(PS31)
Center staple alignment motor/R (M21)

A11RT2C003DA
A. Alignment operation
• The center staple alignment motor/F and /R rotate to open/close the alignment plates via
the alignment belts.
• The center staple alignment motor home sensor/F and /R detect the home position of the
alignment plates.
• The leading edge stopper motor rotates to make the leading edge stopper oscillate via
the belt.
7
B. Alignment control
• Transmitting the FNS signal from the main body, the center staple alignment motor/F and
/R rotate to close the alignment plates, and then they stop the alignment plates at the
SD-508
standby position that is a little wider than the paper width.

• The center staple alignment motor/F and /R perform the alignment operation by rotating
in the forward and reverse direction to move the alignment plate back and forth after a
specified period of time since the center staple pass sensor detects the trailing edge of
the paper.
• The leading edge stopper motor rotates in the forward/reverse direction to make the
leading edge stopper oscillate and align paper in the sub scanning direction. (This is
made from the 11th sheet of paper.)
• The alignment operation is performed for every paper.
Center staple pass sensor

(PS12)
motor/R (M21)
Center staple alignment motor
home sensor/R (PS31)
CONFIGURATION/
motor/F (M20)
OPERATION
Center staple alignment motor

Leading edge stopper home
sensor (M22)
Closing the alignment Standby position of Alignment operation for

plate (FNS signal) the alignment plate every paper
A11RT2E019DA
8
4.2.2 Stopper
• At the leading edge stopper, papers in sub scanning direction are aligned, and papers
SD-508
conveyed to the aligning section are conveyed to the specified position.
• The exit grip holds the paper when shifting it to the specified position and when stapling
papers.
• The stopping position in vertical direction of paper conveyed to the alignment section is
different among the folding mode, the saddle stitching mode, and the tri-folding mode.
A. Stopper operation
• The leading edge stopper motor moves the leading edge stopper up and down in accor-
dance with the paper size. The leading edge stopper home sensor detects the home
position.
CONFIGURATION/
OPERATION
Leading edge stopper home sensor (PS32)
Exit grip
Exit grip
Exit grip solenoid (SD6)

A11RT2C005DA
9
B. Stopper control
(1) Folding mode
• After a specified period of time since the last sheet of paper was aligned, the exit grip
SD-508
solenoid is turned ON and the sheets of paper are held in place.

• After the sheets are held in place, the leading edge stopper motor rotates to move the
leading edge stopper down and lower the sheets to the folding position.
• After a specified period of time since the center fold knife home sensor was turned ON,
the transport motor is turned ON and it starts rotating at low speed. At the moment when
the transport motor is accelerated to high speed, the leading edge stopper motor starts
rotating to move the leading edge stopper up to the alignment position in accordance
with the paper size and stand by for the paper of the subsequent copy.

motor/R (M21)
motor/F (M20)
Leading edge stopper motor
CONFIGURATION/
(M22)
OPERATION
Center fold knife motor (M32)

Center fold knife home sensor
(PS34)
Transport motor High speed

(M33)
Low speed
Last paper of the copy aligned Moving to the folding Moving to stand by for the
position for the paper paper of the subsequent copy
size
A11RT2E020DA
10
(2) Saddle stitching mode

SD-508
leading edge stopper down and lower the sheets to the saddle stitching position.
• After a specified period of time since stapling operation was completed, the center staple
alignment motor/F and /R opens the alignment plates and the leading edge stopper
motor starts rotating to move the leading edge stopper further down and lower the paper
to the folding position.
• After a specified period of time since the center fold knife home sensor was turned ON,
the transport motor is turned ON and it starts rotating at low speed. At the moment when
the transport motor is accelerated to high speed, the leading edge stopper motor starts
rotating to move the leading edge stopper up to the alignment position in accordance
with the paper size and stand by for the paper of the subsequent copy.
Moving to stand by for the

Last paper of the copy aligned paper of the subsequent copy
Center staple alignment motor/R
CONFIGURATION/
(M21)
Center staple alignment motor/F
OPERATION
(M20)
(M22)
Center staple motor (M23)
Staple motor (M24)

(PS34)
High speed
Transport motor
(M33) Low speed
Moving to the saddle stitching Stapling operation Moving to the folding

position for the paper size position for the paper size
A11RT2E021DA
11
(3) Tri-folding mode

SD-508
leading edge stopper down and lower the sheets to the 1st folding position in the tri-fold-
ing.
• At the moment when the center fold knife home sensor is turned ON, the transport motor
is turned ON to start rotating at low speed. At the moment when the transport motor is
accelerated to middle speed, the leading edge stopper motor starts rotating to move the
leading edge stopper up to the alignment position in accordance with the paper size and
stand by for the paper of the subsequent copy.
Last paper of the copy aligned

(M21)
(M20)
CONFIGURATION/

OPERATION
(M22)
Tri-folding change solenoid
(SD5)
(PS34)
High speed
Transport motor
(M33) Middle speed
Low speed
Moving to the 1st folding Moving to the alignment position

position for the paper size for the subsequent copy
A11RT2E022DA
12
Theory of Operation Ver. 2.0 Jul. 2009 5. STAPLER
5. STAPLER
5.1 Drive
SD-508
Stapler Center staple motor (M23)
Clincher
Timing belt
CONFIGURATION/
OPERATION
Stapler home sensor (PS33)
A11RT2C009DA
13
5. STAPLER Theory of Operation Ver. 2.0 Jul. 2009
5.2 Operation
SD-508

• The center staple motor moves the stapler.
• The stapler and the clincher are mounted at the timing belt.
• The stapler home sensor detects the distance between the stapler and the clincher.
Staple motor (M24) Center staple motor (M23)
Stapler
Clincher
Timing belt
CONFIGURATION/
OPERATION
Stapler home sensor (PS33)

A11RT2C009DA
14
B. Stapler movement control

• At the moment when the center staple alignment motor /F is turned OFF, the center sta-
ple motor starts rotating to move the stapler to the front side.
SD-508
• After a specified period of time since the staple motor was turned OFF, the center staple
motor starts rotating and moves the stapler to the rear side.
• After a specified period of time since the center fold knife motor was turned OFF, the cen-
ter staple motor starts rotating to move the stapler to the paper passage center position.

(M21)
(M20)
Center staple motor (M23)
Staple motor (M24)
Moving to the stapling position Moving to the paper passage

(front size) for the paper size center position for the paper size
CONFIGURATION/
OPERATION
Moving to the stapling position (rear size) for the paper size A11RT2E023DA
15
5.2.2 Stapling
• The stapling operation is performed by the stapler motor and the clincher motor.
SD-508
• In the stapling operation, the stapler motor in the stapler pushes out the paper press sec-
tion to the clincher by the cam mechanism to hold the paper and punch out the staple.
Then, the clincher motor in the stapler bends the staple.
Stapler Paper
Cam
mechanism
Clincher
Paper press
section
CONFIGURATION/
OPERATION
Staple
Staple
A11RT2C012DA
16
B. Staple control
(1) Stapling
• After completing the alignment operation of the alignment plate, the staple motor per-
SD-508
forms the stapling operation.
• After a specified period of time, the clincher motor bends the staple.
• The stapling operation is completed when the stapler home sensor detects the home
position and turn ON.

• During the stapling operation, it is determined that the staple has been clogged and the
center staple motor rotates in the reverse direction to replace the stapler to the home
position if the stapler home sensor does not turn ON after a specified period of time
since it turn OFF.
(3) Cartridge detection

• The cartridge set switch detects the presence of a cartridge or the incorrect setting of a
cartridge.
• When no cartridge is set or it is set incorrectly, the main body displays the error message
CONFIGURATION/
on its display panel.
OPERATION
(4) Staple detection control
• When the staples run out, the staple empty switch turns ON and the main body displays
the error message on its display panel.
17
6. FOLDING/SADDLE STITCHING/TRI-FOLDING Theory of Operation Ver. 2.0 Jul. 2009
6. FOLDING/SADDLE STITCHING/TRI-FOLDING
6.1 Drive
SD-508
Tri-folding change solenoid (SD5)
Tri-folding gate
Folding roller
Folding knife
CONFIGURATION/
OPERATION
Tri-folding roller
A11RT2C013DA
18
Theory of Operation Ver. 2.0 Jul. 2009 6. FOLDING/SADDLE STITCHING/TRI-FOLDING
6.2 Operation
6.2.1 Folding knife
SD-508
• The center fold knife motor drives the folding knife.
• The folding knife is used in the folding/saddle stitching/tri-folding mode.
• In the tri-folding mode, it is used at the 1st folding.
A. Folding knife operation

• The center fold knife motor rotates the crank shaft a half turn via the gear and pushes the
paper to the nip section with the folding knife.
• The folding rollers draw and fold the paper.
• The position of the leading edge stopper controls the folding position.
Fold knife
Folding roller
CONFIGURATION/
OPERATION
Center fold knife
home sensor (PS34)
Paper
A11RT2C014DA
B. Folding knife control

• The center fold knife motor turns ON and sticks out the folding knife to the paper after a
specified period of time since the leading edge stopper stops at the folding position.
• The center fold knife motor stops when the folding knife reciprocates and the center fold
knife home sensor turns OFF.
19
6. FOLDING/SADDLE STITCHING/TRI-FOLDING Theory of Operation Ver. 2.0 Jul. 2009
6.2.2 Folding transfer

• The transport motor drives the folding roller.
SD-508
• Then, the folding roller drives the tri-folding roller.
A. Folding transfer control

• The center fold knife motor turns ON after a specified period of time since the leading
edge stopper stops at the folding position.
• When the center fold knife motor turns ON the center fold knife home sensor, the trans-
port motor turns ON and drives the folding roller to perform the 1st folding and the tri-fold-
ing roller to perform the 2nd folding at the tri-folding operation, and then it exits the paper
to the exit tray.
• The transport motor stops after a specified period of time since the fold sensor detects
the trailing edge of the paper bundle.
Paper pressed to the folding roller by the folding knife

(M22)
CONFIGURATION/

OPERATION
(PS34)
Transport motor High speed

(M33)
Low speed
Fold sensor (PS27)
Leading edge stopper moved Paper fold

A11RT2E024DA
20
Theory of Operation Ver. 2.0 Jul. 2009 6. FOLDING/SADDLE STITCHING/TRI-FOLDING
6.2.3 Tri-folding gate

• The tri-folding gate switches between the folding/saddle stitching path and the tri-folding
SD-508
path.
• The tri-folding change solenoid drives the tri-folding gate.
A. Tri-folding 2nd folding operation

• The tri-folding change solenoid drives the tri-folding gate to switch the paper path to the
tri-folding path for leading the paper exited from the folding roller to the tri-folding stopper.
• To perform the 2nd folding, the loop formed when the paper contacts with the tri-folding
stopper are drawn between the folding roller and the tri-folding roller. Then the paper is
exited to the exit tray.
• The position of the tri-folding stopper determines the folding position in the 2nd folding.
Tri-folding stopper Tri-folding change solenoid (SD5)

Fold sensor (PS27)
Folding roller
CONFIGURATION/
OPERATION
Tri-folding
roller
Loop
Tri-folding roller
Exit tray
A11RT2C016DA
B. Tri-folding gate control

• After the leading edge stopper stops at the tri-folding position, the tri-folding change sole-
noid turns ON and drives the tri-folding gate to switch the paper path to the tri-folding
stopper.
• The tri-folding change solenoid turns OFF after a specified period of time since the fold
sensor detects the trailing edge of the paper bundle.
21
7. EXIT SECTION Theory of Operation Ver. 2.0 Jul. 2009
7. EXIT SECTION
7.1 Drive
SD-508
Lift up switch (SW3)

Belt
SD exit sensor/PR (PS29)

CONFIGURATION/
SD exit full sensor

OPERATION
(PS35) SD exit upper limit sensor (PS41)
Exit motor (M34)

SD exit sensor/LED (PS28)
A11RT2C017DA
22
Theory of Operation Ver. 2.0 Jul. 2009 7. EXIT SECTION
7.2 Operation
7.2.1 Exit
SD-508
• Turn ON the exit motor to drive the belt and convey papers by each copy set.
• Press the lift up switch of ahead of the exit tray to covey papers to ahead of the exit tray
randomly.
A. Exit drive
• The exit motor rotates the belt and conveys exited papers.
B. Exit control
• After a specified period of time since the SD exit sensor/LED and /PR was turned ON,
the exit motor starts rotating to turn the belt.
• After a specified period of time since the SD exit full sensor was turned OFF, the exit
motor stops.
C. Exit tray full detection

• The SD exit upper limit sensor and the SD exit full sensor detect the exit tray paper full.
CONFIGURATION/
• It determines the exit tray is full if the exited paper shields the SD exit upper limit sensor
OPERATION
and the SD exit full sensor for the specified period of time.
Paper
Belt
SD exit upper limit sensor (PS41)
SD exit full sensor (PS35)
A11RT2C018DA
23
SD-508
CONFIGURATION/
OPERATION
Blank Page
24
2009.07
Ver. 2.0
Revision history
Revision mark:
corresponding page.
NOTE
2009/07 2.0 1 Change of a control method, Error corrections

CONTENTS
PK-516
PK-516
OUTLINE
2. UNIT CONFIGURATION ......................................................................................... 2
3. PAPER PATH........................................................................................................... 3
OUTLINE
4. PUNCH SECTION .................................................................................................. 5
4.1 Configuration ........................................................................................................ 5
4.2 Drive ..................................................................................................................... 6
CONFIGURATION/
4.2.1 Punch shift drive ........................................................................................... 6
OPERATION
4.2.2 Punch drive ................................................................................................... 7
4.3 Operation .............................................................................................................. 9
4.3.1 Punch standby position movement control ................................................... 9
4.3.2 Punch position correction control ................................................................ 10
4.3.3 Punch control .............................................................................................. 11
5. PUNCH SCRAPS BOX SECTION ........................................................................ 15
5.1 Configuration ...................................................................................................... 15
5.2 Drive ................................................................................................................... 15
5.3 Operation ............................................................................................................ 15
5.3.1 Punch scraps box control............................................................................ 15
i
PK-516
OUTLINE
CONFIGURATION/
OPERATION
Blank Page
ii
Theory of Operation Ver. 2.0 Jul. 2009 1. PRODUCT SPECIFICATION
OUTLINE
PK-516
A. Type
Name Punch unit

Type FS-integrated type punching operation device
B. Functions
Punching method Stops and punches every paper
OUTLINE
No. of holes 2-3 holes / 2-4 holes / 4 holes
2 holes / φ 8.0 mm / 70 mm pitch - 3 holes / φ 6.5 mm / 108 mm pitch
Hole diameter/pitch 2 holes / φ 6.5 mm / 80 mm pitch - 4 holes / φ 6.5 mm / 80 mm pitch
4 holes / φ 6.5 mm / 70 mm, 21 mm pitch
Supported mode Punch mode, through mode
Applicable post processing
Sort, group, staple
mode
C. Paper type
2 hole/Sweden 4 hole punch setting:

A3, B4, A4/A4S, B5/B5S, A5/A5S,
8 x 13, 8 x 13S, 8-1/4 x 13, 8-1/2 x 13, 8-1/8 x 13-1/4, 11 x 17, 8-1/2 x 14,
8-1/2 x 11/8-1/2 x 11S, 5-1/2 x 8-1/2, 5-1/2 x 8-1/2S, 8K, 16K/16KS
Size 7-1/4 x 10-1/2, 7-1/4 x 10-1/2S, 8-2/3 x 13S, 8-1/2 x 13S, 8-1/4 x 13S,
8-1/8 x 13-1/4S, 8-1/2 x 13-1/2S
3 hole/4 hole punch setting:

A3, B4, A4, B5
11 x 17, 8 1/2 x 11, 7 1/4 x 10 1/2, 8K, 16K
Plain paper, bond paper, colored paper, coated paper
Supported paper
(Main unit specifications prioritized)
1 Weight 64 to 300 g/m2
Label paper, tab paper, transparency film, 2nd base paper, holed paper,
Punch prohibited paper and the other paper that may interfere with the operation of the punch unit
or the punch blade
D. Machine specifications
DC 24 V (supplied from the main body)

Power requirements
DC 5 V (supplied from the main body)
Max. power consumption 40 W or less
161 mm (W) x 650 mm (D) x 234 mm (H)
Dimensions
E. Operating environment
NOTE
1 1
2. UNIT CONFIGURATION Theory of Operation Ver. 2.0 Jul. 2009
2. UNIT CONFIGURATION
PK-516
Punch section
OUTLINE
Punch scraps box section
A11TT2C001DA
2
3. PAPER PATH
PK-516
Punch unit
OUTLINE
Paper path from
the main body
Punch scraps box
A11TT2C002DA
3
PK-516
OUTLINE
Blank Page
4
4. PUNCH SECTION
PK-516
4.1 Configuration
Punch unit
Punch blade
Entrance roller
CONFIGURATION/
OPERATION
Punch blade
Punch unit
Front
A11TT2E011DA
NOTE
• North America, Europe and Sweden are same configuration except for a number of
blades.
5
4.2 Drive
4.2.1 Punch shift drive
PK-516
Punch oscillating motor (M302)
Guide shaft Belt
Punch blade
Rack
Front
Punch unit
CONFIGURATION/
OPERATION
A11TT2E012DA
6
4.2.2 Punch drive

A. North America (2 to 3 holes)
PK-516
Punch drive motor (M301)
Punch blades for Punch blades for

the 3-hole punch the 2-hole punch
CONFIGURATION/
OPERATION
Slot
Front
Punch drive plate
A11TT2E013DA
B. Europe (2 to 4 holes)
Punch blades for Punch blades for the

the 4-hole punch 2 and 4-hole punch
Slot
Front
Punch drive plate
A11TT2E014DA
7
C. PK-516 for Sweden (4 holes)

PK-516
Punch blades for the 4-hole punch

CONFIGURATION/
Slot
OPERATION
Front
Punch drive plate
A11TT2E015DA
8
4.3 Operation
4.3.1 Punch standby position movement control
PK-516
Turning ON the device, the punch oscillating motor rotates to move the punch unit to the
home position until the PK punch oscillating home sensor turns ON.
After selecting a punch mode, one of five sensors corresponded to each paper size detects
a paper and the punch unit is shifted.
The punch unit returns to the home position at the end of the job.
<Example: A4 size>
Punch blade
Side edge reference position Punch unit
CONFIGURATION/
OPERATION
Paper transfer direction
Paper
A11TT2E016DA
NOTE
• The paper size detect board is positioned on the front side and its operation is
contrary to that in the above illustration on the right and left sides.
9
4.3.2 Punch position correction control

For the punch unit positioned from the side edge of the paper to the inside, the punch posi-
PK-516
tion is adjusted in the following procedure so that punching is made to the center of paper
at all times. The punch position correction is operated by moving the punch unit back and
forth while conveying the paper.
• When the FNS pass sensor detects the leading edge of the paper, the punch unit is
moved to the front side until the paper size detect board detects the side edge of the
paper.
Then, the punch unit is moved to the rear side until the paper size detect board detects
the side edge of the paper (the side edge reference position detection).
• Once it detects the side edge reference position, the punch unit is moved further so that
the center of the punch blade is positioned to the center of the paper. The moving dis-
tance and its direction are depending on the paper size.
<Example: A4 size> Center of the punch blade

Punch blades
Side edge reference position
Punch unit
CONFIGURATION/
OPERATION
Front side Rear side

Punch unit moving direction
Paper
transfer
direction
Center of the paper Paper

A11TT2E017DA
NOTE
• The paper size detect board is positioned on the front side and its operation is
contrary to that in the above illustration on the right and left sides.
10
4.3.3 Punch control

A. Registration loop control
PK-516
The transport motor/1 turns OFF temporarily to stop conveyance of paper when the speci-
fied time has passed since paper exit sensor detected the leading edge of the paper. Thus
the paper is pressed against the entrance roller forming a loop to correct the bend. When
the specified time has passed, the transport motor/1 turns ON to restart conveying the
paper.
The above operation is not performed when conveying a large paper and in the non-punch-
ing mode.
Entrance roller Entrance roller
Loop
CONFIGURATION/
OPERATION
PK
A11TT2C008DA
11
B. Punch control
Transmitting the start signal from the main body, the transport motor/1 rotates.
In the punch mode, the transport motor/1 stops temporarily a specified period of time after
PK-516
the FNS pass sensor detects the trailing edge of the paper.
At the same time, the punch drive motor is driven to move the punch drive plate horizon-
tally. The punch drive plate has slots to shift punch blades up and down. Punch blades
moving downward conduct the punch operation. The punch drive motor stops and the
punch operation is completed when the PK punch home sensor turns ON.
The transport motor/1 rotates again to convey the paper a specified period of time after it
stops temporarily.
North America (2 to 3 holes)
Punch driver motor (M301)

Punch blade
Punch unit
CONFIGURATION/
OPERATION
PK punch home Slot Punch drive plate

sensor (PS301)
Front
A11TT2E018DA
12
Europe (2 to 4 holes)
PK-516
Punch blade
Punch unit

sensor (PS301)
CONFIGURATION/
OPERATION
Front
A11TT2E019DA
13
Sweden (4 holes)
PK-516

Punch blades
Punch unit

sensor (PS301)
CONFIGURATION/
OPERATION
Front
A11TT2E020DA
14
Theory of Operation Ver. 2.0 Jul. 2009 5. PUNCH SCRAPS BOX SECTION
5. PUNCH SCRAPS BOX SECTION

5.1 Configuration
PK-516
PK punch scraps box
full sensor (PS302)
CONFIGURATION/
OPERATION
Punch scraps box
Front
PK punch scraps box
set sensor (PS304)
A11TT2E021DA
5.2 Drive
• The punch scraps box section comprises no moving parts.
5.3 Operation
5.3.1 Punch scraps box control
A. Punch scraps box full detection
The punch scraps generated by the punch operation falls in the punch scraps box. The PK
punch scraps box full sensor turns ON and transmits the “no punch scraps box” information
to the main body when the punch scraps box becomes full of punch scraps.
B. Punch scraps box detection

The PK punch scraps box set sensor detects whether the punch scraps box is set or not.
The PK punch scraps box set sensor turns OFF and transmits the “no punch scraps box”
information to the main body if the punch scraps box is not set.
15
5. PUNCH SCRAPS BOX SECTION Theory of Operation Ver. 2.0 Jul. 2009
PK-516
CONFIGURATION/
OPERATION
Blank Page
16
2009.07
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
JS-602
JS-602
OUTLINE
OUTLINE
2. CONFIGURATION .................................................................................................. 3
3. CENTER CROSS SECTION................................................................................... 4
4. MECHANICAL OPERATION ................................................................................... 5
4.1 Job tray paper transport mechanism .................................................................... 5
CONFIGURATION/
OPERATION
i
JS-602
OUTLINE
CONFIGURATION/
OPERATION
Blank Page
ii
OUTLINE
JS-602
A. Type
Name Job separator

Type Add-on finishing device externally mounted on top of finisher
Installation Fixed to finisher
OUTLINE
B. Functions
Modes Group, Sort (during copy, print, or fax mode)
C. Paper type
Type Size Weight Tray capacity

100 sheets:
A5S to A3 A4, 8-1/2 × 11 (80 g/m2, 21.25 lb)
60 to 90 g/m2
Plain paper 5-1/2 × 8-1/2S to 50 sheets:
16 to 24 lb
11 × 17 except A4, 8-1/2 × 11 (80 g/m2, 21.25 lb)
(Height: up to 28 mm, 1.1 inch)
Power requirements DC 5 V, DC 24 V (supplied from finisher)

341 mm (W) × 537 mm (D) × 149 mm (H)
Dimensions
13.43 inch (W) × 21.14 inch (D) × 5.87 inch (H)
Conforms to the operating environment of the main body.
NOTE
1
JS-602
OUTLINE
Blank Page
2
2. CONFIGURATION
JS-602
Job tray Job separator cover
CONFIGURATION/
OPERATION
A01CT2C001DA
3
3. CENTER CROSS SECTION Theory of Operation Ver. 1.0 Jul. 2009
3. CENTER CROSS SECTION

JS-602
Job separator exit roll Job separator transport roller

Job separator exit roller Job separator transport roll
CONFIGURATION/
OPERATION
A01CT2C002DA
4
Theory of Operation Ver. 1.0 Jul. 2009 4. MECHANICAL OPERATION
4. MECHANICAL OPERATION
4.1 Job tray paper transport mechanism
JS-602
• The job separator transport roller and job separator exit roller turn to transport the paper
into the job tray as the motor is energized.
• The 3rd entrance switching solenoid is energized to select the paper path into the job
tray.
Job separator exit roller
Job separator transport roller
Paper
CONFIGURATION/
OPERATION
Bypass transport motor
(M3-FN)
SD404
3rd entrance switching solenoid

(SD404)
5
4. MECHANICAL OPERATION Theory of Operation Ver. 1.0 Jul. 2009
JS-602
CONFIGURATION/
OPERATION
Blank Page
6
2009.07
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
PI-505
PI-505
OUTLINE
2. PAPER FEED PATH ................................................................................................ 2
2.1 Auto sheet feeding (online operation) ................................................................... 2
OUTLINE
2.2 Manual sheet feeding (offline operation) .............................................................. 2
3. CONFIGURATION .................................................................................................. 3
4. PAPER FEED SECTION ......................................................................................... 4
CONFIGURATION/
4.1 Drive ..................................................................................................................... 4
OPERATION
4.1.1 Paper feed drive ............................................................................................ 4
4.1.2 Tray lift drive .................................................................................................. 5
4.2 Operation .............................................................................................................. 6
4.2.1 Tray lift mechanism ....................................................................................... 6
4.2.2 Pick-up mechanism....................................................................................... 7
4.2.3 Separation mechanism ................................................................................. 8
4.2.4 Registration control ....................................................................................... 9
4.2.5 Paper size detection control........................................................................ 10
i
PI-505
OUTLINE
CONFIGURATION/
OPERATION
Blank Page
ii
OUTLINE
PI-505
A. Type
Name Post inserter

Type Torque limiter separation type seat feeding device
B. Functions
OUTLINE
Auto sheet feeding Feeds the sheet to finisher automatically under the instruction from the main
(online operation) body.
Manual sheet feeding Feeds the sheet to finisher under the instruction from the operation panel of PI.
(offline operation) You can select the following 5 post processing modes:
• 1 staple/back mode
• 2 staples (flat-stapling) mode
• Punch mode (when PK-516 is installed on finisher)
• Saddle stitching mode (when SD-508 is installed on finisher)
• Tri-folding mode (when SD-508 is installed on finisher)
C. Paper type
Size Tray /Up A4/A4S, B5/B5S, A5

8 1/2 x 11, 8 1/2 x 11S, 5 1/2 x 8 1/2, 7 1/4 x 10 1/2S, 16K, 16KS
Custom paper (Max. 311.1 x 297 mm, Min. 182 x 139 mm)
Tray /Lw A3, B4, A4/A4S, B5/B5S, A5
8 x 13S, 8 1/4 x 13S, 8 1/2 x 13S, 8 1/8 x 13 1/4S, SRA4S, 12 x 18,
11 x 17, 8 1/2 x 14, 8 1/2 x 11, 8 1/2 x 11S, 5 1/2 x 8 1/2, 8K, 16K,
16KS, 7 1/4 x 10 1/2, 7 1/4 x 10 1/2S
Custom paper (Max. 311.1 x 457.2 mm, Min. 182 x 139 mm)
Plain paper, recycle paper, color paper, special paper, coated paper,
Type
high-quality paper
Weight 64 g/m2 to 209 g/m2
Capacity Tray /Up 200 sheets (80 g/m2) or 30 mm or less in height
Tray /Lw 200 sheets (80 g/m2) or 30 mm or less in height
Power requirements DC 24 V, DC 5 V (supplied from the main body)

Max. power
30 W or less
consumption
Dimensions 511 mm (W) x 635 mm (D) x 220 mm (H)
20.12 inch (W) x 25 inch (D) x 8.66 inch (H)
NOTE
1
2. PAPER FEED PATH

2.1 Auto sheet feeding (online operation)
PI-505
Paper path from the tray /Up

OUTLINE
Paper path from the tray /Lw

A10AT1C001DA
2.2 Manual sheet feeding (offline operation)
Paper path from the tray /Lw
A10AT1C002DA
2
3. CONFIGURATION
PI-505
Tray /Up section Pick-up /Up section
Separation /Up
section
Transfer
section
Tray /Lw section
CONFIGURATION/
OPERATION
Pick-up /Lw section
Separation /Lw section
A10AT2C001DA
3
4. PAPER FEED SECTION Theory of Operation Ver. 1.0 Jul. 2009
4. PAPER FEED SECTION

4.1 Drive
PI-505
4.1.1 Paper feed drive
Pick-up solenoid /Up (SD201)

Paper feed roller /Up
Pick-up roller /Up
Transfer clutch /Up (CL201)
Pick-up roller /Lw
Separation roller /Up

Transfer clutch
/Lw (CL202)
Transfer roller
/Up
Registration
CONFIGURATION/
clutch (CL203)
OPERATION
Transfer motor (M203) Paper feed roller

/Lw
Pick-up solenoid /Lw (SD202)
Transfer roller /Lw
Separation roller /Lw
Paper feed roller /Up and /Lw
Pick-up solenoid /Up, /Lw

(SD201, SD202)
Pick-up roller /Up and /Lw
Front
A10AT2C002DA
4
Theory of Operation Ver. 1.0 Jul. 2009 4. PAPER FEED SECTION
4.1.2 Tray lift drive
PI-505
Tray lift motor /Up (M201)
Front
Tray lift motor /Lw (M202)
A10AT2C003DA
CONFIGURATION/
OPERATION
5
4.2 Operation
4.2.1 Tray lift mechanism
PI-505
• The tray lift motors /Up and /Lw move up and down the trays /Up and /Lw by rotating in
the forward and reverse direction to drive the lift arms /Up and /Lw and move up and
down the lift plates /Up and /Lw, respectively.
• At the upper limit positions, the tray upper limit sensors /Up and /Lw detect the actuators
lifted up by the lift plates.
• At the lower position of the tray, the tray lower limit sensors /Up and /Lw detect the actua-
tors coupled with the lift arms /Up and /Lw.
Tray lower limit sensor /Up (PS205) Lift arm /Up

Tray lift plate /Up Tray upper limit sensor /Up (PS204)
Tray lift motor

CONFIGURATION/
/Up (M201)
OPERATION
Tray upper
limit sensor
/Lw (PS209)
Tray lift plate /Lw
Tray lower limit sensor /Lw (PS210) Lift arm /Lw

A10AT2C004DA
6
4.2.2 Pick-up mechanism

• The pick-up solenoids /Up and /Lw turn ON to pick up the paper.
PI-505
• The release arm held upward by the spring lifts up the pick-up roller mounting plate to
release the pick-up roller.
• When the pick-up solenoids /Up and /Lw turn ON, the release arm moves backward, and
then the pick-up roller mounting plate and the pick-up roller fall down by their own weight.
• The pick-up roller driven by the transfer motor presses the paper and picks it up to trans-
fer it to the separation section.
Pick-up roller mounting plate Release arm
Spring
CONFIGURATION/
OPERATION
Pick-up solenoid /Up (SD201)
Pick-up roller
A10AT2C005DA
7
4.2.3 Separation mechanism

• The separation roller is driven to rotate in the opposite direction from the paper transfer
PI-505
direction. When transferring no or 1 sheet of paper, the separation roller rotates in the
paper transfer direction to transfer the paper to the paper transfer section because the
frictional force between the paper feed roller or the paper and the separation roller is
stronger than the frictional force of the torque limiter.
• When transferring 2 or more sheets of paper, the separation roller rotates in the reverse
direction to prevent the bottom sheet from being transferred because the frictional force
between the sheets is stronger than the frictional force of the torque limiter.
Pick-up roller
Paper feed roller
1st sheet
Paper transfer
direction
2nd sheet
CONFIGURATION/
OPERATION
Torque limiter
Separation roller
A10AT2C006DA
8

• Transmitting the FS start signal, the transfer motor rotates in low speed and the pick-up
PI-505
solenoids /UP and /Lw turn ON. At the time, the tray lift motors /Up and /Lw rotate in the
forward direction to lift up the trays /Up and /Lw.
• The tray lift motors /Up and /Lw stop when the tray upper limit sensors /Up and /Lw turn
ON, and after a specified period of time, the transfer clutches /Up and /Lw turn ON and
the paper is picked up from the tray. Only 1 sheet of paper is transferred by the transfer
roller because of the separation roller.
• The transfer motor rotates in high speed when the paper reaches the paper entrance
sensors /Up and /Lw. At the time, the paper is pressed against the transfer roller and
forms a loop because the registration clutch is OFF. After a specified period of time, the
registration clutch turns ON and the transfer motor drives the paper to FS.
• The transfer motor switches to rotate in low speed to feed the subsequent paper since
the paper passed the paper entrance sensors /Up and /Lw, and then the registration
clutch turns OFF after a specified period of time.
Paper reached the paper entrance sensors /Up and /Lw
CONFIGURATION/
Transfer motor 253 mm/s
OPERATION
(M203)
670 mm/s
Transfer clutch /Lw (CL202)
Tray upper limit sensor /Lw (PS209)
Pick-up solenoid /Lw (SD202)
Paper entrance sensor /Lw (PS206)
Registration clutch (CL203)
FS start signal turned ON Tray reached at the upper limit
Registration clutch turned ON

Trailing edge of the paper passed the paper entrance sensors /Up and /Lw
A10AT2C007DA
9

• The paper size VRs /Up and /Lw coupled with the side guide detects the paper size in
PI-505
the main scan direction.

• The paper set sensors /Up and /Lw and the L size sensor /Lw detects the paper size in
the sub scan direction.
Paper size VR /Up (VR201)
L size sensor /Lw (PS212) Side guide plate
Paper set sensor /Up (PS203) Paper size VR /Lw (VR202)

Paper set sensor /Lw (PS208)
A10AT2C008DA
CONFIGURATION/
OPERATION
10
2009.07
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
FS-527
FS-527
OUTLINE
2. PAPER FEED PATH ................................................................................................ 4
2.1 Tray1 ..................................................................................................................... 4
OUTLINE
2.2 Tray2 ..................................................................................................................... 5
2.3 Stapling................................................................................................................. 6
3. CONFIGURATION .................................................................................................. 7
CONFIGURATION/
4. HORIZONTAL CONVEYANCE SECTION............................................................... 8
OPERATION
4.1 Configuration ........................................................................................................ 8
4.2 Horizontal conveyance mechanism ...................................................................... 9
4.2.1 Paper conveyance......................................................................................... 9
4.2.2 Conveyance path switching motor mechanism ........................................... 10
5. CONVEYANCE SECTION .................................................................................... 11
5.1 Configuration ...................................................................................................... 11
5.2 Drive ................................................................................................................... 12
5.3 Operation ............................................................................................................ 13
5.3.1 Upper lower path switching gate ................................................................. 13
5.3.2 Tray1 path switching gate............................................................................ 14
5.3.3 Conveyance operation ................................................................................ 15
6. EXIT TRAY SECTION ........................................................................................... 18
6.1 Drive ................................................................................................................... 18
6.2 Operation ............................................................................................................ 19
6.2.1 Tray lift......................................................................................................... 19
6.2.2 Exit to tray1 ................................................................................................. 20
6.2.3 Exit to tray2 ................................................................................................. 21
6.2.4 Tray2 shift control ........................................................................................ 23
7. ALIGNMENT SECTION ........................................................................................ 25
7.1 Drive ................................................................................................................... 25
7.2 Operation ............................................................................................................ 26
7.2.1 Alignment plate ........................................................................................... 26
7.2.2 Alignment section conveyance mechanism ................................................ 27
i
8. STAPLER .............................................................................................................. 28
8.1 Drive ................................................................................................................... 28
FS-527
8.2 Operation............................................................................................................ 29
8.2.1 Stapler movement....................................................................................... 29
8.2.2 Stapler control............................................................................................. 30
OUTLINE
CONFIGURATION/
OPERATION
ii
OUTLINE
FS-527
A. Type
Name Multi staple finisher

Type Freestanding
Document
Center
alignment
Consumables Staples
OUTLINE
B. Functions
Modes Sort, group, offset, group offset, sort staple
C. Paper type
(1) Non sort/sort/group
Type Size Weight Max. capacity

Exit
200 sheets
tray1
A6S, A5S/A5, B5S/B5, A4S, 8 /2 x 11S
1 3,000
Plain paper B6S, A4S/A4, B4, A3, or less sheets
64 to 90 g/m2
Recycled A3Wide
17 to 24 lb Exit B4, 8 1/2 x 14 1,500
paper 5 1/2 x 8 1/2S/5 1/2 x 8 1/2,
8 1/2 x 11S/8 1/2 x 11,
tray2 or greater sheets
8 1/2 x 14, 11 x 17, A5S, 5 1/2 x 8 1/2S 500
12 1/4 x 18 or less sheets
Envelope —
Tray1 (Sub tray)
OHP
Max. —
transparencies
311.15 mm x 1200 mm
Label 12.25 x 47.24 inch —
Letterhead Min. —
90 mm x 139.7 mm
91 to 120 g/m2
Thick paper 1 3.54 x 5.5 inch
24.25 to 31.9 lb
Tray2 (Main tray) 121 to 157 g/m2 20 sheets
Thick paper 1+ Max.
32 to 41.75 lb
311.15 mm x 457.2 mm
158 to 209 g/m2
Thick paper 2 12.25 x 18 inch
42 to 55.5 lb
Min.
100 mm x 139.7 mm 210 to 256 g/m2
Thick paper 3
3.94 x 5.5 inch 55.75 to 68 lb
257 to 300 g/m2
Thick paper 4
68.25 to 79.8 lb
Long size 210 mm to 297 mm x 127 to 160 g/m2
—
paper * 457.2 mm to 1200 mm 33.75 to 42.5 lb
*: Long size paper is available only for non-sort mode.
1
(2) Sort offset/group offset
Type Size Weight Max. capacity

FS-527
A5, B5S/B5, A4S/A4, B4, A4S, 8 1/2 x 11S 3,000

A3, A3Wide or less sheets *
Plain paper 8 1/2 x 11S/8 1/2 x 11,
64 to 90 g/m2 Exit B4, 8 1/2 x 14 1,500
Recycled 8 1/2 x 14, 11 x 17, 12 1/4 x 18
17 to 24 lb tray2 or greater sheets
paper Max.
311.15 mm x 457.2 mm 500
A5
12.25 x 18 inch sheets
Min.
91 to 271 g/m2
Thick paper 182 mm x 148.5 mm —
OUTLINE
24.25 to 72 lb
7.17 x 5.85 inch
*: 2,000 sheets when SD-509 is mounted
(3) Sort staple
Max. capacity Max.

No. of
No. of sheets A4S, B4,
Type Size Weight sheets
to be stapled 8-1/2 X 11S 8-1/2 X 14 to be
or less or greater stapled
2 to 9
100 copies 50 copies
sheets
10 to 20
A5, B5S/B5, A4S/A4, 50 copies 50 copies
sheets
Plain paper B4, A3
8 1/2 x 11S/8 1/2 x 11, 64 to 90 g/m 2
Exit 21 to 30 50
Recycled 30 copies 30 copies
8 1/2 x 14, 11 x 17 17 to 24 lb tray2 sheets sheets
paper
Max. 31 to 40
25 copies 25 copies
297 mm x 431.8 mm sheets
11.75 x 17 inch 41 to 50
Min. 20 copies 20 copies
sheets
182 mm x 148.5 mm
7.25 x 5.75 inch 30
—
Thick 91 to 209 g/m2 sheets
paper 24.25 to 55.5 lb 15
—
sheets
2
D. Stapling
Staple filling mode Dedicated staple cartridge (5000 staples)
FS-527
Back/Front of the corner A4, A3
(45 degree) 8 1/2 x 11, 11 x 17
Back/Front of the corner
B5, B4
(35 degree)
Stapling position
Back/Front of the corner A4S, B5S, A5
(Parallel) 8 1/2 x 11S, 8 1/2 x 14
A4S/A4, A3, B5S/B5, B4, A5
Side: Parallel 2 point
8 1/2 x 11S/8 1/2 x 11, 8 1/2 x 14, 11 x 17
OUTLINE
Manual staple None
Power
DC 24 V ± 10 % (supplied from the main body)
requirements
Max. power
56 W or less
consumption
528 (W) x 641 (D) x 1,025 (H) mm
20.79 (W) x 25.24 (D) x 40.35 (H) inch
Dimensions
658 (W) x 641 (D) x 1,087 (H) mm *
25.91 (W) x 25.24 (D) x 42.8 (H) inch *
*: Size when the paper output tray is pulled out
3
2. PAPER FEED PATH

2.1 Tray1
FS-527
Tray1
OUTLINE

conveyance unit
Tray1 exit roller

Tray1 path switching gate
A0HRT1C001DB
4
Theory of Operation Ver. 1.0 Jul. 2009 2. PAPER FEED PATH
2.2 Tray2
FS-527
Bypass route Upper lower path switching gate
OUTLINE
Tray2
conveyance unit
A0HRT1C002DB
5
2.3 Stapling
FS-527
Bypass route Upper lower path switching gate

OUTLINE
Tray2

conveyance unit
Tray2 exit roller
Alignment section
Stapler
A0HRT1C003DB
6
3. CONFIGURATION
FS-527
• The following sections are combined in a single unit: the horizontal conveyance section,
conveyance section, alignment section, tray1, tray2, and stapler section.
Tray1 Horizontal conveyance

Alignment section Conveyance section section
CONFIGURATION/
OPERATION
Tray2
Stapler section
A0HRT2C002DB
7
4. HORIZONTAL CONVEYANCE SECTION Theory of Operation Ver. 1.0 Jul. 2009
4. HORIZONTAL CONVEYANCE SECTION

4.1 Configuration
FS-527
• The horizontal conveyance section is composed of the duplex path switching sensor,
paper passage sensor/1, horizontal conveyance cover sensor, paper passage sensor/2,
paper passage motor/1, and duplex path switching motor.
Duplex path switching motor (M2) Duplex path switching sensor (PS3)
Paper passage Paper passage sensor/1 (PS1)

motor/1 (M1)
CONFIGURATION/
OPERATION
Paper passage sensor/2 (PS2)

Horizontal conveyance cover
sensor (PS5)
A0HRT2C001DA
8
Theory of Operation Ver. 1.0 Jul. 2009 4. HORIZONTAL CONVEYANCE SECTION
4.2 Horizontal conveyance mechanism

4.2.1 Paper conveyance
FS-527
• The horizontal conveyance section conveys paper fed out from the main body to the fin-
isher.
• The paper passage motor/1 provides drive for the conveyance rollers.
• On the finisher side, drive from the paper passage motor/1 conveys the paper into the
finisher.
Horizontal conveyance section
Finisher side Main body side
CONFIGURATION/
OPERATION
Paper passage motor/1 (M1)
Conveyance roller
A0HRT2C003DA
9
4. HORIZONTAL CONVEYANCE SECTION Theory of Operation Ver. 1.0 Jul. 2009
4.2.2 Conveyance path switching motor mechanism

• The horizontal conveyance section is provided with a paper path switching mechanism
FS-527
for conveying paper fed from the fusing section onto the duplex section or tray 3 (when
another option of JS-603 is mounted).
• The paper path is changed by the duplex path switching motor and the path switching
guide.
Duplex path switching

sensor (PS3)
Path switching guide

CONFIGURATION/
OPERATION
Duplex path switching

motor (M2)
A0HRT2C024DA
A. Operation
• The path switching guide swings up or down when the duplex path switching motor is
energized.
• The duplex path switching sensor detects the position of the path switching guide, either
the swung-up or swung-down position. The sensor is blocked or unblocked by the cam to
detect the swung-down or swung-up position of the path switching guide as detailed
below.
Path switching guide position Duplex path switching sensor

Swung-up position (paper to finisher) Unblocking
Swung-down position (paper to duplex section) Blocking
10
5. CONVEYANCE SECTION
5.1 Configuration
FS-527
Tray1 exit roller
CONFIGURATION/
OPERATION
Registration
roller
Tray2 exit roller Switchback roller
Conveyance motor (M4)

Exit motor (M5)
A0HRT2C025DA
11
5.2 Drive
FS-527
Tray1 exit roller Exit motor (M5)

Conveyance motor (M4)
Tray2 exit roller
CONFIGURATION/
OPERATION
Conveyance
roller 2
Paper passage roller
Exit driven roller Conveyance roller 1
A0HRT2C004DB
12
5.3 Operation
5.3.1 Upper lower path switching gate
FS-527
• The upper lower path switching gate switches paper to different routes that go to individ-
ual trays and SD-509.
• The paper exit command from the main body moves the upper lower path switching gate
up or down as necessary.
A. Upper lower path switching gate operation

• The upper lower path switching motor drives the route change gate.
CONFIGURATION/
OPERATION
Upper lower path
switching gate
Upper lower path switching gate
Upper lower path switching motor (M6)

A0HRT2C005DB
13
5.3.2 Tray1 path switching gate

• The tray1 path switching gate changes the paper conveyance path between one toward
FS-527
the tray1 and one toward the bypass route.
A. Tray1 path switching gate operation

• The tray1 path switching gate is operated by the tray1 path switching motor.
• When the tray1 path switching motor is energized, the tray1 path switching gate swings
up or down.
• The tray1 path switching home sensor detects the position of the tray1 path switching
gate, either the swung-up or swung-down position.

CONFIGURATION/
OPERATION
Tray1 path switching

motor (M8)
A0HRT2C006DB
Tray1 path switching home sensor (PS7)
14
5.3.3 Conveyance operation

A. Tray1 conveyance
FS-527
• The paper conveyed from the horizontal conveyance section is conveyed via the registra-
tion roller and guided into the tray1 by the upper lower path switching gate and tray1 path
switching gate. It is then fed out into the tray1 by the tray1 exit roller.
Upper lower path switching gate

Tray1
Registration roller
Tray1 exit roller
CONFIGURATION/
OPERATION
A0HRT2C008DB
B. Tray2 conveyance
• The paper conveyed from the horizontal conveyance section is conveyed onto the align-
ment section by way of the registration roller, paper passage roller, switchback roller, and
lower path roller.
Paper passage roller
Tray2 Registration roller
Lower path roller
Switchback roller
A0HRT2C007DB
15
C. Bypass route
• The bypass route is provided to eliminate any time loss during stapling operation relative
to the subsequent sheet of paper and to achieve high productivity.
FS-527
The following describe how two copy sets/stacks are produced as an output, each con-
sisting of two sheets of paper stapled together.
(1) For the 1st copy

• The bypass route is not used for the paper path for the first copy set/stack.
(2) For the 2nd copy
• The first sheet of paper of the second copy set/stack passes through the path to tray2,
but is fed and temporarily brought into a standby state on the conveyance path to the SD-
509 by the switchback roller.
• The second sheet of paper of the second copy set/stack is then conveyed and fed into
the bypass route.
• At the same time that the first copy set/stack is fed out, the first and second sheets of the
second copy set/stack are conveyed onto the alignment section.
Bypass route
CONFIGURATION/
OPERATION
Conveyance path to the SD-509
Tray2
Switchback roller
SD-509
A0HRT2C009DB
16
D. Conveyance to SD-509
• The paper conveyed from the horizontal conveyance section is further conveyed onto the
path toward tray2 and, when the trailing edge of the paper moves past the lower path
FS-527
sensor, the switchback roller is brought to a temporary stop.
• The switchback roller is thereafter turned backward, so that the paper is conveyed into
the SD-509.
Lower path sensor (PS9)
Switchback roller
CONFIGURATION/
OPERATION
SD-509
A0HRT2C010DB
17
6. EXIT TRAY SECTION Theory of Operation Ver. 1.0 Jul. 2009
6. EXIT TRAY SECTION

6.1 Drive
FS-527
Tray2
Elevate motor (M15)
Lift belt
CONFIGURATION/
OPERATION
A0HRT2C011DB
18
Theory of Operation Ver. 1.0 Jul. 2009 6. EXIT TRAY SECTION
6.2 Operation
6.2.1 Tray lift
FS-527
A. Tray lift operation
• The driving force of the worm gear mounted on the shaft of the elevate motor drives the
lift belt.
• The tray2 moves up or down depending on the direction in which the lift belt is driven.
Tray2
Elevate motor (M15)
CONFIGURATION/
OPERATION
Tray2 upper position
switch (SW2)
Lift belt
Tray2 lower position
switch (SW3)
Tray2 upper position sensor (PS24)
Tray2 lower position sensor (PS21)
A0HRT2C012DB
B. Paper detection
• The tray2 upper position sensor keeps the specified distance between the upper surface
of the paper exited to the tray2 and the paper exit opening to eliminate the misalignment
of the exited paper.
• The tray2 upper position sensor and tray2 lower position sensor detect a full-of-paper
condition of the tray2.
• When both of these sensors are activated, a corresponding message appears on the
control panel.
• The tray2 lower position switch detects the lower limit of the tray.
19
6.2.2 Exit to tray1

• The paper conveyed from the horizontal conveyance section is fed out into the tray1 by
FS-527
the tray1 exit roller by way of the registration roller and paper passage roller.
• The upper lower path switching gate and tray1 path switching gate are also operated to
convey the paper into the tray1.
• The paper passage motor/2 provides drive for the tray1 exit roller.
Tray1
Tray1 exit roller
Tray1 path Paper passage motor/2 (M3)
switching gate
CONFIGURATION/
OPERATION
Upper lower path

switching gate
A0HRT2C015DB
20
6.2.3 Exit to tray2

• The exit motor is energized to convey paper onto tray2.
FS-527
• To collect sheets of paper in the alignment section during stapling, the exit roll is tempo-
rarily retracted.
• When the stapling operation is completed, the exit roll is pressed, so that the paper is fed
out into tray2.
• The exit roller retraction motor provides drive for retraction of the exit roll.
A. Normal paper exit operation

• When the leading edge of the paper reaches a point a given distance before the tray2
exit roller, the exit motor is energized and the paper is conveyed onto tray2.
Exit motor (M5)
CONFIGURATION/
OPERATION
Tray2 exit roller
A0HRT2C013DB
B. Paper exit operation during stapling

• When the leading edge of the paper reaches the paper exit sensor of the main body, the
exit roller retraction motor is energized to retract the exit roll.
• After the paper is processed, the exit roller retraction motor is energized to press the exit
roll and the paper is fed out by drive from the exit motor.
21
FS-527
Exit roller retraction motor (M9)
Exit roll
Tray2 exit roller

CONFIGURATION/
OPERATION
Exit motor (M5)

A0HRT2C014DB
Before pressure After pressure
A0HRT2C026DA
22
6.2.4 Tray2 shift control

• The tray2 is moved to the front or rear in order to offset one copy set/stack with respect to
FS-527
another in the sort or group mode.
• The tray2 shift motor provides drive for the front-to-rear shift motion of the tray2.
Tray2 shift motor (M16)

Tray2
CONFIGURATION/
OPERATION
A0HRT2C016DB
23
A. Tray1 shift operation

• When the leading edge of the paper reaches a point a given distance before the tray2
exit roller in the sort/group mode, the tray2 shift motor is energized to perform the shift
FS-527
operation.
• When the tray2 shift motor is energized, the shift frame is moved to the right or left via a
gear train, which results in tray2 operatively connected to the shift frame being moved to
the right or left.
• If a command for the next paper is received, the tray2 shift motor is energized again to
perform the shift operation.
• The shift position of the tray2 is controlled by the tray2 shift home sensor. The sensor is
activated when the tray2 is at its home position (ordinary position).
• The amount of shift operation is 30 mm.
30 mm Tray2 shift home sensor (PS25)

Tray2 shift motor (M16)
CONFIGURATION/
OPERATION
Tray2
Shift frame
A0HRT2C019DB
24
7.1 Drive
FS-527
Alignment plate
CONFIGURATION/
OPERATION
Alignment plate home sensor (PS17)
Alignment plate motor (M13)

A0HRT2C017DB
25
7.2 Operation
7.2.1 Alignment plate
FS-527
• The alignment plates align sheets of paper in the crosswise direction inside the finisher.
• The alignment plate motor rotates in the forward/reverse direction to open/close the
alignment plates to perform the alignment of the paper.
• The alignment plate motor rotates to open/close the alignment plates via the alignment
plate belts.
• The alignment plate home sensor detects the home position of the alignment plates.
Alignment plate
CONFIGURATION/
OPERATION
Alignment plate motor Alignment plate home sensor (PS17)

(M13)
A0HRT2C018DB
26
7.2.2 Alignment section conveyance mechanism

• The paper fed out from the main body falls in the alignment section by its own weight.
FS-527
• The accommodation paddle motor operates the accommodation paddle to convey paper
reliably onto the alignment section.
Accommodation
paddle
CONFIGURATION/
OPERATION
Accommodation paddle
motor (M12)
Rewind paddle
A0HRT2C020DB
27
8. STAPLER
8.1 Drive
FS-527
CONFIGURATION/
OPERATION
A0HRT2C027DA
Stapler unit
Stapler home sensor/1 (PS18)
Stapler movement motor (M11)

Belt
A0HRT2C021DB
28
8.2 Operation
FS-527
• The stapler movement motor moves the stapler.
• Rotation of the stapler movement motor drives the belt through the pulley, which moves
the stapler mounted on the belt.
• The stapler home sensor/1 becomes the stapler’s home position. In the two-point sta-
pling mode, the stapler is stopped at a position a given distance relative to the stapler
home sensor/2.
• In the one-corner stapling mode using A4 or A3 paper, the stapler stops at the stapler
home sensor/1 to staple sheets. For any other paper size, the stapler stops a position a
predetermined distance away relative to the stapler home sensor/1 to staple sheets.
CONFIGURATION/
OPERATION
Belt Stapler
A0HRT2C028DA
29
8.2.2 Stapler control

• The stapling operation is performed by the stapler motor.
FS-527
• In the stapling operation, the stapler motor drives the clincher side to press the paper.
Then, the staple is pushed out from the stapler side and bent at the clincher side.
Stapler (clincher side)
Paper
CONFIGURATION/
OPERATION
Stapler motor (M18)

Stapler (stapler side)
A0HRT2C023DB
30
B. Staple control
(1) Stapling
• After completing the alignment operation of the alignment plate, the stapler motor per-
FS-527
• The stapling operation is completed when the stapler home sensor in the stapler detects
the home position and turn ON.

• The main body determines that staples have been jammed, if the stapler home sensor is
not activated within a predetermined period of time after it has been deactivated during a
stapling operation. The stapler motor is then rotated backward to bring the stapler back
to its home position.
(3) Staple detection and cartridge detection

• When the staples run out, or if there is no cartridge loaded in position, the staple empty
switch turns ON and the main body displays a corresponding staple empty message on
the control panel.
CONFIGURATION/
OPERATION
31
FS-527
CONFIGURATION/
OPERATION
Blank Page
32
2009.07
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
PK-517
PK-517
OUTLINE
2. UNIT CONFIGURATION ......................................................................................... 2
3. PAPER PATH........................................................................................................... 3
OUTLINE
4. CONFIGURATION .................................................................................................. 5
5. OPERATION ........................................................................................................... 5
5.1 Skew correction mechanism ................................................................................. 5
CONFIGURATION/
5.2 Punch mechanism ................................................................................................ 6
OPERATION
5.3 Punch status detection ......................................................................................... 7
5.4 Punch trash box full detection mechanism ........................................................... 8
i
PK-517
OUTLINE
CONFIGURATION/
OPERATION
Blank Page
ii
OUTLINE
PK-517
A. Type
Name Punch kit

Type FS-integrated type punching operation device
B. Functions
OUTLINE
Punching method Stops and punches every paper
No. of holes 2-3 holes / 4 holes / Sweden 4 holes
2 holes / φ 8.0 mm / 70 mm pitch - 3 holes / φ 8.0 mm / 108 mm pitch
Hole diameter/pitch 4 holes / φ 6.5 mm / 80 mm pitch
Sweden 4 holes / φ 6.5 mm / 70 mm, 21 mm pitch
Supported mode Punch mode
Applicable post processing
Sort, group, staple
mode
C. Paper type
2 hole punch setting:

11 x 17, 8-1/2 x 14, 8-1/2 x 11/8-1/2 x 11S

11 x 17, 8-1/2 x 11
Size
A3, B4, A4, B5
Sweden 4 hole punch setting:

A3, B4, A4/A4S, B5
Plain paper, bond paper, thick paper 1/1+/2/3
Supported paper
(Main unit specifications prioritized)
Weight 64 to 256 g/m2
Label paper, tab paper, transparency film, 2nd base paper, holed paper,
Punch prohibited paper and the other paper that may interfere with the operation of the punch kit
or the punch blade
58 mm (W) x 470 mm (D) x 135 mm (H)

Dimensions
NOTE
1
2. UNIT CONFIGURATION Theory of Operation Ver. 1.0 Jul. 2009
2. UNIT CONFIGURATION
PK-517
Punch section
OUTLINE
Punch scraps box section
A10ET1C001DB
2
3. PAPER PATH
PK-517
Punch kit
OUTLINE
Paper path from
the main body
Punch scraps box
A10ET1C002DB
3
PK-517
OUTLINE
Blank Page
4
4. CONFIGURATION
PK-517
CONFIGURATION/
OPERATION
A10ET2C001DA
5. OPERATION
5.1 Skew correction mechanism
• For punch operation, a loop is formed in the paper at the conveyance roller to correct
skew.
• The paper passage sensor/1 detects the leading edge of the paper and the conveyance
roller forms a loop in the paper.
• The paper passage motor/1 is then energized after a given period of time after the paper
passage sensor/1 is activated by the leading edge of the paper, this causes the convey-
ance roller to start turning.
Conveyance roller
Paper passage sensor/1

(PS1)
4512T2C002DA
5
5.2 Punch mechanism

• The paper passage sensor/1 will detect the trailing edge of the paper and stop feeding
PK-517
the paper after the lapse of a predetermined period of time.

• The drive cam will be rotated by the punch motor/1(2) to move the slide cam back and
forth. The slide cam will move the puncher down to make the punch hole at the back
edge of the paper. (The punch hole will be made sheet by sheet.)
Slide cam
Puncher
Punch motor/1 (M100)
CONFIGURATION/
OPERATION
Paper passage
sensor/1 (PS1)
Paper feed direction
A10ET2C002DA
Puncher
Slide cam

A10ET2C004DA
6
5.3 Punch status detection

• The punch status is detected by the punch cam position sensor, punch home sensor/1,
PK-517
and the punch pulse sensor/1.
Punch cam position sensor (PS200)
Punch home sensor/1 (PS100)

Punch home sensor/2 (PS101)
CONFIGURATION/
OPERATION
Punch pulse sensor/1 (PS300)
Punch pulse sensor/2 (PS301) A10ET2C003DA
7
5.4 Punch trash box full detection mechanism

• The punch trash box is provided with the punch hole full sensor. When a punch waste is
PK-517
detected, the corresponding message is displayed on the control panel.

• The punch hole full sensor is a reflector type sensor that detects height of the punch
trash.
• Punch hole full sensor also detects whether or not the punch trash box is mounted.
“Punch dust full” message will be displayed on the control panel when the punch trash
box is not mounted.
Punch hole full sensor (PS30)

CONFIGURATION/
OPERATION
A10ET2C005DA
8
2009.07
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
SD-509
SD-509
OUTLINE
2. PAPER FEED PATH ................................................................................................ 2
OUTLINE
3. CONFIGURATION .................................................................................................. 3
4. ALIGNMENT SECTION .......................................................................................... 4
4.1 Drive ..................................................................................................................... 4
4.2 Operation .............................................................................................................. 5
CONFIGURATION/
4.2.1 Alignment ...................................................................................................... 5
OPERATION
4.2.2 Stopper ......................................................................................................... 7
5. STAPLER ................................................................................................................ 9
5.1 Drive ..................................................................................................................... 9
5.2 Operation ............................................................................................................ 10
5.2.1 Stapling ....................................................................................................... 10
6. FOLDING/SADDLE STITCHING .......................................................................... 11
6.1 Drive ................................................................................................................... 11
6.2 Operation ............................................................................................................ 12
6.2.1 Folding plate................................................................................................ 12
6.2.2 Folding conveyance .................................................................................... 13
7. EXIT SECTION ..................................................................................................... 15
7.1 Configuration ...................................................................................................... 15
7.2 Operation ............................................................................................................ 16
7.2.1 Exit .............................................................................................................. 16
i
SD-509
OUTLINE
CONFIGURATION/
OPERATION
Blank Page
ii
OUTLINE
SD-509
A. Type
Name Saddle sticher SD-509

Type Built into the finisher
Installation Screwed to the finisher
Stapling function Center parallel two points
OUTLINE
B. Paper
(1) Saddle stitching
Type Plain paper, Thick paper 1, Thick paper 2

A3, B4, A4S, A3 Wide, 11 x 17, 8-1/2 x 14, 8-1/2 x 11S
Size Min: 210 mm x 279.4 mm, 8.27 inch X 11 inch
Max: 311.15 mm x 457.2 mm, 12.25 inch X 18 inch
15 sheets (64 g/m2 to 90 g/m2 , 17 to 24 lb)
Max. saddle stitching capacity 14 sheets (64 g/m2 to 90 g/m2 , 17 to 24 lb)
+ 1 sheet (64 g/m2 to 209 g/m2 , 17 to 55.5 lb)
(2) Folding
Type Plain paper

A3, B4, A4S, A3 Wide, 11 x 17, 8-1/2 x 14, 8-1/2 x 11S
Size Min: 210 mm x 279.4 mm, 8.27 inch X 11 inch
Max: 311.15 mm x 457.2 mm, 12.25 inch X 18 inch
Max. number of sheets folded together 3 sheets (60 g/m2 to 90 g/m2 , 16 to 24 lb)
239 mm (W) x 579 mm (D) x 534 mm (H)

Dimensions
E. Consumables
• Staples 5000 (SK-602: Staple kit)
NOTE
1
2. PAPER FEED PATH

SD-509
OUTLINE
A10DT1C001DB
2
3. CONFIGURATION
SD-509
Alignment section
Stapler
Exit section
CONFIGURATION/
OPERATION
A10DT2C001DA
3
4.1 Drive
SD-509
Alignment plate/R Alignment plate/F

motor/R (M23) motor/F (M24)
Leading edge stopper motor (M20) Leading edge stopper

CONFIGURATION/
Leading edge
stopper
OPERATION
A10DT2C002DB
4
4.2 Operation
4.2.1 Alignment
SD-509
• In the folding/saddle stitching mode, the center staple alignment motor/F and /R aligns
paper.
• The center staple alignment motor rotates in the forward/reverse direction to move the
alignment plates, thereby aligning paper in the main scanning direction.
• The leading edge stopper motor is rotated to raise the leading edge stopper up to a posi-
tion of the paper to be stored, thereby aligning paper in the sub-scanning direction.
Paddle
Upper paddle motor (M21) Alignment plate/F

CONFIGURATION/
OPERATION
Alignment plate/R

home sensor/R (PS41) motor/F (M24)
Center staple alignment motor/R (M23)

A10DT2C003DB
A. Alignment operation
• The center staple alignment motor/F and /R rotate to open/close the alignment plates via
the alignment belts.
• The center staple alignment home sensor/F and /R detect the home position of the align-
ment plates.
• The leading edge stopper motor rotates to move the leading edge stopper in the vertical
direction via the belt.
5
B. Alignment control
• When the first sheet of paper undergoes a switchback operation, the center staple align-
ment motor/F and /R start rotating to bring the alignment plates closer to each other and
SD-509
then bring them to a stop at the standby positions at which they are apart from each at a
distance slightly wider than the paper width.
• The center staple alignment motor/F and /R perform the alignment operation by rotating
in the forward and reverse direction to move the alignment plate back and forth after a
specified period of time since the saddle path sensor detects the trailing edge of the
paper.
• The paper alignment operation in the main scanning direction is performed each time a
sheet of paper is fed in.
C. Paddle control
• After the lapse of a predetermined period of time after the saddle path sensor has
detected the leading edge of the paper, the upper paddle motor is rotated to align the
paper in the sub-scanning direction.
• The paddles are rotated each time a sheet of paper is fed in.
CONFIGURATION/
OPERATION
6
4.2.2 Stopper
• At the leading edge stopper, papers in sub scanning direction are aligned, and papers
SD-509
conveyed to the aligning section are conveyed to the specified position.
• The leading edge grip holds the paper when moving it to a specified position, or when
stapling or folding it.
A. Stopper operation
• The leading edge stopper motor moves the leading edge stopper up and down in accor-
dance with the paper size. The leading edge stopper home sensor detects the home
position.
CONFIGURATION/
OPERATION
Leading edge stopper home sensor (PS45)

Leading edge grip
Leading edge grip
Leading edge grip solenoid (SD3)
A10DT2C004DA
7
B. Stopper control
(1) Folding mode
• After the last sheet of paper was aligned, the leading edge grip solenoid is turned ON
SD-509
and the sheets of paper are held in place.

leading edge stopper down and lower the sheets to the folding position.
(2) Saddle stitching mode

• After the last sheet of paper was aligned, the leading edge grip solenoid is turned ON
and the sheets of paper are held in place.
leading edge stopper down and lower the sheets to the saddle stitching position.
• After stapling operation was completed, the center staple alignment motor/F and /R
opens the alignment plates and the leading edge stopper motor starts rotating to move
the leading edge stopper further down and lower the paper to the folding position.
CONFIGURATION/
OPERATION
8
5. STAPLER
5.1 Drive
SD-509
Staple motor
CONFIGURATION/
OPERATION
Drive gear
A10DT2C005DA
9
5.2 Operation
5.2.1 Stapling
SD-509
• The stapling operation is performed by the staple motor.
• In the stapling operation, the staple motor in the stapler pushes out the paper press sec-
tion to the clincher by the drive gear to hold the paper and punch out the staple. Then,
the staple is bent in the clincher.
Clincher Drive gear Staple motor

CONFIGURATION/
OPERATION
Stapler
Staple
A10DT2C006DA
B. Staple control
(1) Stapling
• After completing the alignment operation of the alignment plate, the staple motor per-
• The stapling operation is completed when the sensor in the stapler detects the home
position and turn ON.

• During the stapling operation, it is determined that the staple has been clogged and the
staple motor rotates in the reverse direction to replace the stapler to the home position if
the sensor in the stapler does not turn ON after a specified period of time since it turn
OFF.
10
Theory of Operation Ver. 1.0 Jul. 2009 6. FOLDING/SADDLE STITCHING
6. FOLDING/SADDLE STITCHING
6.1 Drive
SD-509
Folding plate
Folding roller
CONFIGURATION/
OPERATION
Center fold roller
motor (M25)
Center fold plate

motor (M26)
A10DT2C007DB
11
6. FOLDING/SADDLE STITCHING Theory of Operation Ver. 1.0 Jul. 2009
6.2 Operation
6.2.1 Folding plate
SD-509
• The center fold plate motor drives the folding plate.
A. Folding plate operation

• The center fold plate motor rotates the crank shaft a half turn via the gear and pushes the
paper to the nip section with the folding plate.
• The folding rollers draw and fold the paper.
• The position of the leading edge stopper controls the folding position.
Fold plate
Crank shaft
Folding roller
Center fold plate

CONFIGURATION/
home sensor (PS47)

OPERATION
Paper
A11RT2C014DA
B. Folding plate control

• The center fold plate motor turns ON and sticks out the folding plate to the paper after a
specified period of time since the leading edge stopper stops at the folding position.
• The center fold plate motor stops when the folding plate reciprocates and the center fold
plate home sensor turns ON.
12
Theory of Operation Ver. 1.0 Jul. 2009 6. FOLDING/SADDLE STITCHING
6.2.2 Folding conveyance

• The center fold roller motor drives the folding roller.
SD-509
Folding roller
CONFIGURATION/
OPERATION
Center fold roller
motor (M25)
A10DT2C009DA
13
6. FOLDING/SADDLE STITCHING Theory of Operation Ver. 1.0 Jul. 2009
A. Folding conveyance control

• The center fold plate motor turns ON after the leading edge stopper stops at the folding
position.
SD-509
• When the center fold plate motor turns ON the center fold plate home sensor, the center
fold roller motor turns ON and folds the paper.
• The center fold roller motor stops after a specified period of time since the paper detec-
tion sensor/2 detects the trailing edge of the paper bundle.
Paper detection sensor/2 (PS44)

CONFIGURATION/
OPERATION
A10DT2C010DA
B. Folding roller control

• Different folding roller controls are performed depending on the number of sheets of
paper and the size of the paper.
(1) The paper width is 215.9 mm or more and the number of sheets of paper is less
than six
• When the center fold plate home sensor is deactivated after the center fold plate motor
has been energized, the center fold roller motor is energized to start rotating at low
speed.
• The folding roller is made to start rotating at high speed after the lapse of a predeter-
mined period of time after it has started rotating.
• When the paper detection sensor/2 detects the trailing edge of the paper stack, the lead-
ing edge stopper motor is energized to raise the leading edge stopper to the alignment
position defined according to the paper size.
(2) Other than above

• The center fold roller motor is energized to start rotating at low speed a predetermined
period of time before the paper stack reaches the center fold position.
• The center fold plate motor is energized and, after the lapse of a predetermined period of
time after the center fold plate home sensor has been deactivated, the folding roller is
made to start rotating at high speed.
• When the paper detection sensor/2 detects the trailing edge of the paper stack, the lead-
ing edge stopper motor is energized to raise the leading edge stopper to the alignment
position defined according to the paper size.
14
Theory of Operation Ver. 1.0 Jul. 2009 7. EXIT SECTION
7. EXIT SECTION
7.1 Configuration
SD-509
Booklet tray near full Booklet tray full
sensor (PS48) sensor (PS50)
CONFIGURATION/
OPERATION
A10DT2C008DA
15
7.2 Operation
7.2.1 Exit
SD-509
• The paper fed out by the center fold roller motor is stacked in the tray by its own weight.
A. Full-of-paper detection
• The capacity of the tray varies depending on the number of sheets of paper in the paper
sets/stacks fed into the tray and detection of a full-of-paper condition cannot be made
based on the number of sheets of paper stacked in the tray.
The main body therefore counts the number of sheets of paper stacked and detects a
full-of-paper condition when a predetermined number of sheets of paper is reached.
If the booklet tray full sensor remains activated for a predetermined period of time, the
main body determines that paper can no longer be fed into the tray and that there is a
full-of-paper condition in the tray.
B. Full-of-paper detection conditions

• The booklet tray full sensor is activated.
• The booklet tray near full sensor is activated when the power switch is turned ON.
CONFIGURATION/
• The number of sets/stacks stacked in the tray reaches a predetermined value during
OPERATION
copying.
• A set/stack having a paper length different from that fed out earlier is fed out.
The main body does not determine that there is a full-of-paper condition in the tray under
any condition other than above.
16
2009.07
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
JS-603
JS-603
OUTLINE
2. PAPER PATH........................................................................................................... 2
OUTLINE
3. CONFIGURATION .................................................................................................. 3
4. DRIVE ..................................................................................................................... 4
5. OPERATION ........................................................................................................... 5
5.1 Conveyance/exit section ....................................................................................... 5
CONFIGURATION/
5.1.1 Paper conveyance......................................................................................... 5
OPERATION
5.1.2 Conveyance path switching........................................................................... 5
5.1.3 Full-of-paper detecting mechanism............................................................... 6
5.1.4 Exit roller pressure/retraction ........................................................................ 7
i
JS-603
OUTLINE
CONFIGURATION/
OPERATION
Blank Page
ii
OUTLINE
JS-603
A. Type
Type Fixed to the finisher

Document align-
Center
ment
B. Functions
OUTLINE
Modes Sort, group
C. Paper
Size Type Capacity

100 sheets
(17 to 24 lb)
Thick paper 1 (91 to 120 g/m2)
(24.25 to 32 lb)
Thick paper 1+ (121 to 157 g/m2)
A5S, B5S/B5, A4S/A4, B4, A3, A3 Wide (24.25 to 41.75 lb)
5-1/2 X 8-1/2S, 8-1/2 X 11S/8-1/2 X 11, 8-1/2 X
14, 11 X 17, 12-1/4 X 18 Thick paper 2 (158 to 209 g/m2)
Max.: 311.15 mm X 457.2 mm (42 to 55.5 lb)
12.25 inch X 18 inch Special Thick paper 3 (210 to 256 g/m2) 10 sheets
Min.: 139.7 mm X 182 mm paper (55.75 to 68 lb)
5.5 inch X 7.17 inch Thick paper 4 (257 to 300 g/m2)
(68.25 to 80 lb)
OHP film
Label
Envelope
Power require- DC 24 V ± 10 % (supplied from the main body)

ments DC5 V ± 5 %
165 mm (W) X 389 mm (D) X 63 mm (H)
Dimensions
6.5 inch (W) X 15.31 inch (D) X 2.48 inch (H)
NOTE
1
2. PAPER PATH
JS-603
OUTLINE
A10FT1C001DA
2
3. CONFIGURATION
JS-603
CONFIGURATION/
OPERATION
A10FT2C001DB
Conveyance/exit section
A10FT2C002DB
3
4. DRIVE Theory of Operation Ver. 1.0 Jul. 2009
4. DRIVE
JS-603
Tray3 full sensor (PS36)
Tray3 exit roller retraction

motor (M17)
Tray3 exit roller retraction sensor (PS35)

CONFIGURATION/
A10FT2C003DA
OPERATION
4
5. OPERATION
5.1 Conveyance/exit section
JS-603
5.1.1 Paper conveyance
• Drive from the paper passage motor/1 causes the corresponding exit roller to rotate,
thereby conveying the paper into the tray.
• The paper passage motor/1 is energized a predetermined period of time after the paper
has activated the paper passage sensor/1.
• Drive of the paper passage motor/1 rotates the exit roller, so that paper is conveyed into
the tray.
CONFIGURATION/
OPERATION
Exit roller
A10FT2C004DB
5.1.2 Conveyance path switching

• The horizontal conveyance section of FS-527 is provided with a conveyance path switch-
ing mechanism for conveying paper onto JS-603. For details of the mechanism, see the
horizontal conveyance section of FS-527.
5
5.1.3 Full-of-paper detecting mechanism

• The tray3 full sensor is located at the exit of the tray, detecting a full-of-paper condition of
JS-603
the tray.
• The actuator is operated each time paper is fed into the tray. When the level of paper fed
into the tray reaches a predetermined value (capacity), the sensor is blocked and the
main body determines that the tray is full of paper.
• The number of sheets of paper that is detected as a full-of-paper condition is 100 sheets
in terms of plain paper.
• The number of sheets of paper detected as a full-of-paper condition, however, varies
depending on the environmental conditions and the amount of curl in paper.
Tray3 full sensor (PS36)

CONFIGURATION/
OPERATION
Actuator
A10FT2C005DA
6
5.1.4 Exit roller pressure/retraction

• The tray is provided with an exit roller pressure/retraction mechanism that allows paper
JS-603
to be temporarily fed into the tray when a 2-sided print cycle is commanded.
• When a pressure/retraction command is received, the tray3 exit roller retraction motor is
energized. Then, the lifting cam is rotated a half turn, which causes the lifting lever to
swing up and down, so that the exit roller is pressed and retracted.
Lifting cam
Lifting lever Tray3 exit roller retraction motor (M17)
Tray3 exit roller retraction

sensor (PS35)
CONFIGURATION/
OPERATION
Exit roller
A10FT2C006DA
Pressure Retraction
Lifting cam
Lifting lever
Exit roller
A10FT2C007DB
7
A. Exit roller pressure/retraction overview

• The exit roller is normally in its retracted condition. It is pressed during a 2-sided print
cycle and paper exit into tray 3.
JS-603
• When the main body is turned or retracted from the sleep mode, or a cover open/close,
the tray3 exit roller retraction motor is energized to bring the exit roller into its retracted
condition, which is done to determine the condition of the exit roller.
Roller pressure/retraction condition

Normal printing Retracted
2-sided printing (except for small size paper)
Retracted → pressed → retracted
The main body is turned or retracted from the sleep mode
B. Exit roller pressure/retraction operation

• When the tray3 exit roller retraction motor is energized, the lifting cam is rotated a half
turn. The lifting lever is then raised and lowered to complete a pressure/retraction opera-
tion.
• Whether the tray3 exit roller retraction sensor is blocked or unblocked determines the
condition of the exit roller, either pressed or retracted.
CONFIGURATION/
• When the tray3 exit roller retraction sensor is blocked and unblocked, the tray3 exit roller
OPERATION
retraction motor is deenergized to stop the operation.
Tray3 exit roller retraction sensor

Pressed Blocked
Retracted Unblocked
Exit roller Lifting cam Tray3 exit roller retraction

motor (M17)
Lifting lever
Tray3 exit roller retraction sensor (PS35)
A10FT2C008DA
8
2009.01
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
AU-101/102/201
OT-503
AU-101/AU-102/AU-201/OT-503
AU-101/AU-102
1. CONFIGURATION .................................................................................................. 1
2. OPERATION ........................................................................................................... 1
OUTLINE
AU-201
3. CONFIGURATION .................................................................................................. 2
4. OPERATION ........................................................................................................... 2
OT-503
CONFIGURATION/
5. CONFIGURATION .................................................................................................. 3
OPERATION
6. OPERATION ........................................................................................................... 3
i
AU-101/102/201
OT-503
OUTLINE
CONFIGURATION/
OPERATION
Blank Page
ii
AU-101/AU-102
AU-101/102/201
7. CONFIGURATION
OT-503
Ultra-red LED
Finger
Vein image
Camera
A00JT2C256AA
Authentication unit (AU-101) Vein
CONFIGURATION/
OPERATION
Finger
Authentication unit (AU-102) A0P0T2C581AA
8. OPERATION
• A finger vein pattern is used for personal identification.
• Vein patterns are inside the body and cannot be visually recognized. This makes vein
patterns extremely difficult to forge or falsify. The vein pattern authentication system can
provide high security.
• With ultra-red LED radiation, a finger vein pattern is captured by camera and its image is
created. The vein pattern image is registered and a person can be identified if the per-
son’s vein pattern matches the registered one at the time of user authentication.
1
9. CONFIGURATION Theory of Operation Ver. 1.0 Jan. 2009
AU-201
AU-101/102/201
9. CONFIGURATION
OT-503
Abcde Fgdhi
ABCDE_Co.
Non-contact IC card
Authentication unit (AU-201)

A00HT2C302AA
CONFIGURATION/
OPERATION
10. OPERATION
• A non-contact IC card, such as an employee ID card, is used for personal identification.
• The system supports the communications protocol in compliance with Type A, Type B,
and Felica (Type C) of ISO14443.
• It can be used that the card corresponded to Felica, TypeA, SSFC (Shared Security For-
mats Cooperation), FCF (Felica common-use format), or FCF campus.
• Simply placing the IC card on the authentication unit will let the unit read the data from
the card.
2
OT-503
AU-101/102/201
11. CONFIGURATION
OT-503
Fan unit
CONFIGURATION/
OPERATION
Paper exit tray
A092T2C501AA
12. OPERATION
• Output Tray OT-503 is comprised a fan unit and a paper exit tray.
• In order to avoid toner adhesion to other things, three tucking fan motors installed in the
fan unit send outside air to an ejected paper for cool it down.
3
12. OPERATION Theory of Operation Ver. 1.0 Jan. 2009
AU-101/102/201
OT-503
CONFIGURATION/
OPERATION
Blank Page
4
2009.07
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
EK-604/605/SC-507
EK-604/605/SC-507
EK-604
1. CONFIGURATION .................................................................................................. 1
2. OPERATION ........................................................................................................... 1
CONFIGURATION/
OPERATION
EK-605
1. CONFIGURATION .................................................................................................. 2
2. OPERATION ........................................................................................................... 3
SC-507
1. CONFIGURATION .................................................................................................. 4
2. OPERATION ........................................................................................................... 4
i
EK-604/605/SC-507
CONFIGURATION/
OPERATION
Blank Page
ii
EK-604
EK-604/605/SC-507
1. CONFIGURATION
USB terminal (extension) USB terminal (standard)
CONFIGURATION/
OPERATION
Local Interface Kit EK-604
A0YCT2C502AA
2. OPERATION
• The document can be printed directly from, or saved in, the USB memory.
• Connecting the USB keyboard (dealer option: overseas market only) will permit keyboard
input.
1
1. CONFIGURATION Theory of Operation Ver. 1.0 Jul. 2009
EK-605
EK-604/605/SC-507
1. CONFIGURATION
USB terminal (extension) USB terminal (standard)

CONFIGURATION/
OPERATION
A0YCT2C504AA
2
2. OPERATION
EK-604/605/SC-507
• The document can be printed directly from, or saved in, the USB memory.
• Connecting the USB keyboard (dealer option: overseas market only) will permit keyboard
input.
• The local interface kit is mounted when the voice guidance function and functions inter-
acting with the portable phone or PDA (portable data terminal) compatible with Bluetooth
are to be used. It has a built-in speaker and Bluetooth communication receiver.
• Using Bluetooth, the user can print files directly from the portable phone, download and
print PDF or other files from the portable phone, or save them in a box.
CONFIGURATION/
• If an XHTML file is downloaded from the portable phone, an image file can be down-
OPERATION
loaded from the URL described in XHTML and printed as an image onto a location spec-
ified in the XHTML document.
Portable phone, PDA A0YCT2C503AA
3
1. CONFIGURATION Theory of Operation Ver. 1.0 Jul. 2009
SC-507
EK-604/605/SC-507
1. CONFIGURATION
CONFIGURATION/
OPERATION
Security Kit SC-507
A0Y9T2C501AA
2. OPERATION
• The security kit offers the copy guard (copy prohibited) and password copy functions in
addition to the conventional copy protect function. The copy guard security pattern or
password copy security pattern printed on the original is detected to thereby prevent
unauthorized copies from being produced.
* The copy guard security pattern and password copy security pattern can be detected
only by the Konica Minolta machine mounted with the copy guard and password copy
functions.
Copy
Print
Detecting the copy

guard security pat-
tern to discard the
job.
Making a copy from an

output produced by add-
ing the copy guard secu-
rity pattern or password
copy security pattern.
Copying enabled through

password input. A0Y9T2C504AA
4
© 2009 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.
Printed in Japan
Use of this manual should be strictly supervised to
DDA0P0-M-TE2
avoid disclosure of confidential information.

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SERVICE MANUAL THEORY OF OPERATION

This service manual is designed for machine with

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

bizhub C652/C552/C452 Main body

SAFETY AND IMPORTANT WARNING ITEMS

DESCRIPTION ITEMS FOR DANGER,

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

:Precaution when servicing the

:Prohibition when servicing the

:Direction when servicing the

• Using any fuse or thermostat not specified by KMBT.

• Disabling fuse functions or bridging fuse terminals with

• Disabling relay functions (such as wedging paper between

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

• Making any modification to the product unless instructed

• Using parts not specified by KMBT

[2] POWER PLUG SELECTION

Power Cord Set or Power Plug

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

[3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE

Connection to Power Supply

• Connect power plug directly into wall outlet having same

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

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

• Check whether the product is grounded properly.

Power Plug and Cord

• Check whether the power cord is not stepped on or

• Check whether the power cord is damaged. Check

• Do not bundle or tie the power cord.

• Check whether dust is collected around the power plug

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

Prohibited Installation Places

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

When not Using the Product for a long time

Inspection before Servicing

• Before conducting an inspection, be sure to disconnect

Work Performed with the Product Powered On

• Take every care when servicing with the external cover

• Check wiring for squeezing and any other damage.

• Carefully remove all toner remnants and dust from electri-

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

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

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

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

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

• Check the interlock switch and actuator for loosening and

• Never throw the used cartridge and toner into fire.

Handling of Service Materials

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

Handling of Service Materials

• When using any solvent, ventilate the room well.

[4] Used Batteries Precautions

[5] Laser Safety

5.1 Internal Laser Radiation

Print Head Unit

5.2 Laser Safety Label

* Only for the U.S.A.