Bizhub 500 - 420 Service Manual Main Body&Options

SERVICE MANUAL Theory of Operation
500 / 420
2006.02
Ver. 1.0
THEORY OF OPERATION TOTAL CONTENTS
SAFETY AND IMPORTANT WARNING ITEMS ..............................................................S-1

IMPORTANT NOTICE ................................................................................................S-1
DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION .........................S-1
SAFETY WARNINGS .................................................................................................S-2
SAFETY INFORMATION ...............................................................................................S-12
IMPORTANT NOTICE ..............................................................................................S-12
INDICATION OF WARNING ON THE MACHINE .....................................................S-13
MEASURES TO TAKE IN CASE OF AN ACCIDENT ....................................................S-15
Composition of the service manual ................................................................................. C-1
Notation of the service manual ....................................................................................... C-2
bizhub 500 / 420 Main Body

OUTLINE ........................................................................................................................ 1
COMPOSITION/OPERATION ........................................................................................ 9
* For particulars, see the contents of the main body.
DF-607
OUTLINE ........................................................................................................................ 1
COMPOSITION/OPERATION......................................................................................... 5
* For particulars, see the contents of DF-607.
PC-202
OUTLINE ........................................................................................................................ 1
* For particulars, see the contents of PC-202.
PC-402
OUTLINE ........................................................................................................................ 1
LU-201
OUTLINE ........................................................................................................................ 1
* For particulars, see the contents of LU-201.
i
FS-510/PU-501/OT-601
OUTLINE ........................................................................................................................ 1
* For particulars, see the contents of FS-510/PU-501/OT-601.
FS-511/RU-502
OUTLINE ........................................................................................................................ 1
COMPOSITION/OPERATION........................................................................................ 7
* For particulars, see the contents of FS-511/RU-502.
SD-502
OUTLINE ........................................................................................................................ 1
* For particulars, see the contents of SD-502.
MT-501
OUTLINE ........................................................................................................................ 1
* For particulars, see the contents of MT-501.
JS-502
OUTLINE ........................................................................................................................ 1
* For particulars, see the contents of JS-502.
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 using the

copier. General Electric hazard High
precaution temperature
:Prohibition when using the

copier. General Do not touch Do not
prohibition with wet hand disassemble
:Direction when using the

copier. General Unplug Ground/Earth
instruction
S-1
SAFETY 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.)

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:
AC230V
- provided with a plug having configuration intended for
the connection to wall outlet appropriate for the prod-
uct's rated voltage and current, and
- the plug has pin/terminal(s) for grounding, and
- provided with three-conductor cable having enough cur-
rent capacity, and
AC208V 240V
- the cord set meets regulatory requirements for the area.
Use of inadequate cord set leads to fire or electric shock.
• Attach power plug which meets the following criteria:
- having configuration intended for the connection to wall
outlet appropriate for the product's rated voltage and
current, and
- 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 CE from the risk
of injury. However, in daily use, any electrical equipment may be subject to parts wear and
eventual failure. In order to maintain safety and reliability, the CE must perform regular
safety checks.
1. Power Supply
Connection to Power Supply
WARNING
• Check that mains voltage is as specified.
Connection to wrong voltage supply may result in fire or
electric shock. ?V
• Connect power plug directly into wall outlet having same

configuration as the plug.
Use of an adapter leads to the product connecting to kw
inadequate power supply (voltage, current capacity,
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.
result.
• Make sure the power cord is plugged in the wall outlet

securely.
Contact problems may lead to increased resistance,
overheating, and the risk of fire.
S-4
WARNING
• Check whether the product is grounded properly.
If current leakage occurs in an ungrounded product, you
may suffer electric shock while operating the product.
Connect power plug to grounded wall outlet.
Power Plug and Cord
WARNING
• When using the power cord set (inlet type) that came with
this product, make sure the connector is securely inserted
in the inlet of the product.
When securing measure is provided, secure the cord with
the fixture properly.
If the power cord (inlet type) is not connected to the prod-
uct securely, a contact problem may lead to increased
resistance, overheating, and risk of fire.
• Check whether the power cord is not stepped on or

pinched by a table and so on.
Overheating may occur there, leading to a risk of fire.
• Check whether the power cord is damaged. Check

whether the sheath is damaged.
If the power plug, cord, or sheath is damaged, replace
with a new power cord or cord set (with plug and connec-
tor on each end) specified by KMBT.
Using the damaged power cord may result in fire or elec-
tric shock.
• Do not bundle or tie the power cord.

S-5
Power Plug and Cord
WARNING
• Check whether dust is collected around the power plug
and wall outlet.
Using the power plug and wall outlet without removing
dust may result in fire.
• Do not insert the power plug into the wall outlet with a wet
hand.
The risk of electric shock exists.
• When unplugging the power cord, grasp the plug, not the
cable.
The cable may be broken, leading to a risk of fire and
electric shock.
Wiring
WARNING
• Never use multi-plug adapters to plug multiple power cords
in the same outlet.
If used, the risk of fire exists.
• When an extension cord is required, use a specified one.

Current that can flow in the extension cord is limited, so
using a too long extension cord may result in fire.
Do not use an extension cable reel with the cable taken
up. Fire may result.
S-6
2. Installation Requirements
Prohibited Installation Places
WARNING
• Do not place the product near flammable materials or vola-
tile materials that may catch fire.
A risk of fire exists.
• Do not place the product in a place exposed to water such

as rain.
A risk of fire and electric shock exists.
When not Using the Product for a long time
WARNING
• When the product is not used over an extended period of
time (holidays, etc.), switch it off and unplug the power
cord.
Dust collected around the power plug and outlet may
cause fire.
Ventilation
CAUTION
• The product generates ozone gas during operation, but it
will not be harmful to the human body.
If a bad smell of ozone is present in the following cases,
ventilate the room.
a. When the product is used in a poorly ventilated room
b. When taking a lot of copies
c. When using multiple products at the same time
Fixing
CAUTION
• Be sure to lock the caster stoppers.
In the case of an earthquake and so on, the product may
slide, leading to a injury.
S-7
Inspection before Servicing
CAUTION
• Before conducting an inspection, read all relevant docu-
mentation (service manual, technical notices, etc.) and
proceed with the inspection following the prescribed pro-
cedure in safety clothes, using only the prescribed tools.
Do not make any adjustment not described in the docu-
mentation.
If the prescribed procedure or tool is not used, the prod-
uct may break and a risk of injury or fire exists.
• Before conducting an inspection, be sure to disconnect

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

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

detached.
High-voltage exists around the drum unit. A risk of elec-
tric shock exists.
S-8
Safety Checkpoints
WARNING
• Check the exterior and frame for edges, burrs, and other
damages.
The user or CE may be injured.
• Do not allow any metal parts such as clips, staples, and

screws to fall into the product.
They can short internal circuits and cause electric shock
or fire.
• Check wiring for squeezing and any other damage.

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

fire.
• Check electrode units such as a charging corona unit for

deterioration and sign of leakage.
Current can leak, leading to a risk of trouble or fire.
• Before disassembling or adjusting the write unit (P/H unit)
incorporating a laser, make sure that the power cord has
been disconnected.
The laser light can enter your eye, leading to a risk of
loss of eyesight.
• Do not remove the cover of the write unit. Do not supply

power with the write unit shifted from the specified mount-
ing position.
loss of eyesight.
S-9
Safety Checkpoints
WARNING
• When replacing a lithium battery, replace it with a new lith-
ium battery specified in the Parts Guide Manual. Dispose
of the used lithium battery using the method specified by
local authority.
Improper replacement can cause explosion.
• After replacing a part to which AC voltage is applied (e.g.,

optical lamp and fixing lamp), be sure to check the installa-
tion state.
• 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.
• Make sure that all screws, components, wiring, connec-
tors, etc. that were removed for safety check and mainte-
nance have been reinstalled in the original location. (Pay
special attention to forgotten connectors, pinched cables,
forgotten screws, etc.)
A risk of product trouble, electric shock, and fire exists.
Handling of Consumables
WARNING
• Toner and developer are not harmful substances, but care
must be taken not to breathe excessive amounts or let the
substances come into contact with eyes, etc. It may be
stimulative.
If the substances get in the eye, rinse with plenty of water
immediately. When symptoms are noticeable, consult a
physician.
S-10
WARNING
• Never throw the used cartridge and toner into fire.
You may be burned due to dust explosion.
Handling of Service Materials
CAUTION
• Unplug the power cord from the wall outlet.
Isopropyl alcohol and acetone are highly flammable and
must be handled with care. A risk of fire exists.
• Do not replace the cover or turn the product ON before

any solvent remnants on the cleaned parts have fully
evaporated.
• 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
SAFETY INFORMATION
SAFETY INFORMATION
IMPORTANT NOTICE
The Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Admin-
istration implemented regulations for laser products manufactured since August 1, 1976.
Compliance is mandatory for products marketed in the United States.
This copier is certified as a "Class 1" laser product under the U.S.
Department of Health and Human Services (DHHS) Radiation Performance Standard
according to the Radiation Control for Health and Safety Act of 1968. Since radiation emit-
ted inside this copier is completely confined within protective housings and external covers,
the laser beam cannot escape during any phase of normal user operation.
S-12
SAFETY INFORMATION
INDICATION OF WARNING ON THE MACHINE

Caution labels shown below are attached in some areas on/in the machine.
When accessing these areas for maintenance, repair, or adjustment, special care should
be taken to avoid burns and electric shock.
50gap0e001na
S-13
SAFETY INFORMATION
50gap0e002na
CAUTION:
• You may be burned or injured if you touch any area that you are advised by any
caution label to keep yourself away from. Do not remove caution labels. And also,
when the caution label is peeled off or soiled and cannot be seen clearly, replace
it with a new caution label.
S-14
MEASURES TO TAKE IN CASE OF AN ACCIDENT
MEASURES TO TAKE IN CASE OF

AN ACCIDENT
1. If an accident has occurred, the distributor who has been notified first must immediately
take emergency measures to provide relief to affected persons and to prevent further
damage.
2. If a report of a serious accident has been received from a customer, an on-site evalua-
tion must be carried out quickly and KMBT must be notified.
3. To determine the cause of the accident, conditions and materials must be recorded
through direct on-site checks, in accordance with instructions issued by KMBT.
4. For reports and measures concerning serious accidents, follow the regulations speci-
fied by every distributor.
S-15
Blank Page
S-16
Composition of the service manual
This service manual consists of the following sections and chapters:
<Theory of Operation section>
OUTLINE: System configuration, product specifications,

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

MAINTENANCE: Service schedule *, maintenance steps,
list of service tools and directions for use *,
firmware version up method *,
and removal/reinstallation methods of major parts
ADJUSTMENT/SETTING: Utility mode *, service mode *, security and mechanical
adjustment
TROUBLESHOOTING*: List of jam codes, their causes, operation when a jam
occurs and its release method, and list of error codes,
their causes, operation when a warning is issued and esti-
mated abnormal parts.
APPENDIX*: Parts layout drawings, connector layout drawings, timing
chart, overall layout drawing
This section gives, as information required by the CE at the site (or at the customer's
premise), a rough outline of the service schedule and its details, maintenance steps, the
object and role of each adjustment, error codes and supplementary information.
The details of items with an asterisk "*" are described only in the service manual of
the main body.
C-1
Notation of the service manual
A. Product name
In this manual, each of the products is described as follows:
(1) IC board: Standard printer

(2) bizhub 500 / 420: Main body
(3) Microsoft Windows 95: Windows 95
Microsoft Windows 98: Windows 98
Microsoft Windows Me: Windows Me
Microsoft Windows NT 4.0: Windows NT 4.0 or Windows NT
Microsoft Windows XP: Windows XP
When the description is made in combination of the OS's mentioned above:
Windows 95/98/Me
Windows NT 4.0/2000
Windows NT/2000/XP
Windows 95/98/Me/NT/2000/XP
B. Brand name
The company names and product names mentioned in this manual are the brand name or
the registered trademark of each company.
C. Electrical parts and signals

Those listed by way of example below are not exhaustive, but only some instances among
many.
Classification Load symbol Ex. of signal name Description

IN
PS
Sensor PS Door PS1 Sensor detection signal
SIG
102 PS
24V Power to drive the solenoid
Solenoid SD DRV
Drive signal
SOL
24V Power to drive the clutch
Clutch CL DRV
Drive signal
SOL
C-2
24V Power to drive the motor
CONT Drive signal
DRV1
Motor M
DRV2
Drive signals of two kinds
D1
D2
_U
_V
_W
Drive signals (control signals) of three kinds
DRV1
DRV2
DRV3
D1
D2
D3
D4
DRV A
DRV A
DRV B Drive signals (control signals) of four kinds
DRV B Motor, phases A and B control signals
A
Motor M /A
B
/B
AB
BB
CLK, PLL PLL control signal
LCK, Lock, LD PLL lock signal
FR Forward/reverse rotation signal
EM, Lock, LCK, LD Motor lock abnormality
BLK Drive brake signal
P/S Power/stop
S/S
Operating load start/stop signal
SS
CW/CCW, F/R Rotational direction switching signal
ENB Effective signal
TEMP_ER Motor temperature abnormality detection signal
24V Power to drive the fan motor
CONT, DRIVE Drive signal
Fan FM
HL Speed control signal (2 speeds)
EM, Lock, LCK, FEM Detection signal
Others TH1.S, ANG Analog signal
C-3
SG, S.GND, S_GND Signal ground
Ground
PG, P.GND Power ground
DCD Data carrier detection
SIN Serial input
SOUT Serial output
DTR Data terminal operation available
GND Signal ground (earth)
Serial com-
DSR, DSET Data set ready
munication
RTS Transmission request signal
CTS Consent transmission signal
RI Ring indicator
TXD Serial transmission data
RXD Serial reception data
D. Paper feed direction

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

Transverse feed A4
A4
Longitudinal feed A4S
A3 Longitudinal feed A3
C-4
500 / 420
Main body
2006.02
Ver. 1.0
Revision history
After publication of this service manual, the parts and mechanism may be subject to change for
improvement of their performance.
Therefore, the descriptions given in this service manual may not coincide with the actual machine.
When any change has been made to the descriptions in the service manual, a revised version will be
issued with a revision mark added as required.
Revision mark:
• To indicate clearly a section revised, show 1 to the left of the revised section.
A number within 1 represents the number of times the revision has been made.
• To indicate clearly a section revised, show 1 in the lower outside section of the correspond-
ing page.
NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
• When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
• When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.
2006/02 1.0 — Issue of the first edition

Date Service manual Ver. Revision mark Descriptions of revision
Theory of Operation Ver1.0 Feb.2006 CONTENTS
CONTENTS
bizhub 500 / 420

bizhub 500 / 420
OUTLINE
1. SYSTEM CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. PRODUCT SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. UNIT CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
COMPOSITION/OPERATION
5. OVERALL CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.1 Time chart when the power is turned ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.2 Control block diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6. SCANNER SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.3.1 Scan/exposure lamp control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.3.2 Original size detection control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.3.3 AE control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.3.4 Image processing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7. WRITE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.2.1 Laser beam path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.2.2 Write control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.2.3 Image stabilization control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.2.4 Image processing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8. PHOTO CONDUCTOR SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.2.1 Drum drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.2.2 Drum claw drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.3.1 Image creation control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.3.2 Drum claw control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9. CHARGING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.2.1 Charging control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.2.2 Erase lamp (EL) control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10. TRANSFER/SEPARATION SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.2.1 Transfer guide control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.2.2 Transfer/separation control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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CONTENTS Theory of Operation Ver1.0 Feb.2006
10.2.3 Transfer exposure lamp (TSL) control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

11. DEVELOPING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
bizhub 500 / 420
11.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
11.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.3.1 Developer conveyance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.3.2 Developing bias . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11.3.3 Developing suction control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
12. TONER SUPPLY SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
12.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
12.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
12.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.3.1 Toner level detection control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.3.2 Toner supply control to the toner hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.3.3 Toner supply control to the developing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.3.4 Toner conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
13. CLEANING/TONER RECYCLE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
13.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
13.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
13.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
13.3.1 Cleaning operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
13.3.2 Toner collection mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
13.3.3 Toner conveyance operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
14. PAPER FEED SECTION (Tray 1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
14.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
14.1.1 Tray 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
14.1.2 Tray 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
14.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
14.2.1 Paper feed drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
14.2.2 Tray lift drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
14.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
14.3.1 Up/down control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
14.3.2 Paper size detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
14.3.3 Paper feed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
14.3.4 Paper empty control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
14.3.5 Paper remaining detection mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
15. BYPASS SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
15.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
15.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
15.2.1 Paper feed drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
15.2.2 Tray lift drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
15.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
15.3.1 Up/down control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
15.3.2 Paper size detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
15.3.3 Paper feed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
15.3.4 Paper empty control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
16. REGISTRATION SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
16.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
16.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
ii
16.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
16.3.1 Loop control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
bizhub 500 / 420

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

23.2.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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23.3 Parts that operate when the power switch is turned ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
23.3.1 Parts that operate when the main power switch (SW1) is turned ON . . . . . . . . . . . . . . . . . . . 103
23.3.2 Parts that operate when the power switch (SW2) is turned ON . . . . . . . . . . . . . . . . . . . . . . . . 104
iv
Theory of Operation Ver1.0 Feb.2006 1. SYSTEM CONFIGURATION
OUTLINE
bizhub 500 / 420

1. SYSTEM CONFIGURATION
A. System configuration
[23] [27] [28]

[24] [25] [26]
[5]
[1] [6]
[2] [7]
[3] [8]
[4] [9]
[22]
[21]
[20]
[19] [11]
[14]
[17] [15]
[18]
[10] [12]
[16]
[10] [13]
50gat1e001na
[1] Reverse automatic document feeder [15] Dehumidifier heater *2

(DF-607) (standard equipment) [16] Relay unit (RU-502)
[2] Main body [17] Finisher (FS-511)
[3] Image controller (IC-204) [18] Swedish punch kit G *3
[4] Hard disk (HD-505) [19] Job separator (JS-502)
[5] Stamp unit (SP-501) [20] Output tray kit (OT-501)
[6] Spare TX marker stamp 2 [21] Output tray (OT-601)
[7] Key counter kit 4 *1 [22] Finisher (FS-510)
[8] Key counter *1 [23] Mail bin kit (MT-501)
[9] Key counter mount kit *1 [24] Saddle stitcher (SD-502)
[10] Dehumidifier heater 1C [25] Folding unit (included in SD-502)
[11] Paper feed cabinet (PC-402) [26] Punch unit (PU-501)
[12] Paper feed cabinet (PC-202) [27] FAX kit (FK-502)
[13] Desk (DK-501) [28] Mount kit (MK-708)
[14] Large capacity unit (LU-201)
*1 See "6.4 Option counter" in Field Service bizhub 500 / 420 main body for details.
*2 Dehumidifier heater is set up as service part.
*3 Swedish punch kit G is for Europe only.
1
1. SYSTEM CONFIGURATION Theory of Operation Ver1.0 Feb.2006
B. Configuration for optional device connection

bizhub 500 / 420
Note
• Any combination other than those listed below is not available.
No. Combinations for paper feeding Combinations for finishing Remarks

1 DK-501/PC-202/PC-402 *1 OT-501
2 DK-501/PC-202/PC-402 *1 OT-501 JS-502
3 DK-501/PC-202/PC-402 *1 RU-502 + FS-511
4 DK-501/PC-202/PC-402 *1 FS-510 *2*3
5 DK-501/PC-202/PC-402 *1 FS-510 *2*3 SD-502
6 DK-501/PC-202/PC-402 *1 FS-510 *2*3 MT-501
7 PC-202/PC-402 *4 LU-201 OT-501
8 PC-202/PC-402 *4 LU-201 OT-501 JS-502
9 PC-202/PC-402 *4 LU-201 RU-502 + FS-511
10 PC-202/PC-402 *4 LU-201 FS-510 *2*3
11 PC-202/PC-402 *4 LU-201 FS-510 *2*3 SD-502
12 PC-202/PC-402 *4 LU-201 FS-510 *2*3 MT-501
*1 Either one of DK-501, PC-202 and PC-402 can be selected.

*2 FS-510 can be installed optionally with OT-601.
*3 FS-510 can be installed optionally with PU-501.
*4 Either one of PC-202 and PC-402 can be selected.
2
Theory of Operation Ver1.0 Feb.2006 2. PRODUCT SPECIFICATIONS
2. PRODUCT SPECIFICATIONS
bizhub 500 / 420

A. Type
Type Desktop type

Copying method Indirect electrostatic method
Original stand Fixed
Original alignment Left rear standard
Photo conductor OPC
Sensitizing method Laser writing
Paper feed trays Two trays 500 sheet x 2, 80g/m2
Bypass feed 150 sheet x 1, 80g/m2
PC-402 *1 2,500 sheet x 1, 80g/m2
PC-202 *1 500 sheet x 1, 80g/m2
LU-201 *1 2,000 sheet x 1, 80g/m2
*1 PC-402, PC-404, and LU-201 are optional.
3
2. PRODUCT SPECIFICATIONS Theory of Operation Ver1.0 Feb.2006
B. Functions
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Original Sheet, book, solid object

Max. original size A3 or 11 x 17
Copy size Trays 1, 2 Inch: 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S,
A3, A4, A4S, A5S, Foolscap
Metric: A3, B4, A4, A4S, B5, A5S, 11 x 17, 81/2 x 11,
81/2 x 11S, Foolscap, 8K, 16K
Bypass feed Inch: 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S,
A4
Metric: A3, B4, A4, A4S, B5, B5S, A5S, B6S, 81/2 x 11,
81/2 x 11S, Foolscap, 8K, 16K, 16KS
ADU Inch: 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S,
Metric: A3, B4, A4, A4S, B5, B5S, A5S, 11 x 17, 81/2 x 11,
81/2 x 11S, Foolscap
Magnification Fixed magnifica- Inch: x 1.000, x 1.214, x 1.294, x 1.545, x 2.000
tion x 0.500, x 0.647, x 0.772, x 0.785
Metric: x 1.000, x 1.154, x 1.224, x 1.414, x 2.000
x 0.500, x 0.707, x 0.816, x 0.866
Special magnifi- x 0.930
cation setting
Preset zoom set- 3 types
ting
Zoom magnifica- x 0.25 to x 4.00 (at the step of 0.1%)
tion
Vertical magnifi- x 0.25 to x 4.00 (at the step of 0.1%)
cation
Horizontal magni- x 0.25 to x 4.00 (at the step of 0.1%)
fication
Warm-up time 60 seconds or less (bizhub 500)
30 seconds or less (bizhub 420)
First copy out time 3.2 seconds or less (bizhub 500)
3.6 seconds or less (bizhub 420)
Continuous copy speed 50 copies /min. (A4 / 81/2 x 11) (bizhub 500)
42 copies /min. (A4 / 81/2 x 11) (bizhub 420)
Continuous copy count Up to 999 sheets
Original density selection Auto density selection, Manual (9 steps), Manual underprint density (9 steps)
Resolution Scan 600 x 600 dpi
Write Inch: 1,200 (equivalent) x 600 dpi
Metric: 2,400 (equivalent) x 600 dpi
Memory Standard 192 MB Breakdown: 64 MB (on board) + 128 MB (DIMM)
Maximum 320 MB Breakdown: 64 MB (on board) + 256 MB (DIMM) *1
Interface section RJ45 Ethernet, Serial port (RS232-C), Serial port (USB TypeB),
Parallel port (IEEE1284), RJ-11 *2
*1 256 MB (DIMM) is available from distributors.
Specification: 144 pin SO-DIMM, PC100/PC133 MHz Compliant
*2 1 port when MK-708 and FK-502 are optionally installed.
4
Theory of Operation Ver1.0 Feb.2006 2. PRODUCT SPECIFICATIONS
C. Type of paper
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Plain paper *1 All trays High quality paper of 60 to 90 g/m2
Special paper *2 Bypass feed only OHP film, label paper *3, blueprint master paper *3
High quality paper of 50 to 59 g/m2 (thin paper)
All trays High quality paper of 91 to 105 g/m2 (thick paper)
Bypass feed only High quality paper of 106 to 210 g/m2 (thick paper)
*1 Standard specified paper

Plain paper: Inch: Hammermill Tidal MP (20 lbs)
Metric: Konica Minolta Original (80 g/m2), Konica Minolta Profi (80 g/m2)
Recycle paper: Inch: Weyerhaeuser Recycled Laser Copy (20 lbs)
Metric: Nautilus (80 g/m2)
*2 Special paper/recommended paper
Thick paper: Inch: Weyerhaeuser Cougar Cover 65 lbs
Metric: Xerox colortech 200 g/m2
Thin paper: Inch: SOISE BOND 16 lbs
Metric: NEU 60 g/m2
Label paper: Inch: AVERY 5160, 5352
Metric: AVERY DSP 24
OHP film: Inch: 3M CG3700
Metric: Folex overhead X-500, 3M CG3700
Envelope: Inch: Preservation Wove (24 lbs) #6-3/4, #9, #10 (4-1/8 x 9-1/2)
Metric: Briefhullen 211210 (100 g/m2) #C6
Schneider Soehne Distinction 100 (100 g/m2) #lang
Schneider Soehne (Briefumschlage) (100 g/m2) #C5
*3 Label paper is loaded and fed one sheet at a time.
D. Maintenance
Maintenance Every 250,000 prints

Machine service life 2,250,000 prints or 5 years (whichever earlier) (bizhub 500)
1,800,000 prints or 5 years (whichever earlier) (bizhub 420)
E. Machine data
Power source Inch: AC120V 12A, 60Hz

Metric: AC220-240V 10A, 50Hz
Maximum power consump- 1,560 W or less (full option)
tion
Dimensions Main body 677 (W) x 708 (D) x 1,150 (H) mm *1
+ DF-607
+ PC or DK
Weight Approx. 91.2 kg
*1 Overturning prevention board is not included.
5
2. PRODUCT SPECIFICATIONS Theory of Operation Ver1.0 Feb.2006
F. Operating environment
bizhub 500 / 420
Temperature 10 to 30 °C
Humidity 10 to 80%RH (with no condensation)
Note
• The information herein may be subject to change for improvement without notice.
6
Theory of Operation Ver1.0 Feb.2006 3. UNIT CONFIGURATION
3. UNIT CONFIGURATION
bizhub 500 / 420

[17]
[1]
[2]
[16]
[15] [3]
[14]
[4]
[5]
[13]
[6]
[12]
[7]
[8]
[11]
[9]
[10]
50gat1c002na
[1] Scanner section [10] PC or DK (option)

[2] Paper reverse/exit section [11] Paper feed section (tray 1/2)
[3] Fusing section [12] Developing section
[4] Photo conductor section [13] Writing section
[5] ADU [14] Charging section
[6] Transfer/separation section [15] Toner supply section
[7] Registration section [16] Cleaning/toner recycle section
[8] Bypass tray section [17] DF
[9] LU (option)
7
4. PAPER PATH Theory of Operation Ver1.0 Feb.2006
4. PAPER PATH
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[1]
[9]
[8]
[7]
[2]
[6]
[3]
[5] [4]
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[1] Reverse conveyance [6] Tray 2 paper feed

[2] ADU conveyance [7] Tray 1 paper feed
[3] Bypass paper feed [8] Registration conveyance
[4] LU paper feed [9] Paper exit
[5] PC paper feed
8
Theory of Operation Ver1.0 Feb.2006 5. OVERALL CONFIGURATION
bizhub 500 / 420

5. OVERALL CONFIGURATION
5.1 Time chart when the power is turned ON
[1] [2] [3][4] [5] [6] [7] [8] [9]
Item
Normal
Scanner motor rotation
(M2) Reverse
rotation
Exposure lamp (L1)
Fusing heater lamp /1 (L2)
Fusing heater lamp /2 (L3)
Fusing motor (M11)
Drum motor (M1)
Developing motor (M3)
Polygon motor (M5)
Laser (LDB)
Paper lift motor /1 (M7)
Upper limit sensor /1 (PS6)
Paper lift motor /2 (M8)
Upper limit sensor /2 (PS13)
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[1] Fusing heater lamps /1 (L2) and /2 (L3) turn [5] Drum motor (M1) turns ON
ON early [6] Dot diameter adjustment starts
[2] Power switch (SW2) turns ON [7] The fusing temperature gets to the pre-
[3] Initial communication between the overall scribed temperature to start the preliminary
control board (OACB) and the printer control rotation for fusing
board (PRCB) [8] Dot diameter adjustment completed
[4] Shading correction [9] Warming up completed
Note
• Each operation varies according to the setting of the software DipSW in the service mode.
• The power is turned ON with DF closed.
• The power is turned ON with the lift plate of the tray down.
9
5. OVERALL CONFIGURATION Theory of Operation Ver1.0 Feb.2006
5.2 Control block diagram

bizhub 500 / 420
CCD HDD IC FK, MK USB RS232C LAN Parallel OB

I/F I/F I/F I/F
OACB
SC
Write
Section DF
M FM CL SD PS
PRCB
SDB DCPU HV
M PS
JS LU PC FS, RU
[1] [2] [3] [4] [5] [6]

50gat2c090na
[1] Image bus [4] Other buses

[2] Clock synchronous serial bus [5] Individual signal line
[3] UART bus [6] IDE
10
Theory of Operation Ver1.0 Feb.2006 6. SCANNER SECTION
6. SCANNER SECTION
bizhub 500 / 420

6.1 Composition
CCD unit
Mirror unit (CCDB)
Exposure unit
Shading
correction
plate
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6.2 Drive
[4]
[3]
[5]
[1]
[2]
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[1] Scanner wire /Rr [4] Exposure unit

[2] Scanner wire /Fr [5] Scanner motor (M2)
[3] V-mirror unit
11
6. SCANNER SECTION Theory of Operation Ver1.0 Feb.2006
6.3 Operation
bizhub 500 / 420
6.3.1 Scan/exposure lamp control

A. Operation when the power is turned ON
A specified period of time after the power switch (SW2) is turned on, the exposure unit conducts the home posi-
tion search. At this time, the exposure unit conducts the shading correction based on the white reference board
attached to the original glass. For shading correction, 2 places on the white reference board are read for correc-
tion. The home position search varies according to the ON/OFF condition of the scanner home sensor (PS30)
when SW2 is turned ON.
(1) Home position search while in PS30 ON
[2] [1]
[3]
[6]
[4]
[5]
50gat2c034na
[1] Exposure unit stand-by position [4] Shading correction position 2

[2] Scanner home sensor (PS30) [5] Movement of the exposure unit
[3] Shading correction position 1 [6] Exposure lamp (L1) ON
(2) Home position search while in PS30 OFF
[2] [1]
[3]
[6]
[4]
[5]
50gat2c035na

[2] Scanner home sensor (PS30) [5] Movement of the exposure unit
[3] Shading correction position 1 [6] Exposure lamp (L1) ON
12
B. Operation when the start key is turned ON

For the original read mode, the following two types are available: the platen mode and the DF mode. While in the
bizhub 500 / 420

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

The operation in the platen mode varies depending on which is selected for the print density, the AE print and
the manual print.
• When the AE print is selected
[4] [3] [2] [1]
[5]
[6]
[7]
[8]
50gat2c037na
[1] Exposure unit stand-by position [5] AE scan range

[2] Position at which the image read is started [6] Shading correction position 1
[3] Scanner home sensor (PS30) [7] Shading correction position 2
[4] Position at which the running-up of the [8] Exposure lamp (L1) ON
exposure unit is started
• When the manual print is selected
[4] [3] [2] [1]
[5]
[6]
[7]
50gat2c036na

[2] Position at which the image read is started [6] Shading correction position 2
[3] Scanner home sensor (PS30) [7] Exposure lamp (L1) ON
[4] Position at which the running-up of the
exposure unit is started
Note
• When the tray 1 is selected by manual, not by APS, no shading correction is made.
13
(2) When DF is used (when DF is closed)

bizhub 500 / 420
[3] [2] [1]
[4]
[5]
[6]
50gat2c038na

[2] Scanner home sensor (PS30) [5] Shading correction position 2
[3] DF read position [6] Exposure lamp (L1) ON
14
6.3.2 Original size detection control

A. Detection method
bizhub 500 / 420

The original size detection method varies for the DF mode and the platen mode.
(1) DF mode
See DF-607 Service Manual.
(2) Platen mode

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

(Detection length: mm) (ON/OFF)
A3 297 ON
11 x 17 279.4 ON
B4 257 ON
81/2 x 14 *1 215.9 ON
81/2 x 11S 215.9 ON
A4S 210 ON
A4 297 OFF
81/2 x 11 279.4 OFF
B5 257 OFF
A5 210 OFF
B5S 182 OFF
A5 148 OFF
51/2 x 81/2 139.7 OFF
B6 128 OFF
*1 No discrimination is made between 81/2 x 14 and 81/2 x 11S. When the size is 81/2 x 14, this is detected as
81/2 x 11S.
B. Detection timing
(1) Platen mode (while in DF closed)
When the APS timing sensor (PS31) turns on while in DF closed, the original size is detected.
(2) Platen mode (while in DF open)

When the start key is pressed, the original size is detected.
15
6.3.3 AE control
When AE is selected, the density level of the original is detected to adjust it to an appropriate density automati-
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cally. The sampling range of the original density in the AE control varies for the platen mode and the DF mode.
(1) AE sampling range in the platen mode
[5]
[1]
[7]
[6]
[5]
[2] [2]
[4]
[3]
50gat2c039na
[1] Original [5] 10 mm

[2] L/100 mm [6] Leading edge of the original
[3] L mm [7] AE sampling range
[4] 30 mm
(2) AE sampling range in the DF mode
[4]
[1]
[6]
[5]
[4]
[3] [2]
50gat2c040na

[2] 2.9 mm [5] Leading edge of the original
[3] 1.5 mm [6] AE sampling range
16
6.3.4 Image processing

The following items are provided for the image processing. For details, See "22. IMAGE PROCESSING".
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• AOC (Auto offset control)
• AGC (Auto gain control)
• Shading correction
• AE processing
• Range discrimination
• Brightness/density conversion
• Filter/magnification
• Density gamma (conversion)
• Halftone processing (error diffusion)
• Skew adjustment
• Compression
• Storage of image data
17
7. WRITE SECTION Theory of Operation Ver1.0 Feb.2006
7. WRITE SECTION
bizhub 500 / 420
7.1 Composition
Collimator lens unit Cleaner CY2 lens Index lens

Laser drive board (LDB) Dust-proof glass
Index mirror
CY1 lens fθ lens

Polygon mirror Index board (INDEXB)
50gat2c003na
18
Theory of Operation Ver1.0 Feb.2006 7. WRITE SECTION
7.2 Operation
bizhub 500 / 420

7.2.1 Laser beam path
[10]
[9]
[8]
[7] [1]
[6]
[2]
[5]
[3]
[4]
50gat2c041na
[1] Dust-proof glass [6] Polygon mirror

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

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

The following items are provided for the image stabilization control. For details, See "21. IMAGE STABILIZATION
CONTROL".
• MPC (Maximum power control)
• APC (Auto power control)
• Dot diameter adjustment control
19
7. WRITE SECTION Theory of Operation Ver1.0 Feb.2006
7.2.4 Image processing

The following items are provided for the image processing. For details, See "22.2 Image processing in the write
bizhub 500 / 420
section".
• Rotation/elongation
• 2 dots PWM
• PWM
• Frequency conversion
20
Theory of Operation Ver1.0 Feb.2006 8. PHOTO CONDUCTOR SECTION
8. PHOTO CONDUCTOR SECTION
bizhub 500 / 420

8.1 Composition
Drum Drum claw PGC sensor IDC sensor (IDCS)
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21
8. PHOTO CONDUCTOR SECTION Theory of Operation Ver1.0 Feb.2006
8.2 Drive
bizhub 500 / 420
8.2.1 Drum drive
[1]
[2]
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[1] Drum motor (M1) [2] Drum drive shaft
8.2.2 Drum claw drive
[1]
[2]
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[1] Drum claw [2] Drum claw solenoid (SD2)
22
Theory of Operation Ver1.0 Feb.2006 8. PHOTO CONDUCTOR SECTION
8.3 Operation
bizhub 500 / 420

8.3.1 Image creation control
When the print start signal turns ON [1], various motors turn ON to place each unit in the operating condition. At
the same time, the erase lamp (EL) turns ON to neutralize the drum and the charging corona charges the drum.
A specified period of time after the print start signal turns ON, the developing bias turns ON [2] and then a high
voltage is impressed [3] on the guide plate. When the preparation for image creation is made, an image is cre-
ated on the drum surface by laser irradiation and developing.
A specified period of time after the registration clutch (CL1) turns ON [4], a high voltage is impressed on the
transfer corona [5] and the separation corona [6] to turn ON the transfer exposure lamp (TSL) [8] and the drum
claw solenoid (SD2) [9] sequentially. The ON timing [7] of TSL varies according to the type of paper. And the ON
time period of TSL also varies according to the setting environment. An image created on the drum is transferred
onto paper and then the paper is separated from the drum.
A specified period of time after the registration sensor (PS1) detects the trailing edge of paper and turns OFF
[10], each operation turns OFF. However, some operations turn OFF a specified period of time after PS1 detects
the trailing edge of the last paper and turns OFF [11], or a specified period of time after the fusing exit sensor
(PS3) detects the trailing edge of the last paper and turns OFF [13]. For the charging corona, the developing bias
and the guide plate bias, with the OFF timing [12] by the last paper of the transfer corona used as a starting
point, each of the OFF timing is interlocked.
[1][2] [3] [4][5] [6] [10] [11]
Drum motor (M1)
Registration sensor (PS1)
Registration clutch (CL1)
Erase lamp (EL)
Charging corona (HV)
Developing bias (HV)
Transfer corona (HV)
Separation corona (HV)
Guide plate bias (HV)
Transfer exposure lamp (TSL)
Drum claw solenoid (SD2)
Fusing exit sensor (PS3)
[13]
[7] [8] [9] [12] 50gat2c103na
[1] Print start signal ON [8] Transfer exposure lamp (TSL) ON (This var-
[2] Developing bias high voltage impressed ies according to the setting environment.)
[3] Guide plate bias high voltage impressed [9] Drum claw solenoid (SD2) ON
[4] Registration clutch (CL1) ON [10] Trailing edge of the 1st paper detected
[5] Transfer corona high voltage impressed [11] Trailing edge of the last paper detected
[6] Separation corona high voltage impressed [12] Transfer of the last paper OFF
[7] Varies according to the type of paper. [13] Trailing edge of the last paper detected
23
8. PHOTO CONDUCTOR SECTION Theory of Operation Ver1.0 Feb.2006
8.3.2 Drum claw control

bizhub 500 / 420
A. Purpose
Two drum claws are employed to prevent paper from winding up around the drum (winding-up jam). The contact
and severance of the drum claws to and from the drum are made by the ON/OFF of the drum claw solenoid
(SD2).
B. Swing operation
To prevent paper from getting stained at specific points and the drum [3] from being damaged, the drum claw [2]
makes a swing operation of about 7 mm against the drum surface.
The drum claw unit [4] is provided with a projection [7]. This projection is pressed by the cam [6] provided on the
gear [5] to push out the drum claw unit backward. When the gear rotates to release the cam, the drum claw unit
is sent back to the original position by the spring [1]. This operation is repeated to swing the drum claw.
[5] [6] [7] [1]
[4] [3] [2]

50gat2c042na

The following items are provided for the image stabilization control. For details, See "21. IMAGE STABILIZATION
CONTROL".
• Drum rotation control
• Dot diameter adjustment control
24
Theory of Operation Ver1.0 Feb.2006 9. CHARGING SECTION
9. CHARGING SECTION
bizhub 500 / 420

9.1 Composition
Erase lamp (EL) Charging wire Charging control plate
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9.2 Operation
9.2.1 Charging control
A. Charging wire
The high voltage unit (HV) pressurizes 24V DC to impress a minus (–) DC voltage on the charging wire for dis-
charge.
Charging output range: –500 to –1100 µA
B. Charging grid
To obtain a uniform charging wire discharge, a minus (–) high voltage is impressed from the high voltage unit
(HV) to the charging grid.
Charging grid voltage output range: –450 to –1090 V
9.2.2 Erase lamp (EL) control

A. Purpose
To neutralize a residual potential on the drum surface and to obtain a uniform potential on the drum surface, the
erase lamp (EL) is irradiated on the drum before charging.
B. Execution timing
The erase lamp (EL) turns ON in synch with the print start signal turning ON. And it turns OFF a specified period
of time after the fusing exit sensor (PS3) detects the trailing edge of the last paper.
25
10. TRANSFER/SEPARATION SECTION Theory of Operation Ver1.0 Feb.2006
10. TRANSFER/SEPARATION SECTION

bizhub 500 / 420
10.1 Composition
Plunging prevention plate Transfer wire
Separation wire Transfer exposure lamp (TSL)

50gat2c008na
26
Theory of Operation Ver1.0 Feb.2006 10. TRANSFER/SEPARATION SECTION
10.2 Operation
bizhub 500 / 420

10.2.1 Transfer guide control
A. Purpose
To prevent the transfer guide plate from getting stained, a minus (–) DC voltage is impressed from the high volt-
age unit (HV).
Voltage impressed: –500 V
B. Execution timing
The impression of a voltage onto the transfer guide plate is made ON a specified period of time after the devel-
oping bias turns ON. And it turns OFF a specified period of time after the developing bias turns OFF.
10.2.2 Transfer/separation control

A. Transfer
The high voltage unit (HV) pressurizes a 24V DC to impress a plus (+) DC voltage on the transfer wire for dis-
charging.
Transfer DC output range: 0 to –450 µA
B. Separation
For separation, an AC high voltage and a minus (–) DC voltage are employed. The high voltage unit (HV)
impresses a voltage onto the separation wire for discharging.
Separation AC output range: 300 to 1000 µA
Separation DC output range: 0 to –200 µA
10.2.3 Transfer exposure lamp (TSL) control

A. Purpose
The transfer exposure lamp (TSL) is turned ON to secure transferability and prevent a reverse charge to the
drum.
B. Execution timing
The transfer exposure lamp (TSL) turns ON a specified period of time after the registration clutch (CL1) turns ON.
And it turns OFF a specified period of time after the registration sensor (PS1) turns OFF.
27
11. DEVELOPING UNIT Theory of Operation Ver1.0 Feb.2006
11. DEVELOPING UNIT

bizhub 500 / 420
11.1 Composition
Developing roller Developer restriction blade
TCR sensor (TCRS) Agitator screw Agitator plate

50gat2c009na
28
Theory of Operation Ver1.0 Feb.2006 11. DEVELOPING UNIT
11.2 Drive
bizhub 500 / 420

[6]
[5]
[4]
[1]
[3]
[2]
50gat2c010na
[1] Drum [4] Agitator screw

[2] Developing roller [5] Developing unit
[3] Developing motor (M3) [6] Agitator plate
29
11.3 Operation
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11.3.1 Developer conveyance

Developer in the developing unit is supplied by the agitator plate [4] to the developing roller [2]. The thickness of
developer attaching to the developing roller is restricted by the developer restriction blade [5]. After completion
of transfer to the drum [1], developer remaining on the developing roller is sent back to the agitator screws [3].
The 2 agitator screws rotate in the same direction to obtain an improved conveyability when developer is
changed.
[3] [4] [5]
[1]
[2]
50gat2c043na
[1] Drum [4] Agitator plate

[2] Developing roller [5] Developer restriction blade
[3] Agitator screw
30
Theory of Operation Ver1.0 Feb.2006 11. DEVELOPING UNIT
11.3.2 Developing bias

A. Purpose
bizhub 500 / 420

To make toner get easily attached to the drum while in developing, a developing bias is impressed onto the
developing roller [1].
[2] [3] [4]
[1]
50gat2c044na
[1] Developing roller [3] Developing bias shaft

[2] Main pole position adjusting plate [4] Developing bias contact
B. Timing
To prevent unnecessary carriers from attaching to the drum, a developing bias turns ON a specified period of
time after the print start signal turns ON, and it turns OFF a specified period of time after charging turns OFF.
31
11.3.3 Developing suction control

bizhub 500 / 420
A. Purpose
To prevent the splash of toner from the developing roller, the duct [4] is provided at 2 places of the developing
unit [1]. Toner guided into the duct is sucked in by the developing suction fan (FM6) [3] to be collected by the
suction filter /A [2].
[3]
[4]
[2]
[1]
50gat2c045na
[1] Developing unit [3] Developing suction fan (FM6)

[2] Suction filter /A [4] Duct
B. Developing suction fan (FM6) control

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

The following item is provided for the image stabilization control. For details, See "21. IMAGE STABILIZATION
CONTROL".
• Toner density control
32
Theory of Operation Ver1.0 Feb.2006 12. TONER SUPPLY SECTION
12. TONER SUPPLY SECTION
bizhub 500 / 420

12.1 Composition
Toner bottle position

Toner remaining sensor Toner supply motor sensor (PS28) Toner bottle sensor (PS4)
(PZS) (M4)
Toner bottle motor (M10) Toner hopper
Toner bottle
50gat2c011na
33
12. TONER SUPPLY SECTION Theory of Operation Ver1.0 Feb.2006
12.2 Drive
bizhub 500 / 420
[5]
[4]
[1]
[2]
[3]
50gat2e003na
[1] Toner agitator plate [4] Toner bottle motor (M10)

[2] Toner conveyance screw [5] Toner supply motor (M4)
[3] Toner solenoid (SD5)
34
Theory of Operation Ver1.0 Feb.2006 12. TONER SUPPLY SECTION
12.3 Operation
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12.3.1 Toner level detection control
A. Toner level detection control
Toner remaining in the toner hopper is detected by the toner remaining sensor (PZS). When toner remaining in
the hopper is found below the prescribed amount, a toner supply signal is issued to the printer control board
(PRCB). This signal is transmitted to the operation board (OB) through the overall control board (OACB). Accord-
ingly, OB displays a message in LCD on the LCD board (LCDB).
B. Detection timing
• At all times while in printing.
12.3.2 Toner supply control to the toner hopper

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

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

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

Less than 2.01 V 0 second
2.01 to 2.14 V 0.10 seconds
2.14 to 2.22 V 0.15 seconds
2.22 to 2.28 V 0.20 seconds
2.28 to 2.32 V 0.25 seconds
2.32 to 2.39 V 0.40 seconds
2.39 V or more 0.50 seconds
35
12. TONER SUPPLY SECTION Theory of Operation Ver1.0 Feb.2006
12.3.4 Toner conveyance control

bizhub 500 / 420
A. Purpose
To convey toner in the toner bottle to the toner hopper.
B. Operation
The exit [1] of the toner bottle is normally closed. However, by setting the bottle to the toner supply section, the
accordion section is pushed and compressed to let the exit open. A bottle set to the toner supply section
rotates when the toner bottle motor (M10) turns ON. When the toner bottle rotates, toner is conveyed to the exit
of the bottle along the spiral groove engraved on the surface of the toner bottle and flows out into the toner hop-
per.
[1]
D C B A
[2]
D C B
A
50gat2e002na
[1] Exit [2] Rotation
36
Theory of Operation Ver1.0 Feb.2006 13. CLEANING/TONER RECYCLE SECTION
13. CLEANING/TONER RECYCLE SECTION
bizhub 500 / 420

13.1 Composition
Collection screw Scraper Collection paddle
Cleaning blade Drum Neutralizing sheet
50gat2c013na
37
13. CLEANING/TONER RECYCLE SECTION Theory of Operation Ver1.0 Feb.2006
13.2 Drive
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[1]
[2]
[3]
50gat2c014na
[1] Drum motor (M1) [3] Developer agitation drive

[2] Cleaning/recycle section drive
38
Theory of Operation Ver1.0 Feb.2006 13. CLEANING/TONER RECYCLE SECTION
13.3 Operation
bizhub 500 / 420

13.3.1 Cleaning operation
Toner scraped by the cleaning blade [4] is neutralized by the neutralizing sheet [2], then collected by the collec-
tion paddle [1], and finally guided to the collection screw [5]. At this time, toner remaining on the collection pad-
dle is scraped by the scraper [6].
[5] [6]
[1]
[4]
[3]
[2]
50gat2c047na
[1] Collection paddle [4] Cleaning blade

[2] Neutralizing sheet [5] Collection screw
[3] Drum [6] Scraper
13.3.2 Toner collection mechanism

A. Purpose
To reuse toner scraped by the cleaning blade, the toner collection mechanism is provided.
B. Execution timing
The collection paddle to be used to collect toner is driven by the drum motor (M1) and the toner collection oper-
ation is made in synch with the ON/OFF of M1.
13.3.3 Toner conveyance operation

A. Toner conveyance mechanism
Toner collected is conveyed to the hopper in the toner supply section by the collection screw of the cleaning
section.
B. Execution timing
The collection screw is driven by the drum motor (M1) and the toner conveyance operation is made in synch
with the ON/OFF of M1.
39
14. PAPER FEED SECTION (Tray 1/2) Theory of Operation Ver1.0 Feb.2006
14. PAPER FEED SECTION (Tray 1/2)

bizhub 500 / 420
14.1 Composition
14.1.1 Tray 1
Pick-up roller
Lift plate Feed roller
Separation roller
Tray 1
50gat2c015na
14.1.2 Tray 2
Vertical conveyance roller

Pick-up roller
Feed roller
Lift plate
Separation roller
Tray 2
50gat2c104na
40
Theory of Operation Ver1.0 Feb.2006 14. PAPER FEED SECTION (Tray 1/2)
14.2 Drive
bizhub 500 / 420

14.2.1 Paper feed drive
[1]
[13]
[12] [2]
[3]
[4]
[5]
[6]
[7]
[11] [10]
[8]
[9]
50gat2c016na
[1] Feed motor (M9) [8] Feed roller /2

[2] Feed clutch /1 (CL4) [9] Separation roller /2
[3] Feed roller /1 [10] Pick-up roller /2
[4] Separation roller /1 [11] Tray 2
[5] Vertical conveyance roller [12] Tray 1
[6] Vertical conveyance clutch (CL3) [13] Pick-up roller /1
[7] Feed clutch /2 (CL5)
14.2.2 Tray lift drive
[3][4]
[1]
[2] 50gat2c017na
[1] Lift arm [3] Paper lift motor /1 (M7)

[2] Lift plate [4] Paper lift motor /2 (M8)
41
14.3 Operation
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14.3.1 Up/down control

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

Pulling out the tray disengages the coupling [8] of the paper lift motors /1 (M7) and /2 (M8) from the lift drive
shaft. In this way, the driving force of M7 or M8 that holds the lift plate at the upper position is released and the
lift plate goes down by its own weight.
[6] [7] [8]
[9][10]
[1]
[4] [5]
[3] [2] 50gat2c051na
[1] Lift arm [6] Paper lift motor /1 (M7)

[2] Lift plate [7] Paper lift motor /2 (M8)
[3] Lift drive shaft [8] Coupling
[4] Tray set sensor /1 (PS8) [9] Upper limit sensor /1 (PS6)
[5] Tray set sensor /2 (PS14) [10] Upper limit sensor /2 (PS13)
C. Operation timing
When the tray is set, the tray set sensors /1 (PS8) and /2 (PS14) turn ON. In this way, the paper lift motors /1
(M7) and /2 (M8) turn ON to raise the lift plate. When the lift plate goes up and the upper most paper that is
loaded turns ON the upper limit sensors /1 (PS6) and /2 (PS13), M7 and M8 turn OFF to stop the up drive oper-
ation.
When the paper feed operation causes PS6 and PS13 to turn OFF from ON while in the print operation, M7 and
M8 turn ON again to raise the lift plate. In this way, when PS6 and PS13 turn ON again, M7 and M8 turn OFF to
stop the up drive operation.
42
14.3.2 Paper size detection control

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

The rear guide plate [13] is provided with the size detection actuator [1], which rotates in interlock with the rear
guide plate. The size detection actuator is provided with a projection [2]. When this projection comes at the rear
side of the tray, it pushes the detection levers [9] and [6] of the paper size boards /1 (PSB/1) [8] and /2 (PSB/2)
[6] equipped on the back of the main body. 4 detection levers are equipped on each of the paper size board and
they individually turn ON and OFF the paper size detection switches /1 (SW101) to /4 (SW104) provided on each
board. On the other hand, the projections of the size detection actuator vary in their circumterence and the inter-
vals between each of these projections, and accordingly, either one of the 4 detection levers is to be pushed
according to the position of the guide plate. In this way, the paper size in the sub scan direction is detected by
the combination of the ON/OFF of SW101 to SW104.
[12] [13] [1]
[8] [9] [10] [11]
[7] [6][5] [4] [3] [2] 50gat2c048na
[1] Size detection actuator [8] Paper size board /1 (PSB/1)

[2] Projection [9] Detection lever
[3] Paper size sensor /Fr2 (PS17) [10] Paper size sensor /Rr1 (PS10)
[4] Paper size sensor /Rr2 (PS16) [11] Paper size sensor /Fr1 (PS11)
[5] Detection lever [12] Side guide plate
[6] Paper size board /2 (PSB/2) [13] Rear guide plate
[7] Size detection actuator
43
B. Paper size detection table

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Paper size Paper size boards /1 (PSB/1), /2 (PSB/2) Paper size sensor Paper size sensor
SW101 SW102 SW103 SW104 /Rr1 (PS10), /Rr2 /Fr1 (PS11), /Fr2
(PS16) (PS17)
B5 ON ON OFF OFF ON OFF
A5S ON/OFF OFF OFF OFF OFF OFF
A4 ON/OFF OFF OFF OFF ON OFF
81/2 x 11 OFF OFF OFF OFF OFF OFF
81/2 x 11S ON OFF OFF ON OFF ON
B5S OFF OFF ON OFF OFF OFF
A4S OFF ON/OFF ON ON OFF ON
81/2 x 14 ON ON ON OFF ON ON
B4 ON ON ON OFF ON OFF
A3 ON ON/OFF ON ON ON OFF
44
14.3.3 Paper feed control

A. Pick-up mechanism
bizhub 500 / 420

The pick-up roller [4] is brought up and down mechanically by the lever [6] provided on the rear side of the paper
feed unit. When the tray is set, the lever is pushed by the tray to bring down the pick-up roller. In this way, the
pick-up roller comes in contact with paper to pick it up.
[6]
[1]
[5] [3]
[4] [2]
50gat2c098na
[1] Feed roller [4] Pick-up roller

[2] Separation roller [5] When the tray is not set (with the pick-up
[3] When the tray is set (with the pick-up roller roller brought up)
brought down) [6] Lever
45
B. Pick-up control
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(1) Tray 1 pick-up control

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

50gat2c099na
[1] Print start signal ON [3] Paper feed request signal

[2] Pick-up of the 1st paper [4] Pick-up of the 2nd paper
(2) Tray 2 pick-up control

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

50gat2c100na

[2] Pick-up of the 1st paper [5] Pick-up of the 2nd paper
[3] Vertical conveyance of the 1st paper [6] Vertical conveyance of the 2nd paper
46
C. Separation mechanism
The separation roller [5] is pressed against the feed roller [8] by the operating pressure generated by the pres-
bizhub 500 / 420

sure [2] of the spring [4] and the torque of the torque limiter [3]. This operating pressure of the feed roller, sepa-
ration roller and torque limiter becomes a limit torque to prevent the double feed of paper.
When there is no paper between the separation roller and the feed roller, or when only one sheet of paper is con-
veyed, the operating pressure of the feed roller, the paper and the spring is in excess of the limit torque, and
therefore, the separation roller rotates [6] following the rotation of the feed roller. When two or more sheets of
paper are conveyed between the separation roller and the feed roller, the limit torque is greater than the frictional
force between 2 sheets of paper, and accordingly, the separation roller stops and the lower side paper [7] in
contact with the separation roller is not conveyed.
[8] [1]
[2]
[3]
[7] [6] [5] [4]

50gat2c101na
[1] Paper conveyance direction [5] Separation roller

[2] Pressing [6] Driven rotation
[3] Torque limiter [7] 2nd sheet of paper
[4] Spring [8] Feed roller
47
14.3.4 Paper empty control

The paper empty of the tray is detected by the paper empty sensors /1 (PS5) [3] and /2 (PS12) [4]. And to
bizhub 500 / 420
prompt the supply of paper before paper in the tray runs out completely, the paper near-empty sensors /1 (PS9)
[7] and /2 (PS15) [8] are equipped. The lift drive shaft [2] that brings up the lift plate [5] is provided with the actu-
ator [1] and PS9 and PS15 are turned ON and OFF by this actuator. When a sufficient amount of paper is loaded
on the tray, the actuator turns ON PS9 and PS15. However, when the amount of paper gets reduced and the lift
plate goes up, the actuator turns OFF PS9 and PS15. In this way, it is detected that the paper loaded in the tray
comes near to an end.
[7] [8]
[1]
[2]
[3][4]
[6] [5]
50gat2c050na
[1] Actuator [5] Lift plate

[2] Lift drive shaft [6] Coupling
[3] Paper empty sensor /1 (PS5) [7] Near-empty sensor /1 (PS9)
[4] Paper empty sensor /2 (PS12) [8] Near-empty sensor /2 (PS15)
48
14.3.5 Paper remaining detection mechanism

The front cover [4] of the tray is provided with the paper remaining display window [3], and the paper remaining
bizhub 500 / 420

in the tray can be checked through this window. The inside of the paper remaining display window is provided
with the display lever [2] which is interlocked with the up/down position of the lift plate [1]. The display lever is red
in color and it is indicated that the more the red portion that can be seen through the paper remaining display
window, the less paper there remains in the tray.
[4] [1]
[3]
[2] 50gat2c053na
[1] Lift plate [3] Paper remaining display window

[2] Display lever [4] Front cover
49
15. BYPASS SECTION Theory of Operation Ver1.0 Feb.2006
15. BYPASS SECTION

bizhub 500 / 420
15.1 Composition
Pick-up solenoid /BP (SD1)
Feed roller
Separation roller Lift plate
50gat2c019na
50
Theory of Operation Ver1.0 Feb.2006 15. BYPASS SECTION
15.2 Drive
bizhub 500 / 420

[4]
[1] [2]
[3]
50gat2c018na
[1] Feed clutch /BP (CL6) [3] Separation roller

[2] Feed roller [4] Feed motor (M9)
[4] [5] [1]
[3] [2]
50gat2c020na
[1] Cam [4] Feed clutch /BP (CL6)

[2] Lift plate [5] Pick-up solenoid /BP (SD1)
[3] Spring
51
15.3 Operation
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15.3.1 Up/down control

A. Up drive operation
The lift plate [4] is of the construction in which it is pushed up by the spring [5] provided on the lower section.
However, while in the stand-by condition, it is hold down by the cam [3] provided on the lift drive shaft [6]. And
the ON/OFF of the gear [7] of the lift drive shaft is controlled by the stopper [1] that is driven by the pick-up sole-
noid /BP (SD1) [2]. When the feed motor (M9) is turned ON by a print start signal, SD1 turns ON a specified
period of time after that. In this way, the stopper is released and the driving force of M9 is transmitted to the lift
drive shaft. When the cam that holds down the lift plate is released by the rotation of the lift drive shaft, the lift
plate is brought up by the force of the spring. When the lift sensor (PS23) [8] is turned ON by the rotation of the
lift drive shaft, SD1 turns OFF to stop the up drive of the lift plate. This up drive operation causes paper loaded in
the tray to come in contact with the feed roller to allow paper to be fed.
[7] [8] [6]
[2] [1]
[6]
[5] [4] [3] 50gat2c054na
[1] Stopper [5] Spring

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

When the vertical conveyance sensor (PS2) detects the leading edge of paper and turns ON, the pick-up sole-
noid /BP (SD1) turns ON a specified period of time after that and turns OFF a specified period of time after the lift
sensor (PS23) turns OFF. In this way, the cam of the lift drive shaft presses down the lift tray to be placed in the
stand-by condition.
52
15.3.2 Paper size detection control

A. Size detection in the main scan direction
bizhub 500 / 420

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

The paper size is detected by the combination of the ON/OFF of the paper size sensors /BP1 (PS19), /BP2
(PS20), /BP3 (PS21) and /BP4 (PS22).
C. Paper size detection table
Paper size Paper size sensors Paper size VR/BP (VR1)

BP1 BP2 BP3 BP4 detection width (mm)
(PS19) (PS20) (PS21) (PS22)
A6S OFF OFF OFF OFF 80 or more - less than 115
B6S 115 or more - 144 or less
A5 196 or more - 225 or less
B5 242 or more - 268 or less
A5S ON OFF OFF OFF 133 or more - 164 or less
B5S 169 or more - less than 196
A4S 196 or more - 225 or less
81/2 x 11 225 or more - less than 288
A4 288 or more - 330 or less
Foolscap ON ON OFF OFF 188 or more - 235 or less
81/2 x 14 ON ON ON OFF 201 or more - 231 or less
B4 242 or more - less than 268
11 x 17 ON ON ON ON 255 or more - less than 288
A3 288 or more - less than 301
53

bizhub 500 / 420
A. Pick-up control
When the feed motor (M9) is turned ON by the print start signal [1], the pick-up solenoid /BP (SD1) and the ver-
tical conveyance clutch (CL3) also turn ON a specified period of time after that. When SD1 turns ON, the lift
plate goes up [2] and paper comes into contact with the feed roller. After that, the feed clutch /BP (CL6) turns
ON. Through these operations, the driving force of M9 is transmitted to the feed roller and the vertical convey-
ance roller to conduct the pick-up [3] and the vertical conveyance [4] of the 1st sheet of paper. When paper is
conveyed and the vertical conveyance sensor (PS2) turns ON, CL6 turns OFF to complete the pick-up opera-
tion. However, since CL3 keeps turning ON, paper is conveyed to the registration section by the vertical convey-
ance roller. In this way, when the registration sensor (PS1) turns ON, CL3 turns OFF a specified period of time
after that. The pick-up [6] and the vertical conveyance [8] of the 2nd and succeeding sheets of paper are con-
ducted using the paper feed request signal [5] as a starting point. When the last paper turns ON PS2, SD1 turns
ON to bring down [7] the lift plate.
[1] [3] [4] [5] [6] [8]
Feed motor (M9)
Vertical conveyance sensor (PS2)
Pick-up solenoid /BP (SD1)
Feed clutch /BP (CL6)
Vertical conveyance clutch (CL3)
[2] [7] 50gat2c102na

[2] Lift plate goes up [6] Pick-up of the 2nd paper
[3] Pick-up of the 1st paper [7] Lift plate goes down
[4] Vertical conveyance of the 1st paper [8] Vertical conveyance of the 2nd paper
54
B. Separation mechanism
The separation roller [7] is pressed against the feed roller [1] by the operating pressure generated by the pres-
bizhub 500 / 420

sure [4] of the spring [5] and the torque of the torque limiter [6]. This operating pressure of the feed roller, sepa-
ration roller and torque limiter becomes a limit torque to prevent the double feed of paper.
When there is no paper between the separation roller and the feed roller, or when only one sheet of paper is con-
veyed, the operating pressure of the feed roller, the paper and the spring is in excess of the limit torque, and
therefore, the separation roller rotates [3] following the rotation of the feed roller.
When two or more sheets of paper are conveyed between the separation roller and the feed roller, the limit
torque is greater than the frictional force between 2 sheets of paper, and accordingly, the separation roller stops
and the lower side paper [2] in contact with the separation roller is not conveyed.
[8] [1]
[7]
[6]
[5] [4] [3] [2]

50gat2c106na
[1] Feed roller [5] Spring

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

The paper empty of the tray is detected by the paper empty sensor /BP (PS18).
55
16. REGISTRATION SECTION Theory of Operation Ver1.0 Feb.2006
16. REGISTRATION SECTION

bizhub 500 / 420
16.1 Composition
Registration roller
Loop roller
50gat2c021na
56
Theory of Operation Ver1.0 Feb.2006 16. REGISTRATION SECTION
16.2 Drive
bizhub 500 / 420

[1]
[6]
[2]
[3]
[5]
[4]
50gat2c022na
[1] Registration roller [4] Loop roller

[2] Feed motor (M9) [5] Tray 1
[3] Loop clutch (CL2) [6] Registration clutch (CL1)
57
16. REGISTRATION SECTION Theory of Operation Ver1.0 Feb.2006
16.3 Operation
bizhub 500 / 420
16.3.1 Loop control

A. Registration path
Paper fed from the tray 1 [10], the tray 2 [8], the by-pass tray [6], PC/LU [7] and ADU [4] hits against the registra-
tion roller [2] through the loop roller [12]. And until the loop roller turns OFF, a loop is formed [3] and a paper
skew is corrected.
The loop roller is driven by the feed motor (M9) and the loop of paper is controlled by the registration sensor
(PS1) [13] equipped just before the registration roller.
[1]
[13]
[2]
[12]
[3]
[11]
[4]
[10]
[5]
[9]
[6]
[8] [7]
50gat2c055na
[1] Drum [8] Tray 2 paper conveyance

[2] Registration roller [9] Paper feed unit /2
[3] Loop [10] Tray 1 paper conveyance
[4] ADU paper conveyance [11] Paper feed unit /1
[5] Vertical conveyance section [12] Loop roller
[6] By-pass tray paper conveyance [13] Registration sensor (PS1)
[7] PC/LU paper conveyance
58
Theory of Operation Ver1.0 Feb.2006 16. REGISTRATION SECTION
B. Registration operation
The feed motor (M9) and the loop clutch (CL2) are turned ON by the print start signal [1]. In this way, the driving
bizhub 500 / 420

force of M9 is transmitted to the loop roller and paper conveyed from each of the paper feed sections is con-
veyed to the registration roller. When the registration sensor (PS1) detects the leading edge of paper and turns
ON [3], CL2 turns OFF a specified period of time after that. At this time, since paper is being conveyed for a
specified period of time after being hit against the registration roller, a loop [4] is formed and a paper skew is cor-
rected.
The print signal [5] turns ON the registration clutch (CL1) to transmit the driving force of M9 to the registration
roller. At this time, CL2 also turns ON to drive the loop roller for a loop assist [7].
When PS1 detects the trailing edge of paper and turns OFF [8], CL1 also turns OFF a specified period of time
after that to complete the registration operation. However, CL2 keeps tuning ON to conduct a loop formation [9]
of the next paper. After that, the same operations are repeated.
When PS1 detects the trailing edge of the last paper and turns OFF [11], M9, CL1 and CL2 also turn OFF a
specified period of time after that to complete a series of registration operations.
[1] [2] [3] [5] [7] [8] [10] [11]
Feed motor (M9)
Loop clutch (CL2)
[4] [6] [9] 50gat2c056na
[1] Print start signal [8] Detection of the trailing edge of the 1st
[2] Conveyance of the 1st paper paper
[3] Detection of the leading edge of 1st paper [9] Loop formation of the 2nd paper
[4] Loop formation of the 1st paper [10] Print signal for the 2nd paper
[5] Print signal for the 1st paper [11] Detection of the trailing edge of the last
[6] 1st paper registration roller ON paper
[7] Loop assist of the 1st paper, and convey-
ance of 2nd of paper
59
17. ADU SECTION Theory of Operation Ver1.0 Feb.2006
17. ADU SECTION

bizhub 500 / 420
17.1 Composition
Conveyance roller /1
Conveyance roller /2
50gat2c023na
60
Theory of Operation Ver1.0 Feb.2006 17. ADU SECTION
17.2 Drive
bizhub 500 / 420

[1] [2]
[3] [4]
[6]
[5] 50gat2c024na
[1] ADU conveyance clutch /Up (CL7) [4] Conveyance roller /2

[2] Conveyance roller /1 [5] Conveyance roller /3
[3] ADU conveyance clutch /Lw (CL8) [6] Feed motor (M9)
61
17.3 Operation
bizhub 500 / 420
17.3.1 Conveyance path

Paper the one side of which has been printed is conveyed to ADU by the reverse roller [12]. The paper conveyed
to ADU is also conveyed to the loop roller [6], the registration roller [7] and the drum [8] by the conveyance rollers
/1 [2], /2 [3] and /3 [5] and the other side is printed. Paper both sides of which has been printed passes through
the fusing roller [9] and fusing exit roller [10] to be exited from the main body paper exit roller [11].
The conveyance rollers /1, /2 and /3 are driven by the feed motor (M9), but the ON/OFF of the conveyance roller
/1 is controlled by the ADU conveyance clutch /Up (CL7) and that of the conveyance rollers /2 and /3 controlled
by the ADU conveyance clutch /Lw (CL8). This control is used to prevent the interference of each sheet of paper
that circulates through the conveyance path when two or more sheets of paper are printed. And, to detect the
position of paper that is circulating, the ADU conveyance sensor /1 (PS24) [1] and /2 (PS25) [4] are equipped.
[12]
[1]
[11]
[10] [2]
[9]
[3]
[8]
[7]
[4]
[6]
[5]
50gat2c057na
[1] ADU conveyance sensor /1 (PS24) [7] Registration roller

[2] Conveyance roller /1 [8] Drum
[3] Conveyance roller /2 [9] Fusing roller
[4] ADU conveyance sensor /2 (PS25) [10] Fusing exit roller
[5] Conveyance roller /3 [11] Main body paper exit roller
[6] Loop roller [12] Reverse roller
62
17.3.2 Conveyance control

When printing two or more sheets of paper in the double sided print mode, the conveyance control in ADU var-
bizhub 500 / 420

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

1 sheet self-contained double sided print B4 (364 mm) to Ledger (431.8 mm)
2 sheets self-contained double sided print Letter (215.9 mm) to B4 (364 mm)
3 sheets self-contained double sided print B5 (182 mm) to Letter (215.9 mm)
A. 1 sheet self-contained double sided print operation
Note
• A figure in the illustration (shown in the square) represents the page number.
1. With the 1st sheet of paper fed, the image of the

2nd page (the back side of the 1st sheet of paper
when the original is double sided) is printed.
50gat2c058na
2. The 1st sheet of paper is conveyed to the paper

reverse/exit section, and then conveyed to ADU
2 after being turned over.
50gat2c059na
63
3. The 1st sheet of paper in ADU is conveyed with-

bizhub 500 / 420
out interruption.
50gat2c060na
4. The 1st sheet of paper is fed again and the image

of the 1st page (the front side of the 1st sheet of
paper when the original is double sided) is printed.
1
2
50gat2c061na
5. With the 2nd sheet of paper fed while exiting the

1st sheet of paper, the image of the 4th page (the
back side of the 2nd sheet of paper when the
2
original is double sided) is printed.
1
6. After this, the procedure of steps 2 to 5 is
repeated.
50gat2c062na
64
B. 2 sheets self-contained double sided print operation
bizhub 500 / 420

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

50gat2c063na

reverse/exit section and then conveyed to ADU
2 after being turned over. At this time, the 2nd sheet
of paper is fed.
50gat2c064na
3. The image of the 4th page (the back side of the

2nd sheet of paper when the original is double
4 sided) is printed on the 2nd sheet of paper. At this
time, the 1st sheet of paper is conveyed into ADU.
50gat2c065na
65

bizhub 500 / 420

paper when the original is double sided) is printed.
4
At this time, the 3rd sheet of paper is fed and the
2nd sheet of paper is turned over at the paper
1 2
reverse/exit section to be conveyed into ADU.
50gat2c066na
5. While the 1st sheet of paper is being exited, the

image of the 6th page (the back side of the 3rd
sheet of paper when the original is double sided)
is printed on the 3rd sheet of paper. At this time,
2
the 2nd sheet of paper is standing by on this side
1
6 of the conveyance roller /3.
50gat2c067na
6. The 3rd sheet of paper is conveyed to ADU after

being turned over at the paper reverse/exit sec-
6 tion. At this time, the 2nd sheet of paper that has
been standing by is fed again.
2
1
50gat2c068na
7. The image of the 3rd page (the front side of the

2nd sheet of paper when the original is double
sided) is printed on the 2nd sheet of paper. At this
6
time, the 3rd sheet of paper has been conveyed
2
into ADU and the 4th sheet of paper is fed at the
1 3 4
same time.
50gat2c069na
66
8. While the 2nd sheet of paper is being exited, the
bizhub 500 / 420

image of the 8th page (the back side of the 4th
sheet of paper when the original is double sided)
is printed on the 4th sheet of paper. At this time,
4
the 3rd sheet of paper is standing by on this side
3 8
of the conveyance roller /3.
2
1
6
50gat2c070na
9. The 4th sheet of paper is turned over at the paper

reverse/exit section to be conveyed to ADU. At
8 this time, the 3rd sheet of paper that has been
standing by is fed again.
4
3
repeated.
2
1
6
50gat2c071na
67
C. 3 sheets self-contained double sided print operation

bizhub 500 / 420
Note
1. The 1st sheet of paper is fed and the image of the

50gat2c072na

reverse/exit section and then conveyed to ADU
2 after being turned over. At this time, the 2nd sheet
of paper is fed and the image of the 4th page (the
back side of the 2nd sheet of paper when the
original is double sided) is printed.
4
50gat2c073na
3. The 1st sheet of paper is standing by at the con-

veyance roller /3. The 2nd sheet of paper is turned
4 over at the paper reverse/exit section to be con-
veyed to ADU. At this time, the 3rd sheet of paper
is fed and the image of the 6th page (the back
side of the 3rd sheet of paper when the original is
6
double sided) is printed.
2
50gat2c074na
68
4. The 3rd sheet of paper is conveyed to the paper
bizhub 500 / 420

reverse/exit section and the 2nd sheet of paper is
6 4 conveyed in ADU without interruption. However,
the 1st sheet of paper remains standing by at the
conveyance roller /3.
50gat2c075na

6 paper when the original is double sided) is printed.
At this time, the 3rd sheet of paper is turned over
to be sent to ADU and the 2nd sheet of paper is
standing by at the conveyance roller /3. In this
1 2
way, the 4th sheet of paper is fed.
4
50gat2c076na
6. While the 1st sheet of paper is being exited, the

6 sheet of paper when the original is double sided)
2 since the 2nd sheet of paper is standing by at the
1 conveyance roller /3, the 3rd sheet of paper stops
8 when the interval between this sheet and the 2nd
4 sheet of paper comes to the prescribed distance.
50gat2c077na
7. The 4th sheet of paper is conveyed to the paper

reverse/exit section. At this time, the conveyance
8 of the 2nd and the 3rd sheets of paper resumes in
6 ADU.
2
1
50gat2c078na
69
8. The 2nd sheet of paper is fed again and the image

bizhub 500 / 420
of the 3rd page (the front side of the 2nd sheet of

8 paper when the original is double sided) is printed.
The 4th sheet of paper is turned over to be sent to
2
ADU with the 3rd sheet of paper standing by at
1 the conveyance roller /3. In this way, the 5th sheet
3 4
of paper is fed.
6
50gat2c079na
9. While the 2nd sheet of paper is being exited, the

8 sheet of paper when the original is double sided)
4 since the 3rd sheet of paper is standing by at the
3 conveyance roller /3, the 4th sheet of paper stops
2 10 when the interval between this sheet and the 3rd
1 sheet of paper comes to the prescribed distance.
6
repeated.
50gat2c080na
70
Theory of Operation Ver1.0 Feb.2006 18. FUSING SECTION
18. FUSING SECTION
bizhub 500 / 420

18.1 Composition
Fusing heater
Fusing web lamp /1 (L2) Fusing roller Paper exit roller Decurler roller
Fusing heater lamp /2 (L3) Fusing pressure roller Fusing claw

50gat2c025na
18.2 Drive
[1]
[2]
50gat2c026na
[1] Fusing unit drive [2] Fusing motor (M11)
71
18. FUSING SECTION Theory of Operation Ver1.0 Feb.2006
18.3 Operation
bizhub 500 / 420
18.3.1 Fusing roller drive control

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

and label paper mode
bizhub 500 250mm/s 125mm/s
bizhub 420 210mm/s
B. Preliminary rotation control

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

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

The fusing web is driven by the web solenoid (SD4).
The number of ON times is controlled by SD4 according to the web count of the fixed part counter so that the
web shift amount per print becomes constant.
72
18.3.3 Fusing temperature control

The fusing roller is heated by the fusing heater lamps /1 (L2) and /2 (L3). The fusing pressure roller is heated by
bizhub 500 / 420

the thermal conduction from the fusing roller.
The surface temperature of the fusing roller is detected by the thermistors /1 (TH1) [2] and /2 (TH2) [1]. TH1 and
TH2 monitor the surface temperature of the fusing roller at specified intervals to control the ON/OFF of L2 and
L3 through the AC drive circuit in the DC power supply (DCPS) so that a prescribed temperature can be
obtained.
[1] [2]
50gat2c081na
[1] Thermistor /2 (TH2) [2] Thermistor /1 (TH1)
A. Warm-up
Warm-up is conducted when the main power switch (SW1), the power switch (SW2) and the interlock switch
(MS) turn ON, and also when the system returns from the low power mode or the sleep mode.
While in the warm-up, the fusing heater lamps /1 (L2) and /2 (L3) turn ON. And it turns OFF at the prescribed
temperature. The temperature at which the warm-up completes varies for bizhub 500 and 420.
B. While in the print

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

While in the stand-by condition, the temperature of the fusing roller is controlled in 3 steps according to the
elapsed time after the completion of warm-up or printing, whether DF is opened or closed, and whether each
key is pushed down or not.
While in the stand-by, the ON/OFF of the fusing heater lamps /1 (L2) and /2 (L3) are controlled so that the fusing
roller gets to the prescribed temperature.
Through these control operations, an overshoot is avoided and fusibility immediately after the release from the
stand-by condition is secured.
73
D. Low power mode and sleep mode

When each key is not pressed within a specified period of time after the completion of the last print, the system
bizhub 500 / 420
changes into the low power mode or the sleep mode. The starting time for operation can be set individually for
the low power mode and the sleep mode. When the same starting time for operation is set for both modes, the
sleep mode takes precedence over the low power mode.
When the system changes into the low power mode, the ON/OFF of the fusing heater lamps /1 (L2) and /2 (L3)
is controlled so that the fusing roller gets to the prescribed temperature. The controlled temperature at this time
becomes lower than other controlled temperatures. And when the system changes into the sleep mode, the
power supply to L2 and L3 is shut off to put the system in the stand-by condition.
18.3.4 Fusing roller edge cooling control

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

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

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

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

• ON timing
A jam is detected inside the main body.
• OFF timing
A specified period of time after the fusing cooling fans /Fr (FM2) and /Rr (FM8) turn ON.
Note
• When the power switch (SW2) turns OFF due to the occurrence of a jam, or when the interlock
switch (MS) is turned OFF by opening ADU, the power supply to each fan is shut off and, even if it
is within a specified period of time, the fan turns OFF. However, when SW2 and MS are turned ON
within a specified period of time, FM2 and FM8 turn ON again.
74
C. Fusing cooling path

The air inside the machine is sucked in by the fusing cooling fans /Fr (FM2) [6] and /Rr (FM8) [1] to be blown
bizhub 500 / 420

against the edges of the fusing roller [3] through the ducts [2] and [5]. In this way, the edges of the fusing roller
are cooled down and the surface temperature of the edges of the fusing pressure roller [4] that is in contact also
goes down.
[1]
[2]
[6]
[3]
[4]
[5]
50gat2c082na
[1] Fusing cooling fan /Rr (FM8) [4] Fusing pressure roller
[2] Duct [5] Duct
[3] Fusing roller [6] Fusing cooling fan /Fr (FM2)
18.3.5 Envelope conveyance mechanism

When printing envelopes, to prevent the occurrence of paper crease due to the thickness of paper, it is possible
to switch the nip pressure of the fusing roller and the fusing pressure roller. The nip pressure is manually
switched by the envelope lever [1].
[1]
50gat2c083na
[1] Envelope lever
75
18.3.6 Protection against abnormality

When the thermistors /1 (TH1) and /2 (TH2) detects a stipulated temperature (233°C) 5 times at the prescribed
bizhub 500 / 420
intervals, this is deemed to be a high temperature abnormality and the fusing heater lamps /1 (L2) and /2 (L3) are
turned OFF. The thermostat (TS) also monitors an abnormal temperature rise and, when the detected tempera-
ture gets to 220 ± 10°C, the AC power lines to L2 and L3 are shut off.
For each condition in the warm-up, print, stand-by and the low power modes, the detected temperatures of
TH1 and TH2 and the number of times when L2 and L3 turned ON are calculated. And it is considered that a
low temperature abnormality occurs when certain conditions are met. When a low temperature abnormality
occurs, the power supply to L2 and L3 is cut off.
When these fusing temperature abnormalities occur, the system is placed in the SC latch condition with a mes-
sage shown in the touch panel. After repairing with the cause of abnormality identified, it is necessary to release
the SC latch by the software DipSW3-1 for restoration.
RL1 DCPS
TS
CBR NF
RL2
AC L2
drive
section L3
PRCB
TH1
Control
section
RL RL1
drive
section RL2
TH2
50gat2c084na
18.3.7 Jam detection control

Only while in the print, when the detected temperatures of the thermistors /1 (TH1) and /2 (TH2) go down in a
moment more than the prescribed temperature, this is considered as a wind-up jam and the operation of the
main body is stopped with a message shown in the touch panel.
76
Theory of Operation Ver1.0 Feb.2006 19. REVERSE/EXIT SECTION
19. REVERSE/EXIT SECTION
bizhub 500 / 420

19.1 Composition
Reverse roller Exhaust fan /Fr (FM3)

Exhaust fan /Rr (FM9)
Reverse gate Reverse roller
Reverse gate Reverse solenoid (SD3)

50gat2c027na
19.2 Drive
[4] [1]
[3] [2]
50gat2c028na
[1] Reverse motor (M6) [3] Reverse gate

[2] Reverse solenoid (SD3) [4] Reverse roller
77
19. REVERSE/EXIT SECTION Theory of Operation Ver1.0 Feb.2006
19.3 Operation
bizhub 500 / 420
19.3.1 Conveyance control

A. Reverse gate
The reverse gate is driven by the ON/OFF of the reverse solenoid (SD3). Paper conveyed from the fusing section
is switched by the reverse gate between the paper exit section and the reverse section.
B. Conveyance path
(1) Paper exit path
The reverse solenoid (SD3) is normally turned OFF and the reverse gate [1] is held in the position in which it
blocks the conveyance path to the reverse roller [4]. In this manner, paper conveyed from the fusing exit roller
(decurler roller) [2] is guided to the main body paper exit roller [3] along the internal form of the reverse gate to be
exited.
[4]
[1]
[3]
[2]
50gat2c085na
[1] Reverse gate [3] Main body paper exit roller

[2] Fusing exit roller (decurler roller) [4] Reverse roller
78
(2) Reverse path

While in the double sided print, the reverse solenoid (SD3) turns ON when the print on the back side is com-
bizhub 500 / 420

pleted, and the reverse gate [1] is switched in the direction in which the conveyance path to the reverse roller [4]
is opened. In this way, paper conveyed from the fusing exit roller (decurler roller) [2] is guided to the reverse roller
along the external form of the reverse gate.
[4]
[1]
[3]
[2]
50gat2c086na
[1] Reverse gate [3] Main body paper exit roller

[2] Fusing exit roller (decurler roller) [4] Reverse roller
79
19. REVERSE/EXIT SECTION Theory of Operation Ver1.0 Feb.2006
19.3.2 Reverse control

bizhub 500 / 420
A. Switch-back mechanism
While in the double sided print, paper that passes through the reverse gate [3] is conveyed to the outside of the
main body by the reverse roller [5] and then sent back again to the inside of the main body. At this time, the
paper is guided to the conveyance roller /1 [1] side, not to the reverse gate side from the metal frame form of the
conveyance path. In this way, the paper is turned over to be conveyed to the registration section again through
ADU.
The ON/OFF timing of the reverse solenoid (SD3) that drives the reverse gate is controlled by the fusing exit sen-
sor (PS3) [2]. And the switchover between the normal rotation and the reverse rotation of the reverse motor (M6)
that drives the reverse roller is controlled by the reverse sensor (PS27) [4].
[5]
[4]
[1]
[3]
[2]
50gat2c087na
[1] Conveyance roller /1 [4] Reverse sensor (PS27)

[2] Fusing exit sensor (PS3) [5] Reverse roller
[3] Reverse gate
80
B. Reverse control
While in the double sided print, when the fusing exit sensor (PS3) detects the leading edge of paper of which the
bizhub 500 / 420

printing of the back side has been completed and turns ON [1], the reverse solenoid (SD3) turns ON to switch
the reverse gate a specified period of time after the registration clutch (CL1) turns ON for back side printing. In
this manner, the paper is conveyed to the reverse section. A specified period of time after the reverse sensor
(PS27) detects the leading edge of paper and turns ON [2], the reverse motor (M6) rotates in the normal direc-
tion [3] and the reverse roller conveys the paper to the outside of the main body. And then, a specified period of
time after PS3 detects the trailing edge of the paper and turns OFF [4], SD3 turns OFF [5] to bring the reverse
gate back to its original position. And when PS27 detects the trailing edge of the paper and turns OFF [6], the
rotation of M6 is switched [7] from the normal rotation to the reverse rotation and the reverse roller sends the
paper back to the inside of the main body to convey it to ADU. In this manner, the paper is turned over.
[1] [3] [5] [7]
Normal
Reverse motor (M6) rotation
Reverse
rotation
Reverse solenoid (SD3)
Reverse sensor (PS27)
[2] [4] [6] 50gat2c088na
[1] Switchover of the reverse gate [5] Return to the reverse gate
[2] Detection of the leading edge of paper [6] Detection of the trailing edge of paper
[3] Normal rotation of the reverse roller ON [7] Switchover of the reverse roller from the
[4] Detection of the trailing edge of paper normal rotation to the reverse rotation
81
20. INTERFACE SECTION Theory of Operation Ver1.0 Feb.2006
20. INTERFACE SECTION

bizhub 500 / 420
20.1 Composition
Serial port (RS-232C)
Parallel port (based on IEEE1284)
USB port (USB TypeB)
RJ45 Ethernet connector
50gat2c089na
20.2 Specifications
Item Specifications
Serial port (RS-232C) For CS Remote Care
Parallel port (based on IEEE1284) For ISW of the copier/printer
USB port (USB TypeB) For ISW of the copier/printer
RJ45 Ethernet connector (Spare)
82
Theory of Operation Ver1.0 Feb.2006 21. IMAGE STABILIZATION CONTROL
21. IMAGE STABILIZATION CONTROL
bizhub 500 / 420

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

21.2.1 Image stabilization control flow when the power switch (SW2) is turned ON
The following shows the operation flow of the image stabilization control when the SW2 is turned ON.
Power ON E. Environmental decision control
A. Fusing heater lamp early turn-ON
B. Drum rotation
D. Fusing preliminary rotation
C. Dot diameter adjustment control
Stand-by
A. Fusing heater lamp early turn-ON

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

When the power switch (SW2) is turned ON, without waiting for the initialization of the overall control, the fusing
heater lamp is turned ON by the signal on the printer control board (PRCB). However, since turning ON the fus-
ing heater lamps /1 (L2) and /2 (L3) at the same time causes an excessive inrush current, turn ON L3 first, and
then turn ON L2 a little after that. After turning ON L2 and L3, conduct the ON/OFF control at specified intervals
to maintain the prescribed temperature of the fusing roller that is stipulated in each operation mode.
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21. IMAGE STABILIZATION CONTROL Theory of Operation Ver1.0 Feb.2006
B. Drum rotation
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(1) Purpose
• Prevent the drum charge leak such as an image flow at high humidity
• When left in the low/normal humidity condition, prevent the uneven density due to the difference in sensitiv-
ity between the section facing the cleaner and the developing of the drum and other sections.

It turns ON a specified period of time after the power switch (SW2) turns ON, and turns OFF when the dot diam-
eter adjustment is completed. However, when the 30 seconds extension of the early morning drum rotation is
selected in the software DipSW setting, it turns OFF 30 seconds after the completion of the dot diameter adjust-
ment.
Note
• For bizhub 420, since the early morning dot diameter adjustment is not selected by default, no
drum rotation is made.

(1) Purpose
Stabilize the image over a long period of time by preventing the change of the laser 1 dot diameter due to the
write system being stained or the change of developability.
(2) Method
• Create a dot pattern patch of a fixed density on the drum. The laser PWM at this time is maximum.
• Read this dot pattern patch with the IDC sensor (IDCS) and calculate the difference between the sensor
output and the specified value.
• Determine the correction amount of the laser power based on a value calculated to make corrections of the
laser power.
• Repeat several times the control operations described above.

When left for more than 8 hours, executed a specified period of time after the power switch (SW2) is turned ON.
However, this can be changed with the software DipSW setting.
Note
• For bizhub 420, since the early morning dot diameter adjustment is not selected by default, no
execution is made.
D. Fusing preliminary rotation

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

When the detected temperature of the thermistors /1 (TH1) and /2 (TH2) gets to the stipulated temperature.
Note
• The stipulated temperature at which the fusing preliminary rotation is made varies for bizhub 500
and 420.
84
E. Environmental decision control

(1) Purpose
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To detect the environmental temperature and humidity to maintain the image quality, feedback is made to vari-
ous controls.
(2) Method
A temperature sensor and a humidity sensor are equipped inside the machine.

When the power switch (SW2) is turned ON, and only when it has been left unused for more than 8 hours after
the SW2 was turned OFF last time and the fusing temperature is considered below the stipulated temperature,
an environmental decision is made based on a value measured by the sensor.
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21. IMAGE STABILIZATION CONTROL Theory of Operation Ver1.0 Feb.2006
21.2.2 Image stabilization control flow while in the print and the idle
The following shows the image stabilization control flow while in the print and the idle.
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Print start signal ON
Every 20 prints
Start of print
A. Toner density control

B. Developing potential adjustment control
End of print
Stand-by
A. Toner density control

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

(1) Purpose
Because of developer and photosensitive material being deteriorated due to durability, it becomes difficult to
secure the stable amount of toner on the photosensitive material. For that reason, calculate the correction
amount based on the machine inside temperature and the time period during which the photosensitive material
is driven and make corrections of the output values of the charging grid and the developing bias to secure the
stable amount of toner.
(2) Method
Detect the machine inside humidity with the humidity sensor (HUMS) when turning ON the power switch (SW2)
8 hours or more after turning it OFF.
Calculate the correction amount based on the machine inside humidity detected and the time period during
which the photosensitive material is driven.
Make corrections of the output value of the charging grid and the developing bias based on the correction
amount calculated.
When the time period during which SW2 is turned ON after OFF is less than 8 hours, use the value of the
machine inside humidity detected last time.

For each job print.
86
C. Dot diameter adjustment

(1) Purpose
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While in the continuous print, reduce the variance in image density for each print.
(2) Method
• Create a dot pattern patch between images of which more than 20 prints have been run off. The laser PWM
at this time is maximum.
• Read this dot pattern patch with the IDC sensor (IDCS) and calculate the difference between the sensor
output and the specified value.
• Determine the correction amount of the laser power based on a value calculated to make corrections of the
laser power.
• Repeat several times the control operations described above.
87
22. IMAGE PROCESSING Theory of Operation Ver1.0 Feb.2006
22. IMAGE PROCESSING

bizhub 500 / 420
22.1 Image processing in the scanner section
A. Shading correction
B. AE control
C. Area discrimination
D. Brightness/density conversion
E. Filter/magnification
F. Density gamma (conversion)
G. Half tone processing (error diffusion)
H. Compression
I. Storage of image data (option)
88
Theory of Operation Ver1.0 Feb.2006 22. IMAGE PROCESSING
22.1.1 Shading correction

This is the measure to obtain an even distribution from light of the CCD sensor. The following corrections are
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made at the prescribed timing.
a. White correction
The output voltage of each pixel of the CCD sensor when the white reference plate is exposed to the exposure
lamp is stored as the maximum output of the pixel.
b. Black correction
The output voltage of each pixel of the CCD sensor when the exposure lamp is turned off is stored as the mini-
mum output of the pixel.
Conduct calculation to find out what step in this range falls on the image data read from the original based on
the difference between the black and white data for each pixel stored in the steps a. and b. above, and output
the results of the calculation in the 10 bits accuracy.
Voltage at which the read is made

[1]
+1.4 White
0V
Black
Width in which the read is made
[2] After shading correction

255 White
0
Width in which the read is made Black
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[1] AD conversion input [2] Shading correction output
89
22.1.2 AE control
Through the AE control, a density suitable for the original density is automatically selected and the copy is made
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properly.
A. Sampling area
(1) While in the platen mode
[5]
[1]
[7]
[6]
[5]
[2] [2]
[4]
[3]
50gat2c092na

[2] L/100 mm [6] Leading edge of the original
[3] L mm [7] AE sampling range
[4] 30 mm
(2) While in the DF mode
[4]
[1]
[6]
[5]
[4]
[3] [2]
50gat2c093na

[2] 2.9 mm [5] Leading edge of the original
[3] 1.5 mm [6] AE sampling range
B. Execution timing
• While in the platen print: At the pre-scan before the actual scan when the print or the read starts.
• While in the DF print : At the same time as when the original is read.
90
22.1.3 Area discrimination

To make a copy of the original under the correct condition (to make a correct filter processing), check the read
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section to see if it is a character or a dot picture, and use the results at the image processing unit at the later
stage.
22.1.4 Brightness/density conversion

The signal obtained after the shading correction is a signal corresponding to the light reflected from the original,
and this is generally called a brightness signal. In this brightness/density conversion section, the brightness sig-
nal is converted in density as shown in the graph below.
255
Density
0 Brightness 1024 50gat2c094na
91
22.1.5 Filter/magnification
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A. Filter processing
An appropriate filter processing is made according to the type of an original and the magnification selected.
(1) Character : Make the shading of an original conspicuous.

(2) Dot section : Suppress moire.
(3) Picture : Increase the reproducibility of gradation.
B. Magnification processing
For this machine, the sub scan direction magnification is made by the scan speed of the exposure unit (platen
mode) or by the conveyance speed of the DF (DF mode), and the main scan direction magnification is made by
processing images electrically.
(1) Main scan magnification processing while in enlargement

As shown in the drawing below, if the data of each pixel obtained when the original is read by the CCD are D1 to
D5, the positions of the data read when enlarged are E1 to E5. However, when the write is made only with the
data thus read, the following problems occur.
a. There occurs a clearance between data, and this results in a distorted image.
b. The data position does not fall in exactly with the write position.
As shown with dotted lines in the drawing below, when there is no read data that corresponds exactly to the
write position, a density is decided for the write as shown below and appropriate processing is made.
[1] D1 D2 D3 D4 D5
[2] E1 E2 E3 E4 E5
[3] W1 W2 W3 W4 W5 W6 W7 W8
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[1] Position at which the original is read [3] Write position

[2] Data position while in enlargement
92
(2) Main scan magnification processing while in reduction

As shown in drawing below, if the data of each pixel obtained when the original is read by the CCD are D1 to
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D5, the positions of the data read when reduced are R1 to R5. They are overlapping each other and do not cor-
respond to the write position. Therefore, a density is decided for the write as shown below and an appropriate
processing is made.
[1] D1 D2 D3 D4 D5
[2] R1 R2 R3 R4 R5
[3] W1 W2 W3 W4 W5
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[1] Position at which the original is read [3] Write position

[2] Data position while in reduction
(3) Density adjustment

With the density (256 gradation) shown in the axis of coordinate and the position shown in the axis of abscissas,
when E2-E1 in the drawing of "(1) Main scan magnification processing while in enlargement" is shown in 16
steps in the direction of the axis of abscissas, the following drawing is obtained. When the position to the written
data W2 is " ," the density S can be obtained in the following expression.
S = E1 + {(E2 – E1) / 16} x
255
E2
W2
S
Density
E1
0
0 Position 15 50gat2c097na
93
22.1.6 Scanner gamma correction

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

To make effective use of the installed memory and obtain an excellent copy image, error diffusion processing is
employed, which is one of the pseudo-intermediate processing methods.
22.1.8 Compression
To store more image data, data is stored temporarily in the image memory after the images has been com-
pressed.
22.1.9 Storage of image data

The image/setting of the originals read by the scanner or the images sent from the IC can be stored as a file in
the hard disk in the main body. (option)
94
22.2 Image processing in the write section
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A. Rotation/elongation
B. PWM
C. Frequency conversion
A. Rotation/elongation
Rotate the image in the direction of 90 degrees and 180 degrees as necessary.
When outputting images from the memory, expand the compressed data to restore them to their original state.
B. PWM
The period of time the laser is turned ON is changed by changing the pulse width.
C. Frequency conversion
Write in the memory once the data after the PWM conversion and read it in accord with the write clock signal of
the printer.
95
23. OTHERS Theory of Operation Ver1.0 Feb.2006
23. OTHERS
bizhub 500 / 420
23.1 Fan control

23.1.1 Composition
[8] [9] [10]
[7]
[6]
[1]
[5]
[2]
[4]
[3]
50gat2c029na
[1] Exhaust fan /Rr (FM9) [6] Fusing cooling fan /Fr (FM2)
[2] Exhaust fan /Fr (FM3) [7] Fusing cooling fan /Rr (FM8)
[3] Conveyance suction fan (FM5) [8] Power supply cooling fan (FM1)
[4] Drum cooling fan (FM4) [9] Overall control board cooling fan (FM10)
[5] Developing suction fan (FM6) [10] Developing cooling fan (FM7)
96
Theory of Operation Ver1.0 Feb.2006 23. OTHERS
23.1.2 Operation
A. Power supply cooling fan (FM1) control
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(1) Purpose
Cool down the DC power supply (DCPS) and the high voltage unit (HV2) with suction air.
(2) ON timing
• It turns ON a specified period of time after the drum motor (M1) turns ON.
• While in the auto toner supply mode and the TCR adjustment mode, it turns ON in synch with the turn-ON
of M1.
• While in the low power mode and the stand-by condition, it turns ON in synch with the turn-ON of the drum
cooling fan (FM4).
(3) OFF timing

• While in the initial charging mode, the auto toner supply mode and the TCR adjustment mode, it turns OFF
in synch with the turn-OFF of the drum motor (M1).
• In cases other than the above, it turns OFF a specified period of time after M1 turns OFF.
• While in the low power mode and the stand-by condition, it turns OFF in synch with the turn-OFF of FM4.
B. Fusing cooling fan /Fr (FM2) and /Rr (FM8) control

(1) Purpose
• While in the continuous print of small size paper (paper width: 200 mm or less), cool down both edges of
the fusing roller to suppress a temperature rise on the section of the fusing roller through which no paper
passes.
• Suppress a temperature rise when printing large size paper (paper width: 201 mm or more).
• Suppress a fusing overshoot caused by an emergency stop when a jam occurs.
(2) ON timing
• While in the print of small size paper, they turn ON when the fusing exit sensor detects the first job paper .
• While in the print of large size paper, they turn ON when the thermistor /2 (TH2) goes over the prescribed
temperature.
• They turn ON when the print operation is stopped by a jam.
(3) OFF timing

• While in the print of small size paper, they turn OFF in synch with the turn-OFF of the fusing motor (M11).
• While in the print of large size paper, they turn OFF when TH2 detects a temperature lower than the pre-
scribed temperature.
• They turn OFF a specified period of time after it turns ON by a jam.
C. Exhaust fan /Fr (FM3) and /Rr (FM9) control

(1) Purpose
With exhaust air, cool down paper conveyed and remove heat around the reverse section in the machine.
(2) ON timing
• They turn ON in synch with the turn-ON of the drum motor (M1).
(3) OFF timing

• While in the initial charging mode and the TCR adjustment mode, they turn OFF in synch with the turn-OFF
of M1.
• In cases other than the above, they turn OFF a specified period of time after the turn-OFF of M1.
97
D. Drum cooling fan (FM4) control

bizhub 500 / 420
(1) Purpose
Cool around the drum and the toner bottle with suction air.
(2) ON timing
• After completion of the print, it turns ON a specified period of time after the drum motor (M1) turns OFF.
• It turns ON when the machine inside temperature goes over the prescribed temperature.
(3) OFF timing

• It turns OFF a specified period of time after it turns ON after completion of the print.
• While it turns ON after completion of the print, it turns OFF the moment M1 turns ON.
• It turns OFF when the machine inside temperature goes down below the prescribed temperature.
E. Conveyance suction fan (FM5) control

(1) Purpose
Exhaust by sucking air around the conveyance path between the drum and the fusing unit, and stabilize the
conveyability of paper and remove exhaust heat and ozone at the same time.
(2) ON timing
• It turns ON in synch with the turn-ON of the drum motor (M1).
• While in the low power mode and the stand-by condition, it turns ON in synch with the turn-ON of the drum
cooling fan (FM4).
(3) OFF timing

• While in the initial charging and the TCR adjustment mode, it turns OFF in synch with the turn-OFF of M1.
• In cases other than the above, it turns OFF a specified period of time after M1 turns OFF.
• While in the low power mode and the stand-by condition, it turns OFF in synch with the turn-OFF of FM4.
F. Developing suction fan (FM6) control

(1) Purpose
Suck air from the underside of the developing unit to prevent the splash of toner and exhaust air.
(2) ON timing
• It turns ON in synch with the turn-ON of the developing motor (M3).
(3) OFF timing

• It turns OFF a specified period of time after M3 turns OFF.
• While in the TCR adjustment mode, it turns OFF in synch with the turn-OFF of M3.
98
G. Developing cooling fan (FM7)

(1) Purpose
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Take in fresh air to cool down the developing motor (M3).
(2) ON timing
• After completion of the print, it turns ON a specified period of time after M3 turns OFF.
• While in the auto toner supply mode, it turns ON in synch with the turn-ON of M3.
• It turns ON when the machine inside temperature goes over the prescribed temperature.
(3) OFF timing

• After completion of the print, it turns OFF a specified period of time after it turns ON.
• While in the auto toner supply mode, it turns OFF in synch with the turn-OFF of M3.
• It turns OFF when the machine temperature goes down below the prescribed temperature.
H. Overall control board cooling fan (FM10) control

(1) Purpose
Cool down the overall control board (OACB) with suction air.
(2) ON timing
• It turns ON when the power switch (SW2) turns ON.
(3) OFF timing

• It turns OFF when SW2 turns OFF.
99
23.2 Counter control

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23.2.1 Composition
㨇㨉
CN35 CN36
CN939
OACB PRCB CN30 TCT
OB CN936
SDB CN64
3㨪6 KCT
LCDB
50gat2c030na
[1] Coin vendor /2
100
23.2.2 Operation
A. Paper exit counter
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Item Specifications/mechanism
Total counter (TCT) • Display accumulated number of prints in all print modes.
• Counts up by a paper exit signal.
Electronic counter • Display accumulated number of prints on the touch
panel.
• Data collection *1
• Counts up by a paper exit signal.
Key counter (KCT), optional • Counting the designated number of prints allows no fur-
ther copy operation (can be removed).
*1 For data collected, See "10.6 Counter" in Field service bizhub 500/420 Main body. (See P.178)
[2] [1]
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[1] CN936 (KCT connecting connector) [2] Total counter (TCT)
101
B. Coin vendor/2 (Parallel)

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

(3) (2) (1) (0)
A3 L L H L
B4 L L L L
A4 L H H L
A4S H L H L
B5 L H L L
B5S H L L L
Special L H L H
11 x 17 L L H H
81/2 x 14 L L L H
81/2 x 11 L H H H
81/2 x 11S H L H H
51/2 x 81/2 / A5 L L H L
8 x 13, 81/8 x 131/4, 81/4 x 13, 81/2 x 13 H L L H
102
23.3 Parts that operate when the power switch is turned ON
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23.3.1 Parts that operate when the main power switch (SW1) is turned ON
A. Composition
SW2
SW1 PSWB
OB
DCPS
5VDC
IC
12VDC
DCPS
CBR NF OACB FK
section
HD
24VDC SC
PC LU PRCB
50gat2c032na
B. Operation
Turning ON the main power switch (SW1) supplies an AC power source to DC power supply (DCPS).
In this way, each power source of 12V DC and 5V DC is supplied to the overall control board (OACB).
OACB supplies 5V DC to the operation board (OB) to be placed in the condition of standing by for the turn-ON
of the power switch (SW2).
When equipped optionally with the FAX kit (FK-502) and the hard disk (HD-505), each power source of 12V DC
and 5V DC is supplied through OACB.
103
23.3.2 Parts that operate when the power switch (SW2) is turned ON
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A. Composition
SW2
PSWB
OB
SW1
OACB
24VDC
DCPS
RL1
CBR NF
section
RL2
L2, L3
AC drive
section
DCPS
50gat2c033na
B. Operation
Turning ON the power switch (SW2) transmits an ON signal of SW2 to the overall control board (OACB) through
the operation board (OB). In this way, OACB sends out a control signal to the DC power supply (DCPS) and
DCPS supplies each power source of 12V DC and 5V DC to all boards and optional devices, including the
printer control board (PRCB).
After that, OACB sends out to DCPS a control signal that generates a 24V DC power source, which is supplied
to all drive boards and optional devices. And when the main relay (RL1) and the sub relay (RL2) turn ON, an AC
power source is supplied to the fusing heater lamps /1 (L2) and /2 (L3) to start the initial operation of this
machine.
104
DF-607
2006.02
Ver. 1.0
Revision history
Revision mark:
ing page.
NOTE

Theory of Operation Ver. 1.0 Feb. 2006
CONTENTS
DF-607
DF-607
OUTLINE
1. PRODUCT SPECIFICATIONS ................................................................................1
2. PAPER PATH ...........................................................................................................4
2.1 In 1-sided mode ....................................................................................................4
OUTLINE
2.2 In 2-sided mode ....................................................................................................4
3. COMPOSITION .......................................................................................................5
4. DRIVE......................................................................................................................6
5. OPERATION............................................................................................................7
5.1 Document pick-up mechanism..............................................................................7
5.1.1 Pick-up operation ..........................................................................................7
5.2 Document feed/conveyance mechanism ..............................................................8
5.3 Raised/lowered position detecting mechanism...................................................12
5.3.1 DF 15° open/close detection mechanism....................................................12
5.3.2 DF open/close detection mechanism ..........................................................12
i
DF-607
OUTLINE
Blank Page
ii
Theory of Operation Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS
OUTLINE
DF-607
A. Type
Name Reverse Automatic Document Feeder

Paper Feed Paper Feed from top of stack
Type Turnover Switch back system
Paper Exit Straight exit system
Installation Screw cramp to the main unit
OUTLINE
Document Alignment Center
Document Loading Left image side up
B. Functions
Modes 1-Sided Mode / 2-Sided Mode
C. Paper type
1-Sided Mode
Standard Mode 35 to 128 g/m2 (9.25 to 34 lbs)
Plain Paper 2-Sided Mode
50 to 128 g/m2 (13.25 to 34 lbs)
Mixed Original Detection
1-Sided / 2-Sided Mode
Type of Document Mode
50 to 128 g/m2 (13.25 to 34 lbs)
Plain Paper
1-Sided Mode
FAX Mode 35 to 128 g/m2 (9.25 to 34 lbs)
50 to 128 g/m2 (13.25 to 34 lbs)
Inch area
A3, A4S, A4, B4, B5S, B5
Detectable Document 11 x 17, 81/2 x 14, 81/2 x 11S, 81/2 x 11, 81/2 x 51/2S, 81/2 x 51/2
Size*1 Metric area
A3, A4S, A4, A5S, A5, B4, B5S, B5, B6S
11 x 17, 81/2 x 11S, 81/2 x 11
Capacity 80 sheets (80 g/m2) or load height of 11 mm or less.
*1: For the Combined Original Detection Mode, Refer to the Mixed Original Detection Enabled
Size Combination Table.
1
1. PRODUCT SPECIFICATIONS Theory of Operation Ver. 1.0 Feb. 2006
D. Paper feed prohibited originals

• If fed, trouble occurrence will be highly possible.
DF-607
Type of Original Possible Trouble

Feed failure, damage to the original, or drive failure
Original that is stapled or clipped.
due to clip clogging
Book original Feed failure, damage to the original, or drive failure
Original weighing less than 35g/m2 or 128g/m2
Feed failure
or more
Torn original Feed failure, damaged sheet
OUTLINE
Highly curled original (15 mm or more) Original misfeed due to dog-ear or skew
OHP transparencies Feed failure
Label Sheet Feed failure
Offset master Feed failure
Sheets clipped or notched Damaged sheet
Sheets patched Patched part folded or torn sheet
E. Paper feed not guaranteed originals

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

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

For Metric
DF-607
Reference original (original with a maximum width)
A3 A4 B4S B5 A4S A5 B5S A5
Other A3 U { — — — — — —
originals A4 { U — — — — — —
B4S ~ ~ U { — — — —
B5 ~ ~ { U — — — —
A4S ~ ~ ~ ~ U { — —
OUTLINE
A5 ~ ~ ~ ~ { U — —
B5S X X ~ ~ ~ ~ U —
A5S X X X X X X X U
U: Same size {: Same group ~: Different group X: Mix prohibited —: No need to set
For Inch

11 x 17 81/2 x 11 81/2 x 14 81/2 x 11S 51/2 x 81/2 51/2 x 81/2 S
Other 11 x 17 U { — — — —
originals 81/2 x 11 { U — — — —
81/2 x 14 ~ ~ U { { —
81/2 x 11S ~ ~ { U { —
51/2 x 81/2 ~ ~ { { U —
51/2 x 81/2S X X X X X U
G. Maintenance

Machine service life Same as the main body.
H. Machine data
Power Requirements 24V DC ± 10% (supplied from the main body)

Max. Power
48 W or less
Consumption
Dimensions 582 (W) x 558 (D) x 145 mm (H)
Weight Approx. 10 kg
I. Operating environment
Temperature 10 to 30°C
Humidity 10 to 80% RH (with no condensation)
NOTE
• These specifications are subject to change without notice.
3
2. PAPER PATH Theory of Operation Ver. 1.0 Feb. 2006
2. PAPER PATH
2.1 In 1-sided mode
DF-607
OUTLINE
[3] [2] [1]

16eat1c001na
[1] Exit [3] Feed (Scanning the 1st side)

[2] Conveyance and turnover
2.2 In 2-sided mode
[3] [2] [1]

16eat1c002na
[1] Exit [3] Feed (Scanning the 1st side)

[2] Conveyance and switchback Conveyance and turnover (Scanning the 2nd
side)
Conveyance
4
Theory of Operation Ver. 1.0 Feb. 2006 3. COMPOSITION
3. COMPOSITION
DF-607
Document feed section
Conveyance section Switchback section Document exit section
16eat2c001na
5
4. DRIVE Theory of Operation Ver. 1.0 Feb. 2006
4. DRIVE
DF-607
[1]
[2]
16eat2c002na
[1] Original Feed Motor (M1) [2] Original Conveyance Motor (M2)
6
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATION
5. OPERATION
5.1 Document pick-up mechanism
DF-607
• The Document Pick-Up Section consists of the Pick-Up Rollers, Feed Roller and Separation
Roller, and this section is driven by the Original Feed Motor (M1).
5.1.1 Pick-up operation

• When the Start key is pressed, the Original Feed Motor (M1) [3] starts rotating backward,
causing the Pick-Up Roller [4] to lower and start rotating at the same time. At the same time,
the Feed Roller [2] starts rotating.
• The Pick-Up Rollers are in the raised position when in the standby state and in the lowered
position during feeding.
[3]
[4]
[2]
[1] 16eat2c003na
[1] Separation Roller [3] Original Feed Motor (M1)

[2] Feed Roller [4] Pick-Up Roller
7
5. OPERATION Theory of Operation Ver. 1.0 Feb. 2006
5.2 Document feed/conveyance mechanism

• When the original reaches the Registration Sensor, the Original Feed Motor (M1) [5] starts
DF-607
rotating forward and, at the same time that the Pickup Roller goes up, drive is then supplied
to the Registration Roller [3].
• When the Original Conveyance Motor (M2) [4] starts rotating forward, the two Conveyance
Rollers [2] and the Exit/Turnover Roller [1] feed the document toward the exit direction.
Direction of
Parts Details
Rotation
Backward The Pickup Rollers lower and start rotating and the Feed
rotation Roller rotates.
M1
Forward
The Registration Roller rotates.
rotation
Backward The Conveyance Roller and Exit/Turnover Roller rotate in
rotation the direction to turn over the original.
M2
Forward The Conveyance Roller and Exit/Turnover Roller rotate in
rotation the direction to feed the original out.
[5]
[1]
[4]
[3]
[2]
16eat2c004na
[1] Exit/Turnover Roller [4] Original Conveyance Motor (M2)

[2] Conveyance Roller [5] Original Feed Motor (M1)
[3] Registration Roller
8
A. Operation flow in the 1-sided mode
[4]
DF-607
[1]
[3] [2] 16eat2c005na
[1] Exit [3] Scanning the 1st side

[2] Original Exit Sensor (PS10) [4] Original Detection Sensor (PS8)
1. When the Start key is pressed, the Original Feed Motor (M1) starts rotating backward,
causing the Pick-Up Roller to lower and start a paper take-up sequence.
2. A specified period of time after the leading edge of the original turns ON PS8 [4], the
scanning of the 1st side of the original starts.
3. The original is conveyed for a given period of time after the trailing edge of the last
page of the document has deactivated the PS10 [2]. It is then fed into [1] the Exit Tray
and the Original Conveyance Motor (M2) is deenergized.
9
B. Operation flow in the 2-sided mode

1. When the Start key is pressed, the Original Feed Motor (M1) starts turning backward,
causing the Pick-Up Roller to lower and start feeding the 1st page of the document.
DF-607
A specified period of time after the leading edge of the original turns ON the Original
Detection Sensor (PS8) [4], the scanning of the 1st side of the original starts.
The Original Conveyance Motor (M2) is deenergized to stop [1] the original after the
lapse of a given period of time after the trailing edge of the 1st page has deactivated
the Original Exit Sensor (PS10) [2].
[4]
[1]
[3] [2] 16eat2c006na

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

[2] Original Exit Sensor (PS10) [4] Original Detection Sensor (PS8)
2. M2 is turned backward to turn over [3] the original. After the Registration Roller, M2 is
turned forward to allow the Scanner to scan the backside of the 1st page.
3. After the conveyance sequence for turnover has been started, the Pressure Roller
Release Solenoid (SD1) is energized so that the Exit/Turnover Roller is retracted.
[3]
[1]
[2] 16eat2c007na
[1] Stop [3] Turnover

[2] Scanning the 2nd side
10
4. To ensure that pages of the document are in the proper order, the page is turned over
[3] again before being ejected [1] into the Exit Tray.
DF-607
[3]
[1]
[2] 16eat2c008na
[1] Exit [3] Turnover

[2] Scanning the 2nd side
11
5.3 Raised/lowered position detecting mechanism

5.3.1 DF 15° open/close detection mechanism
DF-607
• When DF is closed down to about 15° or less, the Original Cover Angle Detection Lever of
the main body is pressed down to turn ON the APS Timing Sensor (PS31).
5.3.2 DF open/close detection mechanism

• A magnet is provided so that the open/close of DF can be detected on the main body side.
• When DF is closed, the DF Open/Close Switch (SW3) of the main body is turned ON by the
magnet.
[1]
16eat2c009na
[1] DF Open/Close Switch (SW3)
12
PC-202
( 500 / 420)
2006.02
Ver. 1.0
Revision history
Revision mark:
ing page.
NOTE

CONTENTS
PC-202
PC-202
OUTLINE
2. PAPER PATH ...........................................................................................................2
OUTLINE
3. COMPOSITION .......................................................................................................3
4. DRIVE......................................................................................................................4
5. OPERATIONS .........................................................................................................5
5.1 Paper Feed Section ..............................................................................................5
5.1.1 Paper feed mechanism..................................................................................5
5.1.2 Paper lifting motion........................................................................................6
5.2 Tray Section ..........................................................................................................7
5.2.1 Paper size detection ......................................................................................7
5.2.2 Paper level indicator mechanism...................................................................8
i
PC-202
OUTLINE
Blank Page
ii
OUTLINE
PC-202
A. Type
Name 2 way Paper Take-Up Cabinet

Type Front loading type 2 way paper take-up device
Installation Desk type
OUTLINE
B. Paper type
Paper Type Plain paper 56 to 90 g/m2

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

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

Power Consumption 15 W or less
Dimensions 570 mm (W) × 548 mm (D) × 263 mm (H)
E. Operating environment
Temperature Same as the main body.

Humidity Same as the main body.
NOTE
1
2. PAPER PATH
PC-202
[4]
[1]
[2]
OUTLINE
[3]
4061t1c001na
[1] Convey to the main body [3] Tray 4 paper feed

[2] Vertical conveyance through PC [4] Tray 3 paper feed
2
3. COMPOSITION
PC-202
Tray 3
Paper Feed
Section
Tray 4 4061t2c001na
3
4. DRIVE
PC-202
[4] [1]
[3]
[2]
4061t2c002na
[1] Vertical Conveyance Motor /3 (M120) [3] Vertical Conveyance Motor /4 (M121)
[2] Paper Feed Motor /4 (M123) [4] Paper Feed Motor /3 (M122)
4
Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS
5. OPERATIONS
5.1 Paper Feed Section
PC-202
5.1.1 Paper feed mechanism
• The Paper Feed Motor (M122, M123) drives the Pick-up Roller [8] and Feed Roller [6] to
take up and feed a sheet of paper into the main body.
• Then, the Vertical Conveyance Motor /3, /4 (M120, M121) transports the paper through the
vertical conveyance section.
• The Pick-up Roller takes up sheet of paper and the Feed Roller and Separation Roller [5]
ensure that only one sheet of paper is separated and fed into the main body.
• When the Tray is slid in, the lever [7] is pushed to lower the Pick-up Roller.
• The Upper Limit Sensor /3, /4 (PS114, PS123) [9] then detects the upper limit position when
the paper lifting plate is raised.
• The Paper Empty Sensor /3, /4 (PS115, PS124) [1] detects when paper in the Tray runs out.
[7] [8] [9]
[6] [5] [2] [1]
[4] [3]
4061t2c003na
[1] Paper Empty Sensor /3, /4 (PS115, PS124) [6] Feed Roller
[2] Actuator [7] Lever
[3] Pick-up Roller Feed Position [8] Pick-up Roller
[4] Pick-up Roller Home Position [9] Upper Limit Sensor /3, /4 (PS114, PS123)
[5] Separation Roller
5
5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006
5.1.2 Paper lifting motion

• When the Tray is slid into the main body and the Tray Set Sensor /3, /4 (PS112, PS121) is
PC-202
activated, the Paper Lift Motor /3, /4 (M124, M125) starts rotating to raise the Lifting Plate
[3].
• The paper stack of the Tray pushes up the Pick-up Roller [1]. When the upper limit position
is detected by the Upper Limit Sensor /3, /4 (PS114, PS123) [4], it stops raising the lifting
plate.
• As paper is consumed during the print cycle and the Pick-up Roller is lowered, M124, M125
is energized until PS114, PS123 is blocked again.
A. When the Tray is slid in
1. The lifting plate [3] goes up and the top surface of the paper stack pushes up the roller
[1].
2. The lifting motion stops as soon as the Upper Limit Sensor /3, /4 (PS114, PS123)
detects the upper limit position.
[4] [1]
[3] [2] 4061t2c004na
[1] Pick-up Roller [3] Lifting Plate

[2] Lift-up Arm [4] Upper Limit Sensor /3, /4 (PS114, PS123)
B. During a print cycle

1. As the paper is consumed, the Upper Limit Sensor /3, /4 (PS114, PS123) [1] is
unblocked.
2. The lifting plate goes up.
[1]
4061t2c005na
[1] Upper Limit Sensor /3, /4 (PS114, PS123)
6
5.2 Tray Section

5.2.1 Paper size detection
PC-202
• Moving the Sub Scan Direction Restriction Plate of the Tray rotates the Circular Plate [1]
provided on the bottom of the Tray.
• The length of paper in the sub scan direction is detected by the Paper Size Detection Switch
[8] provided on the Paper Size Detect Boards /3 and /4 (PSDB3, PSDB49) [7] that is driven
by the Lever interlocked with the Circular Plate.
• The detection of the length of paper in the main scan direction is made by detecting a notch
on the Lever of the Main Scan Direction Restriction Plate by the Paper Size Sensors /Rr3,
/Fr3 (PS118, PS119) [2] or /Rr4, /Fr4 (PS127, PS128) [3].
• The paper size is determined by the combination of the 4 Paper Size Detection Switches
and the 2 Paper Size Sensors.
• The setting of the Tray is detected by the Tray Set Sensors /3, /4 (PS112, PS121) [6].
[9]
[7] [8] [1]
[5] [6]
[4] [3] [2]

4061t2c006na
[1] Circular Plate [6] Tray Set Sensor /3, /4 (PS112, PS121)
[2] Paper Size Sensor /Rr3, /Rr4 (PS118, [7] Paper Size Detect Board /3, /4 (PSDB3,
PS127) PSDB4)
[3] Paper Size Sensor /Fr3, /Fr4 (PS119, PS128) [8] Paper Size Detection Switch
[4] Paper Lift Motor /3, /4 (M124, M125) [9] Sub scan direction size detection
[5] Main scan direction size detection
7
5.2.2 Paper level indicator mechanism

• All Trays are universal paper size tray.
PC-202
• There is a window in the front cover of the Tray that serves as the Paper Level Indicator [3]
showing the amount of paper that is still available for use.
• A red lever [1] is attached to the bottom plate [5] of the Tray and as the lifting plate [4] raises,
the red lever becomes visible in the window.
• The more the red lever is visible, the lesser the amount of paper will be available for use.
[5]
[4] [1]
[3] [2]
4061t2c007na
[1] Lever [4] Lifting Plate

[2] Operated by the Lifting Plate [5] Tray Bottom Plate
[3] Paper Level Indicator
8
PC-402
( 500 / 420)
2006.02
Ver. 1.0
Revision history
Revision mark:
ing page.
NOTE

CONTENTS
PC-402
PC-402
OUTLINE
1. PRODUCT SPECIFICATION...................................................................................1
2. PAPER PATH ...........................................................................................................2
OUTLINE
3. COMPOSITION .......................................................................................................3
4. DRIVE......................................................................................................................4
5. OPERATIONS .........................................................................................................5
5.1 Paper Feed Section ..............................................................................................5
5.1.1 Paper feed mechanism..................................................................................5
5.2 Tray Section ..........................................................................................................6
5.2.1 Up/down mechanism.....................................................................................6
5.2.2 Shift Gate drive mechanism ..........................................................................7
5.2.3 Shifter drive mechanism................................................................................8
5.2.4 Paper empty detection ..................................................................................9
i
PC-402
OUTLINE
Blank Page
ii
Theory of Operation Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATION
OUTLINE
1. PRODUCT SPECIFICATION
PC-402
A. Type
Name 2500 sheets paper feed cabinet

Type Front loading type LCC
OUTLINE
B. Paper type

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



NOTE
1
2. PAPER PATH
PC-402
[1]
OUTLINE
[2]
[5] [4] [3]

4061t1c201na
[1] Convey to the main body [4] From the Sub Tray to Main Tray
[2] Tray paper feed [5] Sub Tray
[3] Main Tray
2
3. COMPOSITION
PC-402
Tray Section Paper Feed Section
Sub Tray Main Tray
4061t2c201na
3
4. DRIVE
PC-402
[7] [8] [9] [10]
[1]
[2]
[6]
[3]
[5] [4]
4061t2c202na
[1] Paper Lift Motor (M5) [6] Shift Gate Drive Section
[2] Paper Lift Drive Section [7] Tray Lock Solenoid (SD1)
[3] Shifter Drive Section [8] Paper Feed Motor (M1)
[4] Shift Motor (M4) [9] Vertical Conveyance Motor (M2)
[5] Shift Gate Motor (M3) [10] Vertical Conveyance Drive Section
4
5. OPERATIONS
5.1 Paper Feed Section
PC-402
5.1.1 Paper feed mechanism
• The Paper Feed Motor (M1) drives the Pick-up Roller [8] and Feed Roller [6] to take up and
feed a sheet of paper into the main body.
• Then, the Vertical Conveyance Motor (M2) transports the paper through the vertical convey-
ance section.
• The Pick-up Roller takes up sheet of paper and the Feed and Separation Rollers [5] ensure
that only one sheet of paper is separated and fed into the main body.
• When the Tray is slid in, the lever [7] is pushed to lower the Pick-up Roller.
• The Upper Limit Sensor (PS4) [9] then detects the upper limit position when the paper lifting
plate is raised.
• The Paper Empty Sensor (PS3) [1] detects when paper in the Main Tray runs out.
[7] [8] [9]
[6] [5] [2] [1]
[4] [3]
4061t2c203na
[1] Paper Empty Sensor (PS3) [6] Feed Roller

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

5.2.1 Up/down mechanism
PC-402
• The Main Tray [3] is suspended by the cables [1] at the front and rear.
• As the Paper Lift Motor (M5) [5] turns forward or backward, the cables are wound to raise or
lower the Main Tray.
• The Lower Limit Sensor (PS13) [2] detects the Main Tray at its lower limit position.
[1]
[5] [2]
[3]
[4]
4061t2c204na
[1] Cables [4] Sub Tray

[2] Lower Limit Sensor (PS13) [5] Paper Lift Motor (M5)
[3] Main Tray
6
5.2.2 Shift Gate drive mechanism

• If the Main Tray runs out of paper, while the Sub Tray is loaded with paper, the paper stack
PC-402
on the Sub Tray is moved to the Main Tray [2].
• At this time, the Shift Gate Motor (M3) [4] is energized to retract the front and rear Shift
Gates [1].
[1]
[4]
[3]
[2]
[1] 4061t2c205na
[1] Shift Gate move to outside [3] Shifter

[2] Shifter move [4] Shift Gate Motor (M3)
7
5.2.3 Shifter drive mechanism

• After completion of the evacuation of the Shift Gate, starts the movement of the Shifter [2].
PC-402
• The movement of paper from the Sub Tray to the Main Tray is made by the Shifter that is
driven by the Shift Motor (M4) [1].
• The stopping of the movement of the Shifter to the Main Tray side is made by the Shift Posi-
tion Sensor (PS11) [4].
• The movement to the home position starts when the Tray Release Key is pressed.
• The stopping of the movement of the Shifter to the home position is made by the Shift Home
Sensor (PS12) [3].
[3]
[2]
[2]
[4]
[1] [1]
4061t2c206na
[1] Shift Motor (M4) [3] Shift Home Sensor (PS12)

[2] Shifter [4] Shift Position Sensor (PS11)
8
5.2.4 Paper empty detection

• Paper empty detection of Main Tray is performed by Main Tray Empty Board (MEB) [2].
PC-402
• Paper empty detection of Sub Tray is performed by Sub Tray Empty Sensor (PS9) [3].
[4] [1]
[3] [2]
4061t2c207na
[1] Main Tray [3] Sub Tray Empty Sensor (PS9)

[2] Main Tray Empty Board (MEB) [4] Sub Tray
9
PC-402
Blank Page
10
LU-201
2006.02
Ver. 1.0
Revision history
After publication of this service manual, the parts and mechanism may be subject to change for improve-
ment of their performance.
Revision mark:
• To indicate clearly a section revised, show 1 in the lower outside section of the corresponding
page.
NOTE

CONTENTS
LU-201
LU-201
OUTLINE
1. PRODUCT SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. COMPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. PAPER FEED SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1.1 Paper feed drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2.1 Paper feed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2.2 Remaining paper detection control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5. TRAY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1.1 Tray lift drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.2.1 Tray lift control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
i
LU-201
Blank page
ii
Theory of Operation Ver1.0 Feb.2006 1. PRODUCT SPECIFICATION
OUTLINE
LU-201
A. Type
Type Side mount type large volume paper feed tray
B. Functions
Maximum tray capacity 2,000 sheets (80 g/m2)
C. Type of paper
Paper type *1 Plain paper, recycled paper, high quality paper of 60 to 105 g/m2
Paper size A4, 81/2 x 11
*1 Recommended paper
Plain paper Inch: Hammermill Tidal MP (20 lbs)
Metric: Konica Profi (80 g/m2), Konica Minolta Original (80 g/m2)
Recycled paper Inch: Weyehaeuser Recycled Laser Copy (20 lbs)
D. Maintenance
Maintenance Same as the main body

Machine service life Same as the main body
E. Machine data
Power source 24/5V DC (supplied from the main body)

Power consumption 30 W or less (internal heater is not used)
Dimensions 424 (W) x 515 (D) x 295 (H) mm
Temperature Same as the main body

Humidity Same as the main body
Note
1
2. PAPER PATH
LU-201
[3] [4] [5] [1]
[2]
16aat1c001na
[1] Lift plate [4] Feed roller

[2] Separation roller [5] Pick-up roller
[3] Conveyance roller
2
Theory of Operation Ver1.0 Feb.2006 3. COMPOSITION
LU-201
3. COMPOSITION
Paper feed section Tray section
16aat2c001na
3
4. PAPER FEED SECTION Theory of Operation Ver1.0 Feb.2006
4. PAPER FEED SECTION

4.1 Drive
LU-201

A. Front side drive
[3] [4] [1]
[2]
16aat2c002na
[1] Pick-up solenoid (SD151) [3] Feed roller

[2] Conveyance roller [4] Pick-up roller
B. Rear side drive
[3]
[2]
[1]
16aat2c007na
[1] Feed motor (M150) [3] Feed clutch (CL151)

[2] Conveyance roller
4
Theory of Operation Ver1.0 Feb.2006 4. PAPER FEED SECTION
4.2 Operation
LU-201
A. Pick-up mechanism
(1) Drive transmission
The driving force of the feed motor (M150) is transmitted to the paper feed gear /3 [4] through various gears. The
paper feed gear /3 is connected with the pick-up solenoid (SD151) [1] through the claw [2]. When SD151 is
turned OFF, the coupling between the paper feed gear /3 and the paper feed coupling gear /B [3] provided on
the front stage is disengaged and the paper feed gear /3 does not rotate. When SD151 turns ON, the claw is
released to engage the paper feed gear /3 to the paper feed coupling gear /B. In this way, the paper feed gear /
3 rotates and the driving force is transmitted to the paper feed roller unit [6] through the paper feed gear [5] to
pick up paper.
[3] [4] [5] [6]
[2] [1]
16aat2c003na
[1] Pick-up solenoid (SD151) [4] Paper feed gear /3

[2] Claw [5] Paper feed gear
[3] Paper feed coupling gear /B [6] Paper feed roller unit
5
4. PAPER FEED SECTION Theory of Operation Ver1.0 Feb.2006
(2) Paper feed roller unit up/down mechanism

On the inside of the paper feed gear /3 [2], the cam [3] is provided. While in the standby, the cam pushes the lift-
up shaft [1]. The lift-up shaft is in contact with the paper feed roller unit [5] and it lifts up the paper feed roller unit
LU-201
while it is being pushed by the cam. When the paper feed gear /3 rotates, the pressure by the cam on the lift-up
shaft is released and the paper feed roller unit goes down. In this way, the paper feed roller unit goes up and
down while the paper feed gear /3 is rotating a full turn to pick up paper.
[2] [3] [4] [5]
[1] [1]
16aat2c004na
[1] Lift-up shaft [4] Paper feed gear

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

A specified period of time after a start signal from the main body turns ON, the feed motor (M150), the feed
clutch (CL151) and the pick-up solenoid (SD151) turn ON to pick up paper from the tray. SD151 turns OFF a
specified period of time after that. However, it turns ON and OFF according to the paper feed request signal to
pick up the second and succeeding sheets of paper. Paper thus picked up is conveyed to the PC by the con-
veyance roller to be further conveyed to the registration section of the main body through the vertical convey-
ance roller in the PC.
The conveyance roller is provided with CL151 and, when the registration sensor (PS1) of the main body detects
the leading edge of paper and turns ON, it turns OFF a specified period of time after that to stop the conveyance
roller and the paper feed roller unit. At this time, the registration section of the main body stops temporarily to
control the registration and all the rollers that are positioned upstream of the registration roller also stop. In this
way, paper thus supplied is put in the standby condition in each position of the registration section, the convey-
ance path and the LU exit section.
When a print signal is received, a specified period of time after that, each roller in the conveyance path and
CL151 turn ON to resume the conveyance of paper.
6
Theory of Operation Ver1.0 Feb.2006 4. PAPER FEED SECTION
4.2.2 Remaining paper detection control

As paper in the tray gets reduced, the lift plate goes up gradually. The actuator [1] provided on the rear side of
LU rotates in interlock with the up/down operation of the lift plate. The actuator is provided with the remaining
LU-201
paper sensors /1 (PS154) [3] and /2 (PS151) [2] and the remaining paper is detected by the combination of the
ON/OFF of these sensors. And the no paper detection in the tray is made by the paper empty sensor (PS153)
[5].
Remaining paper quantity PS151 PS154

Full quantity OFF ON
Medium quantity ON ON
Small quantity ON OFF
[5]
[4]
[3]
[1]
[2]
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[1] Actuator [4] Direction of rotation when the tray goes up

[2] Remaining paper sensor /2 (PS151) [5] Paper empty sensor (PS153)
[3] Remaining paper sensor /1 (PS154)
7
5. TRAY SECTION Theory of Operation Ver1.0 Feb.2006
5. TRAY SECTION
5.1 Drive
LU-201
[8]
[1]
[2]
[7]
[3]
[4]
[6]
[5]
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[1] Actuator [5] Lift plate

[2] Wire [6] Wire
[3] Coupling [7] Spring
[4] Parallel pin [8] Paper lift motor (M151)
8
Theory of Operation Ver1.0 Feb.2006 5. TRAY SECTION
5.2 Operation
5.2.1 Tray lift control
LU-201
When the upper door is closed, a parallel pin for the up drive of the lift plate is pushed out to be coupled to the
coupling of the paper lift motor (M151). Closing the upper door also turn ON the upper door interlock switch
(MS151) to supply a 24V DC to the load of the drive system. In this way, M151 turns ON to bring up the lift plate.
When the lift plate goes up and the upper limit sensor (PS152) detects the upper surface of paper, M151 turns
OFF to stop the up drive of the lift plate. When PS152 turns OFF by the paper feed operation, M151 turns ON
again to keep on bringing up the lift plate until PS152 turns ON.
When the upper door is opened, the wire is pulled to release the coupling for the up drive of the lift plate. In this
way, the lift plate goes down up to the position in which a balance is kept between the weight of paper and the
spring tension.
[4] [1]
[3] [2]
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[1] Feed roller [3] Pick-up roller

[2] Lift plate [4] Upper limit sensor (PS152)
9
5. TRAY SECTION Theory of Operation Ver1.0 Feb.2006
LU-201
Blank page
10
FS-510/PU-501/
OT-601
2006.02
Ver. 1.0
Revision history
Revision mark:
ing page.
NOTE

FS-510/PU-501/OT-601
CONTENTS
FS-510/PU-501/OT-601
OUTLINE
1.1 FS-510 ..................................................................................................................1
1.2 PU-501..................................................................................................................3
OUTLINE
1.3 OT-601 ..................................................................................................................4
2. PAPER PATH ...........................................................................................................5
2.1 Exiting Paper to the Tray /1 ...................................................................................5
2.2 Exiting Paper to the Tray /2 ...................................................................................6
2.3 Exiting Paper to OT...............................................................................................7
3. COMPOSITION .......................................................................................................9
4. DRIVE....................................................................................................................10
4.1 FS-510 ................................................................................................................10
4.2 PU-501................................................................................................................11
5. OPERATIONS .......................................................................................................12
5.1 Conveyance Section ...........................................................................................12
5.1.1 Entrance/Conveyance section .....................................................................13
5.1.2 Intermediate Conveyance Section...............................................................14
5.1.3 Exit Conveyance Section.............................................................................15
5.2 Up/down Section.................................................................................................16
5.2.1 Up/down mechanism...................................................................................16
5.2.2 Tray Up/Down operation ..............................................................................17
5.2.3 Tray Upper Limit Position Detection Mechanism .........................................18
5.2.4 Shutter Open/Close Mechanism .................................................................21
5.3 Stacker section....................................................................................................22
5.3.1 Paper aligning mechanism (sub scan direction)..........................................22
5.3.2 Paper aligning mechanism (main scan direction)........................................23
5.3.3 Exit mechanism ...........................................................................................25
5.4 Stapling ...............................................................................................................27
5.4.1 Stapling mechanism ....................................................................................27
5.4.2 Stapling Unit moving mechanism ................................................................28
5.4.3 Stapling Position..........................................................................................28
5.4.4 Staple empty detection................................................................................29
i
FS-510/PU-501/OT-601
6. PU-501.................................................................................................................. 30
6.1 Composition ....................................................................................................... 30
6.2 Operation............................................................................................................ 30
6.2.1 Registration mechanism ............................................................................. 30
6.2.2 Punch mechanism ...................................................................................... 31
6.2.3 Punch status detection ............................................................................... 31
6.2.4 Punch Scraps Box full detection mechanism.............................................. 32
7. OT-601 .................................................................................................................. 33
OUTLINE
7.1 Composition ....................................................................................................... 33

7.2 Operation............................................................................................................ 33
7.2.1 Overview..................................................................................................... 33
ii
OUTLINE
FS-510/PU-501/OT-601
1.1 FS-510
A. Type
Name Multi tray finisher built into the main body

Installation Installed in the main body
OUTLINE
Consumables Staples (5,000 staples/cartridge)
B. Functions
Modes Non sort, sort, group, sort staple, and punch (when PU-501 is mounted)
C. Paper type
(1) Non sort
Type Size Weight Max. Capacity

Tray /1 200 sheets
Metric:
A4S, 81/2 x 11S 1000
A3, B4, A4, A4S, B5,
Plain paper 50 to 90 g/m2 or less sheets
B5S, A5, A5S, B6S Tray /2
11 x 17, 81/2 x 11, B4, 81/2 x 14 500
81/2 x 11S, Foolscap or greater sheets
Thick paper 91 to 210 g/m2
Inch:
OHP transparencies -
11 x 17, 81/2 x 14,
Translucent paper 81/2 x 11, 81/2 x 11S, -
20 sheets
Envelope 51/2 x 81/2S -
A3, A4, A4S, A5S,
Label -
Foolscap
Letterhead -
(2) Sort/Group

Metric: Tray /1 200 sheets
A3, B4, A4, A4S, B5,
B5S, A5
11 x 17, 81/2 x 11, A4S, 81/2 x 11S 1000
81/2 x 11S, Foolscap or less sheets
Plain paper 50 to 90 g/m2

Inch: Tray /2
11 x 17, 81/2 x 14,
81/2 x 11, 81/2 x 11S, B4, 81/2 x 14 500
51/2 x 81/2S or greater sheets
A3, A4, A4S, A5S,
Foolscap
1
FS-510/PU-501/OT-601
(3) Sort Staple

A3, B4, A4, A4S, B5,
B5S, A5, A5S, B6S
11 x 17, 81/2 x 14, A4S, 81/2 x 11S 1000
81/2 x 11, 81/2 x 11S, or less sheets
Foolscap
Inch: Tray /2
11 x 17, 81/2 x 14,
OUTLINE
81/2 x 11, 81/2 x 11S, B4, 81/2 x 14 500

A3, A4, A4S, A5S,
Foolscap
D. Stapling
Staple Filling Mode Dedicated Staple Cartridge (5000 staples)

Staple Detection Available (Nearly Empty: 20 remaining staples)
Front: Diagonal 45° 1 point *1 A3, B4, A4, B5
Rear: Diagonal 45° 1 point *1 11 x 17, 81/2 x 11
Front: Parallel 1 point A4S, B5S, A5
Stapling Position
Rear: Parallel 1 point 81/2 x 14, 81/2 x 11S, 51/2 x 81/2S
A3, B4, A4, A4S, B5, B5S, A5
Side: Parallel 2 point
11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S
*1: Diagonal 30° for B5 and B4
E. Maintenance

F. Machine specifications
Power Requirements 24/5V DC (supplied from the main body)

G. Operating environment

2
FS-510/PU-501/OT-601
1.2 PU-501
A. Type
Type FS built-in type punching operation device

Installation Screwed to the FS
Metric:
A3, B4, A4, A4S, B5, B5S
11 x 17, 81/2 x 11, 81/2 x 11S, Foolscap
Paper Size Inch:

2 holes: 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S
OUTLINE
3 holes: 11 x 17, 81/2 x 11
A3, A4
Paper Type Plain Paper (60 to 130 g/m2), Recycled Paper (60 to 130 g/m2)
Metric: 4 holes, Swedish 4 holes (φ 6.5 mm)
Punch Hole
Inch: 2 and 3 holes (can be switched) (φ 8 mm)
Number of Stored Metric (4 holes): For 1,500 sheets of paper (80 g/m2)
Punch Wastes Inch (2, 3 holes): For 1,000 sheets of paper (20 lbs)
B. Maintenance

C. Machine specifications
Power Requirements 24/5V DC (Supplied from FS)

D. Operating environment

3
FS-510/PU-501/OT-601
1.3 OT-601
A. Type
Type Additional Tray to FS

Mode Non sort, sort, group, and sort staple
Number of Bins 1 bin
B. Paper Type
OUTLINE
Mode Size Type Capacity

Metric: Plain Paper, Recycled Paper
200 sheets
A3, B4, A4, A4S, B5, (56 to 90 g/m2,15 to 24 lb)
B5S, A5, A5S, B6S
OHP transparencies
11 x 17, 81/2 x 11,
81/2 x 11S, Foolscap Thick paper
Non sort (91 to 210 g/m2)
Inch:
11 x 17, 81/2 x 14, Special Envelope 20 sheets
81/2 x 11, 81/2 x 11S, Label paper
51/2 x 81/2S
Letterhead
A3, A4, A4S, A5S,
Foolscap Translucent paper
Metric:
A3, B4, A4, A4S, B5,
Sort / group B5S, A5 200 sheets
11 x 17, 81/2 x 11,
Plain Paper, Recycled paper
Inch: (56 to 90 g/m2)
11 x 17, 81/2 x 14,
81/2 x 11, 81/2 x 11S,
Sort staple 200 sheets or 20 copies
51/2 x 81/2S
A3, A4, A4S, A5S,
Foolscap
C. Maintenance



NOTE
4
Theory of Operation Ver. 1.0 Feb. 2006 2. PAPER PATH
FS-510/PU-501/OT-601
2. PAPER PATH
2.1 Exiting Paper to the Tray /1
[2] [1]
[3]
OUTLINE
4349t1c001na
[1] From the main body [3] Exiting paper to the Tray /1
[2] Convey to the Tray /1
5
FS-510/PU-501/OT-601
2.2 Exiting Paper to the Tray /2

OUTLINE
[2] [1]
[3]
4349t1c002na
[1] From the main body [3] Exiting paper to the Tray /2
[2] Convey to the Tray /2
6
Theory of Operation Ver. 1.0 Feb. 2006 2. PAPER PATH
FS-510/PU-501/OT-601
2.3 Exiting Paper to OT
[2] [1]
[3]
OUTLINE
4349t1c003na
[1] From the main body [3] Exiting paper to OT

[2] Convey to OT
7
FS-510/PU-501/OT-601
OUTLINE
Blank Page
8
FS-510/PU-501/OT-601
3. COMPOSITION
Up/down Section
Conveyance Section
PU
OT
Staple Section
4349t2c001na
9
FS-510/PU-501/OT-601
4. DRIVE
4.1 FS-510
[5] [6]
[4] [7]
[1]
[3]
[2]
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[1] Stapler Drive Section [5] Paper Exit Opening Drive Section
[2] Exit Drive Section [6] Conveyance/Alignment Drive Section
[3] Up/down Drive Section [7] Entrance Drive Section
[4] Shutter Drive Section
10
Theory of Operation Ver. 1.0 Feb. 2006 4. DRIVE
FS-510/PU-501/OT-601
4.2 PU-501
[1]
4512t2c001na
[1] Punch Drive Section
11
FS-510/PU-501/OT-601
5. OPERATIONS
5.1 Conveyance Section
• The Conveyance Section is divided into the entrance conveyance section [3], intermediate
conveyance section [1], and the exit conveyance section [2]. It controls to convey the paper
fed from the main body, stop the paper at the punching and folding positions, and drive the
paper for feeding into the exit section.
[3]
[1]
[2]
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[1] Intermediate Conveyance Section [3] Entrance Conveyance Section

[2] Exit Conveyance Section
12
FS-510/PU-501/OT-601
5.1.1 Entrance/Conveyance section
• A paper [5] fed from the main body is conveyed to the intermediate conveyance section.
• The Entrance Motor (M3) [3] provides the drive for conveying a paper.
• When the M3 is energized, the Entrance Roller [1] and Registration Roller [2] are driven to
rotate.
• The Entrance Sensor (PS4) [4] detects a paper in the conveyance section.
[4]
[5]
[1]
[3]
[2]
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[1] Entrance Roller [4] Entrance sensor (PS4)

[2] Registration Roller [5] Paper
[3] Entrance motor (M3)
13
FS-510/PU-501/OT-601
5.1.2 Intermediate Conveyance Section

• A paper conveyed from the entrance conveyance section is brought to a stop at the punch-
ing and folding position.
• A paper is also conveyed to the exit conveyance section.
• Drive for the intermediate conveyance section is provided by the Conveyance Motor (M2)
[3]. Drive of the Intermediate Conveyance Roller /1 [4] and Intermediate Conveyance Roller
/2 [2] is controlled.
• The Conveyance Sensor (PS5) [1] detects paper in the intermediate conveyance section.
[4]
[1]
[3]
[2]
4349t2c005na
[1] Conveyance Sensor (PS5) [3] Conveyance Motor (M2)

[2] Intermediate Conveyance Roller /2 [4] Intermediate Conveyance Roller /1
14
FS-510/PU-501/OT-601
5.1.3 Exit Conveyance Section
• The paper is exited onto each of the trays.
• The Exit Motor (M1) [1] provides drive for the Exit Roller [3], Stacker Paddle [5], and Exit
Paddle [2].
[4]
[5]
[3]
[2] [1]
4349t2c006na
[1] Exit motor (M1) [4] Exit roller release motor (M6)
[2] Exit Paddle [5] Stacker Paddle
[3] Exit Roller
15
FS-510/PU-501/OT-601
5.2 Up/down Section

5.2.1 Up/down mechanism
• The Up/down mechanism is operated to select a specific tray, thereby feeding the paper exit
onto a specific tray.
[1]
4349t2c007na
[1] Tray Lift Motor (M11)
16
FS-510/PU-501/OT-601
5.2.2 Tray Up/Down operation
• The Tray is moved up or down by the Tray Lift Motor (M11) that turns forward or backward
to drive the front and rear belts.
• The Lower Limit Sensor (PS14) [1] detects the Tray at its lower limit position.
• The Tray Overrun Switch (SW3) [2] is provided for protection when the trays overruns nor-
mal position.
[2]
[1]
4349t2c008na
[1] Lower Limit Sensor (PS14) [2] Tray Overrun Switch (SW3)
17
FS-510/PU-501/OT-601
5.2.3 Tray Upper Limit Position Detection Mechanism

• Each of the Tray moves up or down according to the amount of paper fed onto it.
• When the Upper Limit Sensor (PS15) [1] turns ON for each exit of paper, bring down once
the Lift Tray until PS15 turns OFF so that the upper surface of paper on the Tray is kept at
the same level at all times while in the paper exit.
• Bring up again the Tray until PS15 turns ON.
[1]
4349t2c009na
[1] Upper Limit Sensor (PS15)
18
FS-510/PU-501/OT-601
A. Tray Position Detection
• Tray position detection is controlled according to the number of times the Tray Position Sen-
sor (PS3) [1] is activated after the Lower Limit Sensor (PS14) [2] has been activated.
(1) Tray position detection operation

1. During the initial operation sequence, the Tray is subjected to a descent motion until
the Lower Limit Sensor (PS14) is activated.
[2] [1]
4349t2c010na
[1] Tray Position Sensor (PS3) [2] Lower Limit Sensor (PS14)
19
FS-510/PU-501/OT-601
2. After PS14 has been activated, the Up/Down Section is subjected to an ascent motion.
3. When PS3 [1] is activated a first time after the ascent motion of the Up/Down Section
has been started, it is determined that the Up/Down Section is now located at the
paper exit opening for the Tray /1.
[1]
4349t2c011na
[1] Tray Position Sensor (PS3)
4. When PS3 is activated a second time after the ascent motion of the Up/Down Section
has been started, it is determined that the Up/Down Section is now located at the
paper exit opening for the Tray /2.
5. Drive is stopped when PS3 is activated with Upper Limit Sensor (PS15) of the target
tray in the activated position.
* If OT is installed, OT is at the exit port when the position sensor is activated twice and the
Tray /2 is at the exit port when the position sensor is activated three times.
B. Paper Full Detection

• When the Tray Position Sensor (PS3) changes from the activated to deactivated state with
the Upper Limit Sensor (PS15) in the activated state, a paper full condition is detected and
the corresponding message will appear on the operation panel.
20
FS-510/PU-501/OT-601
5.2.4 Shutter Open/Close Mechanism
• The paper exit section is provided with the Shutter [3] and this Shutter is normally in the up
condition (the condition in which the Paper Exit Opening is opened). However, when the Tray
goes up and down, the Paper Exit Opening is closed to prevent an accident such as hands
getting caught in the Paper Exit Opening.
• The Shutter is opened or closed by the Shutter Motor (M12) [2] that turns a gear train for
raising or lowering the Shutter.
• The Shutter Home Sensor (PS16) [4] detects the position of the gear, thereby determining
the position of the Shutter.
• When the Shutter does not close while in the Tray up/down operation, the Shutter Switch
(SW2) [1] turns OFF to shut off a 24V DC and stop the up/down of the Tray at once.
[4]
[1]
[3] [2]
4349t2c012na
[1] Shutter Switch (SW2) [3] Shutter

[2] Shutter Motor (M12) [4] Shutter Home Sensor (PS16)
21
FS-510/PU-501/OT-601
5.3 Stacker section

5.3.1 Paper aligning mechanism (sub scan direction)
• Sheets of paper are aligned properly and stapled together inside the stacker section before
being fed out onto the corresponding tray.
• In the Sort, Group, Staple, or Half Fold/Fold & Staple mode, each copy set is stored in the
Stacker with the Upper Exit Roller separated from the Lower Exit Roller.
• The Stacker Sensor (PS8) detects paper in the Stacker.
• The Stacker Paddle and Aligning Belt are driven when the Exit Motor (M1) is rotated in
reverse.
A. Operation
1. The paper fed out from the main body is held downward by the Drop Lever [7] and
dropped down into the Stacker by the Intermediate Conveyance Roller /2 [4].
2. The paper dropped into the Stacker is pressed against the Paper Stopper [5] by the
Paddle [3] and Aligning Belt [1] so that it is aligned properly in the sub scan direction.
[3] [7] [3] [7] [1]

[5]
[4]
[6]
[1]
[3]
[2]
4349t2c013na
[1] Aligning Belt [5] Paper Stopper

[2] Exit Motor (M1) [6] Stacker sensor (PS8)
[3] Stacker Paddle [7] Drop Lever
[4] Intermediate Conveyance Roller /2
22
FS-510/PU-501/OT-601
5.3.2 Paper aligning mechanism (main scan direction)
• Aligning Plates are moved and the Paddle is rotated so as to align the paper at the stapling
position.
• The paper in the Stacker is aligned in the main scan direction by two Alignment Motors and
aligning plates.
A. Aligning plates
• The aligning plates [6] are moved to the front or rear in accordance with the paper size.
• The Alignment Sensor /Rr (PS6) [4], /Fr (PS7) [1] detects the position of each aligning plate.
[6]
[5]
[7]
[4]
[3]
[2]
[1]
4349t2c014na
[1] Alignment sensor /Fr (PS7) [5] Paper Aligning Portion

[2] Alignment motor /Fr (M5) [6] Aligning Plate
[3] Alignment motor /Rr (M4) [7] Paper Stoppers
[4] Alignment sensor /Rr (PS6)
23
FS-510/PU-501/OT-601
B. Paper aligning sequence

• In normal print and staple mode, the paper is fed into the tray at its center position.
• If no stapling is involved in the Sort or Group Print mode, the aligning plate shifts 15 mm to
the front or rear from the center. This stacks papers in a saw tooth manner, each being off-
set by about 30 mm with respect to the others.
This shifting motion is not performed when papers are fed into the MT or the SD.
[5]
[1]
[2]
[4] [3]
4349t2c015na
[1] 30mm [4] Normal/Staple

[2] Center [5] Aligning Plate
[3] Shift (Sort/Group)
24
FS-510/PU-501/OT-601
5.3.3 Exit mechanism
• The paper exit roller section is provided with the Paper Holding Paddle [3] to hold the paper
exited onto the Tray while in the sort mode so that the paper does not have an uneven edge.
• The subsequent copy set is fed out with the copy sets previously resident on the tray being
held down by the paper holding paddle.
• The Exit Paddle Home Sensor (PS11) [1], Spring Clutch [4], and Exit Paddle Solenoid (SD2)
[2] control the retracted position and paper holding position of the paper holding paddle.
[4] [1]
[3] [2]
4349t2c016na
[1] Exit Paddle Home Sensor (PS11) [3] Paper Holding Paddle
[2] Exit Paddle Solenoid (SD2) [4] Spring Clutch
25
FS-510/PU-501/OT-601
A. Exit Roller up/down mechanism

• While in the sort mode and the staple mode, the Exit Roller /Up is pressed to the Exit Roller
/Lw after the paper is stacked in the Stacker.
• The press/release of the Exit Roller /Up is driven by the Exit Roller Release Motor (M6) [3].
• The Exit Roller Home Sensor (PS12) [4] detects the position of the Exit Roller /Up, whether
it is in the released or pressed position.
[4]
[3] [2] [1]

4349t2c017na
[1] Unblocked (Released) [3] Exit Roller Release Motor (M6)

[2] Blocked (Pressed) [4] Exit Roller Home Sensor (PS12)
26
FS-510/PU-501/OT-601
5.4 Stapling
5.4.1 Stapling mechanism
• Stapling is performed by the Stapling Unit.
• When the Stapling Motor [1] is rotated, the Clinch Arm [3] lowers. The Stapler [2] thereafter
goes up to drive a staple in the paper.
• Five different types of stapling are available: parallel front one point, parallel rear one point,
slant front one point, slant rear one point and parallel two points.
[3]
[1]
[2]
4349t2c018na
[1] Stapling Motor [3] Clinch Arm

[2] Stapler
27
FS-510/PU-501/OT-601
5.4.2 Stapling Unit moving mechanism

• The Stapling Unit is moved by the Stapler Movement Motor (M7) [3].
• M7 drives the belt so that the Stapling Unit is moved to the corresponding stapling position.
• The stapling stop position is controlled by the period of time during which the M7 is kept
energized, as counted from the time when the Stapler Home Sensor (PS10) [4] has been
activated.
[1]
[5]
[4]
[2]
[3]
4349t2c019na
[1] Home [4] Stapler Home Sensor (PS10)

[2] Staple change position [5] Stapling Unit
[3] Stapler Movement Motor (M7)
5.4.3 Stapling Position

• A single stapling unit is moved to perform 2-point stapling.
[3] [2] [1]
4349t2c020na
[1] Parallel two points [3] Parallel one point

[2] Slant one point
28
FS-510/PU-501/OT-601
5.4.4 Staple empty detection
• Staple Empty Sensor [2] detect whether or not there are staples still left.
• When the number of staples left in the staple cartridge becomes about 20, a staple sheet
empty condition results, causing a corresponding empty message to appear on the opera-
tion panel.
• When the empty condition is detected, the corresponding empty indication is given on the
operation panel. At the same time, the Stapling Unit moves to the front.
• When a new staple cartridge is loaded, the stapling motor is energized until the Stapler
Ready Sensor [1] detects a staple, which results in the staple to be fed up to the stapling
position.
[1]
[2]
4349t2c021na
[1] Stapler Ready Sensor [2] Staple Empty Sensor
29
6. PU-501 Theory of Operation Ver. 1.0 Feb. 2006
FS-510/PU-501/OT-601
6. PU-501
6.1 Composition
4512t2c002na
6.2 Operation
6.2.1 Registration mechanism
• For punch and holding operations, a loop is formed in the paper at the Registration Roller [2]
to correct skew of the paper.
• The Entrance Sensor (PS4) [1] detects the leading edge of the paper and the Registration
Roller forms a loop in the paper.
• The Registration Clutch (CL1) is then energized after a given period of time after the PS4 is
activated by the leading edge of the paper, this causes the Registration Roller to start turn-
ing.
[2]
[1]
4512t2c003na
[1] Entrance Sensor (PS4) [2] Registration Roller
30
Theory of Operation Ver. 1.0 Feb. 2006 6. PU-501
FS-510/PU-501/OT-601
6.2.2 Punch mechanism
• After a given period of time after the Entrance Sensor (PS4) [3] has detected the trailing
edge of the paper, the Conveyance Motor (M2) of FS is deenergized and a punch hole oper-
ation is made at the trailing edge portion in each sheet of paper.
• Punch holes are made when the slide cam [1] makes a reciprocating motion, as driven by
the drive cam which is rotated by the Punch Motor (M1) [2] provided in the punch unit.
[1]
[4]
[2]
[3]
4512t2c004na
[1] Slide Cam [3] Entrance Sensor (PS4)

[2] Punch Motor (M1) [4] Puncher
6.2.3 Punch status detection

• The punch status is detected by using the Punch Position Sensor /1 (PS2) [1], /2 (PS3) [2],
Punch Home Sensor, and the Encoder Sensor (PS4) [3].
[1] [2]
[3]
4512t2c005na
[1] Punch Position Sensor /1 (PS2) [3] Encoder Sensor (PS4)

[2] Punch Position Sensor /2 (PS3)
31
6. PU-501 Theory of Operation Ver. 1.0 Feb. 2006
FS-510/PU-501/OT-601
6.2.4 Punch Scraps Box full detection mechanism

• Punch scraps produced as a result of punching operation is stored in the Punch Scraps
Box.
• The Punch Scraps Box is provided with the Punch Scraps Full Sensor (PS1) [1]. When a
punch waste is detected, the corresponding message is displayed on the operation panel.
• PS1 is a reflector type sensor that detects height of the punch scraps.
• PS1 also detects whether a Punch Scraps Box is loaded.
[1]
4512t2c006na
[1] Punch Scraps Full Sensor (PS1)
32
Theory of Operation Ver. 1.0 Feb. 2006 7. OT-601
FS-510/PU-501/OT-601
7. OT-601
7.1 Composition
4625t2c001na
7.2 Operation
7.2.1 Overview
• Mounting the optional OT provides a total of three trays.
• The OT is attached at different positions depending on whether options SD or MT is
mounted or not.
The capacity of each tray is different depending on the position of the OT is attached.
• When the short-circuit connector shipped with OT is mounted, the machine determines that
OT has been mounted.
[5] [6]
[4] [7]
[3] [8]
[2] [1]
4625t2c002na
[1] When MT/SD is installed [5] 200 sheets

[2] FS only [6] 200 sheets
[3] 500 sheets [7] 200 sheets
[4] 200 sheets [8] 200 sheets
33
7. OT-601 Theory of Operation Ver. 1.0 Feb. 2006
FS-510/PU-501/OT-601
Blank Page
34
FS-511/RU-502
2006.02
Ver. 1.0
Revision history
Revision mark:
page.
NOTE

CONTENTS
FS-511/RU-502
FS-511/RU-502
OUTLINE
1.1 FS-511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 RU-502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. COMPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 FS-511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 RU-502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1 RU conveyance section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1.1 Conveyance mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2 FS conveyance section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2.1 Entrance conveyance mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2.2 Gate mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2.3 Sub tray conveyance mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2.4 Main tray/handling tray conveyance mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2.5 Roller separation mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2.6 Conveyance operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.3 Main tray section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.3.1 Main tray up/down mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.3.2 Main tray shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.4 Punch section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.4.1 Punch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.4.2 Punch hole switchover mechanism (for inch area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.5 Staple section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.5.1 Alignment mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.5.2 Stapler movement mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.5.3 Stapling mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.5.4 Staple sheet empty control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
i
FS-511/RU-502
Blank page
ii
OUTLINE
FS-511/RU-502
1.1 FS-511
A. Type
Type Multi staple finisher

Installation Floor-mounted type
Document alignment Center
Consumables Staples
B. Functions
Mode Normal Non-sort, sort, group, sort-staple

Punch Non-sort-punch, sort-punch, group-punch,
sort-staple-punch
C. Type of paper
• Maximum load capacity: (80 g/m2) when loaded with paper of the same size.
(1) Straight
Type of paper Size of paper Weight Max. capacity Exit tray Max. number of
sheets stapled
Plain paper A3, B4, A4, A4S, B5, 60 to 90 g/m2 250 sheets Sub tray —
Recycled paper B5S, A5S, and B6S
Thick paper 51/2 x 81/2S, 81/2 x 11, 91 to 130 g/m2 20 sheets
81/2 x 11S, 81/2 x 14,
Thin paper 50 to 59 g/m2
11 x 17
OHP —
transparencies
Label
Envelope
Label sheet
Letterhead
1
1. PRODUCT SPECIFICATION Theory of Operation Ver1.0 Feb.2006
(2) Non-sort, sort, group

FS-511/RU-502
sheets stapled
Plain paper A3, B4, A4, A4S, B5, 50 to 130 g/m2 3000 sheets Main tray —
Recycled paper B5S (A4S or smaller)
Thick paper 81/2 x 11, 81/2 x 11S, 1500 sheets
81/2 x 14, 11 x 17 (B4 or larger)
Thin paper
(3) Sort-staple, group-staple
sheets stapled
Plain paper A3, B4, A4, A4S, B5, 60 to 90 g/m2 3000 sheets Main tray 50 sheets
81/2 x 11, 81/2 x 11S, 1500 sheets
81/2 x 14, 11 x 17 (B4 or larger)
(4) Punch
a. Metric/Swedish
sheets stapled
Plain paper A3, B4, A4, A4S, B5, 60 to 90 g/m2 — Main tray —
Recycled paper B5S Sub tray
b. Inch 2 holes
sheets stapled
Plain paper 81/2 x 11S, 81/2 x 14 60 to 90 g/m2 — Main tray —
Recycled paper Sub tray
c. Inch 3 holes
sheets stapled
Plain paper 81/2 x 11S, 11 x 17 60 to 90 g/m2 — Main tray —
2
D. Stapling
FS-511/RU-502
Staple filling method Dedicated staple cartridge (5000 staples)
Staple detection Available (near empty: 20 remaining staples)
Staple position *1 Rear: Diagonal 45° 1 point Metric: A3, B4, A4, B5
Front: Diagonal 45° 1 point Inch: 81/2 x 11, 11 x 17
Rear: Diagonal 28° 1 point Metric: B4, B5
Front: Diagonal 28° 1 point Inch: —
Rear: Parallel 1 point Metric: A4S, B5S
Front: Parallel 1 point Inch: 81/2 x 11S, 81/2 x 14
Side: 2 points A4, A4S, A3, B5, B5S, B4, 81/2 x 11, 81/2 x 11S,
81/2 x 14, 11 x 17
Manual staple None
*1 In case of the 1-staple mode, conduct a parallel and a skew adjustment according to the length in the
main scan direction.
Parallel: main scan direction 182 to 216 mm
Diagonal: main scan direction 216 to 297 mm
E. Punch
No. of holes Inch: 2 holes, 3 holes

Metric: 4 holes
Punch scraps full detection None
F. Maintenance
Maintenance Same as the main body.

G. Machine data
Power source 24V DC ± 10 % (supplied from the main body)

Power consumption 64 W or less
Weight 39.2 kg
H. Operating environment
Humidity 10 to 80 % RH (with no condensation)
Note
3
1. PRODUCT SPECIFICATION Theory of Operation Ver1.0 Feb.2006
1.2 RU-502
FS-511/RU-502
A. Type
Type Roller method relay conveyance unit
B. Functions
Conveyance Paper conveyance from the main body to FS
C. Type of paper
Paper size Same as the main body.

Paper type Same as the main body.
Amount of curling b = 10 mm or less
(5 sheets)
h
16fat1c001na
D. Maintenance

E. Machine data
Power source 5.1V DC ± 5 % (supplied from FS)

Dimensions 474.5 (W) x 469.5 (D) x 254.4 (H) mm
Note
4
Theory of Operation Ver1.0 Feb.2006 2. PAPER PATH
2. PAPER PATH
FS-511/RU-502
A. Non-sort mode (sub tray paper exit)
[4] [5] [6] [7]
[1]
[3] [2]
4521t1c004na
[1] Paper exit roller (main body) [5] FS-511

[2] Bypass gate [6] Punch
[3] Main gate [7] RU-502
[4] Sub tray
Note: Even when mixed with the punch mode, the paper path is the same.
B. Non-sort/sort/group mode
[3] [4] [5] [6] [7]
[1]
[2]
4521t1c005na
[1] Paper exit roller (main body) [5] Main gate

[2] Bypass gate [6] Punch
[3] Main tray [7] RU-502
[4] FS-511
Note: Even when mixed with the punch mode, the paper path is the same.
5
C. Staple mode
FS-511/RU-502
[6] [7] [8] [9] [10] [11]
[1]
[5] [4] [3] [2]
4521t1c006na
[1] Paper exit roller (main body) [7] Paper path for other than the 1st paper of
[2] Bypass gate the 2nd and succeeding copies.
[3] Paper path for the 1st paper of the 2nd and [8] FS-511
succeeding copies [9] Main gate
[4] Stapler [10] Punch
[5] Handling tray [11] RU-502
[6] Main tray
Note: Even when the A, B or C mode mentioned above is mixed with the punch mode, the paper path is the
same.
6
Theory of Operation Ver1.0 Feb.2006 3. COMPOSITION
FS-511/RU-502
3. COMPOSITION
Conveyance
Sub tray section Punch section RU-502
Main tray section
Staple section
4521t2c001na
7
4. DRIVE Theory of Operation Ver1.0 Feb.2006
4. DRIVE
FS-511/RU-502
4.1 FS-511
[12] [13] [14]

[11]
[10]
[9]
[8] [1]
[7] [2]
[6]
[5]
[3]
[4]
4521t2e001na
[1] Paddle motor /Lw (M9) [8] Paper exit motor (M3)
[2] Hole punch selector motor (M14) (for inch [9] Paddle motor /Up (M15)
area) [10] Paper exit roller release motor (M13)
[3] Tray lift motor (M7) [11] Conveyance motor /Lw (M2)
[4] Shift motor (M8) [12] Conveyance motor /Up (M4)
[5] Stapler moving motor (M6) [13] Entrance conveyance motor (M1)
[6] Alignment motor (M5) [14] Punch motor (M11)
[7] Intermediate conveyance roller release
motor (M12)
8
Theory of Operation Ver1.0 Feb.2006 4. DRIVE
4.2 RU-502
FS-511/RU-502
[3] [4] [5]
[2]
[1]
16fat2c001na
[1] Main body - fusing motor (M11) [4] Conveyance roller

[2] Entrance conveyance roller (FS-511) [5] Coupling gear
[3] Belt
9
5. OPERATION Theory of Operation Ver1.0 Feb.2006
5. OPERATION
FS-511/RU-502
5.1 RU conveyance section

5.1.1 Conveyance mechanism
• The driving force from the fusing motor (M11) is transmitted through the coupling gear [2] to rotate the con-
veyance roller [5].
• Paper conveyed from the paper exit roller [1] on the main body side is conveyed by the conveyance roller to
the entrance roller [3] on the FS side.
• A jam is detected by the path sensor (PS2) [4].
[4] [5]
[1]
[3]
[2]
16fat2c003na
[1] Paper exit roller (main body) [4] Path sensor (PS2)
[2] Coupling gear [5] Conveyance roller
[3] Entrance roller (FS-511)
10
Theory of Operation Ver1.0 Feb.2006 5. OPERATION
5.2 FS conveyance section
FS-511/RU-502
• The conveyance section is made up of the entrance conveyance mechanism [6] that conducts the convey-
ance drive, the main route conveyance mechanism [2], the sub tray conveyance mechanism [5], the han-
dling/paper exit conveyance mechanism [3], the gate mechanism [1] that switches the paper path and the
roller separation mechanism [4] that conducts the pressure/release of the roller.
[4] [5] [6]
[3]
[2] [1] 4521t2c004na
[1] Gate mechanism [4] Roller separation mechanism

[2] Main route conveyance mechanism [5] Sub tray conveyance mechanism
[3] Main tray/handling tray conveyance mecha- [6] Entrance conveyance mechanism
nism
11
5.2.1 Entrance conveyance mechanism

• The driving force of the entrance conveyance motor (M1) [4] rotates the entrance roller [1] to convey [3]
FS-511/RU-502
paper [2] into FS.
[4]
[1]
[3] [2]
4521t2c005na
[1] Entrance roller [3] Paper conveyance direction

[2] Paper [4] Entrance conveyance motor (M1)
A. Control
(1) Sub tray paper exit
• When the FS start signal turns ON, the entrance conveyance motor (M1) turns ON. And it turns OFF a
specified period of time after the sub tray exit sensor (PS1) detects the trailing edge of the last paper.
(2) Sort/staple
• When the FS start signal turns ON, M1 turns ON. And it turns OFF a specified period of time after the inter-
mediate conveyance sensor (PS3) detects the trailing edge of the last paper.
12
5.2.2 Gate mechanism

• On the conveyance path, the following 2 types of gates are provided: the bypass gate [6] and the main gate
FS-511/RU-502
[3].
• The bypass gate is driven by the bypass gate solenoid (SD1) [5].
• The main gate is driven by the main gate solenoid (SD2) [2].
[6]
[1]
[5]
[4]
[3]
[2]
4521t2c006na
[1] Paper [4] Paper conveyance direction when the

[2] Main gate solenoid (SD2) bypass gate solenoid (SD1) turns ON and
[3] Main gate the main gate solenoid (SD2) turns ON.
[5] Bypass gate solenoid (SD1)

[6] Bypass gate
13
A. Operation
• The paper conveyance path of the bypass gate [1] is switched over in the bypass route direction [2] when
FS-511/RU-502
the bypass gate solenoid (SD1) turns OFF and switched over in the main gate direction [10] when it turns
ON.
• The paper conveyance path of the main gate [9] is switched over in the main route direction [4] when the
main gate solenoid (SD2) turns OFF and switched over in the sub tray route direction [8] when SD2 turns
ON.
• The paper conveyance to the bypass route is used when conveying each of the 1st sheets of paper of the
2nd and succeeding copies in the staple mode to increase the handling capacity of paper even while in the
stapling operation.
Conveyance path SD1 SD2

Sub tray ON ON
Main tray ON OFF
Bypass route OFF —
[5] [6] [7] [8] [9] [10]
[4] [3] [2] [1]
4521t2c007na
[1] Bypass gate [6] Main route conveyance sensor (PS4)

[2] Bypass route [7] Sub tray exit sensor (PS1)
[3] Bypass route conveyance sensor (PS2) [8] Sub tray route
[4] Main route [9] Main gate
[5] Intermediate conveyance sensor (PS3) [10] Main gate direction conveyance path
B. Control
(1) Sub tray paper exit
• A specified period of time after the fusing exit sensor (PS3) of the main body turns ON and detects the lead-
ing edge of paper, the bypass gate solenoid (SD1) turns ON and the main gate solenoid (SD2) also turns
ON to switch over the conveyance path to the sub tray route.
• A specified period of time after the sub tray exit sensor (PS1) turns ON with the trailing edge of paper
detected, SD1 and SD2 turn OFF.
14
5.2.3 Sub tray conveyance mechanism

• The paper conveyance to the sub tray is made while in the non-sort mode.
FS-511/RU-502
• The conveyance motor /Up (M4) [5] drives the conveyance roller /Up [1] and the sub tray paper exit roller [2]
to convey [3] paper [4] to the sub tray.
[5]
[1]
[4]
[3]
[2]
4521t2c008na
[1] Conveyance roller /Up [4] Paper

[2] Sub tray paper exit roller [5] Conveyance motor /Up (M4)
[3] Paper conveyance direction
A. Control
(1) Sub tray paper exit (with no punch)/staple mode (with no punch)
• A specified period of time after the FS start signal turns ON, the conveyance motor /Up (M4) turns ON. And
it turns OFF a specified period of time after the sub tray exit sensor (PS1) turns OFF with the trailing edge of
paper detected.
(2) Sub tray paper exit (punch mode)

• When the FS start signal turns ON, M4 turns ON. However it stops while in the punch operation. M4 turns
ON again after completion of the punch and it turns OFF a specified period of time after PS1 turns OFF.
15
5.2.4 Main tray/handling tray conveyance mechanism

• The conveyance motor /Lw (M2) [7] drives the conveyance roller /Lw [1] and the intermediate conveyance
FS-511/RU-502
roller [9] to convey paper in the main tray direction [4]. When rotating M2 in the reverse direction, paper is
switched back [10].
• The switch back is made for the 1st paper of each of the 2nd and succeeding copies when printing contin-
uously 2 or more copies in the staple mode to convey the 1st and the 2nd sheets of paper overlapped each
other.
• The paper exit motor (M3) [6] drives the paper exit roller [2] to convey paper in the main tray direction. When
rotating M3 in the reverse direction, paper is conveyed [3] to the handling tray [8].
• The paper conveyance to the handling tray is made while in the staple mode.
[7]
[8] [9] [10]
[6]
[1]
[5]
[4]
[3] [2]
4521t2c009na
[1] Conveyance roller /Lw [6] Paper exit motor (M3)

[2] Paper exit roller [7] Conveyance motor /Lw (M2)
[3] Conveyance to the handling tray [8] Handling tray
[4] Main tray paper exit direction [9] Intermediate conveyance roller
[5] Paper [10] Switch back direction
16
A. Switch back control

1. When the FS start signal turns ON, the conveyance motor /Lw (M2) rotates in the normal direction. And
FS-511/RU-502
when the bypass route conveyance sensor (PS2) [3] detects the trailing edge of the 1st paper [1] of the 2nd
copy that has been conveyed to the bypass route, M2 turns OFF.
2. A specified period of time after M2 turns OFF, M2 rotates in the reverse direction to switch back the convey-
ance [2]. And a specified period of time after that, M2 stops to stand by for the 2nd paper.
3. A specified period of time after the main route conveyance sensor (PS4) [7] detects the leading edge of the
2nd paper [8] that has been conveyed through the main route by the conveyance motor /Up (M4), M2
rotates again in the normal direction to convey the 1st and the 2nd sheets of paper overlapped each other.
4. A specified period of time after the intermediate conveyance sensor (PS3) [6] detects the trailing edge of the
last paper, M2 turns OFF.
[5] [6] [7] [8]
[1]
[4] [3] [2]

4521t2c010na
[1] 1st paper of the 2nd copy [5] Paper of the 1st copy
[2] Switch back [6] Intermediate conveyance sensor (PS3)
[3] Bypass route conveyance sensor (PS2) [7] Main route conveyance sensor (PS4)
[4] Handling tray [8] 2nd paper of the 2nd copy
17
B. Handling tray conveyance operation

(1) Sort mode
FS-511/RU-502
• When the FS start signal turns ON, the paper exit motor (M3) rotates in the normal direction to convey
paper to the main tray. M3 turns OFF a specified period of time after the intermediate conveyance sensor
(PS3) detects the trailing edge of the last paper.
(2) Staple mode

1. When the FS start signal turns ON, M3 rotates in the normal direction. It stops a specified period of time after
PS3 [1] detects the trailing edge of paper.
2. A specified period of time after the stop, M3 rotates in the reverse direction to convey [1] paper to the han-
dling tray [2].
3. After completion of the stapling operation, M3 rotates in the normal direction to exit [6] the stapled paper [5]
to the main tray. At this time, the 1st [4] and the 2nd [7] sheets of paper of the next copy are also conveyed
to the main tray simultaneously.
4. A specified period of time after PS3 detects the trailing edge of the 1st and the 2nd sheets of paper of the
next copy, M3 stops and rotates again in the reverse direction to convey paper to the handling tray.
[3] [6] [7]
[2] [1] [5] [4] 4521t2c011na
[1] Paper stack [5] Paper that has been stapled

[2] Handling tray [6] Paper exit to main tray
[3] Intermediate conveyance sensor (PS3) [7] 2nd paper of the next copy
[4] 1st paper of the next copy
18
5.2.5 Roller separation mechanism

• The intermediate conveyance roller and the paper exit roller are provided with a separation mechanism that
FS-511/RU-502
releases the pressure from the roller.
• The intermediate conveyance roller release motor (M12) [1] drives the cam [5] to pressure/release the inter-
mediate conveyance roller [2]. The home position is detected by the roller release home sensor (PS12) [4].
• The paper exit roller release motor (M13) [8] drives the crank [7] to pressure/release the paper exit roller [3].
The home position is detected by the paper exit roller home sensor (PS13) [6].
[8]
[7]
[1]
[6]
[2]
[5]
[4]
[3]
4521t2c012na
[1] Intermediate conveyance roller release [5] Cam

motor (M12) [6] Paper exit roller home sensor (PS13)
[2] Intermediate conveyance roller [7] Crank
[3] Paper exit roller [8] Paper exit roller release motor (M13)
[4] Roller release home sensor (PS12)
19
A. Intermediate conveyance roller separation control

1. When printing continuously a large size paper (217 mm or larger) in the staple mode, the leading edge of the
FS-511/RU-502
2nd paper [4] gets to the intermediate conveyance roller [2] while in the switch back [1] of the 1st paper of
the 2nd and succeeding copies. To prevent this, release the pressure of the intermediate conveyance roller
and separate [3] the roller to get the 2 sheets of paper overlapped each other.
2. When the 2nd paper stops, the intermediate conveyance roller is pressured to convey the 2 sheets of paper
overlapped each other to the handling tray.
[2] [3] [4]
[1]
4521t2c013na
[1] 1st paper of the 2nd copy [3] Separation

[2] Intermediate conveyance roller [4] 2nd paper of the 2nd copy
20
B. Paper exit roller separation control

1. To stack [1] paper in the handling tray [2] while in the staple mode, FS start signal turns ON, and the paper
FS-511/RU-502
exit roller release motor (M13) turns ON. After the pressure of the paper exit roller [3] is released and the
paper exit roller is separated [4], M13 turns OFF.
2. After completion of the stapling operation, M13 turns ON again when the fusing exit sensor (PS3) of the main
body detects the trailing edge of the 2nd paper of the next copy. M13 pressures [7] the paper exit roller to
nip the paper [5], then M13 stops and the paper exits.
[3] [4] [6] [7]
[2] [1] [5] 4521t2c014na
[1] Conveyance to the handling tray [5] Paper

[2] Handling tray [6] Paper exit
[3] Paper exit roller [7] Pressure
[4] Release the pressure of the paper exit roller
21
5.2.6 Conveyance operation

A. Continuous copy in the staple mode (in case of A4S, 3 originals, and 2 copies)
FS-511/RU-502
1. The 1st paper [2], the 2nd paper [3] and the 3rd paper [4] of the 1st copy are conveyed to the handling tray
[1].
2. While in the conveyance of the last paper [7] of the 1st copy, the 1st paper of the 2nd copy is conveyed [6]
to the bypass route.
[2] [3] [4] [5] [7] [6]
[1] 4521t2c015na
[1] Handling tray [5] 1st paper of the 2nd copy

[2] 1st paper of the 1st copy [6] 1st paper of the 2nd copy
[3] 2nd paper of the 1st copy [7] 3rd paper of the 1st copy
[4] 3rd paper of the 1st copy
3. The 1st paper [1] of the 2nd copy thus conveyed to the bypass route is switched back by the conveyance
roller /Lw [2] and the storage roller [3], and then it stops.
4. The 1st paper [4] of the 2nd copy is overlapped with the 2nd paper [5] of the 2nd copy to be conveyed.
[3] [5]
[2] [1] [4]

4521t2c016na
[1] 1st paper of the 2nd copy [4] 1st paper of the 2nd copy
[2] Conveyance roller /Lw [5] 2nd paper of the 2nd copy
[3] Storage roller
22
5. After completion of the stapling operation of the paper [1] of the 1st copy, the paper exit roller [2] is pres-
sured to exit the paper of the 1st copy. At this time, the moment the paper of the 1st copy is exited, the 1st
FS-511/RU-502
and the 2nd sheets of paper [3] of the 2nd copy are also conveyed in the main tray direction.
6. After completion of the exit of the paper [6] of the 1st copy, the pressure of the paper exit roller is released [7]
and the paper exit roller [5] rotates in the reverse direction to convey the 1st and the 2nd sheets of paper [4]
of the 2nd copy to the handling tray.
[2] [3] [6] [7]
[1] [5] [4] 4521t2c017na
[1] Paper of the 1st copy [4] 1st and the 2nd sheets of paper of the 2nd
[2] Pressure the paper exit roller copy
[3] 1st and the 2nd sheets of paper of the 2nd [5] Paper exit roller
copy [6] Paper of the 1st copy
[7] Separation of the paper exit roller
23
5.3 Main tray section

FS-511/RU-502
5.3.1 Main tray up/down mechanism

• The up/down of the main tray is made by the normal/reverse rotation of the tray lift motor (M7) [2].
[5]
[4]
[1]
[3]
[2]
4521t2c018na
[1] Main tray upper limit LED (LED19) [4] Main tray upper limit sensor (PS19)
[2] Tray lift motor (M7) [5] Main tray reset sensor (PS8)
[3] Main tray
A. Control
(1) While in the print operation
• While in the paper exit, when the main tray upper limit sensor (PS19) turns ON, the tray lift motor (M7)
rotates in the reverse direction to bring down the main tray. And M7 turns OFF when PS19 turns OFF. This
operation is repeated and stopped when the tray gets to the bottom according to the amount of paper
exited.
(2) Paper removal control

• When paper loaded on the main tray is removed with the main tray reset sensor (PS8) OFF, M7 rotates in
the normal direction to bring up the main tray, and when PS8 turns ON, M7 turns OFF.
(3) Paper full detection

• For the main tray, when the main tray full sensor (PS7) turns ON, this is detected as the tray being full of
paper and M7 turns OFF.
• When the main tray goes up and the current of M7 is in excess of a prescribed value, this is detected as the
tray being full of paper and M7 turns OFF.
24
5.3.2 Main tray shift mechanism

• While in the sort/group mode, the shift motor (M8) [4] is driven to shift the main tray [5] 30 mm in the main
FS-511/RU-502
scan direction through the shift plate [3].
• The home position is detected by the shift home sensor (PS10) [2].
[1]
[5]
[4]
[2]
[3]
4521t2c019na
[1] Shift encoder sensor (PS11) [4] Shift motor (M8)

[2] Shift home sensor (PS10) [5] Main tray
[3] Shift plate
A. Control
(1) Sort mode
• A specified period of time after the intermediate conveyance sensor (PS3) detects the trailing edge of the
last paper of the copy, the shift motor (M8) turns ON to start the shift operation, and when the shift home
sensor (PS10) detects the shift position, M8 turn OFF.
(2) Staple mode

• A specified period of time after the paper exit roller release motor (M13) turns ON to start the pressure oper-
ation, M8 turns ON to start the shift operation, and when PS10 detects the shift position, M8 turns OFF.
25
5.4 Punch section

FS-511/RU-502
5.4.1 Punch mechanism

• For the punch, a hole is punched on the rear side of paper for each paper.
• The driving force from the punch motor (M11) [5] is transmitted to the eccentric cam [6] by the punch clutch
(CL1) [4]. And when the eccentric cam makes a full turn, the cam holder [3] makes a round trip to punch a
hole.
• The position of the reciprocating operation of the punch is detected by the punch encoder sensor (PS15).
[6]
[1]
[5]
[4]
[3]
[2] 4521t2c020na
[1] Entrance roller [4] Punch clutch (CL1)

[2] Punch blade [5] Punch motor (M11)
[3] Cam holder [6] Eccentric cam
A. Operation
1. A specified period of time after the path sensor (PS2) of the RU detects the trailing edge of paper, the con-
veyance motor /Up (M4) or conveyance motor /Lw (M2) turns OFF to stop at the prescribed punch position.
2. The punch clutch (CL1) turns ON to punch a hole.
3. M4 or M2 turns ON to convey paper.
26
5.4.2 Punch hole switchover mechanism (for inch area)

• The hole punch selector motor (M14) [5] and the hole punch position switch (SW4) [4] are employed to
FS-511/RU-502
move the lock holder [2] as necessary to select the hole positions (2 or 3 holes [1][6]).
[1]
[2] [3]
S4
[4]
[5]
[6]
S4 [7]
4521t2e002na
[1] 2 holes [5] Hole punch selector motor (M14)

[2] Lock holder [6] 3 holes
[3] Punch bars in locked position [7] Punch bars in locked position
[4] Hole punch position switch (SW4)
27
5.5 Staple section

FS-511/RU-502
5.5.1 Alignment mechanism

• While in the staple mode, paper is conveyed to the handling tray for alignment operation.
• The alignment in the main scan direction is made by the movement of the alignment plate, and the align-
ment in the sub scan direction is made by the rotation of the paddle.
A. Alignment plate
• The movement of the alignment plates /Fr [5] and /Rr [1] is made by the normal/reverse drive of the align-
ment motor (M5) [2].
• The alignment plates /Fr and /Rr move with the position at the center of paper as a reference and the home
position is detected by the alignment home sensor (PS9) [4].
• The distance of movement of the alignment plate is variable according to the paper size.
• The alignment operation is made each time paper is conveyed to the handling tray.
[5] [6] [1]
[4] [3] [2] 4521t2c021na
[1] Alignment plate /Rr [4] Alignment home sensor (PS9)

[2] Alignment motor (M5) [5] Alignment plate /Fr
[3] Handling tray [6] Paper exit roller
(1) Control
1. When the intermediate conveyance sensor (PS3) detects the leading edge of the 1st paper of the job, M5
rotates in the normal direction to conduct a size movement.
2. A specified period of time after PS3 detects the trailing edge of paper, M5 rotates in the normal direction to
conduct the paper alignment. And it rotates in the reverse direction to return to the size standby position.
28
B. Paddle
• The paddle /Up [3] and /Lw [6] hit paper against the stopper to conduct the alignment in the sub scan
FS-511/RU-502
direction.
• The drive of the paddle /Up is made by the paddle motor /Up (M15) [5] and the paddle solenoid (SD3) [4].
• The drive of the paddle /Lw is made by the paddle motor /Lw (M9) [1].
[4] [5]
[6]
[1]
[3]
[2]
4521t2c022na
[1] Paddle motor /Lw (M9) [4] Paddle solenoid (SD3)

[2] Paper exit roller [5] Paddle motor /Up (M15)
[3] Paddle /Up [6] Paddle /Lw
(1) Control
1. When the FS start signal turns ON, M15 and M9 also turn ON.
2. A specified period of time after the intermediate conveyance sensor (PS3) detects the leading edge of paper,
SD3 turns ON while a specified period of time.
3. A specified period of time after PS3 detects the trailing edge of the last paper of the copy, M15 and M9 turn
OFF.
4. In case of the last copy, the moment the paper exit motor (M3) turns OFF, M15 and M9 turn OFF.
29
5.5.2 Stapler movement mechanism

• The movement/rotation of the staplers /Fr [4] and /Rr [1] are made by the stapler moving motor (M6) [3].
FS-511/RU-502
• The home position is detected by the stapler home sensor (PS14) [2] and the position is decided according
to the drive amount of M6.
• The 1 stapling at the front corner is made by the stapler /Fr, the 1 stapling at the rear corner made by the
stapler /Rr, and the 2 stapling operations are made by the staplers /Fr and /Rr.
[4] [3] [2] [1] 4521t2c023na
[1] Stapler /Rr [3] Stapler moving motor (M6)

[2] PS14 [4] Stapler /Fr
A. Control
• When the FS start signal turns ON, the stapler moving motor (M6) turns ON, and it stops at the stapling
position.
• After completion of the job, the moment the paper exit motor (M3) turns OFF, it returns to the home posi-
tion.
30
5.5.3 Stapling mechanism

• The stapling operation is made by the stapler.
FS-511/RU-502
• When the stapler motors /Rr (M16) and /Fr (M17) [1] are driven, the clinch arm [3] goes down to drive the
staple blade [2] and hit in a staple.
[3]
[1]
[2]
4521t2c024na
[1] Stapler motors /Rr, /Fr (M16, M17) [3] Clinch arm
[2] Staple blade
A. Control
• A specified period of time after the intermediate conveyance sensor (PS3) detects the trailing edge of the
last paper of the copy, the stapler motors /Rr (M16) and /Fr (M17) turn ON. After completion of the stapling
operation, the motors stop.
31
5.5.4 Staple sheet empty control

A. Detection mechanism
FS-511/RU-502
• The detection of the staple sheet [6] is made by the staple empty sensors /Rr (PS20) and /Fr (PS23) [4].
• The detection of the staple ready is made by the staple ready sensors /Rr (PS21) and /Fr (PS24) [2].
[5] [6]
[4] [2]
[3] [1] 4521t2c025na
[1] No staple condition [4] Staple empty sensors /Rr, /Fr (PS20, PS23)
[2] Stapler ready sensors /Rr, /Fr (PS21, PS24) [5] Stapler cartridge
[3] Staple set condition [6] Staples
B. Empty detection control

• When the remaining staples get reduced to about 20, the staple empty sensors /Rr (PS20) and /Fr (PS23)
turn ON with a message displayed on the main body LCD.
• In the middle of the stapling operation, when an empty condition is detected, the empty display is shown
after completion of a series of operations.
C. Staple ready detection control

• After replacing (installing) a staple cartridge, the stapler motors /Rr (M16) and /Fr (17) drive until the stapler
ready sensors /Rr (PS21) and /Fr (PS24) turn ON, and then send staples to the stapling position.
32
SD-502
( 500 / 420)
2006.02
Ver. 1.0
Revision history
Revision mark:
ing page.
NOTE

CONTENTS
SD-502
SD-502
OUTLINE
2. PAPER PATH ...........................................................................................................2
OUTLINE
3. COMPOSITION .......................................................................................................3
4. DRIVE......................................................................................................................4
4.1 Half-fold section ....................................................................................................4
4.2 Saddle Stitching Section .......................................................................................4
5. OPERATIONS .........................................................................................................5
5.1 Paper Conveyance mechanism ............................................................................5
5.2 Conveyance roller pressure/release .....................................................................6
5.2.1 Pressure/release mechanism........................................................................6
5.2.2 Operation.......................................................................................................7
5.3 Stapling mechanism..............................................................................................8
5.4 Staple guide ..........................................................................................................9
5.4.1 Staple guide mechanism ...............................................................................9
5.4.2 Operation timing ............................................................................................9
5.5 Half-folding mechanism ......................................................................................10
5.5.1 Operation.....................................................................................................11
5.6 Paper guide.........................................................................................................12
5.6.1 Paper guide mechanism..............................................................................12
5.7 Tray paper detection............................................................................................13
i
SD-502
OUTLINE
Blank Page
ii
OUTLINE
SD-502
A. Type
Type FS built-in saddle-stitching device

Center parallel two points
Stapling Function
No. of sheets to be stapled together: 2 to 15
OUTLINE
Consumables Staples (2000 staples/cartridge)
B. Paper type
Type Plain Paper 56 to 90 g/m2

Metric: A3, B4, A4S, B5S
Size
Inch: 11 x 17, 81/2 × 11S
Capacity 200 sheets or 20 copies
C. Maintenance

Power Requirements 24/5V DC (supplied from FS)

Power Consumption 9.5 W or less

NOTE
1
2. PAPER PATH
SD-502
OUTLINE
4511t1c001na
2
3. COMPOSITION
SD-502
Saddle-Stitching Section
Half-Fold Section
4511t2c001na
3
4. DRIVE
4.1 Half-fold section
SD-502
[3]
[2]
[1]
4511t2c013na
[1] Folding Roller [3] Half-folding Blade

[2] Folding Motor (M10)
4.2 Saddle Stitching Section
[3]
[1]
[2]
4511t2c003na
[1] Conveyance Roller /Up [3] Exit Open/Close Motor (M9)

[2] Conveyance Motor (M8)
4
5. OPERATIONS
5.1 Paper Conveyance mechanism
SD-502
• Paper is conveyed by the Exit Rollers of FS and Conveyance Roller /Up [5], /Lw [2].
• The Conveyance Motor (M8) [3] provides the drive for the Conveyance Roller /Lw [2].
• If a center stapling operation is made with a bundle papers stored in the Stacker, a bundle
papers is conveyed to the center stapling position, through a pulse control of the Exit Roller
of FS.
• A bundle papers is thereafter fed out by the Conveyance Roller /Up and /Lw.
[5]
[1]
[4]
[2]
[3]
4511t2c004na
[1] Exit Rollers of FS [4] Exit Open/Close Motor (M9)

[2] Conveyance Roller /Lw [5] Conveyance Roller /Up
[3] Conveyance Motor (M8)
5
5.2 Conveyance roller pressure/release

5.2.1 Pressure/release mechanism
SD-502
• The Conveyance Roller /Up [1] is moved away from, or pressed up against, the Conveyance
Roller /Lw [2], when the paper is fed out as a bundle of papers.
• The Saddle Exit Home Sensor (PS18) [3] is used to control the pressure/release position of
the Conveyance Roller /Up.
[1]
[3] [2]
4511t2c005na
[1] Conveyance Roller /Up [3] Saddle Exit Home Sensor (PS18)
[2] Conveyance Roller /Lw
6
5.2.2 Operation
1. The Conveyance Roller /Up [5] is moved up or down by the cams which are driven by
SD-502
the Exit Open/Close Motor (M9) [6].
2. When a bundle papers moves past the Conveyance Roller /Up and /Lw, the motor is
energized to press the Conveyance Roller /Up up against the Conveyance Roller /Lw,
thereby feeding a bundle papers out into the tray.
[6]
[1]
[1]
[5]
[4] [3] [2]

4511t2c006na
[1] Cam [4] Cams are rotated.

[2] Cams are rotated. + The Conveyance Roller [5] Conveyance Roller /Up
/Up is moved downward (pressing). [6] Exit Open/Close Motor (M9)
[3] The Conveyance Roller /Up is moved upward
(retraction).
7
5.3 Stapling mechanism

• The Staple units [2] position are fixed.
SD-502
• Since the unit are for center stapling only, it is made up of the upper clincher portion [1] and
the lower stapling portion. A bundle papers moves through the space between the upper
and lower portions of the staplers.
• When stapling, the clincher portion moves downward to perform the stapling operation.
[3]
[1]
[2]
4511t2c007na
[1] Clincher Portion [3] Clincher Unit

[2] Staple Unit
8
5.4 Staple guide

• The Staple Guide is used to guide the leading edge of the first sheet of paper when the first
SD-502
sheet of paper is stored, thereby preventing the leading edge from contacting the Stapling
Unit and jamming.
5.4.1 Staple guide mechanism

• The Staple Guide Motor (M14) [3] turns the cams at the front and rear, thereby moving the
Staple Guide up or down.
• The Staple Guide Home Sensor (PS26) [2] detects the position of the Staple Guide.
[3]
[2] [1]
4511t2c008na
[1] Cam [3] Staple Guide Motor (M14)

[2] Staple Guide Home Sensor (PS26)
5.4.2 Operation timing

1. Raising the Staple Guide
(power ON, Sleep cancelled, error reset, paper removed from tray)
2. Lowering the Staple Guide
(When the conveyance of a bundle papers to the center stapling position is completed)
3. Raising the Staple Guide
(When the trailing edge of a bundle papers deactivates the Exit Sensor (PS20))
9
5.5 Half-folding mechanism

• The Entrance Sensor (PS4) [2] of FS detects the trailing edge of the paper.
SD-502
• The paper feed amount is determined for each paper size as counted from the timing when
the trailing edge is detected. Half-folding is effected as follows. Specifically, the paper
undergoes a switchback operation and is conveyed to the half-folding position as the motor
is turned backward.
• The Half-Folding Blade [3] is lowered and the center of the paper is pinched between the
Folding Rollers and this creates a crease in the paper.
• After the half-folding, the paper is conveyed by the Conveyance Roller [7] and then the Reg-
istration Roller [1] as they are driven in that order.
[7] [1]
[3]
[6] [2]
[5]
[3]
[4]
4511t2c009na
[1] Registration Roller [5] Folding Motor (M10)

[2] Entrance Sensor (PS4) [6] Conveyance Sensor (PS5)
[3] Half-Folding Blade [7] Conveyance Roller
[4] Folding Roller Home Sensor (PS22)
10
5.5.1 Operation
• When the Folding Motor (M10) is energized for one cycle of operation, the Conveyance
SD-502
Guides /Lw [2] are retracted to the right and left and the Half-folding Blade [3] makes one
up-and-down reciprocating motion. In synchronism with the sequence of these operations,
the Folding Roller [1] turns one complete turn to pull the paper downward at its center.
• At the same time that the Conveyance Guides /Lw returns to their original position, the Half-
folding Blade goes up.
[1]
[3]
[2]
4511t2c010na
[1] Folding Roller [3] Half-folding Blade

[2] Conveyance Guides /Lw
11
5.6 Paper guide

• When a bundle papers is fed onto the tray, the Paper Guide supports the leading edge of the
SD-502
paper of a large size so as to prevent it from pushing the trailing edge of the paper that has
previously been fed out.
• The Paper Guide is driven only when paper with a length of 257 mm or more will be stored.
• The Paper Guide advances when the Entrance Sensor (PS4) of FS is OFF and retracts
when the trailing edge of the paper passes the Exit Sensor (PS20).
5.6.1 Paper guide mechanism

• The Paper Guide Motor (M13) [3] drives the Paper Guide [2].
• The Paper Guide Home Sensor (PS23) [1] is used to control the home position of the Paper
Guide.
[3]
[2]
[2] [1]
4511t2c011na
[1] Paper Guide Home Sensor (PS23) [3] Paper Guide Motor (M13)
[2] Paper Guide
12
5.7 Tray paper detection

• When paper is fed onto the tray, it pushes the actuator, which causes the Tray Empty Sen-
SD-502
sor (PS21) [1] to detect the paper.
[1]
4511t2c012na
[1] Tray Empty Sensor (PS21)
13
SD-502
Blank Page
14
MT-501
( 500 / 420)
2006.02
Ver. 1.0
Revision history
Revision mark:
ing page.
NOTE

CONTENTS
MT-501
MT-501
OUTLINE
2. PAPER PATH ...........................................................................................................2
OUTLINE
3. COMPOSITION .......................................................................................................3
4. DRIVE......................................................................................................................4
5. OPERATIONS .........................................................................................................5
5.1 Paper conveyance mechanism .............................................................................5
5.2 Paper path selection mechanism ..........................................................................6
5.3 Paper detection .....................................................................................................7
i
MT-501
OUTLINE
Blank Page
ii
OUTLINE
MT-501
A. Type
Type 4 bins Mailbin (available only for printing from PC)

Number of Bins 4 bins
Number of Sheets
125 sheets (80 g/m2)
Stored per Bin
OUTLINE
Storable Paper Plain Paper (56 to 90 g/m2)
Metric: A4, B5, 81/2 x 11
Storable Paper Size
Inch: 81/2 x 11, 51/2 x 81/2S
B. Maintenance

Power Requirements 24V DC (supplied from FS)

Weight Approx. 8 kg

NOTE
1
2. PAPER PATH
MT-501
OUTLINE
4510t1c001na
2
3. COMPOSITION
MT-501
4510t2c001na
3
4. DRIVE
MT-501
[3]
[1]
[2]
4510t2c003na
[1] Conveyance Roller [3] Conveyance Motor (M1)

[2] Exit Roller
4
5. OPERATIONS
5.1 Paper conveyance mechanism
MT-501
• When the Mailbin is selected as the exit source, paper is fed off from the Finisher (FS-510)
and toward the Mailbin.
• Drive for the Conveyance Rollers [2] of the Mailbin is transmitted from the Conveyance
Motor (M1) [1] by way of a belt.
• As each of the Conveyance Rollers is driven, paper fed off from the Finisher is conveyed into
the Mailbin.
[1]
[2]
4510t2c004na
[1] Conveyance Motor (M1) [2] Conveyance Roller
5
5.2 Paper path selection mechanism

• The Gate Solenoid /1, /2, /3 (SD1, SD2, SD3) [1] are energized or deenergized to direct
MT-501
paper fed from the Finisher into a specific tray.

• There are SD1, SD2, SD3 provided that will be energized or deenergized to operate the cor-
responding Gate [2], thereby selecting a specific paper path into a specific tray.
[1]
[2]
4510t2c005na
[1] Gate Solenoid /1, /2, /3 (SD1, SD2, SD3) [2] Gate
6
5.3 Paper detection

• The Paper Detection Sensor /1, /2, /3, /4 (PS1, PS2, PS3, PS4) [2] detects any sheet of
MT-501
paper that is fed into the tray, causing the DF LED to light up green steadily to inform the
user that a sheet of paper has been fed into the tray.
• As the paper stacks up and eventually deactivates the Paper Full Sensor /1, /2, /3, /4 (PS5,
PS6, PS7, PS8) [1], at which time a paper full condition is detected.
[1]
[2]
4510t2c006na
[1] Paper Full Sensor /1, /2, /3, /4 (PS5, PS6, [2] Paper Detection Sensor /1, /2, /3, /4 (PS1,
PS7, PS8) PS2, PS3, PS4)
7
MT-501
Blank Page
8
JS-502
( 500 / 420)
2006.02
Ver. 1.0
Revision history
Revision mark:
ing page.
NOTE

CONTENTS
JS-502
JS-502
OUTLINE
2. PAPER PATH ...........................................................................................................2
OUTLINE
3. COMPOSITION .......................................................................................................3
4. OPERATIONS .........................................................................................................4
4.1 Job Tray Conveyance/Exit.....................................................................................4
i
JS-502
OUTLINE
Blank Page
ii
OUTLINE
JS-502
A. Type
Name Job Separator

Type Expansion tray
OUTLINE
B. Paper type
Exit Tray Size Type Capacity

Inch: 11 x 17, 81/2 x 14, Plain Paper (56 to 90 g/m2) 250 sheets
81/2 x 11, 81/2 x 11S,
OHP transparencies
51/2 x 81/2S
Tray 1 A3, A4, A4S, A5S, Thick paper (91 to 210g/m2)
(Main 8 x 13
Envelope
Body Metric: A3, B4, A4, A4S, B5, Special 20 sheets
Tray) B5S, A5S Label
11 x 17, 81/2 x 11,
81/2 x 11S, 8 x 13 Letterhead
Inch:
11 x 17, 81/2 x 14,
81/2 x 11, 81/2 x 11S,
Tray 2
51/2 x 81/2S Plain Paper (56 to 90 g/m2) 100 sheets
(Job Tray)
Metric: A3, B4, A4, A4S, B5,
B5S, A5S
C. Maintenance
Maintenance None
Power Requirements 5V DC ± 5 % (supplied from the main body)


NOTE
1
2. PAPER PATH
JS-502
OUTLINE
[1]
4347t1c001na
[1] Conveyance from the main body
2
3. COMPOSITION
JS-502
Job Separator section Switchback Unit section
4347t2c001na
3
4. OPERATIONS
4.1 Job Tray Conveyance/Exit
JS-502
• The Switchback Unit functions to convey paper through, and feed it out from, the Job Tray.
• The paper sensor section of the Job Tray is mounted to the Switchback Unit, thereby detect-
ing paper.
• When paper stacks up on the Tray [3], the actuator [2] is pushed up by the paper, indicating
that there is paper at the exit port.
[1]
[3]
[2]
4347t2c002na
[1] Paper Full Sensor (PS1) [3] Tray

[2] Actuator
4
© 2006 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.
Printed in Japan
Use of this manual should be strictly supervised to avoid
NN50GAPE1-0900
disclosure of confidential information.
SERVICE MANUAL Field Service
500 / 420
2006.02
Ver. 1.0
FIELD SERVICE TOTAL CONTENTS
SAFETY AND IMPORTANT WARNING ITEMS ..............................................................S-1

IMPORTANT NOTICE ................................................................................................S-1
DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION .........................S-1
SAFETY WARNINGS .................................................................................................S-2
SAFETY INFORMATION ...............................................................................................S-12
IMPORTANT NOTICE ..............................................................................................S-12
INDICATION OF WARNING ON THE MACHINE .....................................................S-13
MEASURES TO TAKE IN CASE OF AN ACCIDENT ....................................................S-15
Composition of the service manual ................................................................................. C-1
Notation of the service manual ....................................................................................... C-2
bizhub 500 / 420 Main Body

OUTLINE ........................................................................................................................ 1
MAINTENANCE.............................................................................................................. 7
ADJUSTMENT/SETTING ........................................................................................... 147
TROUBLESHOOTING................................................................................................ 273
APPENDIX.................................................................................................................. 311
* For particulars, see the contents of the main body.
DF-607
OUTLINE ........................................................................................................................ 1
MAINTENANCE.............................................................................................................. 5
ADJUSTMENT/SETTING ............................................................................................. 19
* For particulars, see the contents of DF-607.
PC-202
OUTLINE ........................................................................................................................ 1
MAINTENANCE.............................................................................................................. 3
PC-402
OUTLINE ........................................................................................................................ 1
MAINTENANCE.............................................................................................................. 3
i
LU-201
OUTLINE ........................................................................................................................ 1
MAINTENANCE ............................................................................................................. 3
* For particulars, see the contents of LU-201.
FS-510/PU-501/OT-601
OUTLINE ........................................................................................................................ 1
MAINTENANCE ............................................................................................................. 5
* For particulars, see the contents of FS-510/PU-501/OT-601.
FS-511/RU-502
OUTLINE ........................................................................................................................ 1
MAINTENANCE ............................................................................................................. 5
* For particulars, see the contents of FS-511/RU-502.
SD-502
OUTLINE ........................................................................................................................ 1
MAINTENANCE ............................................................................................................. 3
* For particulars, see the contents of SD-502.
MT-501
OUTLINE ........................................................................................................................ 1
MAINTENANCE ............................................................................................................. 3
* For particulars, see the contents of MT-501.
JS-502
OUTLINE ........................................................................................................................ 1
MAINTENANCE ............................................................................................................. 3
* For particulars, see the contents of JS-502.
IC-204
OUTLINE ........................................................................................................................ 1
MAINTENANCE ............................................................................................................. 3
ADJUSTMENT / SETTING ............................................................................................. 7
TROUBLESHOOTING ................................................................................................... 9
* For particulars, see the contents of IC-204.
ii

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

WARNING AND CAUTION
In this Service Manual, each of three expressions " DANGER", " WARNING", and
" CAUTION" is defined as follows together with a symbol mark to be used in a limited
meaning.
When servicing the product, the relevant works (disassembling, reassembling, adjustment,
repair, maintenance, etc.) need to be conducted with utmost care.
DANGER: Action having a high possibility of suffering death or serious injury
WARNING: Action having a possibility of suffering death or serious injury
CAUTION: Action having a possibility of suffering a slight wound, medium

trouble and property damage
Symbols used for safety and important warning items are defined as follows:
:Precaution when using the

copier. General Electric hazard High
precaution temperature
:Prohibition when using the

copier. General Do not touch Do not
prohibition with wet hand disassemble
:Direction when using the

copier. General Unplug Ground/Earth
instruction
S-1
SAFETY 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.

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.)

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:
AC230V
- provided with a plug having configuration intended for
the connection to wall outlet appropriate for the prod-
uct's rated voltage and current, and
- provided with three-conductor cable having enough cur-
rent capacity, and
AC208V 240V
- the cord set meets regulatory requirements for the area.
Use of inadequate cord set leads to fire or electric shock.
• Attach power plug which meets the following criteria:
- having configuration intended for the connection to wall
outlet appropriate for the product's rated voltage and
current, and
- meets regulatory requirements for the area.
Use of inadequate cord set leads to the product connect-
ing to inadequate power supply (voltage, current capacity,
• 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 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
WARNING
• Check that mains voltage is as specified.
Connection to wrong voltage supply may result in fire or
electric shock. ?V
• Connect power plug directly into wall outlet having same

configuration as the plug.
Use of an adapter leads to the product connecting to kw
inadequate power supply (voltage, current capacity,
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.
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.
result.
• Make sure the power cord is plugged in the wall outlet

securely.
Contact problems may lead to increased resistance,
overheating, and the risk of fire.
S-4
WARNING
• Check whether the product is grounded properly.
If current leakage occurs in an ungrounded product, you
may suffer electric shock while operating the product.
Connect power plug to grounded wall outlet.
Power Plug and Cord
WARNING
• When using the power cord set (inlet type) that came with
this product, make sure the connector is securely inserted
in the inlet of the product.
When securing measure is provided, secure the cord with
the fixture properly.
If the power cord (inlet type) is not connected to the prod-
uct securely, a contact problem may lead to increased
resistance, overheating, and risk of fire.
• Check whether the power cord is not stepped on or

pinched by a table and so on.
• Check whether the power cord is damaged. Check

whether the sheath is damaged.
If the power plug, cord, or sheath is damaged, replace
with a new power cord or cord set (with plug and connec-
tor on each end) specified by KMBT.
Using the damaged power cord may result in fire or elec-
tric shock.
• Do not bundle or tie the power cord.

S-5
Power Plug and Cord
WARNING
• Check whether dust is collected around the power plug
and wall outlet.
Using the power plug and wall outlet without removing
dust may result in fire.
• Do not insert the power plug into the wall outlet with a wet
hand.
The risk of electric shock exists.
• When unplugging the power cord, grasp the plug, not the
cable.
The cable may be broken, leading to a risk of fire and
electric shock.
Wiring
WARNING
• Never use multi-plug adapters to plug multiple power cords
in the same outlet.
If used, the risk of fire exists.
• When an extension cord is required, use a specified one.

Current that can flow in the extension cord is limited, so
using a too long extension cord may result in fire.
Do not use an extension cable reel with the cable taken
up. Fire may result.
S-6
2. Installation Requirements
Prohibited Installation Places
WARNING
• Do not place the product near flammable materials or vola-
tile materials that may catch fire.
• Do not place the product in a place exposed to water such

as rain.
A risk of fire and electric shock exists.
When not Using the Product for a long time
WARNING
• When the product is not used over an extended period of
time (holidays, etc.), switch it off and unplug the power
cord.
Dust collected around the power plug and outlet may
cause fire.
Ventilation
CAUTION
• The product generates ozone gas during operation, but it
will not be harmful to the human body.
If a bad smell of ozone is present in the following cases,
ventilate the room.
a. When the product is used in a poorly ventilated room
b. When taking a lot of copies
c. When using multiple products at the same time
Fixing
CAUTION
• Be sure to lock the caster stoppers.
In the case of an earthquake and so on, the product may
slide, leading to a injury.
S-7
Inspection before Servicing
CAUTION
• Before conducting an inspection, read all relevant docu-
mentation (service manual, technical notices, etc.) and
proceed with the inspection following the prescribed pro-
cedure in safety clothes, using only the prescribed tools.
Do not make any adjustment not described in the docu-
mentation.
If the prescribed procedure or tool is not used, the prod-
uct may break and a risk of injury or fire exists.
• Before conducting an inspection, be sure to disconnect

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

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

detached.
High-voltage exists around the drum unit. A risk of elec-
tric shock exists.
S-8
Safety Checkpoints
WARNING
• Check the exterior and frame for edges, burrs, and other
damages.
The user or CE may be injured.
• Do not allow any metal parts such as clips, staples, and

screws to fall into the product.
They can short internal circuits and cause electric shock
or fire.
• Check wiring for squeezing and any other damage.

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.
• 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.
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.
loss of eyesight.
S-9
Safety Checkpoints
WARNING
• When replacing a lithium battery, replace it with a new lith-
ium battery specified in the Parts Guide Manual. Dispose
of the used lithium battery using the method specified by
local authority.
Improper replacement can cause explosion.
• After replacing a part to which AC voltage is applied (e.g.,

optical lamp and fixing lamp), be sure to check the installa-
tion state.
• 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.
• 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.
WARNING
• Toner and developer are not harmful substances, but care
must be taken not to breathe excessive amounts or let the
substances come into contact with eyes, etc. It may be
stimulative.
If the substances get in the eye, rinse with plenty of water
immediately. When symptoms are noticeable, consult a
physician.
S-10
WARNING
• Never throw the used cartridge and toner into fire.
You may be burned due to dust explosion.
Handling of Service Materials
CAUTION
• Unplug the power cord from the wall outlet.
Isopropyl alcohol and acetone are highly flammable and
must be handled with care. A risk of fire exists.
• Do not replace the cover or turn the product ON before

any solvent remnants on the cleaned parts have fully
evaporated.
• 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
SAFETY INFORMATION
SAFETY INFORMATION
IMPORTANT NOTICE
The Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Admin-
istration implemented regulations for laser products manufactured since August 1, 1976.
Compliance is mandatory for products marketed in the United States.
This copier is certified as a "Class 1" laser product under the U.S.
Department of Health and Human Services (DHHS) Radiation Performance Standard
according to the Radiation Control for Health and Safety Act of 1968. Since radiation emit-
ted inside this copier is completely confined within protective housings and external covers,
the laser beam cannot escape during any phase of normal user operation.
S-12
SAFETY INFORMATION
INDICATION OF WARNING ON THE MACHINE

Caution labels shown below are attached in some areas on/in the machine.
When accessing these areas for maintenance, repair, or adjustment, special care should
be taken to avoid burns and electric shock.
50gap0e001na
S-13
SAFETY INFORMATION
50gap0e002na
CAUTION:
• You may be burned or injured if you touch any area that you are advised by any
caution label to keep yourself away from. Do not remove caution labels. And also,
when the caution label is peeled off or soiled and cannot be seen clearly, replace
it with a new caution label.
S-14
MEASURES TO TAKE IN CASE OF

AN ACCIDENT
1. If an accident has occurred, the distributor who has been notified first must immediately
take emergency measures to provide relief to affected persons and to prevent further
damage.
2. If a report of a serious accident has been received from a customer, an on-site evalua-
tion must be carried out quickly and KMBT must be notified.
3. To determine the cause of the accident, conditions and materials must be recorded
through direct on-site checks, in accordance with instructions issued by KMBT.
4. For reports and measures concerning serious accidents, follow the regulations speci-
fied by every distributor.
S-15
Blank Page
S-16
Composition of the service manual
This service manual consists of the following sections and chapters:
<Theory of Operation section>
OUTLINE: System configuration, product specifications,

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

MAINTENANCE: Service schedule *, maintenance steps,
list of service tools and directions for use *,
firmware version up method *,
and removal/reinstallation methods of major parts
ADJUSTMENT/SETTING: Utility mode *, service mode *, security and mechanical
adjustment
TROUBLESHOOTING*: List of jam codes, their causes, operation when a jam
occurs and its release method, and list of error codes,
their causes, operation when a warning is issued and esti-
mated abnormal parts.
APPENDIX*: Parts layout drawings, connector layout drawings, timing
chart, overall layout drawing
This section gives, as information required by the CE at the site (or at the customer's
premise), a rough outline of the service schedule and its details, maintenance steps, the
object and role of each adjustment, error codes and supplementary information.
The details of items with an asterisk "*" are described only in the service manual of
the main body.
C-1
Notation of the service manual
A. Product name
In this manual, each of the products is described as follows:
(1) IC board: Standard printer

(2) bizhub 500 / 420: Main body
(3) Microsoft Windows 95: Windows 95
Microsoft Windows Me: Windows Me
Microsoft Windows NT 4.0: Windows NT 4.0 or Windows NT
Microsoft Windows XP: Windows XP
When the description is made in combination of the OS's mentioned above:
Windows 95/98/Me
Windows NT 4.0/2000
Windows NT/2000/XP
Windows 95/98/Me/NT/2000/XP
B. Brand name
The company names and product names mentioned in this manual are the brand name or
the registered trademark of each company.
C. Electrical parts and signals

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

IN
PS
Sensor PS Door PS1 Sensor detection signal
SIG
102 PS
24V Power to drive the solenoid
Solenoid SD DRV
Drive signal
SOL
24V Power to drive the clutch
Clutch CL DRV
Drive signal
SOL
C-2
24V Power to drive the motor
CONT Drive signal
DRV1
Motor M
DRV2
Drive signals of two kinds
D1
D2
_U
_V
_W
Drive signals (control signals) of three kinds
DRV1
DRV2
DRV3
D1
D2
D3
D4
DRV A
DRV A
DRV B Drive signals (control signals) of four kinds
DRV B Motor, phases A and B control signals
A
Motor M /A
B
/B
AB
BB
CLK, PLL PLL control signal
LCK, Lock, LD PLL lock signal
FR Forward/reverse rotation signal
EM, Lock, LCK, LD Motor lock abnormality
BLK Drive brake signal
P/S Power/stop
S/S
Operating load start/stop signal
SS
CW/CCW, F/R Rotational direction switching signal
ENB Effective signal
TEMP_ER Motor temperature abnormality detection signal
24V Power to drive the fan motor
CONT, DRIVE Drive signal
Fan FM
HL Speed control signal (2 speeds)
EM, Lock, LCK, FEM Detection signal
Others TH1.S, ANG Analog signal
C-3
SG, S.GND, S_GND Signal ground
Ground
PG, P.GND Power ground
DCD Data carrier detection
SIN Serial input
SOUT Serial output
DTR Data terminal operation available
GND Signal ground (earth)
Serial com-
DSR, DSET Data set ready
munication
RTS Transmission request signal
CTS Consent transmission signal
RI Ring indicator
TXD Serial transmission data
RXD Serial reception data
D. Paper feed direction

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

Transverse feed A4
A4
Longitudinal feed A4S
A3 Longitudinal feed A3
C-4
500 / 420
Main body
2006.02
Ver. 1.0
Revision history
Revision mark:
ing page.
NOTE

Field Service Ver1.0 Feb.2006 CONTENTS
CONTENTS
bizhub 500 / 420

bizhub 500 / 420
OUTLINE
1. SYSTEM CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MAINTENANCE
3. PERIODIC CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1.1 Main body (bizhub 500) / DF / PC / LU / FS / MT / SD / RU . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1.2 Main body (bizhub 420) / DF / PC / LU / FS / MT / SD / RU . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Maintenance item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2.1 Main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2.2 DF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2.3 PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.4 LU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2.5 FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2.6 MT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2.7 SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2.8 RU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3 Replacement parts list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3.1 Periodically replacement parts list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4 Life value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4.1 Life value of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5 Maintenance procedure of the external section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5.1 Replacing the ozone filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5.2 Replacing the filter cover assy and the suction filter /A assy . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5.3 Replacing the paper exit suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.6 Maintenance procedure of the write section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.6.1 Replacing the write unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.7 Maintenance procedure of the photosensitive material section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.7.1 Replacing the drum unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.7.2 Replacing the drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.8 Maintenance procedure of the transfer/separation corona section. . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.8.1 Replacing the transfer/separation corona unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.9 Maintenance procedure of the developing section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.9.1 Replacing the developing unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.9.2 Replacing developer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.10 Maintenance procedure of the toner supply section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.10.1 Replacing the filter mounting plate assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.10.2 Replacing the suction cover /2 assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.11 Cleaning/toner recycle section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.11.1 Replacing the cleaning blade assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.12 Maintenance procedure of the paper feed section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.12.1 Replacing the feed roller/pick-up roller (tray 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.12.2 Replacing the separation roller assy (tray 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
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CONTENTS Field Service Ver1.0 Feb.2006
3.12.3 Replacing the feed roller/pick-up roller (tray 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3.12.4 Replacing the separation roller assy (tray 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
bizhub 500 / 420
3.13 Maintenance procedure of the bypass tray section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

3.13.1 Removing/reinstalling the bypass unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.13.2 Replacing the separation roller assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.13.3 Replacing the feed roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.14 Maintenance procedure of the registration section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.14.1 Cleaning the paper dust removing brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.14.2 Replacing the loop roller, the loop bearing, the registration roller /Rt,
and the registration bearings /Rt and /Lt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.15 Maintenance procedure of the fusing section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.15.1 Removing/reinstalling the fusing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.15.2 Replacing the fusing claw assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.15.3 Replacing the fusing web . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.15.4 Replacing the fusing driven roller assy /A and /B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.15.5 Removing/reinstalling the fusing heater lamps /1 (L2) and /2 (L3) . . . . . . . . . . . . . . . . . . . . . . . 84
3.15.6 Replacing the fusing roller, the fusing pressure roller, the heat insulating sleeve /A,
the fusing bearings /Up and /Lw and the fusing input gear assy . . . . . . . . . . . . . . . . . . . . . . . . 86
3.15.7 Replacing the fusing sensor assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.15.8 Replacing the fuse holder assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4. SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.1 Service material list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.2 Jig list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.3 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5. FIRMWARE VERSION UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.1 ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.1.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.1.2 Firmware data flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.1.3 Settings on the main body side while in ISW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.2 ISWTrns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.2.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.2.2 Installation of the ISWTrns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.2.3 Usage of the ISWTrns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.2.4 Error list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6. OTHERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.1 Items not allowed to be disassembled and adjusted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.1.1 Scanner section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.1.2 Write section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.1.3 Developing unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
6.1.4 Drum unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.2 List of parts to be disassembled and reassembled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.3 Disassembling/assembling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.3.1 Removing/reinstalling the rear cover /1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.3.4 Removing/reinstalling the right cover /Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
6.3.5 Removing/reinstalling the right cover /Lw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
6.3.6 Removing/reinstalling the left cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
6.3.7 Removing/reinstalling the front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.3.8 Removing/reinstalling the original glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.3.9 Removing/reinstalling the upper covers /Fr and /Lt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
ii
6.3.10 Removing/reinstalling the upper cover /Rr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

6.3.11 Removing/reinstalling the front cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
bizhub 500 / 420

6.3.12 Removing/reinstalling the operation panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
6.3.13 Removing/reinstalling the CCD unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
6.3.14 Replacing the exposure lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.3.15 Removing/reinstalling the exposure unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
6.3.16 Stretching the scanner wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
6.3.17 Removing/reinstalling the toner supply unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.3.18 Removing/reinstalling the trays 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6.4 Option counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
6.4.1 Configuration of the key counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
6.4.2 Installation procedure of the key counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
ADJUSTMENT/SETTING
7. HOW TO USE THE ADJUSTMENT/SETTING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
8. UTILITY MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
8.1 List of utility mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
9. LIST OF ADJUSTMENT ITEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
10. SERVICE MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
10.1 List of service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
10.2 Setting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
10.2.1 Start and exit of the service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
10.3 Machine Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
10.3.1 Print Positioning: Leading Edge (Printer Area). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
10.3.2 Print Positioning: Side Edge (Printer Area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
10.3.3 Paper Feed Direction Adj. (Printer Area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
10.3.4 Printer Resist Loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
10.3.5 Bypass Tray Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
10.3.6 Image Position: Leading Edge (Scan Area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
10.3.7 Image Position: Side Edge (Scan Area). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
10.3.8 Cross Direction Adjustment (Scan Area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
10.3.9 Feed Direction Adjustment (Scan Area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
10.3.10 Lead Edge Erase Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
10.3.11 Non-Image Area Erase Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
10.4 Imaging Process Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.1 Charging Main Manual Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.2 Transfer Manual Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.3 Separation (AC) Manual Adj.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.4 Separation (DC) Manual Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.5 Grid Charging Manual Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.6 Bias Voltage Manual Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.7 TCR Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.8 Toner Auto Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.9 Toner Density Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
10.4.10 Laser Diameter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
10.4.11 LD1 Offset Adj. / LD2 Offset Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
10.4.12 LD1 Bias Adj. / LD2 Bias Adj.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
10.5 System 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
10.5.1 Marketing Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
iii
10.5.2 Tel/Fax Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

10.5.3 Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
bizhub 500 / 420
10.5.4 Trouble Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

10.5.5 No Sleep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
10.5.6 Foolscap Size Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
10.5.7 Original Size Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
10.5.8 Detected Size Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
10.5.9 Install Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
10.5.10 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
10.6 Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
10.6.1 Display of the Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
10.6.2 Present Parts Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
10.6.3 PM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
10.7 State Confirmation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
10.7.1 Sensor Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
10.7.2 Load Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
10.7.3 Memory/HDD Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
10.7.4 Memory Check (Memory/HDD Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
10.7.5 HDD R/W Check (Memory/HDD Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
10.7.6 HDD Format (Memory/HDD Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
10.7.7 Adj. Data Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
10.7.8 Adj. Data Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
10.8 ADF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
10.8.1 Paper Feed Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
10.8.2 Lead Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
10.8.3 Side Edge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
10.8.4 Resist Loop Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
10.8.5 Original Size Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
10.8.6 Density Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
10.8.7 Scan Position Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
10.8.8 Sensor Auto Adjust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
10.9 Finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
10.9.1 Center Staple Position (SD-502) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
10.9.2 Half-Fold Position (SD-502) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
10.9.3 Punch Horizontal Position (PU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
10.9.4 Punch Resist Loop (PU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
10.10 Firmware Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
10.11 CS Remote Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
10.11.1 Outlines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
10.11.2 Setting Up the CS Remote Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
10.11.3 Software SW setting for CS Remote Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
10.11.4 Setup confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
10.11.5 Calling the Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
10.11.6 Calling the Center from the Administrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
10.11.7 Checking the transmission log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
10.11.8 Detail on settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
10.11.9 List of the CS Remote Care error code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
10.11.10 Troubleshooting for CS Remote Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
10.12 System 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
10.12.1 Data Capture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
iv
10.12.2 Paper Size Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

10.12.3 DipSW Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
bizhub 500 / 420

10.12.4 ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
10.12.5 Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
10.12.6 Trouble Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
10.13 List Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
10.13.1 List output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
10.14 Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
10.14.1 Test pattern list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
10.14.2 Test pattern output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
10.14.3 Running Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
10.15 Fax setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
10.16 Enhanced Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
10.16.1 List of the security setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
10.16.2 Start and termination of the security mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
10.16.3 CE Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
10.16.4 Administrator Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
10.16.5 Administrator Feature Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
10.16.6 CE Authentication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
10.17 Billing Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
10.17.1 List of the billing setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
10.17.2 Start and termination of the billing setting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
10.17.3 Counter Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
10.17.4 Management Function Choice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
11. MECHANICAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
11.1 Mis-centering adjustment of the trays 1 and 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
11.2 Mis-centering adjustment of the bypass tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
TROUBLESHOOTING
12. JAM CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
12.1 Jam code list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
13. MALFUNCTION CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
13.1 Malfunction code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
APPENDIX
14. PARTS LAYOUT DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
14.1 Main body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
14.1.1 Switch/sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
14.1.2 Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
14.1.3 Boards and others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
14.2 DF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
14.3 PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
14.3.1 PC-202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
14.3.2 PC-402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
14.4 LU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
14.5 FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
14.5.1 FS-510. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
14.5.2 FS-511. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
14.6 PU-501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
14.7 SD-502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
v
14.8 MT-501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

14.9 RU-502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
bizhub 500 / 420
14.10 JS-502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344

15. CONNECTOR LAYOUT DRAWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
15.1 Main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
15.1.1 Connector in the board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
15.2 DF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
15.3 PC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
15.4 LU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
15.5 FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
15.6 SD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
15.7 MT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
16. TIMING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
16.1 Main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
16.2 DF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
16.3 LU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
16.4 FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
16.4.1 FS-510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
16.4.2 FS-511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
17. OVERALL WIRING DIAGRAM
17.1 Main body 1/4
17.2 Main body 2/4
17.3 Main body 3/4
17.4 Main body 4/4
17.5 DF
17.6 PC
17.6.1 PC-202
17.6.2 PC-402
17.7 LU
17.8 FS
17.8.1 FS-510/PU-501
17.8.2 FS-511
17.9 SD
17.10 MT
vi
Field Service Ver1.0 Feb.2006 1. SYSTEM CONFIGURATION
OUTLINE
bizhub 500 / 420

1. SYSTEM CONFIGURATION
A. System configuration
[23] [27] [28]

[24] [25] [26]
[5]
[1] [6]
[2] [7]
[3] [8]
[4] [9]
[22]
[21]
[20]
[19] [11]
[14]
[17] [15]
[18]
[10] [12]
[16]
[10] [13]
50gat1e001na
[1] Reverse automatic document feeder [15] Dehumidifier heater *2

(DF-607) (standard equipment) [16] Relay unit (RU-502)
[2] Main body [17] Finisher (FS-511)
[3] Image controller (IC-204) [18] Swedish punch kit G *3
[4] Hard disk (HD-505) [19] Job separator (JS-502)
[5] Stamp unit (SP-501) [20] Output tray kit (OT-501)
[6] Spare TX marker stamp 2 [21] Output tray (OT-601)
[7] Key counter kit 4 *1 [22] Finisher (FS-510)
[8] Key counter *1 [23] Mail bin kit (MT-501)
[9] Key counter mount kit *1 [24] Saddle stitcher (SD-502)
[10] Dehumidifier heater 1C [25] Folding unit (included in SD-502)
[11] Paper feed cabinet (PC-402) [26] Punch unit (PU-501)
[12] Paper feed cabinet (PC-202) [27] FAX kit (FK-502)
[13] Desk (DK-501) [28] Mount kit (MK-708)
[14] Large capacity unit (LU-201)
*1 See "6.4 Option counter" in Field Service bizhub 500 / 420 main body for details.
*2 Dehumidifier heater is set up as service part.
*3 Swedish punch kit G is for Europe only.
1
1. SYSTEM CONFIGURATION Field Service Ver1.0 Feb.2006
B. Configuration for optional device connection

bizhub 500 / 420
Note
• Any combination other than those listed below is not available.
No. Combinations for paper feeding Combinations for finishing Remarks

1 DK-501/PC-202/PC-402 *1 OT-501
2 DK-501/PC-202/PC-402 *1 OT-501 JS-502
3 DK-501/PC-202/PC-402 *1 RU-502 + FS-511
4 DK-501/PC-202/PC-402 *1 FS-510 *2*3
5 DK-501/PC-202/PC-402 *1 FS-510 *2*3 SD-502
6 DK-501/PC-202/PC-402 *1 FS-510 *2*3 MT-501
7 PC-202/PC-402 *4 LU-201 OT-501
8 PC-202/PC-402 *4 LU-201 OT-501 JS-502
9 PC-202/PC-402 *4 LU-201 RU-502 + FS-511
10 PC-202/PC-402 *4 LU-201 FS-510 *2*3
11 PC-202/PC-402 *4 LU-201 FS-510 *2*3 SD-502
12 PC-202/PC-402 *4 LU-201 FS-510 *2*3 MT-501
*1 Either one of DK-501, PC-202 and PC-402 can be selected.

*2 FS-510 can be installed optionally with OT-601.
*3 FS-510 can be installed optionally with PU-501.
*4 Either one of PC-202 and PC-402 can be selected.
2
Field Service Ver1.0 Feb.2006 2. PRODUCT SPECIFICATIONS
bizhub 500 / 420

A. Type
Type Desktop type

Copying method Indirect electrostatic method
Original stand Fixed
Original alignment Left rear standard
Photo conductor OPC
Sensitizing method Laser writing
Paper feed trays Two trays 500 sheet x 2, 80g/m2
Bypass feed 150 sheet x 1, 80g/m2
PC-402 *1 2,500 sheet x 1, 80g/m2
PC-202 *1 500 sheet x 1, 80g/m2
LU-201 *1 2,000 sheet x 1, 80g/m2
*1 PC-402, PC-404, and LU-201 are optional.
3
2. PRODUCT SPECIFICATIONS Field Service Ver1.0 Feb.2006
B. Functions
bizhub 500 / 420
Original Sheet, book, solid object

Max. original size A3 or 11 x 17
Copy size Trays 1, 2 Inch: 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S,
Metric: A3, B4, A4, A4S, B5, A5S, 11 x 17, 81/2 x 11,
81/2 x 11S, Foolscap, 8K, 16K
Bypass feed Inch: 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S,
A4
Metric: A3, B4, A4, A4S, B5, B5S, A5S, B6S, 81/2 x 11,
81/2 x 11S, Foolscap, 8K, 16K, 16KS
ADU Inch: 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S,
Metric: A3, B4, A4, A4S, B5, B5S, A5S, 11 x 17, 81/2 x 11,
Magnification Fixed magnifica- Inch: x 1.000, x 1.214, x 1.294, x 1.545, x 2.000
tion x 0.500, x 0.647, x 0.772, x 0.785
Metric: x 1.000, x 1.154, x 1.224, x 1.414, x 2.000
x 0.500, x 0.707, x 0.816, x 0.866
Special magnifi- x 0.930
cation setting
Preset zoom set- 3 types
ting
Zoom magnifica- x 0.25 to x 4.00 (at the step of 0.1%)
tion
Vertical magnifi- x 0.25 to x 4.00 (at the step of 0.1%)
cation
Horizontal magni- x 0.25 to x 4.00 (at the step of 0.1%)
fication
Warm-up time 60 seconds or less (bizhub 500)
30 seconds or less (bizhub 420)
First copy out time 3.2 seconds or less (bizhub 500)
3.6 seconds or less (bizhub 420)
Continuous copy speed 50 copies /min. (A4 / 81/2 x 11) (bizhub 500)
42 copies /min. (A4 / 81/2 x 11) (bizhub 420)
Continuous copy count Up to 999 sheets
Original density selection Auto density selection, Manual (9 steps), Manual underprint density (9 steps)
Resolution Scan 600 x 600 dpi
Write Inch: 1,200 (equivalent) x 600 dpi
Metric: 2,400 (equivalent) x 600 dpi
Memory Standard 192 MB Breakdown: 64 MB (on board) + 128 MB (DIMM)
Maximum 320 MB Breakdown: 64 MB (on board) + 256 MB (DIMM) *1
Interface section RJ45 Ethernet, Serial port (RS232-C), Serial port (USB TypeB),
Parallel port (IEEE1284), RJ-11 *2
*1 256 MB (DIMM) is available from distributors.
Specification: 144 pin SO-DIMM, PC100/PC133 MHz Compliant
*2 1 port when MK-708 and FK-502 are optionally installed.
4
Field Service Ver1.0 Feb.2006 2. PRODUCT SPECIFICATIONS
C. Type of paper
bizhub 500 / 420

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

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

Machine service life 2,250,000 prints or 5 years (whichever earlier) (bizhub 500)
1,800,000 prints or 5 years (whichever earlier) (bizhub 420)
E. Machine data
Power source Inch: AC120V 12A, 60Hz

Metric: AC220-240V 10A, 50Hz
Maximum power consump- 1,560 W or less (full option)
tion
Dimensions Main body 677 (W) x 708 (D) x 1,150 (H) mm *1
+ DF-607
+ PC or DK
*1 Overturning prevention board is not included.
5
2. PRODUCT SPECIFICATIONS Field Service Ver1.0 Feb.2006
bizhub 500 / 420
Humidity 10 to 80%RH (with no condensation)
Note
6
Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK
MAINTENANCE
bizhub 500 / 420

3. PERIODIC CHECK
3.1 Schedule
3.1.1 Main body (bizhub 500) / DF / PC / LU / FS / MT / SD / RU
Guarantee period: 5 years or 2,250,000 prints
Service item x 10,000 prints No. of

0 25 50 75 100 125 150 175 200 executions
Maintenance 1 z z z z z z z z 8 times
Main body (bizhub 500)
Every 250,000 prints

Maintenance 2 z z z z 4 times
Maintenance 3 z z 2 times
Maintenance 4 z 1 times
Every 1,250,000 prints
DF

PC

LU

FS

MT

SD

RU
7
3. PERIODIC CHECK Field Service Ver1.0 Feb.2006
3.1.2 Main body (bizhub 420) / DF / PC / LU / FS / MT / SD / RU

bizhub 500 / 420
Guarantee period: 5 years or 1,800,000 prints
Service item x 10,000 prints No. of

0 25 50 75 100 125 150 175 executions
Maintenance 1 z z z z z z z 7 times
Main body (bizhub 420)

Maintenance 2 z z z 3 times
Maintenance 4 z 1 times
Every 1,250,000 prints
DF

PC

LU

FS
Every 250,000prints
MT

SD

RU
8
3.2 Maintenance item
bizhub 500 / 420

Note
• For the replacement procedure of periodically replaced parts, see "3.5 Maintenance procedure of
the external section" to "3.15 Maintenance procedure of the fusing section".
• The alcohol described in this section represents the isopropyl alchol.
3.2.1 Main body

A. Maintenance 1 (Every 250,000 prints)
No. Unit Description Quantity Implementation classification Materials

classification Cleaning Check Lubrication Replacement Tools used
1 Preparations Image check z
Exterior z z Alcohol/cleaning pad
2 Photo con- Drum 1 z
ductor sec- DR510
tion • Drum count reset
(Service mode)
Cleaning blade assy 1 z Setting powder
50GA-209
Charge unit z z Cotton swab (wire),
Alcohol/cleaning pad
3 Transfer/sep- Transfer/separation z z Cotton swab (wire)
aration sec- unit
tion
4 Developing Developer 1 z
section DV511
• TCR adjustment
(Service mode)
5 Main body Filter mounting plate 1 z
assy
50GA-336
Ozon filter 1 z
50GA1031
Suction filter /A assy 1 z
40LA-318
Filter cover assy 1 z
50GA-314
Suction cover /2 assy 2 z
50GA-311
6 Scanner Original glass (includ- z Alcohol/cleaning pad
section ing slit glass)
Mirror 1 to mirror 3 z Alcohol/cleaning pad
7 Paper feed Pick-up roller, feed z Alcohol/cleaning pad
section roller (Tray 1, 2)
Separation roller assy z Alcohol/cleaning pad
(Tray 1, 2)
9

bizhub 500 / 420

8 Bypass tray Feed roller z Alcohol/cleaning pad
section
Separation roller z Alcohol/cleaning pad
9 Fusing Fusing roller 1 z
section 50GE5303
(bizhub 500)
50GA5303
(bizhub 420)
Fusing pressure roller 1 z
50GA5304
Fusing web 1 z
50GA-540
• Fusing counter
reset
Heat insulating sleeve /A 2 z
26NA5372
Fusing bearing /Up 2 z
26NA5371
Fusing bearing /Lw 2 z
50GA5359
Fusing driven roller /A 2 z
assy
40400326
Fusing driven roller /B 2 z
assy
40400328
Fusing sensor z Alcohol/cleaning pad
Fusing claw z Alcohol/cleaning pad
Thermostat z Alcohol/cleaning pad
10 Paper reverse Paper exit suction filter 1 z
section 50GA4406
11 Registration Paper dust removing z Blower brush
section brush
Registration roller /Rt z Alcohol/cleaning pad
Registration roller /Lt z Alcohol/cleaning pad
Loop roller z Alcohol/cleaning pad
Reflective sensor z Blower brush
12 Final check Paper through, Image z
check
PM count reset z
Exterior cleaning z
10
B. Maintenance 2 (Every 500,000 prints)
bizhub 500 / 420

1 Transfer/sep- Transfer/separation 1 z
aration sec- unit
tion 50GA-260
2 Fusing Fusing sensor assy 1 z
section 50GA-544
Fuse holder assy 1 z
26NA-535
Fusing claw assy 1 z
50GA-533
Fusing input gear assy 1 z z
50GA-546
C. Maintenance 3 (Every 750,000 prints)

1 Photo con- Drum unit 1 z
ductor sec- 50GA-200
tion
2 Developing Developing unit 1 z
section 50GA-300
3 Paper feed Pick-up roller 2 z Actual: 300,000 feeds
section 40303005
Feed roller 2 z Actual: 300,000 feeds
40303005
Separation roller assy 2 z Actual: 300,000 feeds
(Tray 1, 2)
40300151
4 Bypass tray Paper feed roller 1 z Actual: 200,000 feeds
section 41313001
40340151
11
D. Maintenance 4 (Every 1,250,000 prints)

bizhub 500 / 420

1 Registration Registration bearing /Rt 2 z
section 26NA4536
Registration bearing /Lt 2 z
26NA4537
Loop roller 1 z
50GA3865
Registration roller /Rt 1 z
50GA3848
Loop bearing 2 z
26NA4082
2 Write section Write unit 1 z
50GA-650
3.2.2 DF

1 Preparations Paper through, mage z
condition
Appearance z
2 Paper feed Pick-up roller z Alcohol/cleaning pad
section Actual: 50,000 faces
Feed roller z Alcohol/cleaning pad
Actual: 50,000 faces
Separation roller z Alcohol/cleaning pad
Other rollers z Alcohol/cleaning pad
Each sensor z Blower brush
3 Paper con- Scanning guide z Alcohol/cleaning pad
veyance sec- Actual: 50,000 faces
tion
4 Final check Paper through, image z
check
Exterior cleaning z
12
bizhub 500 / 420

1 Paper feed Pick-up roller 1 z Actual: 200,000 faces
section 43445003
Feed roller 1 z Actual: 200,000 faces
45823014
Separation roller 1 z Actual: 200,000 faces
45823047
3.2.3 PC

1 Preparations Paper through check z
2 Paper feed Pick-up roller z
section Feed roller z
Separation roller z
3 Final check Paper through check z
Exterior cleaning z

1 Paper feed Pick-up roller 1 z Actual: 300,000 feeds
section 40303005
Feed roller 1 z Actual: 300,000 feeds
40303005
40300151
13
3.2.4 LU
bizhub 500 / 420

2 Paper feed Pick-up rubber z Alcohol/cleaning pad
section
Feed rubber z Alcohol/cleaning pad
Separation rubber z Alcohol/cleaning pad
Exterior cleaning z

1 Paper feed Pick-up rubber 1 z Actual: 200,000 feeds
section 40LA1009
Feed rubber 1 z Actual: 200,000 feeds
26NA4011
Separation rubber 1 z Actual: 200,000 feeds
26NA4012
3.2.5 FS

2 Conveyance Each roller z Alcohol/cleaning pad
section, sta-
ple section
3 Staple Paddle z Alcohol/cleaning pad
section
Exterior cleaning z
14
3.2.6 MT
bizhub 500 / 420

section
Exterior cleaning z
3.2.7 SD

section
Exterior cleaning z
3.2.8 RU

section
Exterior cleaning z
15
3.3 Replacement parts list

bizhub 500 / 420
3.3.1 Periodically replacement parts list
Note
• For the replacement procedure of periodically replaced parts, see "3.5 Maintenance procedure of
• The parts count No. given in the table below represents the number of the fixed parts number in
the Service mode.
A. Main body
No. Classification Part name Part number Qt. Actual replace- Parts count Page
ment cycle No. referred to
1 Photo con- Drum DR510 1 250,000 P.28
2 ductor section Cleaning blade assy 50GA-209 1 250,000 P.42
3 Drum unit (without drum) 50GA-200 1 750,000 P.27
4 Transfer/ Transfer/separation unit 50GA-260 1 500,000 P.34
separation
section
5 Developing Developer DV511 1 250,000 P.36
6 section Developing unit 50GA-300 1 750,000 P.35
7 Main body Filter mounting plate assy 50GA-336 1 250,000 P.39
8 Ozon filter 50GA1031 1 250,000 P.19
9 Suction filter /A assy 40LA-318 1 250,000 P.20
10 Filter cover assy 50GA-314 2 250,000 P.20
11 Suction cover /2 assy 50GA-311 4 250,000 P.40
12 Paper feed Pick-up roller 40303005 2 300,000 P.44
section P.51
13 Feed roller 40303005 2 300,000 P.44
P.51
14 Separation roller assy 40300151 2 300,000 P.49
(Tray 1, 2) P.58
15 Bypass tray Paper feed roller 41313001 1 200,000 P.66
16 section Separation roller assy 40340151 1 200,000 P.63
17 Registration Loop roller 50GA3865 1 1,250,000 P.69
18 section Registration roller /Rt 50GA3848 1 1,250,000 P.69
19 Registration bearing /Rt 26NA4536 2 1,250,000 P.69
20 Registration bearing /Lt 26NA4537 2 1,250,000 P.69
21 Loop bearing 26NA4082 1 1,250,000 P.69
22 Fusing Fusing roller 50GE5303 1 250,000 P.86
section (bizhub 500)
50GA5303
(bizhub 420)
16
bizhub 500 / 420

23 Fusing Fusing pressure roller 50GA5304 1 250,000 P.86
section (bizhub 500)
50GA5304
(bizhub 420)
24 Fusing web 50GA-540 1 250,000 P.80
(bizhub 500)
50GA-540
(bizhub 420)
25 Heat insulating sleeve /A 26NA5372 2 250,000 P.86
26 Fusing bearing /Up 26NA5371 2 250,000 P.86
27 Fusing bearing /Lw 50GA5359 2 250,000 P.86
28 Fusing sensor assy 50GA-544 1 500,000 P.89
29 Fuse holder assy 26NA-535 1 500,000 P.91
30 Fusing claw assy 50GA-533 1 500,000 P.78
31 Fusing driven roller /A assy 40400326 2 250,000 P.82
32 Fusing driven roller /B assy 40400328 2 250,000 P.82
33 Fusing input gear assy 50GA-546 1 500,000 P.86
34 Paper reverse Paper exit suction filter 50GA4406 1 250,000 P.22
section
35 Write section Write unit 50GA-650 1 1,250,000 P.23
B. Option
1 DF Pick-up roller 43445003 1 200,000 *1
2 Feed roller 45823014 1 200,000 *1
3 Separation roller 45823047 1 200,000 *2
4 PC Pick-up roller 40303005 1 300,000 *3
5 Feed roller 40303005 1 300,000 *4
6 Separation roller assy 40300151 1 300,000 *5
7 LU Pick-up rubber 40LA4009 1 200,000 *6
8 Feed rubber 26NA4011 1 200,000 *6
9 Separation rubber 26NA4012 1 200,000 *7
*1 (See P.5 in "Field Service DF-607")

*2 (See P.6 in "Field Service DF-607")
*3 (See P.7 in "Field Service PC-202 (bizhub 500/420)" / See P.7 in "Field Service PC-402 (bizhub 500/420)")
*6 (See P.3 in "Field Service LU-201")
*7 (See P.7 in "Field Service LU-201")
17
3.4 Life value

bizhub 500 / 420
3.4.1 Life value of materials
Item Number of prints Remarks

Drum 250,000 The life value is defined only by the number of prints.
Developer 250,000
18
3.5 Maintenance procedure of the external section
bizhub 500 / 420

3.5.1 Replacing the ozone filter
A. Periodically replaced part/cycle
• Ozone filter: Every 250,000 prints
B. Procedure
1. Remove the right cover /Up.
(See P.122)
2. Remove the ozone filter [1].
Note
• When removing the ozone filter, be sure to
pull it out by holding it at the section indicated
by [2].
3. Reinstall the above parts following the removal

steps in reverse.
[1]
[2]
50gaf2c014na
19
3.5.2 Replacing the filter cover assy and the suction filter /A assy
bizhub 500 / 420
A. Periodically replaced parts/cycle

• Filter cover assy: Every 250,000 prints
• Suction filter /A assy: Every 250,000 prints
B. Procedure
1. Remove the screw [1] and then remove the filter
cover assy [2].
[1]
[2]
50gaf2c015na
2. Remove the suction filter /A assy [1].
[1] 50gaf2c016na
20
Note
bizhub 500 / 420

• Be sure to install the suction filter /A assy
with the white filter face [1] inside.

steps in reverse.
[1] 50gaf2c017na
21
3.5.3 Replacing the paper exit suction filter

bizhub 500 / 420

• Paper exit suction filter: Every 250,000 prints
B. Procedure
1. Remove the screw [1] and then remove the paper
exit suction filter cover [2].
[1]
[2]
50gaf2c018na
2. Remove the paper exit suction filter [1].

[1] 3. Reinstall the above parts following the removal
steps in reverse.
50gaf2c019na
22
3.6 Maintenance procedure of the write section
bizhub 500 / 420

3.6.1 Replacing the write unit
Warning
• Be sure not to turn on the write unit with it shifted from its regular installation position.
• Be absolutely sure not to remove the write unit cover. Otherwise, laser beams get in your eyes and
you may suffer loss of sight.
• Be absolutely sure not to remove the write unit for about 2 minutes after you turn off the main
power switch (SW1) or the power switch (SW2).

• Write unite: Every 1,250,000 prints
B. Procedure
1. Remove the developing unit from the main body.
[1]
(See P.35)
2. Remove the drum unit from the main body.
(See P.27)
3. Pull out the dust-proof glass cleaning rod [1].
4. Remove the cleaning knob [4] from the dust-proof
glass cleaning rod [1] by rotating it in the arrow-
marked direction [3] with the section indicated by
[2] as a fulcrum.
5. Replace the dust-proof glass cleaning rod [1] to its
original position.
Note
[2] • Be sure to push in fully the dust-proof glass
cleaning rod [1] so that it does not come in
contact with the main body frame when
[4] removing the unit.
[3]
50gaf2c020na
23
6. Remove the 6 screws [1] and then remove the

[1]
bizhub 500 / 420
write cover [2].
Note
• When installing the write cover, be sure to set
the projections [3] at 3 places into each of the
holes [4] of the frame.
[1] [4] [3] [2] 50gaf2c021na
7. Remove the 2 screws [1].

[1] [2] [3]
8. Remove the connector [2] and then remove the
drum cooling fan assy [3].
50gaf2c022na
9. Remove the screws [1], 1 each, and then remove

[1]
the 2 write section mounting member assy's [2].
Note
• When installing the write section mounting
member assy [2], be sure to install it so that
the spring [3] gets straight.
[2] [3] 50gaf2c023na
24
10. Remove the 3 connectors [1].

bizhub 500 / 420

write unit [3].
Note
• When removing the write unit, be sure to
avoid touching the dust-proof glass.
[3] [2]
[1]
50gaf2c024na
Note
• When installing the write unit [1], be sure to
take note of the position into which the dust-
proof sheet /A [2] is inserted.
• When checking the insertion of the sheet, be
sure to check it with the drum unit removed.
[1] [2]
50gaf2c025na
25
Note
[1]
bizhub 500 / 420
• When installing the write unit, be sure to set

the projections [1] at 2 places provided on the
bottom to the 2 holes [2] of the main body
frame for positioning.

steps in reverse.
[2] 50gaf2c026na
26
3.7 Maintenance procedure of the photosensitive material section
bizhub 500 / 420

3.7.1 Replacing the drum unit
Note
• When removing the drum unit, be sure to hold it at both ends.
• When removing the drum unit, be sure to avoid holding it at the separation claw unit section.
• Be sure to avoid touching the drum with bare hands, and also be careful not to damage it.
• Be sure to avoid turning the drum in any direction other than in the specified direction.
• When storing the drum unit, be sure to store it in the dark place with a drum cover attached.

• Drum unit: Every 750,000 prints
B. Procedure
1. Open ADU.
(See P.122)
2. Pull the lock release lever [1] to open the convey-
ance unit [2].
[1] [2] 50gaf2c027na

[2] [1]
(See P.35)
4. Loosen the screw [1] and remove the drum unit
[2].
steps in reverse.
50gaf2c028na
27
3.7.2 Replacing the drum

bizhub 500 / 420
Note
• Be sure to avoid touching the drum and the cleaning blade with bare hands, and also be careful
not to damage them.
• When storing the drum, be sure to store it in the dark place with a drum cover attached.
• When installing the drum and the cleaning blade, be sure to apply setting powder to the circumfer-
ence of the drum and the cleaning blade, regardless of these parts being new or used ones.
• When setting powder is applied to the drum, be sure to conduct the following operations before
installing the drum unit to the main body.
1) With the charging corona unit removed, rotate the drum one full turn (to prevent setting powder
from splashing onto the charging corona unit and the image from getting defective.)
2) When installing a new drum, be sure to reset the drum counter in the service mode. Failing to
reset it may result in image fogging and toner splashing. (See P.187)
28

• Drum: Every 250,000 prints
bizhub 500 / 420

B. Procedure
(See P.27)
2. Remove the C-clip [1] and pull out the cleaning
[1]
rod [2].
Note
• When installing the cleaning rod, be sure to
take note of the direction of the C-clip.
3. Remove the spring [3].
[2]
[3]
50gaf2c029na
29
4. Remove the connector [1].

5. Open the lock lever [2] and remove the charging
bizhub 500 / 420
corona unit [3].
[1] [3]
[2]
50gaf2c030na
30
6. Remove the screw [1] and then remove the shaft

NG OK
bizhub 500 / 420

mounting plate [2].
7. Pull out the drum shaft [3] for removal.
Note
• When installing the drum shaft, be sure to
[2] [2]
insert the drum shaft until the shaft mounting
plate comes into contact firmly with it as
shown in the drawing.
[3] [3]
[1] bearing [5].
[2]
[3]
[4]
[5]
50gaf2c031na
31
9. Remove the seal blocks [1] and [2].

10. Hold the drum [3] at both ends and remove it.
bizhub 500 / 420
Note
[1] • When removing the drum, be careful not to
damage the photosensitive surface.
• When removing the drum, be careful not to hit
it against the metal frame section [4] of the
cleaning blade.
[3]
[4]
[2]
50gaf2c032na
32
Note
[1]
bizhub 500 / 420

• When installing the drum, using the attached
jig [2] with the drum unit cover [1] before
[2] installing the charging corona unit, rotate the
drum 1 full turn in the arrow-marked direction
[3]. And then check to see if setting powder is
not scraped off, and also if the toner collec-
tion sheet and the cleaning blade do not
turned up.

steps in reverse.
[2]
[3]
50gaf2c033na
33
3.8 Maintenance procedure of the transfer/separation corona section

bizhub 500 / 420
3.8.1 Replacing the transfer/separation corona unit

• Transfer/separation corona unit: Every 500,000 prints
B. Procedure
1. Open ADU.
[3]
(See P.122)
2. Open the conveyance unit.
(See P.27)
3. Release the lock levers [1] and [2] and remove the
transfer/separation corona unit [3].
steps in reverse.
[1] [2] 50gaf2c034na
34
3.9 Maintenance procedure of the developing section
bizhub 500 / 420

3.9.1 Replacing the developing unit
• Developing unit: Every 750,000 prints
B. Procedure
1. Open the front door [1].
2. Loosen the screw [2] and remove the developing
unit [3].
steps in reverse.
[3] [1]
[2]
50gaf2c035na
35
3.9.2 Replacing developer

bizhub 500 / 420

• Developer: Every 250,000 prints
B. Procedure
[2]
(See P.35)
2. Release the locks [1] at 2 places and remove the
developing unit cover /1 [2].
[1]
50gaf2c036na
36
Note
bizhub 500 / 420

• When installing the developing unit cover /1
[1], be sure to install it so that the splash pre-
vention sheet [2] does not get caught into the
[1] [2] [3]
[3] [2]
50gaf2c037na
37
3. Tilt the developing unit [1], and rotate the develop-

[1] [4]
bizhub 500 / 420
ing gear [2] in the arrow-marked direction [3] to

discharge thoroughly developer in the developing
unit [1].
4. Clean developer and toner that adhere to the
Note
• Be absolutely sure not to turn the developing
gear [2] in any direction other than in the
arrow-marked direction [3]. (Never rotate it
clockwise as seen from the direction indi-
cated by [5].)
• If there remains any used developer on the
developing roller, this may cause image fog-
ging.
[5] [3] [2] 50gaf2c041na
5. Put in new developer [1] evenly from above the

[1] agitator screw [2].
[3]
6. Rotate the developing gear [4] in the arrow-
marked direction [5] so that developer [1] gets
deep into the developing unit [3].
7. Repeat steps 8 and 9 to put in the developer [1]
[2] thoroughly.
8. Rotate the developing gear [4] in the arrow-
[6] marked direction [5] and check to see if the spik-
ing of developer is found on the entire surface of
the developing roller [6].
steps in reverse.
[5] [4]
50gaf2c042na
Note
• When developer [1] is replaced, be sure to
conduct the TCR adjustment in the service
mode.
(See P.169)
38
3.10 Maintenance procedure of the toner supply section
bizhub 500 / 420

3.10.1 Replacing the filter mounting plate assy
• Filter mounting plate assy: Every 250,000 prints
B. Procedure
[2] [1]
(See P.35)
2. Open ADU.
(See P.122)
(See P.27)
(See P.27)
5. Release the lock levers [1] at 2 places and remove
the filter mounting plate assy [2].
procedure in reverse.
[1] [2]
50gaf2c043na
39
3.10.2 Replacing the suction cover /2 assy

bizhub 500 / 420

• Suction cover /2 assy: Every 250,000 prints
B. Procedure
(See P.35)
2. Open ADU.
(See P.122)
(See P.27)
[3] (See P.27)
5. Remove the screw [1] and then remove the rail [2].
Note
• When installing the rail, be sure first to insert
the tip into the notch [3].
[2]
[1]
50gaf2c044na
40
6. Remove the 2 suction cover /2 assy's [1].

[1]
bizhub 500 / 420

steps in reverse.
50gaf2c045na
41
3.11 Cleaning/toner recycle section

bizhub 500 / 420
3.11.1 Replacing the cleaning blade assy
Note
• Be sure to avoid touching the edge section of the cleaning blade assy with bare hands.
• When installing the cleaning blade assy, be sure to apply setting powder to the circumference of
the drum and the cleaning blade, regardless of these parts being new or used ones.
• When setting powder is applied to the drum, be sure to conduct the following operations before
installing the drum unit to the main body.
1) With the charging corona unit removed, rotate the drum 1 full turn (to prevent setting powder
from splashing onto the charging corona unit and the image from getting defective.)

• Cleaning blade assy: Every 250,000 prints
B. Procedure
[1] (See P.35)
2. Open ADU.
(See P.122)
(See P.27)
(See P.27)
5. Remove the drum from the drum unit.
[2] (See P.28)
50gaf2c046na
cleaning blade presser plate [2].
7. Remove the cleaning blade assy [1].

[1]
50gaf2c047na
42
Note
[1]
bizhub 500 / 420

• When installing the cleaning blade assy [1], be
sure to insert the transparent sheet section
[2] of the unit the between the collection
screw [3] and the collection paddle [4].

steps in reverse.
[3] [2]
[4]
[1]
50gaf2c048na
43
3.12 Maintenance procedure of the paper feed section

bizhub 500 / 420
3.12.1 Replacing the feed roller/pick-up roller (tray 1)

• Feed roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints)
• Pick-up roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints)
B. Procedure
1. Remove the front cover.
(See P.128)
2. Remove the tray 1.
(See P.143)
3. Remove the connector [1] and the 2 screws [2],
and then remove the paper feed unit /1 [3].
[2]
[1]
[3]
[2]
50gaf2c108na
44
Note
[3] [2]
bizhub 500 / 420

• When installing the paper feed unit /1 [1], be
sure to set the shafts [2] and [3] to the holes
[4] and [5].
[5] [1]
[4] 50gaf2c109na
45

bizhub 500 / 420
separation roller unit /1 [2].

[3][4]
Note
• When installing the separation roller unit /1,
[1]
be sure to set the projections [3], 1 each, to
each of the holes [4].
[2] [3][4]
[1]
50gaf2c110na

[2] 6. Detach the convex section [2] from the hole [3]
and remove the paper feed unit cover [4].
[3]
[1]
[4]
50gaf2c111na
46
7. Remove the C-ring [1] and then remove the bear-
bizhub 500 / 420

ing [2].
[1] 8. Detach the hook [4] of the spring [3] from the
oblong hole [5].
9. Remove the bearing [6] and then remove the
paper feed roller unit [7].
[2]
Note
• When attaching the spring, be sure to put the
hook into the oblong hole (not into the round
hole [8]).
[8] [7]
[5]
[4]
[6]
[3]
50gaf2c161na
10. Remove the E-ring [1] and then remove the bear-
[4] [1]
ing [2].
11. Remove the bearing [3] and then remove the feed
roller assy [4].
[2]
[3] 50gaf2c162na
47
12. Remove the C-ring [1] and then remove the feed
bizhub 500 / 420
roller [2].
[1]
[2] 50gaf2c163na
13. Remove the C-rings [1], 1 each, and then remove

the 2 bearings [2].
14. Remove the pick-up roller assy [3].
[1] [2]
[1]
[3] [2] 50gaf2c164na
15. Remove the C-ring [1] and then remove the pick-
[2] [1] up roller [2].
steps in reverse.
50gaf2c113na
48
3.12.2 Replacing the separation roller assy (tray 1)

bizhub 500 / 420

• Separation roller assy: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints)
B. Procedure
1. Remove the tray 1.
[1] (See P.143)
2. Remove the paper feed unit /1.
(See P.44)
3. Remove the separation roller unit /1.
(See P.44)
[2] [3] separation roller mounting plate assy [2].
50gaf2c117na
Note
• When installing the separation roller mount-
ing plate assy, be sure to fasten it with screws
while pressing it in the arrow-marked direc-
tion [3].
5. Remove the 2 C-rings [1] and pull out the shaft [2].
6. Remove the separation roller mounting plate [3].
[1]
Note
• When removing the separation roller mount-
[2] ing plate, be careful that the spring [4] does
[1] not get lost since it is apt to come off.
ing plate, be sure to install it so that it comes
under the projection [5].
[5] [4] [3]

50gaf2c118na
49
7. Remove the guide [1].

8. Remove the C-ring [2] and then remove the sepa-
bizhub 500 / 420
ration roller assy [3].

steps in reverse.
[1] [3]
[2]
50gaf2c119na
50
3.12.3 Replacing the feed roller/pick-up roller (tray 2)

bizhub 500 / 420

• Pick-up roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints)
B. Procedure
1. Remove the bypass unit.
(See P.60)
2. Pull out the tray 2 [1].
[1]
50gaf2c120na
3. Push the lever [1] to open the vertical conveyance

door [2].
4. Detach the fulcrum [3] of the vertical conveyance
[4]
door from the mounting plate [4] and remove the
vertical conveyance door.
[3]
[1] [2] 50gaf2c121na
51

bizhub 500 / 420
conveyance roller cover [2].
[1] [2] [1]

50gaf2c122na
6. Remove 2 screws [1] and then remove the paper

[2] [3] feed guide /2 [2] in the arrow-marked direction [3].
[1]
[1]
50gaf2c123na
52

[2]
bizhub 500 / 420

paper feed unit /2 [3].
[1]
[3]
[2]
50gaf2c124na
53

bizhub 500 / 420
separation roller unit /2 [2].

[1]
Note
• When installing the separation roller unit /2,
be sure to set the projection [3] to the hole [4].
[3] [4]
[1] [3] [4] [2]

50gaf2c125na

[4] [1] 11. Detach the convex section [2] from the hole [3]
and remove the paper feed roller cover [4].
[2] [3]
50gaf2c126na
54

bizhub 500 / 420

clutch /2 (CL5) [3].
Note
• When installing CL5, be sure to set the stop-
per [4] to the guide plate [5].
[3]
[2] [5]
[4]
[1]
50gaf2c127na
55
14. Detach the hook [2] of the spring [1] from the
[3]
bizhub 500 / 420
oblong hole [3].

[7]
the 2 bearings [5].
16. Remove the paper feed roller unit [6].
[2]
Note
• When attaching the spring, be sure to put the
[1] hook into the oblong hole (not into the round
hole [7]).
[6]
[4]
[4] [5] 50gaf2c165na
17. Remove the E-ring [1] and then remove the bear-
[4] [1]
ing [2].
18. Remove the bearing [3] and then remove the feed
roller assy [4].
[3] [2] 50gaf2c166na
56
bizhub 500 / 420

roller [2].
[1]
[2] 50gaf2c167na

the 2 bearings [2].
21. Remove the pick-up roller assy [3].
[1] [2]
[1]
[3] [2] 50gaf2c168na
22. Remove the C-ring [1] and then remove the pick-
[2] [1] up roller [2].
steps in reverse.
50gaf2c129na
57
3.12.4 Replacing the separation roller assy (tray 2)

bizhub 500 / 420

B. Procedure
(See P.60)
2. Pull out the tray 2.
3. Remove the vertical conveyance door.
(See P.51)
4. Remove the conveyance roller cover.
(See P.51)
5. Remove the paper feed guide /2.
[1] [2] [1]
(See P.51)
6. Remove the paper feed unit /2.
(See P.51)
7. Remove the separation roller unit /2.
(See P.51)
separation roller mounting plate assy [2].
Note
[3] • When installing the separation roller mount-
50gaf2c133na
ing plate assy, be sure to fasten it with screws
while pressing it in the arrow-marked direc-
tion [3].
9. Remove the 2 C-rings [1] and pull out the shaft [2].
10. Remove the separation roller mounting plate [3].
[1]
Note
• When removing the separation roller mount-
[2] ing plate, be careful that the spring [4] does
[1] not get lost since it is apt to come off.
ing plate, be sure to install it so that it comes
under the projection [5].
[5] [4] [3]

50gaf2c134na
58
11. Remove the guide [1].

bizhub 500 / 420

ration roller assy [3].
steps in reverse.
[1] [3]
[2]
50gaf2c135na
59
3.13 Maintenance procedure of the bypass tray section

bizhub 500 / 420
3.13.1 Removing/reinstalling the bypass unit

A. Procedure
1. Remove the right cover /Lw.
[2] [1]
(See P.123)
2. Remove the screw [1] and then remove the
bypass cover /Fr [2].
3. Loosen the screw [3] and then remove the screw
[4] to remove the bypass cover /Rr [5].
[5]
[3] [4] 50gaf2c001na
60

[4]
bizhub 500 / 420

ground terminal [3].
bypass unit [5].
[2] [3] [1]
[5]
[4] 50gaf2c002na
61

bizhub 500 / 420
steps in reverse.
8. After installing the bypass unit, open the tray 2
paper feed guide [1] and the bypass feed guide [2]
in the arrow-marked direction [3] to check to see if
they operate smoothly.
[1] [3] [2]
50gaf2c003na
62
3.13.2 Replacing the separation roller assy

bizhub 500 / 420

Note
• When replacing the separation roller assy, be sure also to replace the feed roller at the same time.
B. Procedure
[2] [2]
(See P.60)
2. Remove the 2 springs [1].
[2]
[1] 50gaf2c004na
63
4. Detach the hook [1] from the hole [2] and remove
[3]
bizhub 500 / 420
the push-up plate assy [3].
[1] [2]
50gaf2c005na
Note
[1] [3] [1]
• When installing the push-up plate assy, be
sure to install it while pressing the push-up
plate [3] so that each of the springs [1] does
not comes off each cross-headed boss [2].
[2] [2] 50gaf2c006na
64

[2] [1]
bizhub 500 / 420

separation roller fixing plate assy [2].
50gaf2c007na
6. Detach the support axis [2] of the holder [1] from

[3] [5] [4] [1]
the mounting plate [3] and remove the holder.
Note
• When removing the holder [1], the spring [4]
provided under the holder is apt to come off.
Be careful that it does not get lost.
• When installing the holder [1], be sure to
install it so that it comes under the projection
[5].
[2] 50gaf2c008na

[3] [1]
ration roller assy [3] from the holder [2].
steps in reverse.
[2] 50gaf2c009na
65
3.13.3 Replacing the feed roller

bizhub 500 / 420

Note
• When replacing the feed roller, be sure also to replace the separation roller assy at the same time.
B. Procedure
(See P.60)
2. Remove the push-up plate assy.
(See P.63)
3. Press the conveyance guide [1] in the arrow-
marked direction [2] to remove the support axis [3]
from the hole [4], and then remove the convey-
ance guide.
[4] [3] [2]
[1] 50gaf2c010na
4. Open the lever [1]. Remove the 2 screws [2] and

[3]
then remove the paper roller cover [3].
[2] [1] 50gaf2c169na
66

[1] [2] [3]
bizhub 500 / 420

clutch /BP (CL6) [2].
Note
per [3] to the guide plate [4].
[4] 50gaf2c170na
6. Remove the gear [1].
[1] 50gaf2c171na
67
7. Remove the C-ring [1] and then remove the bear-

bizhub 500 / 420
ing [2].
8. Remove the bearing [3] and slide the shaft [4].
[3] [4] [2] [1]
50gaf2c172na

roller [2] from the shaft [3].
Note
• When installing the feed roller, be sure to take
note of the direction of the arrow mark [4].

steps in reverse.
[2] [4] [1] [3]
50gaf2c173na
68
3.14 Maintenance procedure of the registration section
bizhub 500 / 420

3.14.1 Cleaning the paper dust removing brush
A. Periodic cleaning cycle
• Paper dust removing brush: Every 250,000 prints
B. Procedure
1. Open ADU.
[2]
(See P.122)
(See P.27)
(See P.35)
(See P.27)
5. Remove the suction cover /2 assy.
(See P.40)
6. With the lever [1] pulled, remove the paper dust
removing brush [2] and clean the paper dust
removing brush with a blower brush.
[1]
50gaf2c174na
steps in reverse.
3.14.2 Replacing the loop roller, the loop bearing, the registration roller /Rt, and the registration
bearings /Rt and /Lt
• Loop roller: Every 1,250,000 prints
• Loop bearing: Every 1,250,000 prints
• Registration roller /Rt: Every 1,250,000 prints
• Registration bearing /Rt: Every 1,250,000 prints
• Registration bearing /Lt: Every 1,250,000 prints
B. Procedure
1. Open ADU.
(See P.122)
(See P.27)
(See P.35)
(See P.27)
5. Remove the suction cover /2 assy.
(See P.40)
[1]
50gaf2c175na
69

bizhub 500 / 420
ADU drive assy [2].
Note
• When installing the ADU drive assy, be sure to
set the stopper [4] of the registration clutch
(CL1) [3] to the guide plate [5].
[2] [1]
[3]
[1]
[3]
[4]
[5]
50gaf2c154na
70

[5] [6] [1]
9. Remove the screw [2].
bizhub 500 / 420

10. Remove the C-clip [3] and slide CL1 [4] in the
arrow-marked direction [5].
11. Remove the 2 C-clips [6] to release the bearing
[7].
Note
• When installing the 2 C-clips [6], be sure to
install them with their collars come face to
face each other.
12. Remove the C-clip [8] and then remove the bear-
ing [9].
[10] [3] [4] [7] 13. Remove the registration unit [10].
[2] [9] [8]

50gaf2c155na
71
14. Remove the bearing [1] and CL1 [2].

[6] [5] [4] [3]
15. Remove the E-ring [3] and then remove the loop
bizhub 500 / 420
clutch (CL2) [4].
Note
per [5] to the screw [6].
16. Remove the screw [7] and then remove the regis-
tration main body assy [8].
[7] [2] [1]
[8]
50gaf2c156na
72
17. Remove the E-rings [1], 1 each, and release the 2

[3]
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loop bearings [2].
18. Remove the loop roller [3].
19. Remove the 2 loop bearings from the loop roller.
[2] [1] [2]
50gaf2c157na
73
20. Remove the 2 springs [1].

21. Remove the E-rings [2], 1 each, and then remove
bizhub 500 / 420
the 2 registration bearings /Lt [3].

22. Remove the registration roller /Lt [4].
Note
• When attaching the spring, be sure to couple
the hook [5] of the spring at the position as
shown in the drawing left.
[4] [5] [2] [3] [1]
[1] [3] [2]

50gaf2c158na
74
23. Remove the E-rings [1], 1 each, and then remove
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the 2 registration bearings /Rt [2].
24. Remove the registration roller /Rt [3].
steps in reverse.
[1] [2] [3]
[2] [1]
50gaf2c159na
75
3.15 Maintenance procedure of the fusing section

bizhub 500 / 420
3.15.1 Removing/reinstalling the fusing unit
Caution
• Since the fusing section gets hot immediately after turning off the main power switch (SW1) or the
power switch (SW2), you may suffer a burn. Be sure to conduct the operations when the tempera-
ture goes down sufficiently.
A. Procedure
1. Open ADU.
[2] [1]
(See P.122)
(See P.122)
(See P.27)
4. Loosen the screw [1] and remove the front auxil-
iary cover [2].
50gaf2c085na
76

6. Remove the screw [2] and then remove the filter
bizhub 500 / 420

[4]
cover [3].
[1]
8. Loosen the 2 screws [5]. And after sliding the
entire reverse unit [6] in the arrow-marked direc-
tion [7], tilt the front side in the arrow-marked
direction [8] for removal.
[8] [3] [2] [5]
[6] [5] [7]
[4]
50gaf2c086na
77

[2]
bizhub 500 / 420
fusing unit [2].
Note
• When lifting the fusing unit, be sure to hold it
at both ends.
• When installing/removing it, be careful not to
damage rollers.

steps in reverse.
[1] 50gaf2c087na
3.15.2 Replacing the fusing claw assy

• Fusing claw assy: Every 500,000 prints
B. Procedure
1. Remove the fusing unit.
(See P.76)
2. Remove the C-clip [1].
3. Open the fusing front guide assy [2].
[1] [2] 50gaf2c088na
4. Slide the fusing front guide assy [1] for removal.
[1] 50gaf2c089na
78

6. Remove the screw [2] and raise the fusing claw
bizhub 500 / 420

assy [3].
7. Remove the connector [4] from the fusing claw
assy.
Note
• The fusing claw assy varies for bizhub 500
[1] and 420. Be sure to check a punch mark [5]
and replace it with a right fusing claw assy.
bizhub 500: 50 GA
bizhub 420: 42 GA
• When installing the fusing claw assy, be care-
ful not to neglect attaching the connector [4].
• When installing the fusing claw assy, be sure
to insert the positioning sections [6] at 2
[2] [5] [4] places into each of the projections [7].
• When installing the fusing claw assy, be care-
ful not to damage the roller surface with the
tip of the claw.

steps in reverse.
[3] [7] [6]
50gaf2c091na
79
3.15.3 Replacing the fusing web

bizhub 500 / 420

• Fusing web: Every 250,000 prints
B. Procedure
[4] [2]
(See P.76)
2. Remove the fusing claw assy.
(See P.78)
5. Apply pressure from the inside of the ducts [3] at 2
places to release the lock and remove the fusing
web [4].
Note
• The fusing web varies for bizhub 500 and 420.
[1] [5] [3] Be sure to check a punch mark [5] and
50gaf2c092na
replace it with a right fusing web.
bizhub 500: 50 GA
bizhub 420: 42 GA
• When installing the fusing web, be sure to
install the screw [1] first.
Note
[2]
• When installing the fusing web, be sure to
insert the projections [1] at 2 places into the
positioning holes [2].
[1] 50gaf2c093na
80
• The performance of a new fusing web [1] is

[1] [2] [5] [8]
bizhub 500 / 420

guaranteed from the position at which a
brown line [2] is broken. When replacing the
fusing web, be sure to take up the fusing web
up to the position at which the distance [5]
from the nip section [4] of the fusing roller [3]
and the fusing web to the brown line becomes
0 to 10 mm or less.
• When taking up the fusing web, be sure to
[4] [3]
bring down the release lever [6] to release the
cleaner lock gear [7] and rotate the web drive
gear [8].
• When replacing the fusing web, be sure to
reset the fusing web counter in the service
mode.
(See P.187)

step in reverse.
[1]
[7] [6] [6] 50gaf2c094na
81
3.15.4 Replacing the fusing driven roller assy /A and /B

bizhub 500 / 420

• Fusing driven roller assy /A: Every 250,000 prints
• Fusing driven roller assy /B: Every 250,000 prints
B. Procedure
[1] [2] [4] [3] 1. Remove the fusing unit.

(See P.76)
2. Remove the fusing claw assy from the fusing unit.
(See P.78)
3. Remove the fusing web from the fusing unit.
(See P.80)
4. Remove the screw [1] and then remove the fusing
unit cover /Fr [2].
fusing unit cover /Rr [4].
Note
[8] • When removing the fusing unit cover /Rr, be
careful that the internal gear does not fall
down.
6. Remove the 2 screws [5] and the 2 screws [6].

7. Release the 2 envelope levers [7].
8. Remove the fusing casing [8] without touching the
envelope lever.
Note
• When installing the fusing casing [8], be sure
to install first the screw [5] (upper side).
[6] [7] [5] 50gaf2c095na
82

[3] [2] [3]
10. Remove the 2 fusing driven roller assy's /A [2] and
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the 2 fusing driven roller assy's /B [3].
Note
• The gear [4] is not fixed. Take care when mov-
ing it.

steps in reverse.
[1]
[4]
50gaf2c096na
83
3.15.5 Removing/reinstalling the fusing heater lamps /1 (L2) and /2 (L3)

bizhub 500 / 420
Note
• Be careful not to touch the lamp sections of L2 and L3 with bare hands. When touched, be sure to
clean them with a roller cleaner.
A. Procedure
[1]
(See P.76)
(See P.78)
(See P.80)
4. Remove the fusing casing.
(See P.82)
5. Remove the fastons [1] and [2], 2 each.
Note
• When removing the faston, be sure to remove
it by holding the connector section. Be abso-
lutely sure not to pull out by holding the wiring
harness section.
[2] 50gaf2c097na
84
[8] [1]
6. Remove the screw [1] and then remove the lamp
bizhub 500 / 420

fixing plate /Fr [2].
7. Pull out the fusing heater lamps /1 (L2) [3] and /2
(L3) [4] in the arrow-marked direction [5] and
remove them.
Note
• When installing each of the fusing heater
lamps, be sure to set the projections [6] of
each lamp to the notch [7] of the lamp fixing
plate /Fr [2].
• After installing each of the fusing heater
lamps, be sure to check to see if it is not in
touch with the inner face of the fusing roller
[8].
[5] [3] [2] • Be sure to install the fusing heater lamp L2 [3]
(main) on the upper side with L3 [4] (sub) on
the lower side.

steps in reverse.
Note
• When installing the fusing heater lamp, be
sure to take note of the direction of installa-
tion.
Lamp Destination
North America Europe/Others
[7] [6] [4] 50gaf2c098na
Fr Rr Fr Rr
L2 Red Red Blue Blue
L3 Red Black Blue Black
85
3.15.6 Replacing the fusing roller, the fusing pressure roller, the heat insulating sleeve /A, the fusing
bizhub 500 / 420
bearings /Up and /Lw and the fusing input gear assy
• Fusing roller: Every 250,000 prints
• Fusing pressure roller: Every 250,000 prints
• Heat insulating sleeve /A: Every 250,000 prints
• Fusing bearing /Up: Every 250,000 prints
• Fusing bearing /Lw: Every 250,000 prints
• Fusing input gear assy: Every 500,000 prints
B. Procedure
[7] [8] [6] [5] (See P.76)
(See P.78)
(See P.80)
(See P.82)
[1] [4] 5. Remove the fusing heater lamps /1 (L2) and /2
(L3).
(See P.84)
lamp fixing plate /Rr [2].
fusing input gear assy [4].
Note
• When installing the fusing input gear assy, be
sure to set the D cut section [6] of the shaft
[5] to the D cut hole [8] of the frame [7].
8. Release the 2 envelope levers [9].

[2] [3]
Note
• The envelope lever varies in the number of the
release steps for bizhub 500 and 420. Be sure
to release it up to the limit in either case.
bizhub 500: 2 steps
bizhub 420: 3 steps
[9] 50gaf2c099na
86
9. Remove the C-ring [1] and then remove the gear

[5] [2] [1]
bizhub 500 / 420

[2].
10. Remove the heat insulating sleeve /A [3] and the
fusing bearing /Up [4].
Note
• When installing the heat insulating sleeve /A
and the fusing bearing /Up, be sure to install
[4] [3] [10]
them with their respective collar [5] outside.
• When installing the heat insulating sleeve /A,
be sure to apply Multemp FF-RM to its inside
and outside peripheries.
11. Remove the C-ring [6] and then remove the heat
insulating sleeve /A [7] and the fusing bearing /Up
[8].
Note
• When installing the heat insulating sleeve /A
[12] [11] [7] [8] and the fusing bearing /Up, be sure to install
them with their respective collar [9] outside.
• When installing the heat insulating sleeve /A,
be sure to apply Multemp FF-RM to its inside
and outside peripheries.
12. After sliding once the fusing roller [10] in the

arrow-marked direction [11], remove it in the
[9]
[6] arrow-marked direction [12].
50gaf2c100na
Note
• According to the model, the fusing roller var-
ies in the diameter and the wall thickness.
When replacing it with a new one, be sure to
install one that is suitable for the model.
Model Diameter Wall thickness

bizhub 500 φ 35 mm t 2.0 mm
bizhub 420 φ 35 mm t 0.8 mm
87
13. Remove the fusing pressure roller [1].

bizhub 500 / 420
Note
• The fusing pressure roller varies in the diame-
ter for bizhub 500 and 420. When replacing it
with a new one, be sure to install one that is
suitable for the model.
Model Diameter
bizhub 500 φ 35 mm
bizhub 420 φ 35 mm
[1] 50gaf2c101na
14. Remove the 2 fusing bearings /Lw [2] from the

fusing pressure roller [1].
Note
• When installing the fusing bearing /Lw, be
sure to install it with its collar section [3]
inside. Coat the cored bar section with
grease.
[2] [3] [3] [2]

steps in reverse.
[1] 50gaf2c102na
88
3.15.7 Replacing the fusing sensor assy
bizhub 500 / 420

Caution
• After installing the fusing sensor assy, be sure to check to see if it is in touch with the fusing roller.

• Fusing sensor assy: Every 500,000 prints
B. Procedure
[1] [3] [2]
(See P.76)
(See P.78)
(See P.80)
(See P.82)
5. Remove the fusing heater lamps /1 (L2) and /2
(L3).
(See P.84)
6. Remove the fusing roller and the fusing pressure
roller.
[4] (See P.86)
7. Remove the faston [1].
Note
it by holding its base section. Be absolutely
sure not to pull it out by holding the wiring
harness section.

[5] [3] 9. Remove the 3 screws [3].
10. Remove the web support assy /2 [4] and pull it
out in the arrow-marked direction [5].
50gaf2c104na
89

[2]
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the fusing sensor assy [2].
Note
• When installing the fusing sensor assy, be
careful not to deform the sensor section.
• After installing the fusing sensor assy, be sure
to check to see if the wiring harness is not in
touch with the fusing roller.
Caution
• After installing the fusing sensor assy, be sure
[1] 50gaf2c105na
to check to see if the thermistors /1 (TH1) and
/2 (TH2) are in touch with the fusing roller.
Note
[1]
• The fusing sensor assy is made up of TH1 and
TH2. The sections of TH1 and TH2 have been
adjusted when they were assembled, and be
absolutely sure not to loosen the screw [1].

steps in reverse.
50gaf2c106na
90
3.15.8 Replacing the fuse holder assy
bizhub 500 / 420

Caution
• After installing the fuse holder assy, be sure to check to see if it is in touch with the fusing roller.

• Fuse holder assy: Every 500,000 prints
B. Procedure
[1] [4] [3]
(See P.76)
(See P.78)
(See P.80)
(See P.82)
5. Remove the fusing heater lamps /1 (L2) and /2
(L3).
(See P.84)
6. Remove the fusing roller and the fusing pressure
[2] 50gaf2c107na
roller.
(See P.86)
7. Pull out the web support assy /2.
(See P.89)
8. Remove the faston [1].
Note
it by holding its base section. Be absolutely
sure not to pull it out by holding the wiring
harness section.

fuse holder assy [3].
Note
• When installing the fuse holder assy, be care-
ful not to deform the thermostat section.
• After installing the fuse holder assy, be sure
to check to see if the wiring harness is not in
Caution
• After installing the fuse holder assy, be sure
to check to see if the thermostat (TS) [4] is in

steps in reverse.
91
4. SERVICE TOOLS Field Service Ver1.0 Feb.2006
4. SERVICE TOOLS
bizhub 500 / 420
4.1 Service material list

Material No. Name Shape Remark
000V-19-0 Setting powder 25 g
000V-18-0 Cleaning pad 10 pcs/1 pack
00GR0026 Multemp FF-RM 25 g
00GR0021 Solvest 240 Multemp FF-RM is rec-

ommended.
92
Field Service Ver1.0 Feb.2006 4. SERVICE TOOLS
4.2 Jig list
bizhub 500 / 420

Parts No. Name Shape Quantity Remark
26NA2134 Drum rotation mem- 1 Mounted to the drum
ber unit
26NAJG01 Optic unit positioning 2

jig
40347940 Test chart 1 Without a KONICA

(A3 size) MINOLTA logo
40347942 Test chart 1 Without a KONICA

(A3 size) MINOLTA logo
40347940 Test chart 1

(11 x 17 size)
120A9711 Adjustment chart 1 For DF adjustment

(A3 size)
120AJG02 Adjustment chart 1 For DF adjustment

(11 x 17 size)
120A9712 White chart 1 For DF adjustment

(A4 size)
120AJG03 White chart 1 For DF adjustment

(81/2 x 11 size)
00VC-2-0 Drum cover 1
00VD-100 Blower brush 1
93
4. SERVICE TOOLS Field Service Ver1.0 Feb.2006
Parts No. Name Shape Quantity Remark

bizhub 500 / 420
00VE-100 Tester 1
14G54631 Stapler unit position- 1 For SD staple adjust-

ing jig ment
4.3 Materials
A. Item
Parts name Useful life Type name

Toner bottle 32,200 prints TN511
Drum 250,000 prints DR510
Developer 250,000 prints DV511
94
Field Service Ver1.0 Feb.2006 5. FIRMWARE VERSION UP
5. FIRMWARE VERSION UP
bizhub 500 / 420

5.1 ISW
5.1.1 Outline
A. ISW (In-System Writer)
The operation to rewrite firmware stored in the flash ROM that is built in each control board in the main body
with the board left built in the main body is called an ISW. Executing ISW allows you to upgrade the firmware ver-
sion without replacing the board, or install the latest firmware when replacing the board. As a tool to execute
ISW, there is ISWTrns (PC software) that rewrites firmware with the personal computer (PC) locally connected to
the main body.
(1) ISWTrns
This is a software for Windows to rewrite flash ROM of the main body and rewrites firmware with the main body
and the PC locally connected with a parallel cable or UBS cable.
Note
• When upgrading the ISWTrns version, be sure to uninstall the old version of ISWTrns before install-
ing the new version of ISWTrns. When installed by overwriting, this may result in the installation by
the USB driver unavailable.
• When the main body uses the USB to conduct the ISW, it is necessary to install the USB driver of
the ISWTrns. For procedure for installation, see "5.2.3 Usage of the ISWTrns A. Installation of the
USB driver (Windows2000/XP)." After installing the ISWTrns, be absolutely sure to install the USB
driver of the ISWTrns.
(See P.100)
5.1.2 Firmware data flow

The following shows the flow of the ISW data.
PC Overall control board (OACB) Printer control board (PRCB) DF control board (DFCB)
FS control board (FSCB)
FAX control board (FK-502)
When executing the ISW over the entire system, be sure to execute it in the order given below. (To minimize the
occurrence of troubles resulting from the mismatch of the firmware version)
Step Type of programs

1 Fax board controller 1, Fax board controller 2, Finisher, DF
2 Image controller
3 Operation panel message data
4 MFP controller
Note
• When replacing the OACB, be sure to conduct the ISW of the MFP controller first. When the firm-
ware of the MFP controller is not contained in the OACB, no display is shown on the touch panel.
• The finisher above refers to the FS-510. The ISW of the FS-511 is conducted by changing the
EPROM.
95
5. FIRMWARE VERSION UP Field Service Ver1.0 Feb.2006
5.1.3 Settings on the main body side while in ISW

Following the description given below, be sure to make appropriate settings on the main body side to conduct
bizhub 500 / 420
the operations of the firmware version upgrade and writing.
A. Types of the setting

• Power ON mode
This mode is used when the firmware of the MFP controller is not installed to the overall control board
(OACB) or when it is damaged. In a case like this, it is not possible to enter the service mode. The firmware
writing of the MFP controller can be made with the power switch ON.
• Service mode
This mode is used when the firmware of the MFP controller is installed properly. Selecting [ISW] of [System
2] in the service mode allows you to write the firmware.
B. When upgrading the firmware
Applicable board Display when the power is turned ON Mode

Overall control board Normal Service mode
Other boards Normal Service mode
C. When writing the firmware afresh (When replacing the board or when failed in rewriting the firm-
ware)
Applicable board Display when the power is turned ON Mode

Overall control board Data LED turns ON with nothing Power ON mode
shown on the touch panel.
Other boards ISW error displayed Service mode
For the overall control board (OACB), when something is wrong with the firmware or no firmware is written, the
normal start-up cannot be made. In a case like this, when the power switch is ON, the data LED turns ON with
nothing shown on the touch panel, and the system is placed in the firmware stand-by mode.
For other boards, when the firmware of the MFP controller is normal and something is wrong with other firm-
ware, an ISW error is shown on the touch panel section when the power is turned ON.
96
5.2 ISWTrns
bizhub 500 / 420

5.2.1 Specifications
A. ISWTrns (PC software)
(1) Operating environment of the software
• OS: Windows95/98/98SE/Me/NT4.0/2000/XP
• CPU: Pentium 75 MHz or above
• Memory: 16 MB or more
• Free space in hard disk: 100 MB or more
• Others: PC provided with parallel (printer) or USB interface (type A)
(2) Transmission time

• Varies according to each PC
(3) Parts required to conduct the ISW

• Personal computer (PC): 1
IBM-compatible PC/AT, Provided with D-sub25 pin parallel (printer) interface or USB interface
• ISWTrns setup program
• Parallel cable or USB cable: 1
• Firmware
Item Specifications
Board to be rewritten Overall control board (OACB), Printer control board (PRCB), FAX control
board (FK-502), FS control board (FSCB), DF control board (DFCB)
Rewritable firmware MFP controller
Operation panel message data
Image controller
FAX board controller 1
FAX board controller 2
Finisher
ADU
Note
• For boards other than the above, ROM replacement is required.
97
5.2.2 Installation of the ISWTrns

Install the ISWTrns program to the PC.
bizhub 500 / 420
(1) Procedure
Step Operation
1 Start the PC.
2 Copy the setup files to the PC and double click the [Setup.exe] icon to start the install program.
Note
• When there remains the ISWTrns of the old version, uninstall the old version first, and
then install the new version.
3 "ISWTrns setup screen"
Following the instructions on the screen, check the folder to which an installation is made, and then
click [Next].
Note
• For default, "C:\Program Files\KONICA MINOLTA\ISWTrns" is set as a folder to which an
installation is made.
• When changing the folder to which an installation is made, click [Browse] and specify
the folder.
4 Following the instructions on the screen, check the folder to which the ISWTrns program is stored
and then click [Next].
Note
• For default, "ISWTrns" is set as a folder to which an installation is made.
• When changing the folder to which an installation is made, enter the folder name
directly, or select one from the existing folder displayed.
5 Following the instructions on the screen, click [Finish].
6 The installation of the ISWTrns program is automatically completed.
7 Select [ISWTrns] from the start menu or double-click the [ISWTrns] icon on the desk top to start up
the ISWTrns program.
98
Step Operation
bizhub 500 / 420

8 "ISWTrns screen"
Click [OK] to set the storage folder of the firmware.
Note
• This screen is shown only when the program is started for the first time after installing
the ISWTrns.
9 "Option screen"
Click [Make Folder]
Note
• A folder (C:\Program Files\KONICA MINOLTA\ISWTrns) into which the ISWTrns program
is installed as a storage folder is set by default.
• When changing the storage folder, click [Browse] to specify it arbitrarily or enter it
directly in the editor box in full path.
• Clicking [Make Folder] creates hierarchical folders with the storage folder set above as
a route.
10 "Option screen"
Click [OK].
Note
• This operation allows the data folder created in step 9 to be stored in the INI file of the
ISWTrns program.
99
5.2.3 Usage of the ISWTrns

A. Installation of the USB driver (Windows2000/XP)
bizhub 500 / 420
When a connection is made between the PC and the main body with a USB cable, the installation of the USB
driver is automatically started by the plug-and-play. However, this may result in the installation of the Windows
USB driver (USBPRINT.SYS) and be sure to set the USB driver following the steps given below.
(1) Procedure
Step Operation
1 Connect the USB cable to the main body.
2 Connect the USB cable to the USB connector of the USB.
3 From the screen below, select "Install from a list or specific location," and then click [Next].
The driver is stored in the C:\WINDOWS\Drivers\Usb.
4 In the "Please choose your search and installation options" screen, select "Don't search. I will choose
the driver to install," and then click [Next].
5 Check the driver name and click [Next].
Driver name: KONICA MINOLTA 500/420 USB Driver for ISW
6 When the "Completing the Found New Hardware Wizard" screen is displayed, click [Finish] to exit the
installation.
7 Check the "Device Manager screen" to see if the USB driver has been correctly installed.
Driver name: KONICA MINOLTA 500/420 USB Driver for ISW
100
B. Firmware copy
By using the ISWTrns, firmware that transfers it to the main body is copied into the specified folder.
bizhub 500 / 420

(1) Procedure
Step Operation
1 Start the PC.
2 Select [ISWTrns] from the start menu or double click the [ISWTrns] icon on the desktop to start up the
ISWTrns.
3 Click [Option (O)] from the menu and then click [Option (O)].
4 "Option screen"
Click [Data Copy].
5 "File Copy screen"

Click [Browse].
Select the folder into which firmware is stored as a copied file.
Note
• The folder selected is shown in the upper display section of the "Original Files."
• In the lower display section of the "Original Files," the firmware related files stored in the
folder are shown.
6 Select a file you want to copy from the lower display section of the "Original Files."
Note
• The plural transferred files (rewritten data) can be selected.
• When copying all of the files that are displayed, skip this step and proceed to the step 7.
101
Step Operation
bizhub 500 / 420
7 Click [Copy] automatically copies the selected file into the specified folder created by installing the
ISWTrns.
Note
• When copying all of the files that are displayed in the lower display section of the "Origi-
nal Files", click [Copy All] instead of [Copy].
• In the upper display section of the "Copied Files", a folder name created at the setup of
the ISWTrns is displayed.
• In the list shown in the lower display section of the "Copied Files," files the copy of
which has been successfully completed are listed in full path. In the "Failed to Copy
Files", files the copy of which have been failed are listed. As the causes of failure, follow-
ing are considered.
A. There exists a file of the same name and "O/W" is not checked.
B. A folder into which a file is stored is not found.
C. An overwrite is made on an overwrite-prohibited file.
• When changing a file that is currently stored into a new data, click the overwrite check
box to make a check mark.
8 After completion of copy, click [Refresh].
9 Click [Cancel] to get back to "option screen."
10 "Option screen"
Click [OK].
C. Preparation for transfer of the main body

(1) Checking the firmware version
Before rewriting firmware, be sure to check the current firmware version following the procedure given below.
Step Operation
1 Enter the Service mode.
2 Press the [Firmware Version] in "Service mode screen".
3 Indication of "Firmware Version screen"
102
(2) ISW transfer standby

Open the Service mode of the main body to put the ISW transfer in the standby condition.
bizhub 500 / 420

Step Operation
1 Enter the Service mode.
2 Press the [System 2] in "Service mode screen."
3 Press the [ISW] in the sub menu shown to the right of the screen.
4 "Board Type Selection screen"
5 Press the key corresponding to the firmware to be rewritten.

e.g.: MFP controller
"ISW Execution Check MFP Controller screen"
6 Press the [Yes] in "Execution Check screen".
7 Press the Start key.
103
D. Connection to the main body

bizhub 500 / 420
(1) When using the parallel cable

Preparations are made of the following when a connection is made.
• PC which firmware have been copied.
• Parallel cable
1) Procedure
Step Operation
1 Turn OFF the power of the main body.
2 Turn OFF the power of the PC.
3 Connect the parallel cable [2] to the IEEE1284 port [1] of the PC.
[1]
[2]
50gaf2c176na
4 Connect the parallel cable [1] of the PC to the ISW connector [2] of the main body.
[2]
[1]
50gaf2c177na
104
(2) When using the USB cable

Preparations are made of the following when a connection is made.
bizhub 500 / 420

• PC which firmware have been copied.
• UBS cable
1) Procedure
Step Operation
1 Connect the UBS cable [2] to the USB port [1] of the PC.
[1]
[2]
50gaf2c178na
Note
• Be sure to connect the UBS cable to the ISW connector of the main body after the set-
ting is made in the following condition.
105
E. Rewriting of firmware
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(1) Relationship between the ISW and the display of the operation panel
When the ISWTrns starts up, the main screen is displayed. In the main screen, the transmission file (firmware) is
selected, the information is diplayed, the checksum and the transmission file are sent out. For detailed informa-
tion of the functions, refer to the following.
[2] [3]
[4]
[1]
[5]
[6]
[7]
[9]
[8]
[10]
[1] File status information list

View detailed information about the version file when select firmware.
[2] Select type frame
Select condition for a transfer file. When selecting all of the 4 types of the combo boxes, a folder [4] is set
from the information set in the ISWTrns.INI file. The setting of the selected combo boxes are saved to the
ISWTrns.INI file and it is display initially when it is started next time.
[3] Version selection frame
This frame let you select which version of a transfer file you want transmitted when more than one version is
stored in a folder.
[4] Version storage folder edit box
When the select type frame of [2] is decided, a folder name is displayed in full path from the information of
the data folder set in the option window and the INI file. When the firmware is in a folder other than the
specified data folder, this can be changed by clicking [Browse] [6] to specify the file location or entering
directly the file location. A firmware corresponding to the INI file conditions in the folder shown here is dis-
played in the list box of [5].
[5] Version file selection list box
Displays files that is in the folder selected at [4]. When more than one version files are stored in the same
folder, all versions are displayed in this list box. The list displayed here is sorted in the order of names, and
an item displayed last is selected when the list is displayed. Changing the selected item decides a firmware
version to be transmitted.
[6] Version file [Browse]
This key is used when the firmware is in a folder other than the specified data folder. Display the folder
selection screen to select the folder of [4].
[7] Send file information frame
Display the list of firmware to be actually transmitted based on the information selected in the frames [2] and
[3], and click [FileCheck] [9] to display the checksum of the file and the consistency (OK, NG, ??) of the
checksum.
[8] Send file information display list
When version files are selected at [5], files to be actually transmitted are displayed. The number of files actu-
ally transmitted is described in the checksum attached to the firmware.
Click [FileCheck] at [9] to calculate the checksum of the entire displayed files. And compare the obtained
value with the checksum value stored in the checksum file (*.sum) attached to the firmware to display the
result.
106
[9] [FileCheck]
With a transmission file displayed in "SendFile info" of [8], press this key to calculate the file checksum
bizhub 500 / 420

(checksum of the entire file) of the displayed transmission file and show a result beside the transmission file.
And also, compare the result of the checksum with the checksum file attached to the firmware and display
the obtained result in the form shown below.
"OK": Accord
"NG": Not accord
"??": Checksum file (*.sum) not found
[10] [FileSend]
The transmission of the transferred file is started.
(2) Procedure
e.g.: When conducting the ISW of the MFP controller for bizhub 500.
Step Operation
1 Start the ISWTrns program.
2 Click [Set-up (S)] from the menu and then click [Communication setting (C)].
3 "Set Communication screen"
Select a port through which the transmission is made and click [OK].
Note
• When [Parallel] is selected, be sure also to specify [Port].
4 Select the machine type, the destination and the board types.
• Machine type: 500, Country: EU, Board type: CONTROL (ALL)
5 The data to be used is displayed in the version selection frame and the send file information frame.
107
Step Operation
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6 Press the [FileCheck] to check if the data to be used has any problem.
7 Place the main body in the ISW standby condition.

8 Check to see if "Please execute the data transfer. The data reading is begun." is displayed.
9 When a connection is made with a USB cable, connect the USB cable [2] to the USB connector [1] of
the main body.
[1]
[2]
50gaf2c179na
Note
• Be sure to press the start key before connecting the USB cable. When connecting the
USB cable before the start key is pressed, the main body is put in the stand-by position
for the print data with no ISW data accepted.
10 Click [FileSend] of the ISWTrns.
108
Step Operation
bizhub 500 / 420

11 The following window is displayed on the PC while in the data transfer.
12 When the data transfer is completed, the following window is displayed and click [OK].
"ISWTrns"
13 When the data writing is completed, the reboot is automatically made to show the trouble reset dis-
play. When conducting the ISW successively after that, press [Trouble reset]. And then, after check-
ing to see if "OK" is displayed, press the key that sets the number of sheets in the order shown below
and start the service mode.
Stop -> 0 -> 0 -> Stop -> 0 -> 1
Note
• When the ISW other than for the MFP controller is completed, no reboot is made auto-
matically. In cases like this, when conducting the ISW for another board successively,
press [OK] on the screen showing a message "ISW completed," and select again a
board type that conducts the rewrite on the board type selection screen.
14 Check the firmware version in the service mode to see if the rewriting is completed successfully.
5.2.4 Error list

A. Overall control board firmware abnormality
When the main body detects an overall control board firmware abnormality after turning ON the power switch,
the data LED turns ON with nothing displayed on the LCD of the operation panel (ISW stand-by condition). For
details of the data LED display, refer to the table below.
No. Operation Data LED

1 CPU in initialization when the power is turned on OFF
2 Flash memory in checking OFF
3 When an error is detected while in memory check (ISW ON
standby status)
4 ISW processing (data being received from the PC and flash • While in the data reception:
memory being written) It flashes at high speed.
• While in the flash memory write:
It flashes at low speed.
5 When an abnormality is detected while in data transmission Start key LED (orange) turns ON
6 When an error is detected while in writing flash memory Start key LED (orange) turns ON
7 Memory check successfully completed: while in rebooting OFF
109
B. ISWTrns error list

The ISWTrns displays messages when an error is shown or the operation is completed. The table below shows
bizhub 500 / 420
the contents of the message and the status of the ISWTrns.
Message Status of the ISWTrns

Cannot open a checksum file Opening of a checksum file failed. Possible causes include a corrupted
file and a file in use.
Cannot read a checksum file Loading of a checksum file into memory failed. Possible causes include
a shortage of memory and an OS problem.
Cannot open a file Opening of a send file failed. Possible causes include a corrupted file
and a file in use.
Cannot open the LPT port Opening of the LPT port failed.
Communications port setup A call to GetCommState failed.
acquisition error
Communications port setup error A call to SetCommState failed.
Cannot open a send file Opening of a send file failed. Possible causes include a corrupted file
and a file in use.
Cannot send a Term Test file Transmission of a communications test block failed.
1. The main body is not ready to receive.
2. The cable is out of position.
3. Transmission of the wrong send file was attempted.
Unsuccessful file transmission The transmission of a send file failed. Possible causes include a cable
out of position.
Unsuccessful transmission to the Output to the LPT port failed. Possible causes include a cable out of
LPT port position.
Invalid folder name An invalid folder name was entered. Start a folder name with a drive
name, such as C:\.
Default data folder is not set. A data folder is not set in ISWTrns.INI. This message is displayed when
Please select folder. ISW Trns launches for the fist time.
Unsuccessful thread creation The creation of a thread failed.
No send file available No file to copy file is selected or exists in the folder.
Unable to copy several files 1. The destination folder does not exist.
2. When the overwrite check box is not checked, an attempt is made to
copy to a file having the same file name.
3. An attempt is made to overwrite a protected file.
4. Any other cause (such as a file being used by another application or
OS problem)
Send file not found, or invalid file The number of divisions of a send file recorded in the checksum file and
name in the folder. Check. the number of files actually existing do not match.
1. A file having an invalid file name exists in the data folder. Delete possi-
bly invalid file names from the folder list.
2. The number of files in a divided file is wanting. Identify the wanting
files in the folder list and recopy them.
3. When the checksum file is damaged, copy it to the folder again.
110
C. Main body error list

The following shows the error displays.
bizhub 500 / 420

Error display Descriptions
Finisher not connected The finisher is in the condition in which no connection is made.
Parameter error A parameter abnormality occurs on the program.
Sequence error An abnormality occurs with the processing sequence on the program.
Memory full error The memory is full.
Device initialization error A USB or parallel device initialization error occurs.
Machine type/board incompatible The data transferred from the PC is not the data for bizhub 500/420, or
not for the board selected from the panel.
Time-out error While in the file transfer from the PC, a time-out error occurs.
Checksum error A checksum error occurs with the ROM file.
Flash erasure error An abnormality occurs while in the flash erasure.
Engine power source error Printer control board (PRCB) power source abnormality. Other abnormal-
ities occur with PRCB (when selecting the image controller, finisher or
ADF).
Write error An error occurs with the write answer check (when selecting the fax
board controller 1 or the fax board controller 2).
Task generation error A task generation error occurs.
Other errors Errors other than the above occur, such as an OS error.
D. ISWTrms troubleshooting
When an error occurs while in the execution of the ISWTrns program.
Condition Cause Measure taken

1 The ISWTrns does not The ISWTrns.EXE file is damaged Set it up again.
start up. The setup files itself is damaged. Check the setup files and set it up
again.
2 When an item in the The transferred file is not stored in the Check to see if the firmware file is
combo box is selected, specified folder. stored in the folder displayed in the
the transferred file is "File" text box of "Version."
not displayed. Use the "Data Copy" function if the file
storage location is unknown.
The data folder in the option screen is Check the setting of the data folder.
set incorrectly.
The file name is illegal (or has been The file name must be used with no
changed.) change made. When the file name is
changed, the display or selection of
the file becomes unavailable. When
the file name is changed, return it to
former state.
The folder name is illegal (or has been When the folder name created by the
changed.) "Make Folder" in the option screen
has been changed, it cannot be
found. Return it to former state and
check it again.
111
Condition Cause Measure taken

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3 "NG" is displayed while The transferred firmware is damaged. Copy the firmware and check it again.
in the file checksum. When "NG" still recurs, contact the
supplier of the firmware.
4 "??" is displayed while When the firmware was copied to the Copy the checksum file to the same
in the file checksum. PC, the copying of the checksum file firmware as the one for the firmware
(*.sum) was forgotten. at the same time. (If you use the "Data
Copy" function, a copy is made auto-
matically.)
5 An error "Cannot The file is being used by anther pro- Exit another program. The error still
The transfer of the file failed.
open a file" is dis- gram or system. recurs, reboot Windows.

played.
An error "Cannot The connection of the cable is loos- Check the cable to see if it is con-
send a Term Test ened. nected securely or if there is any prob-
file" is displayed. lem found with the cable itself.
The main body is not in the receiving Check the main body to see if it is in
condition. the receiving condition.
An error "Unsuc- The connection of the cable is loos- Check the cable to see if it is con-
cessful transmis- ened. nected securely or if there is any prob-
sion to the LPT lem found with the cable itself.
port" is displayed. Wrong data has been sent. Check the file status screen to see if
the receiving mode on the main body
side (type of receiving board) corre-
sponds with the transferred file on the
PC side.
The length of the cable is out of spec- Use a cable the length of which is less
ifications. than 2 m.
The parallel port of the PC is set to See the PC manual to release the
the ECP mode. ECP mode.
There is a compatibility problem Conduct a test with a PC with an
between the parallel port of the PC actual performance of transmission,
and the port on the main body side. and check to see if there is a compat-
ibility problem found.
112
Field Service Ver1.0 Feb.2006 6. OTHERS
6. OTHERS
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6.1 Items not allowed to be disassembled and adjusted
6.1.1 Scanner section
A. CCD unit
(1) Parts not allowed to be removed
• 7 screws that are used to assemble the CCD unit.
• 4 attaching screws of the lens reference plate assy
[3] [1]
[5]
[2]
[2]
[4] [3] 50gaf2c136na
[1] Screws not allowed to be removed [4] CCD unit

[2] Screws not allowed to be removed [5] Lens reference plate assy
[3] CCD unit attaching screws (Can be
removed when replacing the CCD unit.)
(2) Reason for prohibition

Since the accuracy of the CCD unit is guaranteed as a unit, no accuracy is guaranteed if it is disassembled.
Therefore, screws that lead to the disassembly of the CCD unit must not be removed.
The lens reference plate assy becomes a reference for the installation of the CCD unit and removing it may
cause the light axis to shift. Therefore, the attaching screws of the lens reference assy must not be removed.
113
6. OTHERS Field Service Ver1.0 Feb.2006
B. Mirror unit/exposure unit

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(1) Positions not allowed to be adjusted

• Positions at which the mirror unit and the exposure unit are installed
[2] [1] 50gaf2c137na
[1] Mirror unit [2] Exposure unit

The distance between the mirror unit and the exposure unit has an effect on the magnification in the sub scan
direction of the original to be read. Accordingly, the positions at which the mirror unit and the exposure unit are
installed must not be arbitrarily adjusted. However, when removing the exposure unit and the scanner wire, the
adjustments can be made only if they are reinstalled by using the optics unit positioning jig.
114
6.1.2 Write section

A. Write section cover
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• 4 attaching screws of the write section cover
[1]
[2]
50gaf2c138na
[1] Screws not allowed to be removed [2] Write section cover

The inside of the write section becomes a laser beam path. Opening the cover allows the entry of dust and dirt
into the inside and they may block the laser beam path. Therefore, the attaching screws of the write section
cover must not be removed.
115
B. Write attaching plate

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• 5 attaching screws of the write mounting board
[2]
[1]
[1] [1]
50gaf2c139na
[1] Screws not allowed to be removed [2] Write attaching plate

The write attaching plate is a reference for the attaching angle of the write section against the drum. Removing it
may impair the parallelism of the drum with the write section, thus resulting in the image being deformed. There-
fore, the attaching screws of the write attaching plate must not be normally removed.
116
6.1.3 Developing unit

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• 2 attaching screws of the developer restriction blade
• 1 fixing screw of the magnet adjustment plate
• Ds adjustment screws
Developing unit at 2 places (inside the cover)
[6]
[4] [5]
[3]
[2] [1] 50gaf2c140na
[1] Developer restriction blade [5] Screws not allowed to be removed

[2] Developing roller (Ds adjustment screws)
[3] Screws not allowed to be removed [6] Screws not allowed to be removed
[4] Magnet adjustment plate

Each of the developer restriction blade and the magnet adjustment plate is used to determine the height of
developer on the developing roller. And the Ds adjustment screws are also used to determine the distance
between the drum and the developing roller. These parts are adjusted to an appropriate value in advance.
Therefore do not remove these attaching screws and fixing screws.
117
6.1.4 Drum unit

bizhub 500 / 420

• Ds adjustment screws, 2 pcs.
[1]
50gaf2c188na
[1] Screws not allowed to be removed (Ds adjustment screws)

The Ds adjustment screws are used to determine the distance between the drum and the developing roller and
they are adjusted to an appropriate value in advance. Therefore, do not remove these fixing screws.
118
6.2 List of parts to be disassembled and reassembled
bizhub 500 / 420

Note
• This list shows the explanation of the disassembly and reassembly of the parts which are consid-
ered necessary to replace (other than periodically replaced parts). However, these parts except for
the covers are not required to be disassembled while in normal service operations.
• For the method of replacing the periodically replaced parts, see "3.5 Maintenance procedure of
No. Section Part name Page referred to

1 Cover Rear cover /1 P.120
2 Rear cover /2 P.120
3 Rear cover /3 P.121
4 Right cover /Up P.122
5 Right cover /Lw P.123
6 Left cover P.123
7 Front door P.124
8 Upper cover /Rt P.125
9 Original glass P.125
10 Upper cover /Fr P.127
11 Upper cover /Lt P.127
12 Upper cover /Rr P.127
13 Front cover P.128
14 Operation panel Operation panel P.129
15 Scanner section CCD unit P.130
16 Exposure lamp P.133
17 Exposure unit P.134
18 Scanner wire P.137
19 Toner supply section Toner supply unit P.139
20 Paper feed section Tray 1 P.143
21 Tray 2 P.143
119
6.3 Disassembling/assembling procedure

bizhub 500 / 420
Caution
• When disassembling or assembling the parts, be sure the power cord has been unplugged from
the power outlet.
6.3.1 Removing/reinstalling the rear cover /1

A. Procedure
[1]
rear cover /1 [2].
steps in reverse.
[2] [1] 50gaf2c049na

A. Procedure
1. Remove the rear cover /1.
(See P.120)
(See P.121)
the 2 handles [2].
[2]
[2] [1] 50gaf2c050na
120

[2]
bizhub 500 / 420

rear cover /2 [2].
steps in reverse.
[1] 50gaf2c051na

A. Procedure
Note
• The screw [1] is attached with the washer [2].
Be careful that it does not get lost.

rear cover /3 [4].
steps in reverse.
[1][2]
[4] [3] 50gaf2c052na
121
6.3.4 Removing/reinstalling the right cover /Up

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A. Procedure
1. Open the bypass tray.
(See P.123)
2. Pull the ADU release lever [1] to open ADU [2].
[2]
[1] 50gaf2c053na
[1] [2] 3. Remove the 2 screws [1] and then remove the
right cover /Up [2].
steps in reverse.
50gaf2c054na
122
6.3.5 Removing/reinstalling the right cover /Lw

A. Procedure
bizhub 500 / 420

1. Open the bypass tray [1].
right cover /Lw [3].
steps in reverse.
[1]
[3]
[2] 50gaf2c055na
6.3.6 Removing/reinstalling the left cover

A. Procedure
1. Loosen the 2 screws [1].
[1]
2. Remove the 4 screws [2] and then remove the left
cover [3].
steps in reverse.
[3]
[2] 50gaf2c056na
123
6.3.7 Removing/reinstalling the front door

bizhub 500 / 420
A. Procedure
2. Remove the screw [2] and then remove the sup-
port plate [3] and the front door at the same time.
Note
[5]
• When installing the front door, be sure first to
fit the installation hole [4] to the shaft [5].
[4]
steps in reverse.
[1]
[2]
[3]
50gaf2c057na
124
6.3.8 Removing/reinstalling the original glass

A. Procedure
bizhub 500 / 420

[1]
upper cover /Rt [2].
[2] 50gaf2c058na

glass attaching plate /Up [2].
[1] [2] 50gaf2c059na
125
3. Loosen the 2 screws [1] and slide the glass

[6] [1] [5]
bizhub 500 / 420
attaching plate /Lw [2].

4. Loosen the screw [3] and slide the glass holding
plate [4].
5. Remove the original glass [5].
Note
• When removing the original glass, be careful
not to stain the position to which the shading
correction plate [6] is attached.
[2]
[3]
[4]
50gaf2c060na
Note
[1] [3]
• When installing the original glass [1], be sure
to fix first the glass attaching plate /Lw [2]
while pressing it against the original glass
and then fix the glass holding plate [3] while
also pressing it against the original glass.

steps in reverse.
[2] 50gaf2c061na
126
6.3.9 Removing/reinstalling the upper covers /Fr and /Lt

A. Procedure
bizhub 500 / 420

1. Remove the original glass.
[4] [5]
(See P.125)
2. Loosen the screw [1].
upper cover /Fr [3].
upper cover /Lt [6].
steps in reverse.
[6]
[2] [3] [1] 50gaf2c062na
6.3.10 Removing/reinstalling the upper cover /Rr

A. Procedure
[2]
(See P.125)
2. Remove the upper covers /Fr and /Lt.
(See P.127)
3. Remove DF from the main body.
upper cover /Rr [2].
steps in reverse.
[1] 50gaf2c063na
127
6.3.11 Removing/reinstalling the front cover

bizhub 500 / 420
A. Procedure
[1] 2. Pull out the tray 1 [2].
3. Remove the screw [3] and then remove the front
cover [4].
steps in reverse.
[4] [2]
[3]
50gaf2c160na
128
6.3.12 Removing/reinstalling the operation panel

A. Procedure
bizhub 500 / 420

1. Remove the 4 screw caps [1] and then remove
the 4 screws [2].
2. Remove the connector [4] of the operation board
[1]
(OB) [3] and then remove the operation panel [5].
Note
• When installing the operation panel, be sure
to install the connector [4] without fail.

steps in reverse.
[2]
[5]
[3]
[4]
50gaf2c064na
129
6.3.13 Removing/reinstalling the CCD unit

bizhub 500 / 420
A. Procedure
[2] [1]
(See P.125)
2. Remove the 2 screws [1] and the remove the lens
light blocking cover assy [2].
lens light blocking cover [5].
5. Remove the 3 screws [6] and then remove the rib-
bon cable cover [7].
Note
• Be careful not to damage the scanner wire.
[4] [3] [5] [4] [6]
[4] [7] 50gaf2c066na
6. Remove the ribbon cable [2] from the CCD board

(CCDB) [1].
[1] [2] 50gaf2c065na
130
Note
bizhub 500 / 420

• When removing the ribbon cable [1], be sure
to bring down the lock lever [3] of the connec-
tor [2] in the arrow-marked direction to
release the lock and pull out the ribbon cable.
[2] [1] [3] 50gaf2c067na
• When installing the ribbon cable [1], be sure

to check to see if the lock lever [2] is
released. And insert deep it into connector [3]
securely while taking note that the conductor
side of the ribbon cable comes to the oppo-
site side of the lock lever.
[3] [2] [1] 50gaf2c068na
• After that, bring the lock lever [1] back to its

original position and lock the ribbon cable
[2].
[2] [1] 50gaf2c069na
131

bizhub 500 / 420
CCD unit [2].

steps in reverse.
Note
• After installing the CCD unit, be sure to con-
duct the image adjustment in the service
mode. (See P.163, P.164, P.165, P.166, P.167,
P.168)
[1] [2] 50gaf2c070na
132
6.3.14 Replacing the exposure lamp
bizhub 500 / 420

Note
• Be careful not to touch the lamp section of the exposure lamp (L1) with bare hands.
A. Procedure
1. Remove the original glass. At this time, remove
[3] [2] [1]
also the glass attaching plate /Lw.
(See P.125)
3. Remove the harness clamp [2].
4. Remove the 2 screws [3] and slide the exposure
lamp (L1) [4] for removal.
steps in reverse.
[4]
[3]
50gaf2c073na
133
6.3.15 Removing/reinstalling the exposure unit

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Note
• When installing the exposure unit, be sure to use the optics unit positioning jig.
• When installing the exposure unit, be sure to conduct the image adjustment in the service mode.
(See P.163, P.164, P.165, P.166, P.167, P.168)
A. Procedure for removal

[3] also the glass attaching plate /Lw.
(See P.125)
(See P.127)
3. Remove the upper cover /Rr.
(See P.127)
4. Remove the operation panel.
(See P.129)
5. Remove the wiring harness [2] from the 2 harness
clamps [1].
operation panel unit /Lw assy [4].
[2] [1] [4] 50gaf2c071na
134
7. Move the exposure unit [1] to the notch [2] of the

[7] [5] [3]
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frame.
9. Remove the screws [4] and [5] and then remove
the exposure unit from the exposure unit mount-
ing plates /Fr [6] and /Rr [7].
10. Slide the exposure unit [1] for removal.
[1] [2]
[4]
[6]
50gaf2c074na
135
B. Procedure for reinstallation

1. Move the V-mirror unit [1] to the vicinity of the V-
bizhub 500 / 420
mirror positioning hole [2].

2. Insert the optics unit positioning jig [3] into the V-
[10] mirror positioning hole and fix the V-mirror unit.
Note
• Be sure to insert the optics unit positioning jig
[8]
from the front side and pass it through the V-
mirror unit.
[6]
3. Insert the optics unit positioning jig [5] into the
exposure unit positioning hole [4].
4. Hit the exposure unit [6] against the optics unit
positioning jig [5].
5. Install the exposure unit to the exposure unit
mounting plates /Fr [7] and /Rr [8] with the screws
[9] and [10].
6. Pull off the 2 optics unit positioning jigs.
7. For the parts to be installed in the succeeding
steps, be sure install them following the removal
steps in reverse.
[1] [2] [3] [4] [5]
[9]
[7]
50gaf2c075na
136
6.3.16 Stretching the scanner wire
bizhub 500 / 420

Note
• Be sure to wind the scanner wire around the pulley closely with no scanner wire overlapping each
other.
• When restretching or replacing the scanner wire, be sure to use the optics unit positioning jig.
• When restretching or replacing the scanner wire, be sure to conduct the image adjustment in the
service mode. (See P.163, P.164, P.165, P.166, P.167, P.168)
A. Procedure
[1]
also the glass attaching plate /Lw.
(See P.125)
(See P.127)
(See P.127)
4. Remove the operation panel.
(See P.129)
5. Remove the operation panel unit /Lw assy.
(See P.134)
6. Move the V-mirror unit [1] to the vicinity of the V-
mirror positioning hole [2].
7. Insert the optics unit positioning jig [3] into the V-
[2] [3] mirror positioning hole and fix the V-mirror unit.
50gaf2c076na
Note
• Be sure to insert the optics unit positioning jig
[3] from the operation panel side and pass it
through the V-mirror unit.
137
8. Loosen the 2 hexagon socket screws [3] of the

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[8] [7] [6] [1] drive pulley on the side so that the drive pulley [1]
can rotate freely against the pulley shaft [2].
9. Drop the metal ball [5] provided at the intermedi-
ate section of the scanner wire [4] into the drive
[3] pulley installation hole and, with this as a starting
point, wind the wire 6 turns [6] outwards and 5
[4]
[11] turns [7] inwards.
[5] [9]
Note
[2] • The scanner wires are color-coded. Be sure
to use the one painted black on the front side
[12] with the one with no paint on the rear side.
• For each scanner wire that is wound around
the pulley, be sure to use on the outside the
one at the end of which the metal ball [8] is
[12]
provided and on the inside the one at the end
of which the screw thread [9] is provided.
• For each scanner wire, be sure to pull out the
[1] [6] [7] [8]
one that is wound on the outside in the paper
[10]
feed direction [10] from the upper side of the
drive pulley and the one wound on the inside
in the paper exit direction [11] from the upper
[3]
side of the drive pulley.
[4]
10. After completion of the winding of the scanner
[9] [5] wire, be sure to fix it with the tape [12] so that it
does not come off.
50gaf2c077na
11. Pass the scanner wire [2] provided with the metal
[1] ball [1] through the pulley [4] on the paper exit side
[3] [4] [8] after passing through under the V-mirror unit [3],
[6] [2] and pass further through the pulley [5] inside the
V-mirror unit. And then hook it to the notch [6] of
the frame.
12. Pass the scanner wire provided with the screw
[5]
[2] thread through the pulley [7] on the paper feed
side. And then pass it from above through the pul-
ley [8] on the outside of the V-mirror unit and fur-
[7]
ther through under the V-mirror unit and, with the
[4] nut [9] and the washer [10], fix it at the tension of
1.3 kg to 1.7 kg.
[5]
[10] [9]
[8] 50gaf2c078na
138
Note
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• When fixing the screw thread side of the
scanner wire, be sure fix it with a tension of
1.3 to 1.7 kg applied by a spring balance in the
arrow-marked direction [1].
• When fixing the scanner wire, be sure to
check to see if the V-mirror unit has been
fixed with the optics unit positioning jig.
• Be sure to tighten up the set screw of the
[1]
drive pulley that has been loosened.
50gaf2c079na
• Be sure to peel off the tape that has been
used for fixing.
13. Install the exposure unit.

(See P.134)
Note
• Be sure to slide the exposure unit and check
to see if it operates smoothly.
6.3.17 Removing/reinstalling the toner supply unit
Note
• Be sure to remove the toner bottle in advance.
A. Procedure
[1]
(See P.125)
(See P.127)
(See P.127)
(See P.122)
(See P.120)
system unit cover [2].
[1] [2]
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139
7. Remove the 2 screws [1] and then remove the rib-

[1]
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bon cable cover [2].

8. Remove the ribbon cable [3].
overall control board mounting box [6].
[6] [3] [2] [5]
[5] [4] 50gaf2c081na
140

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ozone filter mounting assy [3].
[2] [3]
[1]
50gaf2c082na

15. Remove the board support [3] and the remove the
drum motor (M1) [4].
[2]
[3]
[1]
[4] 50gaf2c083na
141

[2] [1]
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toner supply unit [3].

steps in reverse.
[3] [2]
[2]
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142
6.3.18 Removing/reinstalling the trays 1 and 2
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Note
• The trays 1 and 2 are of the same form and of the same mechanism. The procedure given here
shows mainly the operations employed for the tray 1.
• When there remains paper in the tray, be sure to remove it thoroughly before starting operations.
A. Procedure
1. Pull out the tray 1 [1].
2. Remove the screw [2] and then remove the stop-
per [3].
[6]
Note
• When installing the stopper, be sure to set the
positioning hole [4] to the projection [5].
3. While holding down the stopper [6], pull out the

tray 1 for removal.
Note
• When installing the tray 1, be sure to check to
see if the tray can be pulled out and pushed in
smoothly.
• When installing the tray 1, be sure to check to
see if the tray is not thoroughly pulled out.
[1]
[4] [5]
[3]
[2]
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143
6.4 Option counter

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6.4.1 Configuration of the key counter

As shown below, the key counter is configured as a product so that it can be supplied according to the applica-
tion. In principle, the key counter can be installed by obtaining the key counter kit 4.
[1] Cover [2] Mounting [3] Key [4] Counter [5] Screws [6] Screws [7] Screws
plate counter socket for the for the for the
cover counter mounting
socket plate
Key counter kit 4* z z z z z z z
Key counter z z z z
mounting kit*
Key counter z
* In the kit, parts (such as a mounting plate, mylar, wire saddle and screws) that are not used for 500/420
are included.
[1] [2] [3]
[4] [5] [6] [7]

50gaf2c183na
144
6.4.2 Installation procedure of the key counter

1. Remove the upper cover /Lt.
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(See P.127)
2. Remove the split cover [1] of the upper cover /Lt.
3. Put the harness [2] for the key counter through the
upper cover /Lt.
[1] 4. Install the upper cover /Lt.
[2]
50gaf2c184na
5. Install the mounting plate [4] with the 3 screws [3].
[4]
[3]
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6. Hook up the connector of the key counter socket.

7. Install the counter socket [6] with the 2 screws [5].
[5] [6]
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8. Install the cover [8] with the 2 screws [7].
[8]
[7]
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145
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146
Field Service Ver1.0 Feb.2006 7. HOW TO USE THE ADJUSTMENT/SETTING SECTION
ADJUSTMENT/SETTING
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7. HOW TO USE THE ADJUSTMENT/SETTING SECTION
7.1 Composition
This part "ADJUSTMENT/SETTING" describes items to be adjusted and the method of adjustment that is
required by this machine, it also gives detailed explanations.
A. Checking before starting work

When conducting claims in the field, it is necessary to check first the following:
1. Are the power supply and voltage secured in accordance with the specifications?
2. Is the power supply properly grounded?
3. Is any equipment that repeatedly consumes a lot of electricity connected to the same power supply? (e.g.:
Electric noise sources such as elevator and air conditioner)
4. Are environmental conditions suitable for the machine?
• High temperature and high humidity, direct sunlight, air ventilation, etc.
• Levelness of the location on which the machine is installed.
5. Does the cause of poor images lie in the original itself?
6. Is density selected properly?
7. Is the original glass stained?
8. Is proper paper used for copy?
9. Are copy consumable replaced with new ones at their life? (e.g.: Developer, drum, cleaning blade, etc)
10. Is toner filled?
B. Checkpoints when conductions on-site service

Due attention should be paid to the following when repairing the machine.
1. Be sure to unplug the power cord from the power outlet. Also, when operating the machine with the power
supplied, be careful of the scan of the exposure unit and be sure not to get caught by the gear.
2. The fusing section may be very hot. Be careful not to get burnt when handling it.
3. The developing unit is strongly magnetized. Be careful not to bring a watch and instrument near to the unit.
4. Be careful not to damage the drum with a tool.
5. Be careful not to touch IC directly with bare hands.
147
8. UTILITY MENU Field Service Ver1.0 Feb.2006
8. UTILITY MENU
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8.1 List of utility mode

Note
• For detail on the utility mode, refer to "User's guide".
[1] One-Touch [1] Scan [1] Address [1] E-Mail

Registration Book [2] FTP
[3] SMB
[4] User Box
[2] Group
[3] Program
[4] Subject/Text [1] Subject
(for E-mail) [2] Text
[2] Fax [1] Address [1] Abbr. Dial
Book [2] E-Mail
[3] User Box
[2] Group
[3] Program
[3] User Box [1] Public/Personal User Box (HDD installed) /Confidential RX User Box
(HDD not installed)
[2] Bulletin Board User Box
[2] User Setting [1] System Set- [1] Language Selection
ting [2] Measurement Unit Setting
[3] Paper Tray [1] Paper Type
Setting [2] Auto Tray Select Setting
[3] Auto Tray Switch ON/OFF
[4] No Matching Paper in Tray Setting
[5] Print Lists
[4] Reset Set- [1] System Auto Reset
ting [2] Auto Reset
[3] Job Reset
[2] Display Set- [1] Sub Screen Display ON/OFF
ting [2] Scan Basic Screen Default Setting
[3] Fax Basic Screen Default Setting
[4] Copy Screen
[5] Fax Active Screen
[3] Initial Setting
[4] Copier Setting
[5] Scanner Setting
148
Field Service Ver1.0 Feb.2006 8. UTILITY MENU
[2] User Setting [6] Printer Set- [1] Basic Setting
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ting [2] Paper Setting
[3] PCL Setting [1] Typeface
[2] Symbol Set
[3] Font Size
[4] Line/Page
[5] CR/LF Mapping
[4] PS Setting
[5] Print Report
[3] Administrator [1] System Set- [1] Power Save Setting
Setting ting [2] Output Set- [1] Print/Fax Output Setting
ting [2] Output Tray Setting
[3] Date/Time Setting
[4] Daylight Saving Time Setting
[5] Weekly [1] Weekly Timer ON/OFF Setting
Timer Setting [2] Time Setting
[3] Date Setting
[4] Select Time for Power Save
[5] Password for Non-Business Hours
[6] Restrict User [1] Restrict Access to Saved Program Jobs
Access [2] Delete Saved Program Jobs
[3] Restrict Access to Job Settings
[7] Expert [1] Original Image Density
Adjustment [2] Erase Adjustment
[3] Finisher [1] Center Staple Position
Adjustment [2] Half-Fold Position
[3] Punch Horizontal Position
[4] Punch Resist Loop Size
[8] List/Counter [1] Management List
[2] Paper Size/Type Counter
[0] Standard Size Setting
[2] Administra- [1] Administrator Registration
tor/Machine [2] Input Machine Address
Setting
[3] One-Touch [1] Scan [1] Address [1] E-Mail
Registration Book [2] FTP
[3] SMB
[4] User Box
[2] Group
[3] Program
149
8. UTILITY MENU Field Service Ver1.0 Feb.2006
[3] Administrator [3] One-Touch [2] Fax [1] Address [1] Abbr. Dial
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Setting Registration Book [2] E-Mail

[3] User Box
[2] Group
[3] Program
[3] User Box [1] Public/Personal Use Box
[2] Bulletin Board User Box
[4] One-Touch [1] Address Book List
Registration List [2] Group List
[3] Program List
[4] E-Mail Subject/Text List
[4] User [1] Authentication Method
Authentication/ [2] User Authentication Setting
Account Track [3] Account Track Setting
[4] Print without Authentication
[5] Counter List
[5] Network [1] Network Setting
Setting [2] TCP/IP Setting
[3] Netware Setting
[4] IPP Setting
[5] FTP Setting
[6] SMB Setting
[7] AppleTalk Setting
[8] LDAP Set- [1] Enabling LDAP
ting [2] Setting Up LDAP
[9] E-Mail Set- [1] E-Mail TX (SMTP)
ting [2] E-Mail Rx (POP)
[0] Detail Set- [1] Device Setting
ting [2] Time Adjustment Setting
[3] Status Notifi- [1] Notification Address Setting
cation Setting [2] Notification Item Setting
[3] Notification Time Setting
[4] PING Confirmation
[5] PSWC Setting
[6] SLP Setting
[7] LPD Setting
[8] SNMP Setting
[9] Prefix/Suffix [1] ON/OFF Setting
Setting [2] Prefix/Suffix Setting
[6] Copier Setting
[7] Printer Set- [1] I/F Timeout
ting
150
Field Service Ver1.0 Feb.2006 8. UTILITY MENU
[3] Administrator [8] Fax Setting [1] Header Information
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Setting [2] Header/Footer Position
[3] Telephone Line Setting
[4] TX/RX Setting
[5] Function [1] Function ON/OFF Setting
Setting [2] Dial-In Setting
[3] Memory RX
[4] Closed Network RX
[5] Forward TX Setting
[6] Remote RX
[7] Confidential RX Password Check
[8] PC-Fax RX Setting
[9] TSI User Box Setting
[6] PBX CN Set
[7] Report Settings
[8] Job Settings List
[9] System [1] IS OpenAPI Setting
Connection [3] Prefix/Suffix Auto Setting
[0] Security Set- [1] Administrator Password
ting [2] User Box Admin. Setting
[3] Administrator Security Level
[4] Security Details
[5] HDD Setting [1] Check HDD Capacity
[2] Delete Unused User Box
[3] Delete Secure Print Documents
[5] Overwrite All Data
[6] HDD Lock Password
[6] Manage- [3] Network Fuction Setting
ment Function
Setting
151
9. LIST OF ADJUSTMENT ITEMS Field Service Ver1.0 Feb.2006
9. LIST OF ADJUSTMENT ITEMS

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After completion of PM
related to fusing unit
Scanner wire, expo-

Replacement parts
Roller parts related

Replacement parts/Others
Page referred to
sure/mirror unit
NVRAM board
to paper feed
Developer
Write unit
CCD unit
Slit glass
Drum
Adjustment/setting items
DF
Machine Printer Print Positioning: Leading Edge P.157 h e {
Area Print Positioning: Side Edge P.158 i f {
Paper Feed Direction Adj. P.159 g d c {
Printer Resist Loop P.161 c {
Bypass Tray Adjustment P.162
Scan Image Position: Leading Edge P.163 d f {
Area Image Position: Side Edge P.164 f g {
Cross Direction Adjustment P.165 e e {
Feed Direction Adjustment P.166 c g d {
Lead Edge Erase Adjustment P.167 j {
Non-Image Area Erase Check P.168 {
Imaging TCR Adjustment P.169 c {
Process Toner Density Adjustment P.170 d c {
Adjustment Laser Diameter Adjustment P.171 e d {
LD1 Offset Adj. P.172 d f e {
LD2 Offset Adj. e g f {
Counter Present Parts Life (Reset) P.178 { {
PM Counter (Reset) P.189 { c { {
PM Counter (Set) {
ADF Paper Feed Direction P.212 d h {
Lead Edge P.213 e i {
Side Edge P.214 g j {
Resist Loop Adj. P.215 c {
Original Size Adj. P.215 h {
Density Adj. P.216 { j k {
Scan Position Adjustment P.217 g f {
Sensor Auto Adjustment P.218 i {
Finisher Center Staple Position P.219 {
Half-Fold Position P.220 {
Punch Horizontal Position P.221 {
Punch Resist Loop P.222 {
Note
• After changing developer, be sure to avoid the printing operation before completion of the TCR
adjustment.
• When replacing the NVRAM board (NRB), be sure to conduct the TCR adjustment after changing
developer.
• When replacing the overall control board (OACB) due to the board being damaged, the NRB that
has been provided on the damaged OACB should be reused on a new OACB in principle. When the
NRB is considered to be damaged and replaced with a new one, be sure to refer to the support
division of the authorized distributor.
• In the NRB, all sorts of various adjustment data, setting data and counter data are stored. Accord-
ingly, when replacing the NRB, be sure to conduct all of the adjustments and the settings and then
replace the parts (drum, developer, cleaning blade, fixing web) the control of which are adjusted
by the counter. Be sure to refer to the support division of the authorized distributor for particulars.
152
Field Service Ver1.0 Feb.2006 10. SERVICE MODE
10. SERVICE MODE
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10.1 List of service mode
Adjustment/setting items page
Machine Printer Area Print Positioning: Leading Edge P.157
Print Positioning: Side Edge P.158
Paper Feed Direction Adj. P.159
Printer Resist Loop P.161
Bypass Tray Adjustment P.162
Scan Area Image Position: Leading Edge P.163
Image Position: Side Edge P.164
Cross Direction Adjustment P.165
Feed Direction Adjustment P.166
Lead Edge Erase Adjustment P.167
Non-Image Area Erase Check P.168
Imaging Process Charging Main Manual Adj. P.169
Adjustment Transfer Manual Adj. P.169
Separation (AC) Manual Adj. P.169
Separation (DC) Manual Adj. P.169
Grid Charging Manual Adj. P.169
Bias Voltage Manual Adj. P.169
TCR Adjustment P.169
Toner Auto Supply P.169
Toner Density Adjustment P.170
Laser Diameter Adjustment P.171
LD1 Offset Adj. P.172
LD2 Offset Adj.
LD1 Bias Adj. P.172
LD2 Bias Adj.
System 1 Marketing Area P.173
Tel/Fax Number P.174
Serial Number P.174
Trouble Isolation P.175
No Sleep P.175
Foolscap Size Setting P.175
Original Size Detection Original Glass Original Size Detect P.176
ADF Original Size Detect
Original Glass Small Size Detect
Detected Size Setting P.176
Install Date P.177
153
10. SERVICE MODE Field Service Ver1.0 Feb.2006

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System 1 Initialization Utility/Administrator Job memory Setting P.177

Setting Data Data
FAX Setting Data
Network Setting Data
Destination Storage Data
CS Remote Care Setting Data
Service Mode Setting Image Process Adj.
(Adj.) Data Data
Machine and ADF
Adjustment Data
All History Data
Counter Total Service P.179
Fax Communication Error P.179
Mode P.179
ADF Counter P.181
Service Call P.181
JAM P.183
Present Parts Life P.187
Optional Parts Life P.178
PM P.189
Reuse P.184
Each Size P.186
Pape Jam History P.184
Jam Counter History P.183
Time Series Trouble (SC) P.183
Each Section Trouble (SC) P.181
State Confirmation Sensor Check P.190
Load Check P.198
Memory/HDD Condition P.205
Memory/HDD Adjust- Memory Check P.205
ment HDD R/W Check P.205
HDD Format P.206
Adj. Data Table P.206
ADF Paper Feed Direction P.212
Lead Edge P.213
Side Edge P.214
Resist Loop Adj. P.215
Original Size Adj. P.215
Density Adj. P.216
Scan Position Adjustment P.217
Sensor Auto Adjustment P.218
154
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Finisher Center Staple Position P.219
Half-Fold Position P.220
Punch Horizontal Position P.221
Punch Resist Loop P.222
Firmware Version P.223
CS Remote Care P.224
System 2 Data Capture P.238
Paper Size Setting • Tray3 P.238
• LCT
DipSW Setting P.238
ISW P.253
Option P.253
Trouble Reset P.253
List Output • Machine Management List P.254
• Adjustments List
• Service Parameter
• Protocol Trace
• Fax Setting List
Test Mode Full Image Halftone P.255
Gradation Pattern (No.2)
Beam Gap Check
Line Check Pattern
Test Pattern Output Mode P.262
Running Mode P.263
Test Fax Line1 *1
FAX Modem/NCU *1
NetWork
System
Fax File Format
Communication
List Output
Function Parameter
Initialization
Enhanced Security CE Password P.266
Administrator Password P.266
Administrator Feature Level P.267
CE Authentication P.267
Billing Setting Counter Setting P.269
Management Function Choice P.270
*1 (See the FK-502 Service Manual)
155
10.2 Setting Method

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This machine is provided with a service mode for various types of adjustments/settings. Data adjusted and/or
set in this mode are stored in the NVRAM board (NRB).
10.2.1 Start and exit of the service mode

You can access the service mode while the power is both turned ON and OFF. In either way, the started service
mode is the same, but how to exit differs.
A. Starting and exiting service mode while the power is ON
1. Check to see if the regular copy screen is displayed.

2. Press the Utility/Counter key.
3. "Meter Count/ Utility screen"
Press [Details].
4. "Meter Count screen"
Press the Stop key and key pad in the order shown below.
Stop → 0 → 0 → Stop → 0 → 1
Note
• When the CE password is set, a password is required to input to enter the service mode.
5. "Service Mode screen"
The service mode is in the start-up condition.
6. Select an item to set.
The setup screen of each item is displayed.
7. Conduct required operations, and press [END/OK] after completion of the operations.
The setting made at step 6 becomes effective.
Press [Exit] to return to the regular copy screen.
B. Starting and exiting service mode while the power is OFF
1. While pressing the Utility/Counter key, turn ON the power switch (SW2).
2. Trouble reset screen appears.
3. Press the [Trouble reset].
4. On the Operation panel, press the following keys.
Stop → 0 → 0 → Stop → 0 → 1
5. Service Mode screen appears.
Note
• When the CE password has been set, you must enter the password to enter the service mode.
6. Press the key for an item you want to configure.
The setting screen for each item appears.
7. Conduct necessary operations and turn OFF the SW2 after completion of operations.
8. The new settings become effective after restart.
156
10.3 Machine Adjust
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10.3.1 Print Positioning: Leading Edge (Printer Area)
Adjusts the leading edge timing of the printer image.
This adjustment is used to change the restart timing of paper of the registration roller and adjust the relative
position in the sub scan direction of the image against the paper.
The adjustment can be made for each paper feed (each tray, bypass feed and ADU). And for the bypass feed, it
is possible to make an adjustment for each type of paper (plain paper, thick paper, thin paper, OHP, envelope
and label).
Note
• Be sure to complete the Paper Feed Direction Adj. (Printer Area) before starting this adjustment.
(See P.159)
A. Procedure

Press [Machine].
2. "Machine Adjust screen"
Press [Printer Area].
3. "Printer Area screen"
Press [Print Positioning: Leading Edge].
4. "Print Positioning: Leading Edge screen"
Select an item to adjust and then press [Test Copy].
Note
• When [Batch] is pressed, no test copy is available.
5. "Test Copy screen"
With paper set in the tray selected, press the Start key to output the test pattern (No. 16).
When paper is fed from the bypass feed, set the corresponding type of paper. And then press the Start
key to output the test pattern (No. 16).
6. Press [END].
7. Measure the leading edge timing with a scale.
[1]
Standard value [1]: 20 ± 0.5 mm
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8. "Print Positioning: Leading Edge screen"

Enter a value through the [+]/[–] or numeric keys and press [Setting].
Setting range: – 12.8 (shorter) to + 12.7 mm (longer)
1 step = 0.1 mm
Press [Restore] to return to a value before change.
9. Repeat steps 4 to 8 until it gets within the standard value.
10. Press [END].
157
10.3.2 Print Positioning: Side Edge (Printer Area)

Changes the laser write timing and also changes the image position on the drum in the main scan direction to
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adjust the mis-centering of the printer image.

For each paper feed (each tray, bypass feed, ADU) and for each paper size (common, small size, large size), the
adjustment can be made.
Note
• Be sure to complete the Cross Direction Adjustment (Scan Area) before making this adjustment.
(See P.159)
A. Procedure

Press [Machine].
Press [Printer Positioning: Side Edge].
4. "Print Positioning: Side Edge screen"
Select an item to adjust and press [Test Copy].
Note
With paper set in the tray selected, press the Start key to output the test pattern (No. 16).
6. Press [END].
7. Fold the output paper into two in the main scan direction to check it for any discrepancy against the
center line of the print.
Standard value: 0 ± 1.5 mm or less
8. "Print Positioning: Side Edge screen"
Setting range: – 12.8 (image: to the rear) to + 12.7 (image: to the front) mm
1 step = 0.1 mm
10. Press [END].
158
10.3.3 Paper Feed Direction Adj. (Printer Area)

A. Printer
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Adjusts the magnification of the printer in the sub scan direction.
This adjustment is used to change uniformly the process speed of the drum and the registration roller and
change the magnification in the sub scan direction of the image on the drum.
The adjustment can be made for each type of paper (normal paper, OHP, thick paper, envelope, label and cus-
tom paper)
Note
• The background of the test pattern to be output is fogging. However, this is not abnormal.
• For thin paper, the setting of normal paper is applicable.
(1) Procedure

Press [Machine].
Press [Paper Feed Direction Adj.]
4. "Paper Feed Direction Adj. screen"
Press [Printer].
5. Select an item for the type of paper and press [Test Copy].
Set A3 (for metric) or 11 x 17 (for inch) paper that is the type of paper selected. And then press the Start
key to output the test pattern (No. 16).
7. Press [END].
8. Measure the magnification in the sub scan direc-
tion with a scale.
Standard value [1]: ± 0.5% or less (190 ± 1 mm or
less)
[1]
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Setting range (normal paper): – 5.0 (smaller) to + 5.0 % (larger)
Setting range (other than the above): – 2.0 (smaller) to + 2.0 % (larger)
1 step = 0.1 %
11. Press [END].
159
B. Fixing motor clock

Makes appropriate a paper feed loop amount between the registration roller and the fusing roller to prevent the
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transfer slippage at the position about 20 mm from the trailing edge of the transfer paper.
The adjustment can be made for each type of paper (normal paper, OHP, thick paper, envelope, label, custom
paper and user paper).
Note
• Printer magnification in the paper through direction: The adjustment of the printer should have
been completed. (See P.159)
• For thin paper, the setting of normal paper is applicable.
(1) Procedure

Press [Machine].
Press [Paper Feed Direction Adj.]
Press [Fixing Motor Clock].
5. Select an item for the type of paper and press [Test Copy].
Set A3 (for metric) or 11 x 17 (for inch) paper that is the type of paper selected. With the print count set at
5, press the Start key to output the test pattern.
7. Press [END].
8. Check all of the 5 output sheets of paper to see if
there occurs no transfer jitter.
Approx.20mm
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Setting range (normal paper): – 5.0 (smaller) to + 5.0 % (larger)
Setting range (user paper): – 0.5 (smaller) to + 0.5 % (larger)
Setting range (other than the above): – 2.0 (smaller) to + 2.0 % (larger)
1 step = 0.1 %
Press [Restore] to return to the value before change.
11. Press [END].
160
10.3.4 Printer Resist Loop

Adjusts the paper loop amount at the registration roller section to adjust a paper skew, wrinkles, or a jam at the
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registration section.
The adjustment can be made for each paper feed (each tray, bypass feed and ADU) and for each paper size
(large size, intermediate size and small size). And for the bypass feed, it is also possible to make an adjustment
for each type of paper (normal paper, thick paper, thin paper, OHP, envelope, and label).
A. Procedure

Press [Machine].
Press [Printer Resist Loop].
3. "Printer Resist Adjustment screen"
Select an item to adjust and press [Test Copy].
Note
With the paper selected set in the tray, press the Start key to output the test pattern (No. 16).
5. Press [END].
6. Check to see if there occurs no paper skew, wrinkle, or jam at the registration section.
7. "Printer Resist Adjustment screen"
Setting range:
For bypass feed thick paper (large/small), bypass feed thin paper (large/small), bypass feed OHP (large/
small), bypass feed envelope (large/small), and bypass feed label (large/small):
– 16.64 (smaller) to + 16.51 mm (larger)
1 step = 0.13 mm
For other than the above:

• Setting range for bizhub 500: – 32.00 to + 31.75 mm 1 step = 0.25 mm
• Setting range for bizhub 420: – 26.88 to + 26.67 mm 1 step = 0.13 mm

9. Press [END].
161
10.3.5 Bypass Tray Adjustment

Conduct this adjustment when the paper size of the bypass tray is not detected correctly.
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A. Procedure

Press [Machine].
Press [Bypass Tray Adjustment].
3. "Bypass Tray Adjustment screen"
Press [Max. Width] to expand the guide plate of the bypass tray to the maximum, and then press the Start
key.
4. When the adjustment is completed normally, "OK" is displayed in the "Result" area.
5. Press [Min. Width] to narrow the guide plate of the bypass tray to the minimum, and then press the Start
key.
6. When the adjustment is completed normally, "OK" is displayed in the "Result" area.
7. Press [Test Copy].
Check to see if the size of paper set in the bypass tray is detected correctly and then press [END].
9. Repeat steps 3 to 8 when the paper size is not correct.
10. Press [END].
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10.3.6 Image Position: Leading Edge (Scan Area)

Adjusts the leading edge timing while in the scan in the platen mode.
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This adjustment is used to adjust the position at which the read is started in the sub scan direction while the
original is being scanned by the exposure unit.
A. Procedure

Press [Machine].
Press [Scan Area].
3. "Scan Area screen"
Press [Image Position: Leading Edge].
4. "Scan Area (Image Position: Leading Edge) screen"
Press [Test Copy].
With the test chart set on the original glass, select A3 (for metric) or 11 x 17 (for inch) paper and press the
Start key.
6. Press [OK].
7. Check the scanner leading edge position (original glass).
Standard value: a. Envelope 0 ± 2.5 mm or less
b. Other paper 0 ± 1.5 mm or less
8. "Scan Area (Image Position: Leading Edge) screen"
Setting range: – 2.0 (shorter) to +2.0 mm (longer)
1 step = 0.1 mm
10. Press [END].
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10.3.7 Image Position: Side Edge (Scan Area)

Adjusts the mis-centering of the image in the main scan direction while in the scan in the platen mode.
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Note
• Be sure that the adjustment of the Print Position: Side Edge has been completed.
(See P.158)
A. Procedure

Press [Machine].
Press [Scan Area].
Press [Image Position: Side Edge].
4. "Scan Area (Image Position: Side Edge) screen"
Press [Test Copy].
Start key.
6. Press [OK].
7. Fold the output paper into two at the center in the main scan direction and check it for discrepancy
against the center line of the print.
Setting range: – 2.96 (image: to the rear) to + 2.96 mm (image: to the front)
1 step = 0.04 mm
10. Press [END].
164
10.3.8 Cross Direction Adjustment (Scan Area)

Adjusts the magnification of the image in the main scan direction while in the scan in the platen mode and in the
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DF mode.
A. Procedure

Press [Machine].
Press [Scan Area].
Press [Cross Direction Adjustment].
4. "Scan Area (Cross Direction Adjustment) screen"
Press [Test Copy].
With the test chart set on the original glass or ADF, select A3 (for metric) or 11 x 17 (for inch) paper and
press the Start key.
6. Press [OK].
7. Measure the magnification in the main scan direc-
tion with a scale.
Standard value [1]: ± 0.5 % or less (200 ± 1 mm
or less)
[1]
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Setting range: – 5,0 (smaller) to + 5.0% (larger)
1 step = 0.1%
10. Press [END].
165
10.3.9 Feed Direction Adjustment (Scan Area)

Adjusts the magnification of the image in the sub scan direction while in the scan on the original glass.
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This adjustment is used to change the scan speed of the exposure unit.
A. Procedure

Press [Machine].
Press [Scan Area].
Press [Feed Direction Adjustment].
4. "Scan Area (Feed Direction Adjustment) screen"
Press [Test Copy].
Start key.
6. Press [OK].
7. Measure the magnification in the sub scan direc-
tion with a scale.
Standard value [1]: ± 0.5 % or less (200 ± 1 mm
or less)
[1]
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8. "Scan Area (Feed Direction Adjustment) screen"

Setting range: – 1.00 (smaller) to + 1.00% (larger)
1 step = 0.05%
10. Press [END].
166
10.3.10 Lead Edge Erase Adjustment

Adjusts the leading edge erasure amount.
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A. Procedure

Press [Machine].
Press [Lead Edge Erase Adjustment].
3. "Lead Edge Erase Adjustment screen"
Press [Test Copy].
With A3 (for metric) or 11 x 17 (for inch) paper selected, press the Start key to output the test pattern (No.
16).
5. Press [OK].
6. Check the printer leading edge erasure amount.
[1]
Standard value [1]: 3.5 mm or less
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7. "Lead Edge Erase Adjustment screen"

Setting range: – 2.0 (erasure: smaller) to + 2.0 mm (erasure: larger)
1 step = 0.1 mm
9. Press [END].
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10.3.11 Non-Image Area Erase Check

When installing this machine, or when moving its installation location, check to see if the non-image area erase
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check mechanism of the copy applied setting operates correctly in its installation location, and adjust automati-
cally the sensitivity with which the non-image area is detected.
Pre-arrangements:
• Open DF fully to the limit.
• Avoid putting anything on the original glass.
• Clean the original glass.
A. Procedure

Press [Machine].
Press [Non-Image Area Erase Check].
3. "Non-Image Area Erase Check screen"
Press the Start key.
4. Check to see if "OK" is displayed.
5. Press [OK].
When anything other than "OK" is displayed, see "B. Problems and their countermeasures" to check again
the non-image area erase setting.
B. Problems and their countermeasures

When a problem is detected by checking the non-image area erase check, an error number is displayed as
shown below.
(1) Error 1
Countermeasure - 1
When the non-image area erase function is not used very frequently, or when copy originals that have a dark
background are not copied very frequently in non-image area erase, the copier can be used in the current instal-
lation location. However, when copy originals that have a dark background are frequently copied, install the
copier in a location where less external light gets in (darker) than the present location, and check the non-image
area erase check mode again.
(2) Error 2
Countermeasure - 2
When the non-image area erase function is not used very frequently, the copier can be used in the current instal-
lation location. However, if the non-image area erase function is frequently used, install the copier in a location
where less external light gets in (darker) than the present location, and check the non-image area erase check
mode again. At this time, when there is a bright light source such as a fluorescent light installed directly above
the copier, reconsider the installation location, or take some measures to shield the light source and check the
mode again.
168
10.4 Imaging Process Adjustment
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10.4.1 Charging Main Manual Adj.
Do not conduct this adjustment in the field.
10.4.2 Transfer Manual Adj.

10.4.3 Separation (AC) Manual Adj.

10.4.4 Separation (DC) Manual Adj.

10.4.5 Grid Charging Manual Adj.

10.4.6 Bias Voltage Manual Adj.

10.4.7 TCR Adjustment

When changing developer, conduct this adjustment before starting the copy operation. The developer counter
is automatically reset.
Note
• When changing developer, be sure not to conduct the copy operation before completion of the
TCR adjustment.
A. Procedure

Press [Imaging Process Adjustment].
2. "Process screen"
Press [TCR Adjustment].
3. "TCR Adjustment screen"
4. Check to see if "OK is displayed, and also check the TCR adjustment data value.
Note
• The adjustment is completed in about 180 seconds.
• When there occurs a TCR adjustment error due to the developer agitating operation not com-
pleted successfully, the message "operating ..." disappears and an error code is displayed.
(See P.285)
5. Press [OK].
10.4.8 Toner Auto Supply

Since this is normally conducted automatically, do not conduct this adjustment in the field.
169
10.4.9 Toner Density Adjustment

This adjustment can be used to increase and/or decrease the toner density of developer.
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Use this adjustment when an image fogging occurs due to the increased toner density of developer and you
want to decrease the toner density.
A. Procedure

2. "Process screen"
Press [Toner Density Adjustment].
3. "Toner Density Adjustment screen"
Enter a value through the [+]/[–] or numeric keys.
Setting range: – 2 (toner density reduced) to + 2 (toner density increased)
1 step = 1
Note
• The set value is a value relative to the present set value. When the set value is set to "0," this
returns the toner density back to the normal level.
4. Press the Start key.
5. While in the adjustment, a message "operating ..." is displayed. And after completion of the adjustment, it
disappears.
Note
• The toner density is automatically adjusted according to a value set.
• When an error code is displayed while in the toner density adjustment, be sure to check the
expected defective parts given in the error code list and then conduct again the toner density
adjustment.
(See P.285)
6. Press [OK].
170
10.4.10 Laser Diameter Adjustment

The MPC value can be corrected by entering a set value to change the image density (dot diameter).
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Major cases in which this adjustment is used.
• When you want to change the image density.
• When replacing the write unit or TCSB (toner control sensor board), or when cleaning the dust proof glass.
A. Procedure

2. "Process screen"
Press [Laser Diameter Adjustment].
3. "Laser Diameter Adjustment screen"
Setting range: – 3 (thinner) to + 3 (denser)
1 step = 1
Note
• When an adjustment is made in the denser direction, this increases the dot diameter with the
toner consumption also increased.
5. While in the adjustment, a message "operating ..." is displayed. And after completion of the adjustment, it
disappears.
6. Press [OK].
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10.4.11 LD1 Offset Adj. / LD2 Offset Adj.

Adjusts the 2 laser beam amount (LD1/LD2) equally.
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Be sure to make this adjustment when replacing the write unit, drum and developer.
Note
• Make sure that the TCR adjustment, the toner density adjustment and the dot diameter adjust-
ment have been completed.
A. Procedure

2. "Process screen"
With an item displayed by [ ↑ ]/[ ↓ ], press "LD1 Offset Adj." / "LD2 Offset Adj.".
3. "LD1 Offset Adj. screen" / "LD2 Offset Adj. screen"
Select "Normal Paper" or "Thick Paper" and press [Test Copy].
With corresponding A3 (for metric) or 11 x 17 (for inch) paper set, press the Start key to output the test
pattern.
5. Press [END].
6. Check the test pattern.
Standard value: Check to see if the density of the
image patterns created by LD1/LD2 is the same,
and if the starts of the patterns in the high-lighted [1]
section are aligned between the 2 reference lines
[1] (± 1 gap is OK).
[1] Reference lines
LD1 LD2 LD1 LD2 LD1 LD2 LD1 LD2
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7. "LD1 Offset Adj. screen" / "LD2 Offset Adj. screen"

When outside the standard value, enter a value through the [+]/[–] or numeric keys and press [Setting].
Setting range: – 128 (thinner) to + 127 (denser)
1 step = 1 (Pressing the button for a long period allows the value to be changed in increments of 10
steps.)
8. Repeat steps 2 to 7 until it gets inside the standard value.
9. Press [OK].
10.4.12 LD1 Bias Adj. / LD2 Bias Adj.

172
10.5 System 1
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10.5.1 Marketing Area
Sets the marketing area of the main body and the fax.
• Marketing area of the main body:
Japan, US, Europe, Other 1, Other 2, Other 3, Other 4
• Fax Target:
US (America), CA (Canada), JP (Japan), AU (Australia), NZ (New Zealand), EU (Europe), DE (Germany), GB
(England), FR (France), CH (Switzerland), NL (Netherlands), BE (Belgium), AT (Austria), NO (Norway), SE (Swe-
den), FI (Finland), IE (Ireland), DK (Denmark), IT (Italy), ES (Spain), PT (Portuguese), PL (Poland), ZA (South
Africa), TW (Taiwan), SA (Saudi Arabia), CN (China), MY (Malaysia), SG (Singapore), KR (Korea), HK (Hong
Kong), OT (Argentine)
A. Procedure

Press [System 1].
2. "System Input screen"
Press [Marketing Area].
3. "Marketing Area screen"
Press [Japan] to [Other 4] to select a marketing area.
4. When no FK-502 is provided, press [END] to complete the marketing area.
When FK-502 is provided, press [Fax Target].
5. "Fax Target screen"
Select the marketing area of the fax by [+]/[–].
6. Press [END] for registration.
7. "Marketing Area screen"
Press [END] to complete the marketing area.
173
10.5.2 Tel/Fax Number

Sets the telephone number and the fax number of the service station that are displayed on the screen when a
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service call occurs.

These telephone and fax numbers are also displayed as the service center contact of the basic screen help of
the user screen.
A. Procedure

Press [System 1].
Press [Tel/Fax Number].
3. "Service Telephone/Fax Number Setting"
Press [TEL] or [FAX].
4. Enter the telephone number or fax number through the copy count setting key.
5. When setting both the telephone number and the fax number, repeat steps 3 to 4.
6. Press [END].
Note
• Pressing the Clear key erases all the figures of the items selected.
10.5.3 Serial Number

Sets and displays the serial numbers of the main body and the optional devices.
Caution
• Be absolutely sure not to change the serial numbers of the main body set when installing them.
Otherwise, a fusing temperature abnormality may result.
A. Procedure

Press [System 1].
Press [Serial Number].
A serial number that is registered is displayed.
3. "Serial Number Input screen"
Press a device to be registered: [Printer (Body)], [Option Tray], [LCT], [Finisher], [Fax #1], [Fax #2], [Punch
Kit], [Suddle Kit], [Mail Bin Kit].
4. "Soft Keyboard screen"
Enter a serial number through the alphabet and numeric keys.
5. Press [OK].
Press [Clear] if you want to make the settings entered invalid.
6. Repeat steps 3 to 5 to enter the serial number of each device.
7. Press [OK].
174
10.5.4 Trouble Isolation

When each function (device) is in trouble, isolating a trouble allows the limited use of this machine.
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A. Procedure

Press [System 1].
Press [Trouble Isolation].
3. "Trouble Isolation screen"
Press [1] or [2] to display an item and set the isolation by [Set] or [Unset] of each item.
4. Press [END].
10.5.5 No Sleep
Sets the availability/unavailability of the sleep while in the administrator mode.
A. Procedure

Press [System 1].
Press [No Sleep].
3. "No Sleep screen"
Set the availability/unavailability of the sleep by [Permit] or [Prohibit].
4. Press [END].
10.5.6 Foolscap Size Setting

Sets the Foolscap size.
A. Procedure

Press [System 1].
Press [Foolscap Size Setting].
3. "Foolscap Size Setting screen"
Press [81/2 x 13], [81/4 x 13], [81/8 x 131/4] or [8 x 13] to set a Foolscap size.
4. Press [END].
175
10.5.7 Original Size Detection

Sets the detection size of the original size on the original glass and ADF.
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A. Procedure

Press [System 1].
Press [Original Size Detection].
3. Press [Original Glass Original Size Detect] of the menu.
4. "Original Glass Original Size Detect screen"
Press one of the 4 types to set a size series to be detected on the original glass.
5. Press [ADF Original Size Detect] of the menu.
6. "ADF Original Size Detect screen"
Press one of the 4 types to set a size series to be detected on ADF.
7. Press [Original Glass Small Size Detect] of the menu.
8. "Original Glass Small Size Detect screen"
Press either [Detected Size] or [A4S / 81/2 x 11S] to set the minimum size to be detected on the original
glass.
9. Press [OK].
10.5.8 Detected Size Setting

Sets the size detection of the bypass tray and those other than the bypass tray in B series or K size (8K/16K
size).
A. Procedure

Press [System 1].
Press [Detected Size Setting].
3. "8K/16K Select screen"
Press [B series] or [K size] to set the size series to be detected.
4. Press [END].
176
10.5.9 Install Date

Sets the start date of the total counter.
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A. Procedure

Press [System 1].
Press [Install Date].
3. "Install Date screen"
Press Year (4 digits), Month (2 digits), Day (2 digits) with the copy count setting key and press [Entry].
4. Check the display "The present contents of a setting" to see if it is replaced with a set value that has been
input.
5. Press [END].
10.5.10 Initialization
Initializes the setting/adjustment data controlled in non-volatile memory to the value set when shipped from the
factory.
Data that can be initialized are as follows.
Data classification Data

Utility/Administrator Setting Data • Job Memory Setting Data
• FAX Setting Data
• Network Setting Data
Destination Storage Data
CS Remote Care Setting Data
Service Mode Setting (Adj.) Data • Image Process Adj. Data
• Machine and ADF Adjustment Data
All History Data
A. Procedure

Press [System 1].
Press [Initialization].
3. "Initialize screen"
Press either one of the data items in the data classification.
4. "Utility / Administrator Setting Data" / "Destination Storage Data" / "CS Remote Care Setting Data" /
"Service Mode Setting (Adj.) Data" / "Counter Data"
Select a data to initialize.
Pressing [All Select] selects all the data items in the data classification.
5. Pressing the Start key initializes the data selected of the data classification selected.
6. When initializing the data of each classification, repeat steps 3 to 5.
7. Press [OK].
177
10.6 Counter
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10.6.1 Display of the Counter

Displays the following data held by this machine on the touch panel.
The counter can be also checked by the output list, CSRemoteCare.
• Total Service
• Fax Communication Error
• Mode
• ADF Counter
• Service call
• JAM
• Present parts life
• Optional parts life
• PM
• Reuse
• Each size
• Paper Jam History
• Jam counter history
• Time series trouble (SC)
• Each section trouble (SC)
A. Procedure

Press [Counter].
2. "Counter screen"
Press a counter item you want to check.
The counter spread over 2 pages. The displayed page can be switched over by [ ↑ ] or [ ↓ ].
3. Each "Counter screen"
When there are two or more pages of items, the page can be switched over by [ ↑ ] or [ ↓ ].
Note
• For the individual data check screens of "JAM Counter History" and "Each Section Trouble
(SC)," [Clear Counter] is displayed.
Pressing [Clear Counter] displays "Clear Counter Check screen" and pressing [Yes] clears the block data.
Pressing [No] returns to the previous screen with no block data cleared. While in the visit to the user for the
PM execution, clear these data to check the JAM and SC counts that have occurred since the previous
visit.
4. Press [OK].
178
B. Total Service
Displays the total copy count printed in the service mode and the user mode.
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Note
• The maximum count is 99,999,999.
No. CSRC parameter Item collected Count condition

1 — Total Service Number of paper printed and exited in
the single and double sided copy
modes.
2 — Total Service (2-Sides) Of the above, the number of paper
printed and exited in the double sided
print mode.
C. FAX Communication Error

Displays the number of errors that occurred while in sending and receiving FAX with errors while in sending sep-
arated from those while in receiving.
Note
• The maximum count is 999,999.
No. CSRC parameter Item collected Count condition

1 — FAX TX Error Number of errors that occurred while in
the FAX sending.
2 — FAX RX Error Number of error that occurred while in
the FAX receiving.
D. Mode
Displays the use condition for each of the modes used by the copier/scanner/printer/FAX.
Note
No. CSRC parameter Item Count condition

(F1)
1 01 No. of Prints in Half-Fold Mode 1 count made while in the folding exit.
2 02 No. of Prints in Center Staple Mode 1 count made while in the stitch-and-
fold exit.
3 05 No. of Staples 1 1 count for 1 staple when stapling in
the 1-staple mode.
4 06 No. of Staples 2 1 count for 1 staple when stapling in
the 2-staple mode.
5 07 No. of Punches 1 count made while in the punch.
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(F1)
6 08 BOX Housing: Copy – Proof Print 1 count for each completion of a job.
7 09 BOX Housing: Copy – BOX Hold
8 0A BOX Housing: Print – Proof Print
9 0B BOX Housing: Print – BOX Hold
10 0C BOX Housing: Print
– Classified Document
11 0D BOX Housing: Scanner – BOX Hold
12 0E BOX Housing: FAX Scanning 1 count for each completion of a job
– BOX Hold
13 0F BOX Housing: FAX RX
– Distribute by F-Code
14 10 BOX Housing: FAX RX – Distribute by TSI
15 11 BOX Housing: FAX RX – BOX Hold 1 count for each completion of a job. F
code and other than TSI.
16 12 Output from Box: Copy Image – Print 1 count for each completion of a job.
Except for the print for checking.
17 13 Output from Box: Copy Image 1 count for each completion of a job.
– E-Mail TX
18 14 Output from Box: Copy Image – FTP TX
19 15 Output from Box: Copy Image – SMB TX
20 16 Output from Box: Print Image 1 count for each completion of a job.
– Print (Except Proof Print) Except for the print for checking.
21 17 Output from Box: Print Image – E-Mail TX 1 count for each completion of a job
22 18 Output from Box: Print Image – FTP TX
23 19 Output from Box: Print Image – SMB TX
24 1A Output from Box: Scan Image – Print
25 1B Output from Box: Scan Image
– E-Mail TX
26 1C Output from Box: Scan Image – FTP TX
27 1D Output from Box: Scan Image – SMB TX
28 1E Output from Box: FAX Scan Image
– Print
29 1F Output from Box: FAX Scan Image
– FAX TX
30 20 Output from Box: FAX Scan Image
– E-Mail/IFAX TX
31 21 Output from Box: FAX RX Image – Print
32 22 Output from Box: FAX RX Image
– FAX TX
33 23 Output from Box: FAX RX Image
– E-Mail/IFAX TX
180
E. ADF Counter
Displays the number of the paper through by modes of ADF.
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Note
• 1 count for the single sided copy and 2 counts for the double sided copy.
No. CSRC parameter Item Remarks

(F0)
1 00 N of originals fed in ADF mode
2 01 N of originals fed in RADF mode
3 02 N of originals fed in RDH mode No count is made with "0" at all times.
4 03 N of originals fed in RRDH mode No count is made with "0" at all times.
5 07 N of originals fed in mixed original ADF mode
6 08 N of originals fed in mixed original RADF
mode
7 0C N of 2 sided SDF original fed No count is made with "0" at all times.
F. Service Call
Displays troubles that have occurred for each SC.
Note
• The block trouble count is not available for CSRC.
• When the service mode DipSW3-1 is set to "1" (latched), SC34, 35 and 36 make no count.
No. CSRC SC cord No. CSRC SC cord No. CSRC SC cord

parameter parameter parameter
(E0) (E0) (E0)
001 00 02 01 018 11 11 07 035 22 22 02
002 01 02 02 019 12 11 08 036 23 23 01
003 02 02 03 020 13 11 09 037 24 23 02
004 03 02 04 021 14 11 10 038 25 23 03
005 04 02 05 022 15 11 11 039 26 24 01
006 05 02 06 023 16 11 12 040 27 24 02
007 06 02 07 024 17 11 13 041 28 24 03
008 07 03 01 025 18 11 14 042 29 27 01
009 08 10 01 026 19 11 15 043 2A 27 02
010 09 10 02 027 1A 11 16 044 2B 27 03
011 0A 10 03 028 1B 11 17 045 2C 28 01
012 0B 11 01 029 1C 11 18 046 2D 28 02
013 0C 11 02 030 1D 11 19 047 2E 28 03
014 0D 11 03 031 1E 11 20 048 2F 28 04
015 0E 11 04 032 1F 11 21 049 30 32 01
016 0F 11 05 033 20 20 01 050 31 33 01
017 10 11 06 034 21 22 01 051 32 33 02
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(E0) (E0) (E0)
052 33 35 01 093 5C B1 11 134 85 B1 64
053 34 35 02 094 5D B1 12 135 86 B1 65
054 35 37 01 095 5E B1 13 136 87 B1 66
055 36 38 01 096 5F B1 14 137 88 B1 67
056 37 38 02 097 60 B1 15 138 89 B1 68
057 38 38 03 098 61 B1 16 139 8A B1 69
058 39 38 04 099 62 B1 17 140 8B B1 70
059 3A 38 05 100 63 B1 18 141 8C B1 71
060 3B 38 06 101 64 B1 19 142 8D B1 72
061 3C 38 07 102 65 B1 20 143 8E B1 73
062 3D 38 08 103 66 B1 22 144 8F B1 74
063 3E 39 01 104 67 B1 23 145 90 B1 75
064 3F 39 02 105 68 B1 25 146 91 B1 76
065 40 39 03 106 69 B1 26 147 92 B1 77
066 41 39 04 107 6A B1 27 148 93 B1 78
067 42 40 01 108 6B B1 28 149 94 B1 80
068 43 41 01 109 6C B1 29 150 95 B1 81
069 44 44 01 110 6D B1 30 151 96 B1 82
070 45 47 01 111 6E B1 31 152 97 B1 83
071 46 50 01 112 6F B1 32 153 98 B1 84
072 47 50 02 113 70 B1 33 154 99 B1 85
073 48 50 03 114 71 B1 34 155 9A B1 86
074 49 50 04 115 72 B1 35 156 9B B1 87
075 4A 53 01 116 73 B1 36 157 9C B1 88
076 4B 53 02 117 74 B1 37 158 9D C1 03
077 4C 53 03 118 75 B1 40 159 9E C1 81
078 4D 54 01 119 76 B1 41 160 9F C1 82
079 4E 54 02 120 77 B1 42 161 A0 C1 83
080 4F 60 01 121 78 B1 43 162 A1 C2 84
081 50 60 02 122 79 B1 44 163 A2 C2 85
082 51 60 03 123 7A B1 45 164 A3 C2 86
083 52 61 01 124 7B B1 46 165 A4 C2 87
084 53 62 01 125 7C B1 50 166 A5 C2 88
085 54 67 01 126 7D B1 51 167 A6 D0 01
086 55 67 02 127 7E B1 52 168 A7 D0 02
087 56 80 01 128 7F B1 53 169 A8 D2 01
088 57 83 01 129 80 B1 54 170 A9 D2 03
089 58 B0 01 130 81 B1 60 171 AA D2 81
090 59 B0 02 131 82 B1 61 172 AB D2 82
091 5A B0 03 132 83 B1 62 173 AC E0 01
092 5B B1 10 133 84 B1 63 174 AD E0 02
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(E0) (E0) (E0)
175 AE E0 03 193 C0 E0 8E 211 D2 E0 A0
176 AF E0 04 194 C1 E0 8F 212 D3 E0 A1
177 B0 E0 05 195 C2 E0 90 213 D4 E0 A2
178 B1 E0 06 196 C3 E0 91 214 D5 E0 A3
179 B2 E0 07 197 C4 E0 92 215 D6 E0 A4
180 B3 E0 81 198 C5 E0 93 216 D7 E0 A5
181 B4 E0 82 199 C6 E0 94 217 D8 E0 A6
182 B5 E0 83 200 C7 E0 95 218 D9 E0 A7
183 B6 E0 84 201 C8 E0 96 219 DA E0 A8
184 B7 E0 85 202 C9 E0 97 220 DB E0 A9
185 B8 E0 86 203 CA E0 98 221 DC E0 AA
186 B9 E0 87 204 CB E0 99 222 DD E0 AB
187 BA E0 88 205 CC E0 9A 223 DE E0 AC
188 BB E0 89 206 CD E0 9B 224 DF E0 AD
189 BC E0 8A 207 CE E0 9C 225 E0 E0 AE
190 BD E0 8B 208 CF E0 9D 226 E1 E0 AF
191 BE E0 8C 209 D0 E0 9E 227 E2 E0 B0
192 BF E0 8D 210 D1 E0 9F 228 E3 E0 B1
G. Time Series Trouble (SC)

For the latest 50 SC's, displays the SC code of cause, the total count, the date of occurrence, the time of occur-
rence, and the firmware version.
Note
• Press the corresponding SC item to display a firmware version.
H. JAM Counter History

Displays the number of occurrences for each jam code. (Except for stationary jams)
Note
• The jam code is a code that is displayed when DipSW10-7 is set at "1."
No. CSRC Jam cord No. CSRC Jam cord No. CSRC Jam cord
parameter Upper Lower parameter Upper Lower parameter Upper Lower
(J0) (J0) (J0)
01 00 10 — 07 06 13 2 13 0C 13 11
02 01 11 — 08 07 13 5 14 0D 14 0
03 02 12 0 09 08 13 6 15 0E 14 1
04 03 12 1 10 09 13 7 16 0F 15 0
05 04 13 0 11 0A 13 8 17 10 15 1
06 05 13 1 12 0B 13 9 18 11 20 1
183
No. CSRC Jam cord No. CSRC Jam cord No. CSRC Jam cord
bizhub 500 / 420
parameter Upper Lower parameter Upper Lower parameter Upper Lower

(J0) (J0) (J0)
19 12 20 2 40 27 61 5 61 3C 66 2
20 13 20 3 41 28 61 6 62 3D 66 3
21 14 20 4 42 29 61 7 63 3E 66 4
22 15 20 5 43 2A 61 8 64 3F 66 5
23 16 20 6 44 2B 62 1 65 40 66 6
24 17 20 7 45 2C 62 2 66 41 66 7
25 18 20 8 46 2D 62 3 67 42 66 8
26 19 20 9 47 2E 62 4 68 43 72 16
27 1A 20 10 48 2F 62 5 69 44 72 17
28 1B 30 — 49 30 62 6 70 45 72 18
29 1C 31 — 50 31 62 7 71 46 72 21
30 1D 32 — 51 32 62 8 72 47 72 25
31 1E 33 — 52 33 63 1 73 48 72 43
32 1F 34 — 53 34 63 2 74 49 72 81
33 20 50 1 54 35 63 3 75 4A 72 82
34 21 60 1 55 36 63 4 76 4B 72 84
35 22 60 2 56 37 63 5 77 4C 72 85
36 23 61 1 57 38 63 6 78 4D 72 90
37 24 61 2 58 39 63 7 79 4E 97 1
38 25 61 3 59 3A 63 8 80 4F 97 2
39 26 61 4 60 3B 66 1 81 50 97 3
I. Paper Jam History

For the latest 100 jams, displays JAM code, Total Count, Date of Occurrence, Paper Tray, Paper Size, and
Zoom.
J. Reuse
Displays the accumulated hours of the parts and the number of occurrences of the job that uses the parts.
Note

(F5)
1 00 Power condition /1 (Total Power ON 1 count for 1 minute.
time)
2 01 Power condition /2 (EN-5V ON time) 1 count for 1 minute.
3 02 Low power mode time 1 count for 1 minute.
4 03 WUP time Accumulated hours during which the
fusing heater turns on in the warm-up
condition. 1 count for 1 second.
184
bizhub 500 / 420

(F5)
5 04 Print operating time (single sided mode) Accumulated hours from start to stop
of the print. 1 count for 1 second (not
including the time period during which
the counter stops due to a jam).
6 05 Print operating time (double sided mode) Accumulated hours from start to stop
of the print. 1 count for 1 second (not
including the time period during which
the counter stops due to a jam).
7 06 Correction operation count Number of counts the image stabiliza-
tion control (the fusing temperature
lower than 50 °C) is executed. 1 count
for each execution.
8 07 APS sensor ON time Accumulated hours during which the
APS sensor turns ON. 1 count for 1
second.
9 08 Platen scan count Counts the number of occasions in
which the scan is made in the platen
mode.
10 09 The number of occurrences of the stop Counts the number of occasions in
due to toner running out. which the system stops due to no
toner.
11 0A Polygon stop operation time
12 0B The number of occurrences of the Main Counts the number of NMI's.
Power OFF
13 0C The number of occurrences of the feed 1 count is made each time the feed
door closed door is closed.
14 0D The number of starting all print jobs
15 0E Tray 1 paper feed count 1 count is made when paper is fed
from the tray 1 each time 1 sheet of
paper is exited.
16 0F Tray 2 paper feed count 1 count is made when paper is fed
paper is exited.
17 10 Tray 3 paper feed count 1 count is made when paper is fed
paper is exited.
18 11 Tray 4 paper feed count 1 count is made when paper is fed
paper is exited.
19 12 The number of prints made by selecting 1 count is made when paper is fed
the bypass paper feed tray from the bypass tray each time 1 sheet
of paper is exited.
20 13 The number of prints made by selecting 1 count is made when paper is fed
the LCT paper feed tray from LCT each time 1 sheet of paper is
exited.
185
K. Each Size
Displays the number of print of each paper size.
bizhub 500 / 420
Note
• 1 count each time paper is exited (0 count for a blank sheet and 2 counts for the double sided
print).
No. CSRC parameter Paper size Remarks

1 01 A3
2 02 A4
3 03 A5
4 04 A6
5 05 B4
6 06 B5
7 07 B6
8 08 12 x 18 Not used
9 09 11 x 17
10 0A 81/2 x 14
11 0B 81/2 x 11
12 0C 71/4 x 101/2 Not used
13 0D 51/2 x 81/2
14 0E Foolscap
15 0F Post card
16 10 4x6 Not used
17 11 8K
18 12 16K
19 13 Others Not used
186
10.6.2 Present Parts Life

Displays the counter of an intended part.
bizhub 500 / 420

And, when replacing an intended part, the counter of the replaced part is reset to manage the service history.
A. Procedure for the display/reset

Press [Counter].
2. "Counter/Data screen"
Press [Present Parts Life].
3. "Parts Counter (Fixed) screen"
Press [ ↑ ]/[ ↓ ] to check the counter or display a part to be reset.
4. "Parts Counter (Fixed) screen"
Check the count value of an intended part.
When resetting it, press a part to be reset and then press the Clear key.
5. Press [OK].
B. Fixed parts counter list
No. CSRC Unit Parts name Parts No.

parameter
(Z1)
1 00 DC (including charge unit) Drum —
2 01 Cleaning blade assy 50GA-209
3 02 Drum unit (including charge unit) 50GA-200
4 03 Transfer/separation section Transfer/separation unit 50GA-260
5 04 Developing unit Developer —
6 05 Developing unit 50GA-300
7 06 Main body Filter mounting plate assy 50GA-336
8 07 Ozon filter 50GA1031
9 08 Suction filter /A assy 40LA-318
10 09 Filter cover assy 50GA-314
11 0A Suction cover /2 assy 50GA-311
12 0B Paper feed unit Tray 1 pick-up roller 40303005
13 0C Tray 1 paper feed roller 40303005
14 0D Tray 1 separation roller 40300151
15 0E Tray 2 pick-up roller 40303005
16 0F Tray 2 paper feed roller 40303005
17 10 Tray 2 separation roller 40300151
18 11 Bypass unit Bypass paper feed roller 41313001
19 12 Bypass separation roller 40340151
20 13 Registration section Paper feed connection roller 50GA3865
21 14 Registration roller /A 50GA3848
22 15 Registration bearing /1 26NA4536
23 16 Registration bearing /2 26NA4537
24 17 Paper feed slide bearing 26NA4082
187
No. CSRC Unit Parts name Parts No.

bizhub 500 / 420
parameter
(Z1)
25 18 Fusing unit Fusing roller (bizhub 500) 50GE5303
Fusing roller (bizhub 420) 42GA5303
26 19 Fusing pressure roller (bizhub 500) 50GA5304
Fisung pressure roller (bizhub 420) 42GA5304
27 1A Fusing cleaner assy (bizhub 500) 50GA-540
Fusing cleaner assy (bizhub 420) 42GA-540
28 1B Heat insulating sleeve /A 26NA5372
29 1C Fusing bearing /Up 26NA5371
30 1D Fusing bearing /Lw 50GA5359
31 1E Fusing sensor assy 50GA-544
32 1F Fuse holder assy 26NA-535
33 20 Fusing claw assy (bizhub 500) 50GA-533
Fusing claw assy (bizhub 420) 42GA-533
34 21 Fusing driven roller A assy 40400326
35 22 Fusing driven roller B assy 40400328
36 23 Reverse unit Paper exit suction filter 50GA4406
37 24 Write unit Write unit 50GA-650
38 25 LU-201 Pick-up rubber 40LA4009
39 26 Paper feed rubber 26NA4011
40 27 Separation rubber 26NA4012
41 28 DF-607 Pick-up roller 43445003
42 29 Paper feed roller 45823014
43 2A Separation roller 45823047
44 2B PC-202 (tray 3/tray 4) Tray 3 pick-up roller 40303005
45 2C PC-402 (tray 3 only) Tray 3 paper feed roller 40303005
46 2D Tray 3 separation roller 40300151
47 2E Tray 4 pick-up roller 40303005
48 2F Tray 4 paper feed roller 40303005
49 30 Tray 4 separation roller 40300151
50 31 Fusing unit Fusing input gear assy 50GA-546
188
10.6.3 PM
Sets the PM execution cycle or resets the PM counter.
bizhub 500 / 420

Note
• The PM cycle setting has been input in advance and be sure not to change this setting normally.
A. Procedure for the counter reset

Press [Counter].
Press [PM].
3. "PM Counter screen"
Check the PM counter.
When resetting it, press the Clear key.
4. Press [OK].
B. Procedure for the cycle setting

Press [Counter].
Press [PM].
3. "PM Counter screen"
Enter a PM cycle value (1 to 999999) through the copy count setting button and press [Set].
4. Press [OK].
189
10.7 State Confirmation

bizhub 500 / 420
10.7.1 Sensor Check

This machine is provided with an input/output check function as a self-diagnostic function. For the sensor check
(input check), the state confirmation of each signal can be made.
A. Procedure

Press [State Confirmation].
2. "State Confirmation screen"
Press [Sensor check].
3. "Sensor Check screen"
Press [Check Code] and, when entering the sensor check code in 3 digit through the copy count setting
button, a state (ON/OFF or value) is displayed in the Result area.
4. For the multi mode, press [Multi Code] and enter a three-digit multi code through the copy count setting
key.
5. When conducting the sensor check of other signal sources, repeat steps 3 to 4.
B. List of sensors
Display and signal source

Classification
Multi code
Symbol
ON OFF
Code
Name
0 0 TCRS Drum temperature 0 to 255 *1

Analog signal
1 0 TCRS TCR sensor

2 0 TCRS TCR sensor
3 0 TH1 Thermistor /1
4 0 TH2 Thermistor /2
5 0 IDCS IDC sensor
6 0 HUMS Humidity sensor
7 0 VR1 Paper size VR/BP (bypass)
10 1 PS18 paper empty sensor /BP (bypass) No paper Paper
Paper feed
2 PS23 Lift sensor (bypass) Up position Down position

3 — Connect detection signal (bypass) Connection Non-connection
4 PS19 Paper size sensor /BP1 (bypass) Paper No paper
5 PS20 Paper size sensor /BP2 (bypass)
11 1 PS5 Paper empty sensor /1 No paper Paper
2 PS9 Near-empty sensor /1 Near-empty Non-near-empty
3 PS6 Upper limit sensor /1 Upper limit Not at upper limit
4 PS8 Tray set sensor /1 Set Not set
5 PS10 Paper size sensor /Rr1 *2
6 PS11 Paper size sensor /Fr1
190
Classification
Multi code
bizhub 500 / 420

Symbol
ON OFF
Code
Name
12 1 PS12 Paper empty sensor /2 No paper Paper

Paper feed
2 PS15 Near-empty sensor /2 Near-empty Non-near-empty

3 PS13 Upper limit sensor /2 Upper limit Not at upper limit
4 PS14 Tray set sensor /2 Set Not set
5 PS16 Paper size sensor /Rr2 *2
6 PS17 Paper size sensor /Fr2
13 1 PS115 Paper empty sensor /3 (PC-202) No paper Paper
2 PS113 Near-empty sensor /3 (PC-202) Near-empty Non-near-empty
3 PS114 Upper limit sensor /3 (PC-202) Upper limit Not at upper limit
4 PS112 Tray set sensor /3 (PC-202) Set Not set
5 PS116 Paper feed sensor /3 (PC-202) Paper No paper
6 PS117 Vertical conveyance sensor /3 (PC-202)
7 PS118 Paper size sensor /Rr3 (PC-202) *2
8 PS119 Paper size sensor /Fr3 (PC-202)
14 1 PS124 Paper empty sensor /4 (PC-202) No paper Paper
2 PS122 Near-empty sensor /4 (PC-202) Near-empty Non-near-empty
3 PS123 Upper limit sensor /4 (PC-202) Upper limit Not at upper limit
4 PS121 Tray set sensor /4 (PC-202) Set Not set
5 PS125 Paper feed sensor /4 (PC-202) Paper No paper
6 PS126 Vertical conveyance sensor /4 (PC-202)
7 PS127 Paper size sensor /Rr4 (PC-202) *2
8 PS128 Paper size sensor /Fr4 (PC-202)
15 1 PS153 Paper empty sensor (LU) No paper Paper
2 PS155 LU exit sensor (LU) Paper No paper
3 PS152 Upper limit sensor (LU) Upper limit Not at upper limit
4 PS154 Remaining paper sensor /1 (LU) *3
5 PS151 Remaining paper sensor /2 (LU)
6 MS151 Upper door interlock switch (LU) Open Close
7 PS156 LU set sensor (LU) Not set Set
8 — Connect detection signal (LU) Connection Non-connection
16 1 PS5 Right door open/close sensor (PC-402) Open Close
2 PS6 Tray set sensor (PC-402) Not set Set
3 PS7 Lower limit over run sensor (PC-402) Over run Not over run
4 PS2 Vertical conveyance sensor (PC-402) Paper No paper
5 PS1 Paper feed sensor (PC-402)
6 MEB Main tray empty board (PC-402)
7 PS9 Sub tray empty sensor (PC-402)
8 PS3 Paper empty sensor (PC-402)
9 PS4 Upper limit sensor (PC-402) Upper limit Not at upper limit
191

Classification
Multi code
bizhub 500 / 420
Symbol
ON OFF
Code
Name
16 10 PS13 Lower limit sensor (PC-402) Lower limit Not at lower limit
Paper feed
11 PS12 Shift home sensor (PC-402) Home position Other than

home position
12 PS11 Shift position sensor (PC-402) Shift position Not at shift
position
13 PS14 Shift gate position sensor (PC-402) Gate lock Gate release
14 PS10 Paper lift motor encoder sensor (PC-402) 0 to 255
15 SW1 Tray release switch ON OFF
17 1 PS19, Paper size sensor /BP1, /BP2, /BP3, /BP4 0 to 15 *4
PS20, (bypass)
PS21,
PS22
2 PSB/1 Paper size board /1 0 to 15 *5
3 PSB/2 Paper size board /2
4 PSDB3 Paper size detect board /3 (PC-202)
5 PSDB4 Paper size detect board /4 (PC-202)
20 1 PS1 Registration sensor Paper No paper
Conveyance
2 PS2 Vertical conveyance sensor

22 0 PS3 Fusing exit sensor
23 0 MS Interlock switch Open Close
24 0 PS7 Feed door open/close sensor
25 0 PS111 Right door open/close sensor (PC-202)
40 1 PS30 Scanner home sensor Other than Home position
Optical device
home position
2 PS31 APS timing sensor DF close DF open
50 1 — Serial communication check when the OK NG

Specific function
power is turned ON (DF)

2 — Serial communication check when the
power is turned ON (FS)
power is turned ON (SubCPU)
power is turned ON (Main body)
51 1 — Main body identification signal bizhub 420 bizhub 500
2 — Machine type code "129" = "128" =
bizhub 420 bizhub 500
52 1 — JS connection detection Connection Non-connection
JS
2 — — — —
3 PS1 Paper full sensor Full Other than full
192
Classification
Multi code
bizhub 500 / 420

Symbol
ON OFF
Code
Name
57 1 PZS Toner remaining sensor Detected Not detected

Analog signal
2 PS4 Toner bottle sensor

Toner supply
58 0 TH1/ The higher value of thermistor /1 and ther- 0 to 255

Analog signal
TH2 mistor /2
60 1 PS5 Original empty sensor Original No original

DF
2 PS6 Original feed sensor

3 PS9 Original registration sensor
4 PS8 Original detection sensor
5 PS10 Original exit sensor
6 PS7 Cover open/close sensor Close Open
7 SW3 DF open/close switch (Main body side)
8 MOSDB Mix original size detection board Original No original
9 MOSDB Mix original size detection board
10 MOSDB Mix original size detection board
11 PS1 Original size sensor /1
15 VR1 Original size VR 0 to 255 *1
70 1 PS4 Entrance sensor Paper No paper
FS-510
2 PS5 Conveyance sensor

3 PS6 Alignment sensor /1 Home position Other than
4 PS7 Alignment sensor /2 home position
5 SW3 Tray overrun switch Not at upper Upper limit/
limit/lower limit lower limit
6 SW2 Shutter switch Not open Close
7 SW1 Door switch Close Open
8 — — — —
9 PS4 Encoder sensor (PU) Light blocking Light passing
through
10 PS23 Paper guide home sensor (SD) Home position Other than
home position
193

Classification
Multi code
bizhub 500 / 420
Symbol
ON OFF
Code
Name
70 11 PS14 Lower limit sensor Lower limit Not at lower limit

FS-510
12 PS15 Upper limit sensor Upper limit Not at upper limit

13 — OT-601 connection detection Connection Non-connection
14 PS3 Tray position sensor Tray detected Tray not
detected
15 PS16 Shutter home sensor Close Open
16 — — — —
17 PS11 Exit paddle home sensor Home position Other than
18 PS12 Exit roller home sensor home position
19 PS8 Stacker sensor Paper No paper
20 PS10 Stapler home sensor Other than Home position
home position
21 — Stapler ready sensor Ready Unready
22 — Staple empty sensor No staple Staple
23 — Staple home sensor Home position Other than
home position
24 — — — —
25 PS2 Punch position sensor /1 (PU) Home position at Home position
odd numbered at initialization
times
26 PS3 Punch position sensor /2 (PU) At the center Not at the
of stroke center of stroke
27 PS1 Punch scraps full sensor (PU) Full Other than full
28 PS22 Folding roller home sensor (SD) Home position Other than
home position
29 SW4 Guide plate switch Close Open
30 PS23 Paper guide home sensor (SD) Home position Other than
home position
31 PS20 Exit sensor (SD) Paper No paper
32 PS21 Tray empty sensor (SD)
33 — Staple home sensor /Rr (SD) Home position Other than
home position
34 — Stapler ready sensor /Rr (SD) Ready Unready
35 — Staple empty sensor /Fr (SD) No staple Staple
36 — Staple home sensor /Fr (SD) Home position Other than
home position
37 — Stapler ready sensor /Fr (SD) Ready Unready
38 — Staple empty sensor /Fr (SD) No staple Staple
39 SW4 SD interlock switch (SD) Set Not set
40 PS18 Exit home sensor (SD) Open Close
41 PS1 Paper detection sensor /1 (MT) No paper Paper
194
Classification
Multi code
bizhub 500 / 420

Symbol
ON OFF
Code
Name
70 42 PS5 Paper full sensor /1 (MT) Full Other than full

FS-510

44 PS6 Paper full sensor /2 (MT) Full Other than full
70 1 PS1 Sub tray exit sensor Paper No paper
FS-511
2 PS3 Intermediate conveyance sensor

3 PS4 Main route conveyance sensor
4 PS2 Bypass route conveyance sensor
5 PS6 Sub tray full sensor Full Other than full
6 PS7 Main tray full sensor
7 PS9 Alignment home sensor Home position Other than
8 PS14 Stapler home sensor home position
9 PS12 Roller release home sensor Released Pressed
10 PS13 Exit roller home sensor
11 PS5 Alignment tray sensor Paper No paper
12 PS22 Stapler home sensor /Rr Home position Other than
home position
13 PS20 Staple empty sensor /Rr No staple Staple
14 PS21 Stapler ready sensor /Rr Ready Unready
15 PS25 Stapler home sensor /Fr Home position Other than
home position
16 PS23 Staple empty sensor /Fr No staple Staple
17 PS24 Stapler ready sensor /Fr Ready Unready
18 PS19 Main tray upper limit sensor Paper surface Paper surface
detected not detected
19 PS8 Main tray reset sensor Other than Paper
paper removal removal
20 SW2 Main tray upper limit switch Upper limit Not at upper limit
21 PS10 Shift home sensor Front home Rear home
position position
22 — — — —
23 PS15 Punch encoder sensor Light passing Light blocking
24 PS11 Shift encoder sensor through
25 — — — —
26 — — — —
27 PS2 Path sensor (RU) Paper No paper
195

Classification
Multi code
bizhub 500 / 420
Symbol
ON OFF
Code
Name
80 1 PS24 ADU conveyance sensor /1 Paper No paper

ADU/Reverse
2 PS25 ADU conveyance sensor /2

81 1 PS27 Reverse sensor
2 PS26 ADU open/close sensor Open Close
3 — Set Not set
*1 Resolution 1024 is also displayed as resolution 256.

*2 The size in the main scan direction is shown by the combination of the ON/OFF of the paper size sensors
/Rr and /Fr.
Sensor check Tray 1 11-5 11-6 Paper size

Tray 2 12-5 12-6
Tray 3 13-7 13-8
Tray 4 14-7 14-8
Sensor check display ON OFF A3, B4, A4, B5
ON ON 11 x 17
OFF ON A4S, 81/2 x 11S
OFF OFF A5S, B5S, 81/2 x 11S
*3 ON/OFF combination of remaining paper sensor /1 (PS154) and /2 (PS151) represents an amount of
paper remained in LU.
Sensor check 15-4 15-5

Remaining paper sensor /1 (PS154) /2 (PS151)
Full amount ON OFF
Medium amount ON ON
Small amount OFF ON
196
*4 The combination of the ON/OFF of the paper size sensors /BP1 (PS19), /BP2 (PS20), /BP3 (PS21) and
/BP4 (PS22) is shown in 4-bit data (0 to 15).
bizhub 500 / 420

Sensor check display PS19 PS20 PS21 PS22
0 OFF OFF OFF OFF
1 ON OFF OFF OFF
2 OFF ON OFF OFF
3 ON ON OFF OFF
4 OFF OFF ON OFF
5 ON OFF ON OFF
6 OFF ON ON OFF
7 ON ON ON OFF
8 OFF OFF OFF ON
9 ON OFF OFF ON
10 OFF ON OFF ON
11 ON ON OFF ON
12 OFF OFF ON ON
13 ON OFF ON ON
14 OFF ON ON ON
15 ON ON ON ON
*5 The combination of the ON/OFF of the paper size boards and the paper size detection boards (4 in all) is
shown in 4-bit data (0 to 15).
Sensor check display State of each of the 4 sensors on the paper size boards
17-2 (tray 1), 17-3 (tray 2), /1 (PSB /1) and /2 (PSB /2) and the paper size detect
17-4 (tray 3), 17-5 (tray 4) boards /3 (PSDB /3) and /4 (PSDB /4)
1 2 3 4
0 OFF OFF OFF OFF
1 ON OFF OFF OFF
2 OFF ON OFF OFF
3 ON ON OFF OFF
4 OFF OFF ON OFF
5 ON OFF ON OFF
6 OFF ON ON OFF
7 ON ON ON OFF
8 OFF OFF OFF ON
9 ON OFF OFF ON
10 OFF ON OFF ON
11 ON ON OFF ON
12 OFF OFF ON ON
13 ON OFF ON ON
14 OFF ON ON ON
15 ON ON ON ON
197
10.7.2 Load Check

This machine is provided with an input/output check function as a self-diagnostic function. For the load check,
bizhub 500 / 420
the check and adjustment (output check) of the load operation can be made.
A. Procedure

Press [Load check].
3. "Load Check screen"
Press [Check Code] and enter a load check code in 3 digits through the copy count setting key.
4. For the multi mode, press [Multi Code] and enter a multi code in 3 digits through the copy count setting
key.
The load check operation starts with a message "Operating" displayed.
6. Press the Stop key.
The load check is completed with a message "Fin" displayed.
7. When conducting other load operations or the output check of signals, repeat steps 3 to 6.
B. List of loads
High voltage/image Classification
Multi code
Symbol
Code
Name Restrictive conditions
0 0 L1 Exposure lamp
1 0 M4, Toner supply motor, toner solenoid Same as 55-003
SD5 turn ON at the same time
20 1 CL4 Feed clutch /1

Paper feed
2 CL5 Feed clutch /2

3 CL6 Feed clutch /BP
4 SD1 Pick-up solenoid /BP
5 SD151 Pick-up solenoid (LU)
21 1 M9 Feed motor (LS250)
2 Feed motor (LS210)
3 Feed motor (LS125)
4 M122 Paper feed motor /3 (LS250) (PC-202) Valid only when the paper empty sen-
5 Paper feed motor /3 (LS210) (PC-202) sor /3 (PS115) detects a no paper
condition.
7 Paper feed motor /4 (LS210) (PC-202) sor /4 (PS124) detects a no paper
condition.
198
Paper feed Classification
Multi code
bizhub 500 / 420

Symbol
Code
21 8 M150 Feed motor (LS250) (LU)

9 Feed motor (LS210) (LU)
11 M9, Feed motor (LS250), registration
CL1, clutch, loop clutch turn ON at the
CL2 same time
sor /3 (PS115) detects a no paper
condition.
sor /4 (PS124) detects a no paper
condition.
14 M150 Feed motor (LS125) (LU)
22 1 M120 Vertical conveyance motor /3 (LS250)
(PC-202)
2 Vertical conveyance motor /3 (LS210)
(PC-202)
(PC-202)
4 M121 Vertical conveyance motor /4 (LS250)
(PC-202)
(PC-202)
(PC-202)
7 M120, Vertical conveyance motor /3, /4
M121 (LS250) (PC-202)
8 Vertical conveyance motor /3, /4
(LS210) (PC-202)
9 Vertical conveyance motor /3, /4
(LS125) (PC-202)
10 M2 Vertical conveyance motor (LS250)
(PC-402)
11 Vertical conveyance motor (LS210)
(PC-402)
12 Vertical conveyance motor (LS125)
(PC-402)
23 1 M7 Paper lift motor /1 The upper limit sensor /1 (PS6) turns
ON, or it is stopped by the stop but-
ton.
2 M8 Paper lift motor /2 The upper limit sensor /2 (PS13) turns
ton.
199
Paper feed Classification
Multi code
bizhub 500 / 420
Symbol
Code
23 3 M124 Paper lift motor /3 (PC-202) The upper limit sensor /3 (PS114)
turns ON, or it is stopped by the stop
button.
4 M125 Paper lift motor /4 (PC-202) The upper limit sensor /4 (PS123)
turns ON, or it is stopped by the stop
button.
5 M151 Paper lift motor (LU) The upper limit sensor (PS152) turns
ton.
6 M9, Feed motor, pick-up solenoid /BP turn Valid only when the paper empty sen-
SD1 ON at the same time sor/BP (PS18) detects a no paper
condition.
25 1 CL1 Registration clutch
2 CL2 Loop clutch
3 CL3 Vertical conveyance clutch
4 CL151 Feed clutch (LU)
29 0 SD2 Drum claw solenoid ON
31 1 M2, L1 Scanner motor, exposure lamp After home position search, A3
Optical device
makes a single scan operation.

2 Scanner motor, exposure lamp After home position search, A3
makes a continuous scan operation.
32 1 M5 Polygon motor (LS250)
2 Polygon motor (LS210)
34 0 M2, L1 Shading correction operation
36 0 LDB Laser PWM (0 to 255)
37 0 LDB, Laser turns ON forcibly The polygon motor (M5) turns ON
M5 and OFF at the same time.
38 0 LDB, LD alarm check The polygon motor (M5) turns ON at
M5 the same time and the results are dis-
played when it turns OFF.
999 LD alarm, data clear
39 0 L1 Platen stop APS The exposure lamp turns ON with
APS processed forcibly.
40 1 M11 Fusing motor (LS250)
Main body
2 Fusing motor (LS210)

3 Fusing motor (LS125)
41 1 M1 Drum motor (LS250) The charging corona turns ON at the
same time.
2 Drum motor (LS210) The charging corona turns ON at the
same time.
3 Drum motor (LS125) The charging corona turns ON at the
same time.
200
Main body Classification
Multi code
bizhub 500 / 420

Symbol
Code
41 4 M1 Drum motor (LS250)

5 Drum motor (LS210)
6 Drum motor (LS125)
42 1 FM3, Exhaust fan /Fr, /Rr turn ON at the
FM9 same time
2 FM4 Drum cooling fan
3 FM2, Fusing cooling fan /Fr, /Rr turns ON at
FM8 the same time
4 FM1 Power supply cooling fan
5 FM6 Developing suction fan
6 FM5 Coveyance suction fan
7 FM7 Developing cooling fan
43 1 TCT Total counter 1 count up
2 KCT Key counter 1 count up
44 1 — — —
2 M3 Developing motor (LS210)
3 Developing motor (LS125)
45 1 L2 Fusing heater lamp /1 Caution
2 L3 Fusing heater lamp /2 • Since no high temperature
3 L2, L3 Fusing heater lamp /1, /2 turn ON at detection is made, be careful
the same time not to turn on for more than 10
seconds. Otherwise, the fusing
4 L2, Fusing heater lamp /1, fusing motor
roller may deform, thus caus-
M11 turn ON at the same time
ing a fire.
5 L3, Fusing heater lamp /2, fusing motor
M11 turn ON at the same time
6 L2, L3, Fusing heater lamp /1, /2, fusing
M11 motor turn ON at the same time
48 0 PKB Operation panel check (panel key-
Operation panel
board LEDs all turm ON)

49 0 LCD Operation panel check
1 — — —
51 1 EL Only erase lamp 24V ON

Specific function
2 EL Erase lamp
52 0 TSL Transfer exposure lamp
53 0 SD4 Web solenoid
55 1 M4 Toner supply motor
2 SD5 Toner solenoid
3 M4, Toner supply motor, toner solenoid
SD5 turn ON at the same time
201
Specific function Classification
Multi code
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Symbol
Code
56 1 M10 Toner bottle motor (CW)

2 Toner bottle motor (CCW)
57 0 PZS Toner remaining sensor ON/OFF
1 Toner remaining sensor ON
59 0 RL1 Main relay
60 1 M1 Original feed motor
DF
2 M2 Original conveyance motor

3 FM3 Cooling fan
4 SD1 Pressure roller release solenoid
5 SD2 Stamp solenoid
6 LB Print lamp (LED board) green ON
7 LB Print lamp (LED board) red ON
8 M1, 1 side original scan continuous opera-
M2, tion (no original)
9 SD1 2 sides original scan continuous oper-
ation (no original)
10 1 side original scan continuous opera- Operates according to the original
tion (original) size set.
11 1 side mixed original scan continuous
operation (original)
12 2 sides original scan continuous oper-
ation (original)
70 1 M2 Conveyance motor (10 seconds ON)
FS-510
2 — — —
3 M4, After alignment motor /Rr, /Fr opera-
M5 tion, home position search
4 — — —
5 M11 Tray lift motor up Stops when the upper limit sensor
(PS15) turns ON after the tray posi-
tion sensor (PS3) detects the tray 2.
6 M11 Tray lift motor initial operation After the tray goes down, it goes up
when the lower limit sensor (PS14)
turns ON and it stops when PS15
turns ON. It becomes valid after exe-
cuting the load check 70-5.
7 M12 Shutter close/open operation once At the same time, the paper exit roller
release/pressure operation is made
by the paper exit roller release motor
(M6).
8 — — —
9 — — —
10 — — —
202
FS-510 Classification
Multi code
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Symbol
Code
70 11 M6 Release/press operation of exit roller

once
12 M9 Open/close operation once of paper
exit opening (SD)
13 — — —
14 — — —
15 — — —
16 — — —
17 M7 After 2-staple positioning, home posi-
tion search
18 — — —
19 — — —
20 — — —
21 — — —
22 — — —
23 M10, Folding once (SD)
M14
24 to 52 — — —
53 M1, Exit motor (1 second ON), stacker
SD1 paddle solenoid ON/OFF
54 M1, Exit motor (1 second ON), exit paddle
SD2 solenoid ON/OFF
55 to 77 — — —
78 M1 Punching once (PU)
79 M2 Switching the number of punches Inch only
80 1 M6 Reverse motor (LS250) rotating for-
ADU/Reverse
ward
2 Reverse motor (LS210) rotating for-
ward
3 Reverse motor (LS125) rotating for-
ward
4 Reverse motor (LS250) rotating back-
ward
ward
ward
81 1 CL7 ADU conveyance clutch /Up
2 CL8 ADU conveyance clutch /Lw
3 M9, Feed motor, ADU conveyance clutch
CL7 /Up turn ON at the same time
203
ADU/Reverse Classification
Multi code
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Symbol
Code
81 4 M9, Feed motor, ADU conveyance clutch

CL8 /Lw turn ON at the same time
5 M9, Feed motor, ADU conveyance clutch
CL7, /Up, /Lw turn ON at the same time
CL8
83 0 SD3 Reverse solenoid
90 0 — PM counter clear
Adjustment/special mode
91 0 — Process counter clear No use allowed in the field.

1 — Drum counter clear No use allowed in the field.
92 — — NVRAM board data reset No operation available in the field.
93 0 — Field initial set
204
10.7.3 Memory/HDD Condition

Displays the memory capacity and the hard disc capacity (total/free space).
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A. Procedure

Press [Memory/HDD condition].
The memory package capacity, and the total capacity and the free capacity of HDD are displayed.
3. Press [END].
10.7.4 Memory Check (Memory/HDD Adjustment)

Checks the memory operation.
A. Procedure

Press [Memory/HDD Adjustment].
3. Press [Memory Check] from the menu.
4. "Memory Check screen"
Press [Rough Check] or [Detail Check].
When completed normally, it is displayed that the memory check result is "OK."
6. Press [END].
10.7.5 HDD R/W Check (Memory/HDD Adjustment)

Conducts the read/write check of the hard disc.
A. Procedure

3. Press [HDD R/W Check] from the menu.
4. "HDD R/W Check screen"
When completed normally after checking, it is displayed that the check result is "OK."
5. Press [END].
205
10.7.6 HDD Format (Memory/HDD Adjustment)

Formats HDD.
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Note
• When formatting HDD, all the data stored in HDD gets lost and becomes unrecoverable.
A. Procedure

3. Press [HDD Format] from the menu.
The screen for confirmation is display.
4. Press [Yes].
When formatting is executed and completed, a message "The formatting of HDD is completed" is dis-
played.
5. Turn OFF the power switch (SW2) and the main power switch (SW1) in this order.
6. After waiting for 10 seconds or more, turn ON SW1 and SW2 in this order.
Note
• Turning ON SW1 not waiting for 10 seconds or more after turning it OFF may damage HDD. Be
sure to turn ON SW1 10 seconds or more after turning it OFF.
10.7.7 Adj. Data Table

Displays the adjustment data set for this machine.
A. Procedure

Press [Adj. Data Table].
3. "Adj. Data Table screen"
Press [ ↑ ] or [ ↓ ] to display necessary items.
4. Pressing [NVRAM Value] switches the display into the step number display set and pressing also [Adjust
Value] switches the display into the adjustment value (the value of 1 step x the number of steps).
5. Press [OK].
206
10.7.8 Adj. Data Table
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Display Adjustment item
1/28 Print position adjustment: leading edge (tray 1)
Print position adjustment: leading edge (tray 2)
Print position adjustment: leading edge (LCT)
Print position adjustment: leading edge (bypass (normal paper))
Print position adjustment: leading edge (bypass (thick paper: large))
2/28 Print position adjustment: leading edge (bypass (thick paper: small))
Print position adjustment: leading edge (bypass (thin paper))
Print position adjustment: leading edge (bypass (OHP))
Print position adjustment: leading edge (bypass (envelope))
Print position adjustment: leading edge (bypass (label: large))
Print position adjustment: leading edge (bypass (label: small))
Print position adjustment: leading edge (ADU)
3/28 Print position adjustment: side edge (tray 1 (common))
Print position adjustment: side edge (tray 1 (small size))
Print position adjustment: side edge (tray 1 (large size))
Print position adjustment: side edge (tray 2 (common))
4/28 Print position adjustment: side edge (tray 3 (small size))
Print position adjustment: side edge (LCT)
Print position adjustment: side edge (ADU (common))
5/28 Print position adjustment: side edge (ADU (small size))
Print position adjustment: side edge (ADU (large size))
Print position adjustment: side edge (bypass (common))
Print position adjustment: side edge (bypass (small size))
Print position adjustment: side edge (bypass (large size))
Magnification in the printer feed direction (printer: normal paper)
Magnification in the printer feed direction (printer: OHP (large))
207

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6/28 Magnification in the printer feed direction (printer: OHP (small))

Magnification in the printer feed direction (printer: thick paper (large))
Magnification in the printer feed direction (printer: thick paper (small))
Magnification in the printer feed direction (printer: envelope)
Magnification in the printer feed direction (printer: label (large))
Magnification in the printer feed direction (printer: label (small))
Magnification in the printer feed direction (printer: custom paper)
7/28 Magnification in the printer feed direction (fixing motor clock: normal paper)
Magnification in the printer feed direction (fixing motor clock: OHP (large))
Magnification in the printer feed direction (fixing motor clock: OHP (small))
Magnification in the printer feed direction (fixing motor clock: thick paper (large))
Magnification in the printer feed direction (fixing motor clock: thick paper (small))
Magnification in the printer feed direction (fixing motor clock: envelope)
Magnification in the printer feed direction (fixing motor clock: label (large))
8/28 Magnification in the printer feed direction (fixing motor clock: label (small))
Magnification in the printer feed direction (fixing motor clock: custom paper)
Magnification in the printer feed direction (fixing motor clock: user paper)
Printer registration loop amount (tray 1 (small))
Printer registration loop amount (tray 1 (large))
Printer registration loop amount (tray 2 (middle1))
9/28 Printer registration loop amount (tray 2 (middle2))
Printer registration loop amount (tray 3 (middle))
Printer registration loop amount (tray 4 (middle))
10/28 Printer registration loop amount (tray 4 (large))
Printer registration loop amount (option tray)
Printer registration loop amount (LCT)
Printer registration loop amount (bypass (normal (small)))
Printer registration loop amount (bypass (normal (middle)))
Printer registration loop amount (bypass (normal (large)))
Printer registration loop amount (bypass (thick paper: small))
11/28 Printer registration loop amount (bypass (thick paper: large))
Printer registration loop amount (bypass (thin paper: small))
Printer registration loop amount (bypass (thin paper: large))
Printer registration loop amount (bypass (OHP: small))
Printer registration loop amount (bypass (OHP: large))
Printer registration loop amount (bypass (envelope))
Printer registration loop amount (bypass (label: small))
208
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12/28 Printer registration loop amount (bypass (label: large))
—
Printer registration loop amount (ADU (small))
Printer registration loop amount (ADU (large))
Tray adjustment (maximum width)
Tray adjustment (minimum width)
Scan area (scanning position: leading edge)
13/28 Scan area (scanning position: side edge)
Magnification in the scanner feed crossover direction
Magnification in the scanner feed direction
Printer leading edge erasure amount adjustment
Charging main manual
Transfer manual
Separation AC manual
14/28 Separation DC manual
Carging grid manual
Developing grid manual
TCR
Toner density
Dot diameter
LD1 offset (normal paper)
15/28 LD1 offset (thick paper)
LD2 offset (normal paper)
LD2 offset (thick paper)
LD1 bias (normal paper)
LD1 bias (thick paper)
LD2 bias (normal paper)
LD2 bias (thick paper)
16/28 Magnification in the ADF feed direction (single sided: 50%)
Magnification in the ADF feed direction (single sided: 100%)
Magnification in the ADF feed direction (double sided: 50%)
17/28 Magnification in the ADF feed direction (double sided: 400%)
ADF leading edge (single sided)
ADF leading edge (double sided (front side))
ADF leading edge (double sided (back side))
ADF side edge (single sided)
ADF side edge (double sided (front side))
ADF side edge (double sided (back side))
209

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18/28 ADF registration loop amount (single sided)

ADF registration loop amount (double sided)
ADF original size (maximum width)
ADF original size (minimum width)
ADF density
ADF scan position
Center staple position (B5S)
19/28 Center staple position (A4S)
Center staple position (B4)
Center staple position (A3)
Center staple position (81/2 x 11S)
Center staple position (11 x 17)
Center staple position (8K)
Center staple position (81/2 x 14)
20/28 Half-fold position (B5S)
Half-fold position (A4S)
Half-fold position (B4)
Half-fold position (A3)
Half-fold position (81/2 x 11S)
Half-fold position (11 x 17)
Half-fold position (8K)
21/28 Half-fold position (81/2 x 14)
Punch horizontal position
Punch registration loop amount (B5S)
Punch registration loop amount (B5)
Punch registration loop amount (A4S)
Punch registration loop amount (A4)
Punch registration loop amount (B4)
22/28 Punch registration loop amount (A3)
Punch registration loop amount (81/2 x 11S)
Punch registration loop amount (81/2 x 11)
Punch registration loop amount (81/2 x 14S)
Punch registration loop amount (11 x 17)
Punch registration loop amount (8K)
Punch registration loop amount (16K)
23/28 Punch registration loop amount (16KS)
Punch registration loop amount (FLS)
Test pattern density
DipSW No.01
DipSW No.02
DipSW No.03
DipSW No.04
210
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24/28 DipSW No.05
DipSW No.06
DipSW No.07
DipSW No.08
DipSW No.09
DipSW No.10
DipSW No.11
25/28 DipSW No.12
DipSW No.13
DipSW No.14
DipSW No.15
DipSW No.16
DipSW No.17
DipSW No.18
26/28 DipSW No.19
DipSW No.20
DipSW No.21
DipSW No.22
DipSW No.23
DipSW No.24
DipSW No.25
27/28 DipSW No.26
DipSW No.27
DipSW No.28
DipSW No.29
DipSW No.30
DipSW No.31
DipSW No.32
28/28 DipSW No.33
DipSW No.34
DipSW No.35
DipSW No.36
DipSW No.37
DipSW No.38
DipSW No.39
211
10.8 ADF
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10.8.1 Paper Feed Direction

Adjusts the magnification in the sub scan direction while in the DF original scan.
This adjustment adjusts the magnification of the image data in the sub scan direction by changing the scan
speed of DF.
The adjustment is made for each mode (single sided, double sided (front/rear)) and expansion/reduction ratio
(50%, 100%, 200%, 400%).
Note
• Make sure that the adjustment of the magnification in the printer paper feed direction has been
completed.
(See P.159)
A. Procedure

Press [ADF].
2. "ADF Adjustment screen"
Press [Paper Feed Direction].
3. "Paper Feed Direction screen"
Press the magnification that adjusts the 1-Sided or 2-Sided.
Select A3 (for metric) or 11 x 17 (for inch) paper, and press the Start key with the adjustment chart set to
DF.
6. Press [OK].
7. Measure the magnification in the paper feed direction with a scale.
Standard value (while in the life size): ± 0.5% or less (200 ± 1 mm or less)
8. "Paper Feed Direction screen"
Setting range: – 2.0 (shorter) to + 2.0% (longer)
1 step = 0.1%
10. Repeat steps 3 to 9 for each magnification.
11. Press [OK].
212
10.8.2 Lead Edge

Adjusts the position at which the image read is started while in the DF original scan.
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This adjustment adjusts the leading edge position of the image by changing the image read start timing after the
leading edge of the original passes through the read position.
The adjustment is made for each mode (1-Sided, 2-Sided (Front/Back)).
A. Procedure

Press [ADF].
Press [Lead Edge].
3. "ADF Adjustment: Lead Edge screen"
Press [1-Sided], [2-Sided (Front)], or [2-Sided (Back)] to select the mode.
DF.
6. Press [END].
7. Measure the leading edge position of the image with a scale.
8. "ADF Adjustment: Lead Edge screen"
Setting range: – 5.0 (slower start of read) to + 5.0 mm (faster start of read)
1 step = 0.1 mm
10. Repeat steps 3 to 9 for each mode.
11. Press [OK].
213
10.8.3 Side Edge

Adjusts the mis-centering of the image in the main scan direction while in the DF original scan.
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The adjustment is made for each mode (1-Sided, 2-Sided (Front/Back)).
Note
• Make sure that the adjustment of the printer position: side edge has been completed.
(See P.158)
A. Procedure

Press [ADF].
Press [Side Edge].
3. "ADF Adjustment: Side Edge screen"
Press [1-Sided], [2-Sided (Front)], or [2-Sided (Back)] to select the mode.
DF.
6. Press [END].
7. Fold the output paper into two at the center in the main scan direction, and check the discrepancy of the
print center line.
Standard value: ± 3.0 mm or less
8. "ADF Adjustment: Side Edge screen"
Setting range: – 2.96 (image: to the rear) to + 2.96 mm (image: to the front)
1 step = 0.04 mm
11. Press [OK].
214
10.8.4 Resist Loop Adj.

Adjusts the original loop amount (1-Sided or 2-Sided) at the registration roller section of DF to adjust a paper
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skew, wrinkles or an original jam at the registration section.
This adjustment adjusts the re-start timing of the DF registration roller.
A. Procedure

Press [ADF].
Press [Resist Loop Adj.].
3. "Resist Loop Adj. screen"
Press [1-Sided] or [2-Sided] to select the mode.
5. Select paper according to the item selected at step 3. Set A3 (for metric) or 11 x 17 (for inch) original that
is used more frequently set to DF and press the Start key.
6. Press [END].
Return to the registration loop amount adjustment screen.
7. "Resist Loop Adj. screen"
Setting range: – 5.0 (smaller) to + 5.0 mm (larger)
1 step = 0.5 mm
8. Repeat steps 5 to 7 until it becomes appropriate.
10. Press [OK].
10.8.5 Original Size Adj.

This adjustment is made when the original size detection does not function properly at DF.
A. Procedure

Press [ADF].
Press [Original Size Adj.].
3. "Original Size Adj. screen"
Press [Max. Width].
4. With A3 (for metric) or 11 x 17 (for inch) paper set to DF, press the Start key.
5. Check to see if the result is OK.
6. Press [Min. Width].
7. With B6S (for metric) or 5.5 x 8.5S (for inch) size paper set to DF, press the Start key.
8. Check to see if the result is "OK".
9. Press [OK].
215
10.8.6 Density Adj.

This adjustment is made when the slit glass is replaced.
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The slit glass at the scanner section is coated, and therefore, its transmittance of the exposure lamp is different
when compared to the original glass.
Prearrangements
• Clean the slit glass.
• Check the whole area of the white chart to see if it is not soiled.
A. Procedure

Press [ADF].
Press [Density Adj.].
3. "Density Adj. screen"
Set the white chart to DF.
Note
• Be sure to set the white chart in the A4 direction.
When the white chart is scanned and the auto adjustment of density is completed successfully, "OK" is
displayed.
5. When an error message is displayed, turn OFF and ON the power switch (SW2) of the main body and
repeat steps 3 to 4 until it is completed successfully.
6. Press [OK].
216
10.8.7 Scan Position Adjustment

Adjusts the read start position of the exposure unit in the sub scan direction.
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A. Procedure

Press [ADF].
Press [Scan Position Adjustment].
3. "Scan Position Adjustment screen"
Press [Test Copy].
ADF.
5. Press [END].
6. Check the read position.
[1]
50gaf3c012na
7. "Scan Position Adjustment screen"

Setting range: – 2.0 (faster) to + 2.0 mm (slower)
1 step = 0.1 mm
10. Press [OK].
217
10.8.8 Sensor Auto Adjust

This adjustment is made when an erroneous detection occurs with the reflective sensor, or after the DF control
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board (DFCB) and each of the reflective sensors are replaced. Conducting this adjustment backs up the sensi-
tivity value of each of the reflective sensors to RAM in DFCB.
Prearrangement
• Clean each of the reflective sensors of DF.
Note
• After conducting [Initialization + Auto Adjust], the value of the original size VR (VR1) is reset. Be
sure to conduct [Original Size Adjustment].
A. Procedure

Press [ADF].
Press [Sensor Auto Adjust].
3. "ADF Sendor Adjustment screen"
Press [Initialize And Sensor Auto Adj.] or [ADF Sensor Auto Adj.].
Check the check results, the initialization, and the sensors 1 to 4 to see if they are "OK."
5. Press [END].
218
10.9 Finisher
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10.9.1 Center Staple Position (SD-502)
Adjusts the stapling position in the sub scan direction while in the stitch-and-fold by SD-502.
Note
• Before conducting this adjustment, make sure that the adjustment of the half-fold position has
been completed.
(See P.220)
A. Procedure

Press [Finisher].
2. "Finisher Adjustment screen"
Press [Center Staple Position].
3. "Center Staple Position Adj. screen"
Press each key and select the paper size to be adjusted.
With 5 or more originals (2 or more sheets at the finish of the stitch-and-fold) set to DF, select suitable
paper and press the Start key.
6. Press [END].
7. Check the stitch-and-fold position of paper and
the position of the staple in the sub scan direction. [1]
4511f3c005na
8. "Center Staple Position Adj. screen"

Setting range: – 5.0 (to the right) to + 5.0 mm (to the left)
1 step = 0.5 mm
10. Press [OK].
219
10.9.2 Half-Fold Position (SD-502)

Adjusts the folding position while in the stitch-and-fold print by SD-502.
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A. Procedure

Press [Finisher].
Press [Half-Fold Position].
3. "Half-Fold Position Adjustment screen"
Press each key to select the paper size to be adjusted.
With the original set to DF, select a paper size and press the Start key.
6. Press [END].
7. Fold the output paper along the folding line and
check the paper edge to see if it is not shifted [1]. [1]
4511f3c006na
8. "Half-Fold Position Adjustment screen"

Setting range: – 5.0 (to the right) to + 5.0 mm (to the left)
1 step = 0.5 mm
Note
• When there occurs a shift shown at step 7, enter a value on the minus (–) side.
10. Press [OK].
220
10.9.3 Punch Horizontal Position (PU)

Adjusts the position of the punch holes by PU-501 in the sub scan direction.
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A. Procedure

Press [Finisher].
2. "Finisher Adjustment"
Press [Punch Horizontal Position].
3. "Punch Horizontal Position Adj. screen"
Press [Test Copy].
4. With the original set to DF, select a suitable paper size and press the Start key.
5. Press [END].
Return to the punch horizontal position adjustment screen.
6. Check the distance between the paper edge and
[1]
the center of the punch hole.
Standard value [1]: 11 mm (metric) , 9.5 mm (inch)
and 10.5 mm (swedish)
4512f3c003na
7. "Punch Horizontal Position Adj. screen"

Setting range: – 5.0 (shorter) to + 5.0 mm (longer)
1 step = 0.5 mm
9. Press [OK].
221
10.9.4 Punch Resist Loop (PU)

Adjusts the registration loop amount while in the punch by PU-501.
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This adjustment is made when there occurs a tilt with the punch hole, or when a jam occurs frequently in the
punch mode.
A. Procedure

Press [Finisher].
Press [Punch Resist Loop].
3. "Punch Resist Loop screen"
Press [Test Copy].
4. With the original set to DF, select a suitable paper size and press the Start key.
5. Press [END].
6. Check the punch holes to see if they are parallel
with the paper edge. And also check to see if a
jam occurs.
4512f3c004na
7. "Punch Resist Loop screen"

Setting range: – 4 (longer) to + 4 mm (shorter)
1 step = 1 mm
Note
• When a jam occurs in the punch mode, set a value to the minus (–) side.
• When the line of punch holes is slanted, set a value to the plus (+) side.
9. Press [OK].
222
10.10 Firmware Version
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Displays the version of the firmware (main body and optional).
• MFP Controller
• Image Controller
• Operation Panel Message Data
• Finisher
• ADF
• Fax board controller 1
• Fax board controller 2
• MFP Controller BOOT Program
• Image Controller BOOT Program
A. Procedure

Press [Firmware Version].
2. "Firmware Version screen"
Press [1] or [2] to display the intended item.
3. Press [END].
223
10.11 CS Remote Care

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10.11.1 Outlines
• CS Remote Care enables the machine and the computer at CS Remote Care center to exchange data
through telephone line in order to control the machine.
• CS Remote Care enables the machine to call the computer at the center when trouble occurs. It also ena-
bles the computer at the center to contact the machine for the necessary data.
• Data which CS Remote Care handles can be divided into the following groups.
a. Data which show the status of use of the machine such as Total count, PM count.
b. Data which show the abnormal situation on the machine such as where and how often errors occur.
c. Data on adjustment
d. Data on setting
10.11.2 Setting Up the CS Remote Care
Note
• At this moment on February 2006, the use of the communication means other than the modem is
unavailable.
• For resetting up the machine which CS Remote Care has already been set up, clear the RAM for
CS Remote Care before resetting.
For clearing RAM, see "(3) RAM Clear" in "C. Detail Setting" in "10.11.8 Detail on settings".
(See P.232)
• When using the telephone line for connection, use the recommended modem.
(For recommended modem, contact responsible person of KONICA MINOLTA.)
Step Procedure
0 Register the device ID to the application at CS Remote Care Center.
The initial connection is not available unless the device ID is registered.
1 Connecting the modem
Turn the power for the modem OFF. Connect the machine and the modem with a modem cable.
Connect the modem and the wall jack with a modular cable.
* For connecting the modular cable, see the manual for the modem.
2 Clearing the RAM
1. Select [Service Mode] → [CS Remove Care], and touch [Detail Setting].
2. Touch [RAM Clear].
3. Select Set, and touch [END].
(See P.233)
3 Selecting the CS Remote Care function
Select [Service Mode] → [CS Remove Care] → [System Selection], and touch [Modem].
4 Inputting the ID Code
1. Select [Service Mode] → [CS Remote Care] → [ID Code], and touch [ID Code].
2. Input the seven digits ID of the service person, and touch [ID Code] again.
(See P.232)
5 Setting the date and time for CS Remote Care
1. Select [Service Mode] → [CS Remote Care], and touch [Detail Setting].
2. Touch [Date & Time Setting].
3. Input the date, time and the time zone using the 10-Key Pad, and touch [Set].
(See P.232)
224
Step Procedure
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6 Setting the Center ID
2. Touch [Machine Setting] → [Center ID], and input the Center ID (five digits).
(See P.232)
7 Setting the Device ID
2. Touch [Machine Setting] → [Device ID], and input Device ID (nine digits).
(See P.232)
8 Setting the telephone number of the Center
2. Touch [Machine Setting] → [Center Telephone Number].
3. Input the telephone number of the Center using the 10-Keys Pad and [P], [T], [W], [-] keys.
(See P.232)
9 Inputting the Device telephone number
2. Touch [Machine Setting] → [Device Telephone Number].
3. Input the Device telephone number using the 10-Key Pad and [P], [T], [W], [-] keys.
(See P.232)
10 Inputting the AT command for initializing the modem
1. Select [Service Mode] → [CS Remote Care] → and touch [Detail Setting].
2. Touch [AT Command].
3. Input AT Command.
Note
• Change this Command only when it is necessary. (They do not need to be changed in
normal condition.)
• For details on AT Command, see the manual for the modem.
(See P.234)
11 Setting the DIPSW for CS Remote Care
Note
• This setting is not normally necessary. Take this step only when necessary in a spe-
cific connecting condition.
12 Executing the initial transmission
Select [Service Mode] → [CS Remote Care], and touch [Detail Setting].
Touch [initial transmission] on the right bottom of the screen to start initial transmission.
When the machine is properly connected with the Center, CS Remote Care setting screen will be
displayed.
Note
• The initial transmission key at the right bottom of the screen will be displayed only
when the Center ID, the Device ID, Telephone number of the Center and the Device
telephone number have been input.
(See P.232)
225
10.11.3 Software SW setting for CS Remote Care

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Note
• SW bits data are written into the NVRAM every time a change is made. In case you changed bit
data by accident, be sure to restore the previous state.
A. Input procedure
1. Select [Service Mode] → [CS Remote Care] → [Detail Setting], and touch [Software Switch Setting].
2. Touch [Switch No.], and input the SW number (two digits) using the 10-Key Pad.
3. Touch [Bit Assignment], and select SW bit number using the arrow keys, and input 0 or 1 using the 10-Key
Pad.
(For setting by hexadecimal numbers, touch [HEX Assignment] key, and input using the 10-Key Pad or A
to F keys.)
4. Touch [Fix].
Note
• About functions of each switch, see to "B. List of software SW for CS Remote Care".
B. List of software SW for CS Remote Care
Note
• Do not change any bit not described on this table.
SW No. Bit Functions 0 1 Default

SW 01 0 Dial Mode Pulse Tone 1
1 Reservation — — 0
4 Baud rate *1 *1 0
5 *1 *1 0
6 *1 *1 0
7 *1 *1 1
SW 02 0 Emergency transmission Do not call Call 1
1 Auto call on date specification Do not call Call 1
5 Auto call on the IC Life Do not call Call 1
6 Auto call on CCD Clamp/Gain Do not call Call 1
Adjustment failure
226
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SW 03 0 Reservation — — 0
1 Auto call on the toner empty Do not call Call 1
3 Auto call on the waste toner bottle full Do not call Call 1
4 to 7 Reservation — — 0
SW 04 0 to 7 Reservation — — 0
SW 05 0 Modem redial interval *2 *2 1
1 *2 *2 1
2 *2 *2 0
3 *2 *2 0
SW 06 0 Modem redial times *3 *3 0
1 *3 *3 1
2 *3 *3 0
3 *3 *3 1
4 *3 *3 0
5 *3 *3 0
6 *3 *3 0
SW 07 0 Redial for response time out Do not redial Redial 1
1 to 7 Reserved — — 0
SW 08 0 Retransmission interval on E-Mail deliv- *4 *4 0
1 ery error *4 *4 1
2 *4 *4 1
3 *4 *4 0
SW 09 0 Retransmission times on E-Mail *5 *5 0
1 delivery error *5 *5 1
2 *5 *5 0
3 *5 *5 1
4 *5 *5 0
5 *5 *5 0
6 *5 *5 0
227

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SW 11 0 Timer 1 *6 *6 0
1 RING reception → CONNECT *6 *6 0
2 reception *6 *6 0
3 *6 *6 0
4 *6 *6 0
5 *6 *6 1
6 *6 *6 0
7 *6 *6 0
SW 12 0 Timer 2 *7 *7 0
1 Dial request completed → CONNECT *7 *7 0
2 reception *7 *7 0
3 *7 *7 0
4 *7 *7 0
5 *7 *7 0
6 *7 *7 1
7 *7 *7 0
SW 14 0 Timer 4 *8 *8 0
1 Line connection → Start request *8 *8 0
2 telegram delivery *8 *8 0
3 *8 *8 0
4 *8 *8 0
5 *8 *8 1
6 *8 *8 0
7 *8 *8 0
SW 15 0 Timer 5 *9 *9 0
1 Wait time for other side's response *9 *9 1
2 *9 *9 1
3 *9 *9 1
4 *9 *9 1
5 *9 *9 0
6 *9 *9 0
7 *9 *9 0
SW 18 0 Attention display Do not call Call 1
To set weather to give the alarm display
when using the modem but the power
for the modem is OFF.
SW 19 to SW 0 to 7 Reservation — — 0
40
228
*1 Baud rate
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Mode 01-7 01-6 01-5 01-4
9600 bps 0 1 1 0
19200 bps 0 1 1 1
"38400 bps" 1 0 0 0
*2 Modem redial interval
Mode 05-3 05-2 05-1 05-0

1 minute 0 0 0 1
2 minutes 0 0 1 0
"3 minutes" 0 0 1 1
4 minutes 0 1 0 0
5 minutes 0 1 0 1
6 minutes 0 1 1 0
7 minutes 0 1 1 1
8 minutes 1 0 0 0
9 minutes 1 0 0 1
10 minutes 1 0 1 0
*3 Modem redial times
Mode 06-6 06-5 06-4 06-3 06-2 06-1 06-0

0 to 9 times 000 0000 to 000 1001
"10 times" 0 0 0 1 0 1 0
11 to 99 times 000 1011 to 110 0011
*4 Retransmission interval on E-Mail delivery error
Mode 08-3 08-2 08-1 08-0

0 minute 0 0 0 0
10 minutes 0 0 0 1
20 minutes 0 0 1 0
30 minutes 0 0 1 1
40 minutes 0 1 0 0
50 minutes 0 1 0 1
"60 minutes" 0 1 1 0
70 minutes 0 1 1 1
80 minutes 1 0 0 0
90 minutes 1 0 0 1
100 minutes 1 0 1 0
110 minutes 1 0 1 1
120 minutes 1 1 0 0
229
*5 Retransmission times on E-Mail delivery error

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Mode 09-6 09-5 09-4 09-3 09-2 09-1 09-0

0 to 9 times 000 0000 to 000 1001
"10 times" 0 0 0 1 0 1 0
11 to 99 times 000 1011 to 110 0011
*6 Timer 1 (RING reception → CONNECT reception)
Mode 11-7 11-6 11-5 11-4 11-3 11-2 11-1 11-0

0 to 31 sec 0000 0000 to 0001 1111
"32 sec" 0 0 1 0 0 0 0 0
33 to 255 sec 0010 0001 to 1111 1111
*7 Timer 2 (Dial request completed → CONNECT reception)
Mode 12-7 12-6 12-5 12-4 12-3 12-2 12-1 12-0

0 to 63 sec 0000 0000 to 0011 1111
"64 sec" 0 1 0 0 0 0 0 0
65 to 255 sec 0100 0001 to 1111 1111
*8 Timer 4 (Line connection → Start request telegram delivery)
Mode 14-7 14-6 14-5 14-4 14-3 14-2 14-1 14-0

0 to 31 (x 100 msec) 0000 0000 to 0001 1111
"32 (x 100 msec)" 0 0 1 0 0 0 0 0
33 to 255 (x 100 msec) 0010 0001 to 1111 1111
*9 Timer 5 (Wait time for other side's response)
Mode 15-7 15-6 15-5 15-4 15-3 15-2 15-1 15-0

0 to 29 sec 0000 0000 to 0001 1101
"30 sec" 0 0 0 1 1 1 1 0
31 to 255 sec 0001 1111 to 1111 1111
230
10.11.4 Setup confirmation

• Follow the steps below to make sure that CS Remote Care has been properly set up.
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1. Call the Service Mode to the screen.
2. Touch [CS Remote Care].
3. Check to make sure that only selected item is displayed.
10.11.5 Calling the Maintenance

• When CE starts maintenance, inputting the ID code of CE (seven digits: numbers which CE can identify.
They are controlled by the distributor.) will transmit the information to the Center side and tells that the main-
tenance has started. When the maintenance is finished, touching [Maintenance Complete] key will transmit
the information to the Center and tells that it is finished.
A. When starting the Maintenance
1. Select Service Mode and touch [CS Remote Care].

2. Touch [ID Code], and input ID Code.
3. Touch [ID Coke].
* The Start key blinks while maintenance is being carried out.
B. When finishing the Maintenance
1. Select Service Mode and touch [CS Remote Care].

2. Touch [Maintenance Complete].
10.11.6 Calling the Center from the Administrator

• When the CS Remote Care setup is complete, the administrator can call the CS Remote Care center.
1. Select [Administrator Setting], and touch [System Connection].

2. Touch [Admin. transmission].
When the setup is not complete or another transmission is being carried out, the Admin. transmission key
will not be displayed, and the transmission is not available.
Note
• For transmitting data of the machine by calling the center on the specified date and time, refer to
the manual for CS Remote Care Center.
10.11.7 Checking the transmission log

• The transmission log list will be output to be checked.
1. Select [Service Mode] → [CS Remote Care], and touch [Detail setting].
2. Touch [Communication Log Print].
3. Load Tray 1 or Bypass tray with A4S paper.
4. Press the Start key to output transmission log.
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10.11.8 Detail on settings

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A. System Selection
Functions • To select the system type for remote diagnosis.

Use • Use to newly build or change the system.
Setting/ • Select E-Mail, Modem, or Fax.
Procedure • Fax is available only when the optional Fax kit is being installed.
E-Mail (Not Used) Modem Fax (Not Used)
B. ID Code
Functions • To register the Service ID.

Use • Use when registering and changing Service ID.
Setting/ • Enter a 7-digit code from the 10-Key Pad. (0000001 to 9999999)
Procedure <Registration>
• Touch ID Code and enter the Service ID.
• Touch [ID code] to register the ID.
• The [Detail Setting] will appear when the ID has been registered.
C. Detail Setting
(1) Basic Setting
Functions • Execute the primary setting.

Use • Use to change the set contents.
• Use to register the machine to the CS Remote Care Center.
Setting/ 1. Call the Service Mode to the screen.
Procedure 2. Touch [CS Remote Care].
3. Touching the [Detail Setting] will display the primary setting.
Primary Setting
• Set the Center ID, Device ID, and the phone No.
• When e-mail is selected for system and all setup procedures are completed, E-mail
address of the Center is displayed.
* When entering the phone No, 10-Keys and keys on the screen have following meanings.
[–] Pose : Waits to start transmitting after dialing
[W] Wait : Detects the dial tone of the other end
[T] Tone dial : Carry out tone dialing
[P] Pulse dial : Carry out pulse dialing
[*], [#] : To be used as necessary
Initial Transmission
• Touching the Initial Transmission key will sent the information to the CS Remote Care
Center to register the machine.
(Only when the Modem or Fax is selected on the system Input.)
232
(2) Date & Time Setting
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Functions • To set the data and time-of-day
Use • Use to set or change the date and time-of-day.
Setting/ 1. Call the Service Mode to the screen.
3. Touch [Detail Setting] to access Date & Time Setting.
4. Enter the date (month, day and year), time-of-day, and the time zone from the 10-Key
Pad.
5. Touch [SET] to start the clock.
(3) RAM Clear
Functions • To clear the following data at the Center

ID Code, Primary Setting, Date/Time Input (Time Zone), Software SW Setting and AT
Command.
Use • To be used for setting CS Remote Care.
• To be used for reset the every data of the Center to default.
Note
• If RAM Clear is selected during transmission, RAM clear processing will be
implemented at the time the transmission is completed regardless of whether it
is done properly or not.
Setting/ • The default setting is “Unset.”
Procedure
Set “Unset”
(4) Communication Log Print
Functions • To print out the Communication Log.

Use • Use to output and use the Communication Log.
Setting/ 1. Call the Service Mode on the screen.
3. Touch [Detail Setting] to access Communication Log Print.
4. Load Tray 1 or Bypass Tray with A4S or 81/2 x 11 paper.
5. Press Start key to print out the Communication Log.
(5) Software Switch Setting
Functions • To change the CS Remote Care settings.

Use • To change the settings for CS Remote Care as necessary.
Setting/ For procedures on settings, see "10.11.3 Software SW setting for CS Remote Care".
Procedure (See P.226)
233
(6) Response Time Out

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Functions
Use
• Not Used. (To be used when connected by E-mail.)
Setting/
Procedure
D. AT Command
Functions • To set the command to be issued at the time of Modem Initialization.

• This setting is available only when [Modem] is selected for the system setting.
Use • To set the command to be issued at the time of Modem Initialization.
Setting/ • Enter the command and touch [SET] to register.
Procedure
E. Server set
Functions
Use
• Not Used.
Setting/
Procedure
10.11.9 List of the CS Remote Care error code
Note
• Error codes in the shaded region may occur when transmitting from the machine to the center.
Error code Error Solution

0001 The line is busy (Busy detection) • Transmit again manually.
0002 Failure of the Modem default setting at transmitting • Check if the power of the modem
(When the transmission completes with modem ini- is ON.
tial setting failed) • Check the connecting condition
between the modem and the
main unit.
0003 Timeout of CONNECT at transmitting • Transmit again manually
(No response to ATD) • Check if the power of the modem
is ON.
• Check the connecting condition
main unit.
0004 Timeout of Incoming request response • Contact responsible person of
(No response to incoming (starting) request MSG) KONICA MINOLTA.
234
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0005 Timeout of CONNECT at receiving • Check if the power of the modem
(No response to ATA) is ON.
• Check the connecting condition
main unit.
0006 Shut down of the data modem line (Host) • No solution, because the line is
(Carrier OFF is detected) shut down at the host side.
0007 Shut down of the data modem line (Main unit) • Contact responsible person of
(Line is shut down forcibly due to event) KONICA MINOLTA.
0008 Timeout of start request telegram delivery • Transmit again manually.
(Start request telegram is not delivered after line con-
nection)
0009 Timeout of finish request telegram delivery • Transmit again manually.
(Finish request telegram is not delivered (Start of
shut down).)
000A Receiving rejection • Check the setting condition of the
(Receiving is made when the main unit is set to reject host side.
receiving.) • Check the setting condition of the
main unit side.
000B RS232C Driver Over Run • If the same error is detected sev-
(When the modem detects Over Run.) eral times, turn the modem power
OFF and ON.
000C If the same error is detected several times, turn the • If the same error is detected sev-
modem power OFF and ON. eral times, turn the modem power
OFF and ON.
000D Break Interrupt (BI) Indicator • If the same error is detected sev-
(When the modem detects Break Interrupt (BI) Indi- eral times, turn the modem power
cator.) OFF and ON.
000E Receiving RING Buffer Full • Contact responsible person of
(When the Receiving RING Buffer is full.) KONICA MINOLTA.
000F Transmitting RING Buffer Full • Contact responsible person of
(When the Transmitting RING Buffer is full.) KONICA MINOLTA.
0010 RX FIF0 ERROR • Contact responsible person of
(when Read / Write error occurs at RX FIF0) KONICA MINOLTA.
0011 Baud Rate ERROR • Check the Baud rate of the soft-
(When selected Baud Rate is out of the specification ware DipSW.
(9600 bps to 38400 bps).)
0012 TX FIF0 Level Error • Contact responsible person of
(When the threshold of the selected TX FIF0 is not KONICA MINOLTA.
error value (1, 3, 9, 13).)
0013 RX FIF0 Level Error • Contact responsible person of
(When the threshold of the selected RX FIF0 is not KONICA MINOLTA.
error value (0, 4, 8, 14).)
0014 Receiving Data Over Error • Contact responsible person of
(When the data whose size exceeds the transmitting KONICA MINOLTA.
RING buffer is requested.)
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0015 Status Error • Contact responsible person of

(During modem operation is being confirmed) KONICA MINOLTA.
0016 Status Error (During receiving) • Contact responsible person of
KONICA MINOLTA.
0017 Status Error • Contact responsible person of
(During line is being shut down) KONICA MINOLTA.
0018 Machine ID has already been registered • Set the initial registrations again
(Request telegram 2 (SET-UP) comes from the main for all including the host side.
unit that has already registered Machine ID.)
0019 Center ID Error • Check Center ID setting of the
(Center ID of the host is not identical with the one of main unit side.
start request telegram.) • Check Center ID setting of the
main unit side.
001A Device ID inconsistency • Check Device ID setting of the
(Device ID of the host is not identical with the one of main unit side.
start request telegram.) • Check the setting of the host
side.
001B Device ID Unregistered • Check Device ID setting of the
(Request telegram 2 (Constant data transmitting, main unit side.
Emergency call) comes from the main unit that has • Check the setting of the host
not registered Machine ID yet.) side.
001C Grammar Error • Contact responsible person of
(Received response telegram is unregulated format.) KONICA MINOLTA.
001D Impossible to change (Unchangeable items) • Contact responsible person of
(Host requests to change the setting of items which KONICA MINOLTA.
are not allowed to change.)
001E Impossible to change (During printing) • Try again when the machine is not
(Setting cannot be changed because the setting printing.
change is made during the machine is printing or
starts printing.)
001F Impossible to change (Unread items) • Contact responsible person of
(The host tries to make writing on the items the cur- KONICA MINOLTA.
rent value has not been read.)
0020 Timeout of Telegram Delivery • Try communication again.
(At waiting mode of telegram delivery the machine
fails to receive the telegram in a given time.)
0021 Telegram Size Over • Contact responsible person of
(The machine receives the telegram whose size KONICA MINOLTA.
exceeds the specification.)
0022 Transmitting Phase Response NG • Contact responsible person of
(Transmitting phase response MSG is not appropri- KONICA MINOLTA.
ate.)
0023 Timeout of Transmitting Phase Response MSG • Contact responsible person of
(Transmitting phase response MSG is timeout.) KONICA MINOLTA.
236
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0024 Event Data Acquisition Function Error • Contact responsible person of
(Although the transmitting phase response MSG is KONICA MINOLTA.
OK, the function for Data acquisition shows “No
event,”.)
0025 Timeout of Driver transmitting check MSG • Contact responsible person of
(Transmitting check MSG from the driver task is tim- KONICA MINOLTA.
eout.)
0026 Detection of Internal Contradiction • Contact responsible person of
(Unknown event is detected. Condition value is not KONICA MINOLTA.
correct or so on.)
0027 Transmission / Receiving collision • Try communication again.
(Receiving is detecting during transmitting process-
ing)
10.11.10 Troubleshooting for CS Remote Care

If communication is not done properly during use of the modem, check the condition by following the proce-
dures shown below.
1. Shift the screen in the order of [Service Mode] → [CS Remote Care] → [Detail Setting].
At this time, in the cases of Initial transmitting / Administrator transmitting / Maintenance Start transmitting
/ Maintenance Finish transmitting, the communication result will be displayed at the top of the screen.
* For the communication result, the following message will be displayed based on its success or failure.
Display of Cause Solution

Communication result
Communicating — —
Communication Although the machine tries to commu- • See the list of error message and
trouble with the nicate with the Center, there is any confirm the corresponding point.
Center trouble and the communication com- (See P.234)
pletes unsuccessfully.
Complete success- — —
fully
Modem trouble Although the machine tries to commu- • Check if the Power of modem in
nicate with the Center, there is any ON.
trouble in the modem. • Check if there is any problem in
connection between the modem
and the main unit.
Busy line Although the machine tries to commu- • Communicate with the Center
nicate with the Center, the line to the again.
Center is busy.
No response Although the machine tries to commu- • Communicate with the Center
nicate with the Center, there is no again.
response from the Center. • Check the communication envi-
ronment of the Center side.
237
10.12 System 2
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10.12.1 Data Capture

Set the availability/unavailability of the capture of the print job data.
Keeping the print data captured allows the reproduction of a print with which a trouble occurred.
(For particulars, see "IV. Troubleshooting" of "Field Service IC-204.")
10.12.2 Paper Size Setting

Set the paper size of LU.
A. Procedure

Press [System 2].
Press [Paper Size Setting].
3. "Paper Size Setting screen"
Select [Tray 3] or [LCT] and press [Paper size].
4. Press [A4] or [81/2 x 11].
5. Press [OK] twice to return to [System Input screen].
10.12.3 DipSW Setting

Set the software DipSW.
Note
• Be sure not to change the setting of DipSW that is not given in this service manual.
A. Procedure

Press [System 2].
Press [DipSW Setting].
3. "Software Switch Setting screen"
Press [SW No.].
4. Press the [+]/[–] or numeric keys to enter the DipSW No.
In "SW Setting value", 8-bit data of the DipSW number selected is displayed in binary digit and hexadeci-
mal digit.
5. Press [Bit No.].
6. Press the [+]/[–] or numeric keys to enter the bit number.
7. Press either of [OFF (0)] or [ON (1)] of "Bit Data" to set a value.
8. Press [Set].
9. Repeat steps 3 to 8 to set necessary software DipSW.
10. Press [OK].
238
B. List of software DipSW
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Note
• Be sure not to change bits with no particular reference made of the function.
DIPSW No. Bit Function 0 1 Default setting

Japan Inch Metric
DipSW1 0 Operation at key counter Ignore. Decide promptly 0 1 1
removal as a jam.
1 PM counting method of A3 (11 1 count 2 counts 0 0 0
x 17)
2 — — — 0 0 0
3 — — — 0 0 0
4 — — — 0 0 0
5 — — — 0 0 0
6 — — — 0 0 0
7 Restriction of the FS-510 sta- None Stop once at 20 0 0 0
pled copy count copies.
DipSW2 0 No toner stop condition 1 Decided by Stop at once 0 0 0
DipSW3-2 after paper exit.
1 — — — 0 0 0
2 — — — 1 1 1
3 — — — 1 1 1
4 — — — 0 0 0
5 — — — 1 1 1
6 — — — 1 1 1
7 — — — 0 0 0
DipSW3 0 — — — 0 0 0
1 SC latch (fusing SC) Latch released Latched` 0 0 0
2 No toner stop condition 2 When a job Stop at the break 0 0 0
completed of the copy print.
3 — — — 0 0 0
4 — — — 1 1 1
5 — — — 0 0 0
6 — — — 0 0 0
7 — — — 0 0 0
DipSW4 0 Detection of the toner level *1 *1 0 0 0
1 (toner supply display) *1 *1 0 0 0
2 Print stop condition after toner *2 *2 1 1 1
3 supply display *2 *2 1 1 1
4 — — — 0 0 0
5 Job stop when there remains Not stop Stop 1 1 1
no toner
6 — — — 0 0 0
7 — — — 0 0 0
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Japan Inch Metric

DipSW5 0 — — — 0 1 0
1 — — — 0 0 1
2 — — — 0 0 0
3 — — — 0 0 0
4 — — — 0 0 0
5 Toner save setting *3 *3 0 0 0
6 *3 *3 0 0 0
7 — — — 0 0 0
DipSW6 0 Preliminary drum rotation of Not rotate Rotate 0 0 0
when the power is on
1 — — — 0 0 0
2 Selection of K size for machine Metric series Corresponding 0 0 0
dispatched to Taiwan (bypass) size to K size
3 — — — 0 0 0
4 — — — 0 0 0
5 — — — 1 1 1
6 — — — 1 1 1
7 — — — 0 0 0
DipSW7 0 — — — 1 0 0
1 — — — 0 0 0
2 — — — 1 0 0
3 — — — 0 0 0
4 — — — 0 1 0
5 — — — 0 0 0
6 — — — 0 0 0
7 — — — 0 0 0
DipSW8 0 Selection of the non-image Square erase Diagonal erase 1 0 0
auto erase mode
1 — — — 1 0 0
2 Print inhibition when getting at Invalid Valid 0 0 0
PM
3 — — — 0 0 0
4 — — — 0 0 0
5 — — — 0 0 0
6 — — — 0 0 0
7 — — — 0 0 0
240
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Japan Inch Metric
DipSW9 0 — — — 0 0 0
1 — — — 0 0 0
2 — — — 0 0 0
3 — — — 0 0 0
4 — — — 0 0 0
5 — — — 0 0 0
6 — — — 0 0 0
7 — — — 0 0 0
DipSW10 0 — — — 0 0 0
1 — — — 1 1 1
2 — — — 1 1 1
3 — — — 0 0 0
4 — — — 0 0 0
5 — — — 0 0 0
6 — — — 1 0 0
7 Jam code display Not displayed Displayed 0 0 0
DipSW11 0 — — — 0 0 0
1 — — — 1 1 1
2 — — — 0 0 0
3 — — — 0 0 0
4 — — — 0 0 0
5 — — — 0 0 0
6 — — — 0 0 0
7 — — — 0 0 0
DipSW12 0 — — — 0 0 0
1 — — — 0 0 0
2 — — — 0 0 0
3 Print count setting up to the *4 *4 0 0 0
4 print inhibition when getting at *4 *4 0 0 0
5 PM *4 *4 0 0 0
6 — — — 0 0 0
7 — — — 0 0 0
DipSW13 0 — — — 0 0 0
1 — — — 0 0 0
2 — — — 0 0 0
3 Jaggy filter selection OFF ON 0 0 0
4 — — — 0 0 0
5 — — — 0 0 0
6 Discrimination level of the non- *5 *5 1 1 1
7 image auto erase mode *5 *5 0 0 0
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Japan Inch Metric

DipSW14 0 — — — 0 1 0
1 — — — 0 1 0
2 — — — 0 1 0
3 — — — 0 1 0
4 — — — 0 0 0
5 — — — 0 0 0
6 — — — 0 0 0
7 — — — 0 0 0
DipSW15 0 — — — 0 0 0
1 — — — 0 0 0
2 — — — 0 0 0
3 — — — 0 0 0
4 — — — 0 0 0
5 — — — 0 0 0
6 Stop/non-stop due to overload Stop at 400 Not stop 0 0 0
when not connected to FS/job sheets
tray.
7 — — — 1 1 1
DipSW16 0 Fusing temperature while in the *6 *6 0 0 0
1 low power mode *6 *6 0 1 1
2 Heater operation Heater turns ON Heater is OFF while 1 1 1
at all times. in the sleep mode.
3 Print permission before con- Permit Prohibit 1 1 1
ducting TCR adjustment
4 — — — 0 0 0
5 — — — 0 0 0
6 Dot diameter adjustment con- *7 *7 1 1 1
7 trol *7 *7 0/1 0 0
DipSW17 0 Foolscap size setting *8 *8 0 0 0
1 *8 *8 0 0 0
2 *8 *8 0 0 0
3 — — — 0 0 0
4 — — — 0 0 0
5 — — — 0 0 0
6 — — — 0 0 0
7 Separation claw operation OFF Normal OFF 0 0 0
mode (for destination to China)
242
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Japan Inch Metric
DipSW18 0 Separation of a defective part Normal Separated 0 0 0
from the tray 1 (upper stage of
the main body)
1 Separation of a defective part Normal Separated 0 0 0
from the tray 2 (lower stage of
the main body)
2 — — — 0 0 0
3 — — — 0 0 0
from the tray 3 (PC-202 upper
stage/PC-402)
from the tray 4 (PC-202 lower
stage)
from the tray 5 (LU)
7 — — — 0 0 0
from the printer controller (IC)
from the FAX kit (FK)
2 — — — 0 0 0
from HDD
4 — — — 0 0 0
5 — — — 0 0 0
6 — — — 0 0 0
from DF
from the network
from IEEE1284
from USB
3 — — — 0 0 0
4 — — — 0 0 0
from SD
6 — — — 0 0 0
7 — — — 0 0 0
243

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Japan Inch Metric

DipSW21 0 — — — 1 0 1
1 — — — 0 0 0
2 Platen/ADF size recognition 81/2 x 14 Foolscap 0 0 0
switchover
3 — — — 0 0 0
4 — — — 0 0 0
5 Platen small size (81/2 x 11/A4 *9 *9 0 1 0
or less) setting
6 — — — 0 0 0
7 — — — 0 0 0
DipSW22 0 — — — 1 1 1
1 — — — 0 0 0
2 — — — 0 0 0
3 — — — 0 0 0
4 — — — 0 0 0
5 — — — 0 0 0
6 — — — 0 0 0
7 — — — 0 0 0
DipSW23 0 — — — 1 1 1
1 — — — 1 1 1
2 — — — 1 1 1
3 — — — 1 1 1
4 Tray full detection at the exit of Not detected Detected 0 0 0
100 sheets while in the FS
non-staple (FS-510)
5 Tray full detection at the exit of Not detected Detected 1 1 1
100 sheets while in the FS sta-
ple (FS-510)
6 — — — 0 0 0
7 — — — 0 0 0
DipSW24 0 Mixed original direction setting Not detected Detected 0 0 0
1 — — — 0 0 0
2 — — — 0 0 0
3 — — — 0 0 0
4 — — — 0 0 0
5 — — — 0 0 0
6 — — — 0 0 0
7 — — — 0 0 0
244
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Japan Inch Metric
DipSW25 0 — — — 0 0 0
1 — — — 0 0 0
2 — — — 0 0 0
3 Switchover of the TSL control Normally All OFF 0 0 0
ON/OFF
4 — — — 0 0 0
5 — — — 0 0 0
6 — — — 0 0 0
7 — — — 0 0 0
DipSW26 0 Polygon motor stop timer 15 seconds 30 seconds 0 0 0
1 — — — 0 0 0
2 — — — 0 0 0
3 Reference image position for At the center On the rear 0 0 0
bypass custom paper side of paper
4 — — — 0 0 0
5 — — — 0 0 0
6 — — — 0 0 0
7 — — — 0 0 0
DipSW27 0 — — — 0 0 0
1 — — — 0 0 0
2 — — — 0 0 0
3 — — — 0 0 0
4 — — — 0 0 0
5 Density setting when the *10 *10 0 0 0
6 printer toner save function is *10 *10 0 0 0
7 selected. *10 *10 0 0 0
DipSW28 0 Image leading edge position *11 *11 0 0 0
1 adjustment while in the image *11 *11 0 0 0
2 rotation *11 *11 0 0 0
3 *11 *11 0 0 0
4 Image leading edge position *12 *12 0 0 0
5 adjustment while in the platen *12 *12 0 0 0
6 memory copy *12 *12 0 0 0
7 *12 *12 0 0 0
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Japan Inch Metric

DipSW29 0 Transfer/separation output *13 *13 0 0 0
1 selection of the user paper *13 *13 0 0 0
2 (tray) *13 *13 1 1 1
3 TSL (transfer exposure lamp) *14 *14 0 0 0
4 control of the user paper (tray) *14 *14 0 0 0
5 — — — 0 0 0
6 — — — 1 1 1
7 — — — 0 0 0
DipSW30 0 Transfer/separation output *15 *15 0 0 0
1 selection of the user paper *15 *15 0 0 0
2 (bypass) *15 *15 0 0 0
3 TSL control of the user paper *16 *16 0 0 0
4 (bypass) *16 *16 0 0 0
5 — — — 0 0 0
6 — — — 0 0 0
7 FCOT-EE setting No pre-scan Pre-scan 0 0 0
DipSW31 0 — — — 1 1 1
1 — — — 0 0 0
2 — — — 0 0 0
3 — — — 0 0 0
4 — — — 0 0 0
5 — — — 0 0 0
6 — — — 1 1 1
7 — — — 1 1 0
DipSW32 0 — — — 0 0 0
1 — — — 0 0 0
2 — — — 0 0 0
3 — — — 0 0 0
4 — — — 0 0 0
5 — — — 0 0 0
6 — — — 0 0 0
7 — — — 0 0 0
DipSW33 0 Switchover of the punch hole *17 *17 0 1 0
1 number (PU) *17 *17 0 0 1
2 — — — 0 0 0
3 — — — 0 0 0
4 — — — 0 0 0
5 — — — 0 0 0
6 — — — 0 0 0
7 Mixplex function provided/not Provided Not provided 0 0 0
provided
246
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Japan Inch Metric
DipSW34 0 System ON/OFF while in the ON OFF 1 1 1
sleep or the power switch
(SW2) OFF
1 FS-510 paper exit tray position *18 *18 0 0 0
2 *18 *18 0 0 0
3 *18 *18 0 0 0
4 Print start permission when Permit Prohibit 0 0 0
SD-502 is supplied with paper.
5 — — — 0 0 0
6 USB function ISW mode Printer mode 1 1 1
7 — — — 0 0 0
DipSW35 0 — — — 0 0 0
1 — — — 0 0 0
2 — — — 0 0 0
3 — — — 0 0 0
4 — — — 0 0 0
5 — — — 0 0 0
6 — — — 0 0 0
7 Engine power source control Power OFF Power not OFF 0 0 0
by the SC detection
DipSW36 0 IPX used or not used Not used Used 1 1 1
1 Telnet used or not used Not used Used 0 0 0
2 Fusing temperature setting *19 *19 0 0 0
3 when normal paper is selected *19 *19 0 0 0
when thick paper, envelope or
label is selected
when thin paper is selected.
7 when OHP is selected. *22 *22 0 0 0
247
*1 Toner level detection (toner supply display) Mode 4-1 4-0

Set the copy count that is printed until the print oper-
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After 0 print or its equiva- 0 0

ation is terminated from the toner near empty is dis-
lent
played after the toner level sensor (PZS) detects toner
After 100 print or its 0 1
empty for a certain period of time.
equivalent
equivalent
equivalent
*2 Print stop condition after the toner supply display Mode 4-3 4-2
Set the copy count that is printed until the print is pro-
100 prints or its equiva- 0 0
hibited after a message set by DipSW4-0/1 is dis-
lent
played.
lent
lent
lent
*3 Toner save setting Mode 5-6 5-5

Toner consumption can be reduced by bringing the
No adjustment made 0 0
developing bias and the charging grid potential down
Toner consumption 0 1
below 50V (20 steps). And it is also possible to
increased (Image density
increase the image density a little by bringing the
increased)
potential up above 50V (20 steps).
Toner consumption 1 0
reduced (Image density
reduced)
No adjustment made 1 1
*4 Setting of the print count made up to the time of Mode 12-5 12-4 12-3
the print inhibition when gettint to PM
1000 prints 0 0 0
When getting at DipSW8-2PM with the print inhibition
2000 prints 0 0 1
set to "1," the print stops after getting at the PM
3000 prints 0 1 0
count shown on the right.
4000 prints 0 1 1
5000 prints 1 0 0
248
*5 Discrimination level of the non-image auto erase Mode 13-7 13-6

mode
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Corresponding to dark 0 0
This setting is made in the non-image erase mode of
original
an applicable function. The image area detection
Standard 0 1
threshold value is set when the non-image erase
Corresponding to light 1 0
function set by the administrator is set to no limit.
interference
— 1 1
*6 Fusing temperature while in the low power Mode 16-1 16-0

Set the fusing temperature while in the low power
The fusing heater lamps /1 (L2) and /2 0 0
mode.
(L3) turn on when the thermistors /1
(TH1) and /2 (TH2) are respectively at
70 °C, and turn OFF when they are at
80 °C.
(L3) turn ON when the thermistors /1
130 °C.
160 °C.
80 °C.
*7 Dot diameter adjustment control Mode 16-7 16-6

Change the timing when the dot diameter adjustment
The humidity is 60% or 0 0
is made.
more and the power
switch turns OFF for more
than 8 hours.
The power switch turns 0 1
OFF for more than 8
hours.
At all times 1 0
None 1 1
249
*8 Foolscap size setting Mode 17-2 17-1 17-0

Set the definition of the foolscap size.
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81/2 x 13 0 0 0
8 /4 x 13
1 0 0 1
8 /8 x 13 /4
1 1
0 1 0
8 x 13 0 1 1
*9 Platen small size (81/2 x 11/A4 or less) setting Mode 21-5

Default setting is "1" for inch and "0" for metric.
A notice is made in a size detected by 0
APS.
A notice is made as A4 (Japan) / 1

81/2 x 11 (inch) size.
*10 Density setting when selecting the printer toner Mode 27-7 27-6 27-5
save function.
Standard 0 0 0
When "Toner save mode" for the printer driver turns
– 4 (thin) 0 0 1
ON, set the printer density in the range shown in the
table. –3 0 1 0
–2 0 1 1
–1 1 0 0
+1 1 0 1
+2 1 1 0
+ 3 (dense) 1 1 1
*11 Adjustment of the image leading edge while in Mode 28-3 28-2 28-1 28-0
the image rotation
+ 0 mm 0 0 0 0
While in the location in the 1-sided/2-sided copy,
+ 0.5 mm 0 0 0 1
adjust the slippage at the leading edge when there
occurs a leading edge slippage of 3 to 4 mm on the – 0.5 mm 1 0 0 1
back page. + 3.5 mm 0 1 1 1

– 3.5 mm 1 1 1 1
*12 Adjustment of the image leading edge position Mode 28-7 28-6 28-5 28-4
while in the platen memory copy
+ 0 mm 0 0 0 0
While in the platen copy, the paper exit direction is
+ 0.5 mm 0 0 0 1
reversed for the normal print and the memory print.
Adjust the discrepancy when the image leading edge – 0.5 mm 1 0 0 1
position is slipped. + 3.5 mm 0 1 1 1

– 3.5 mm 1 1 1 1
250
*13 Selection of the transfer/separation output of the Mode 29-2 29-1 29-0
user paper (tray)
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Normal paper (Japan) 0 0 0
Set the transfer/separation output that is applicable
Normal paper (inch) 0 0 1
when selecting the user paper in [Paper type] of [Util-
Normal paper (metric) 0 1 0
ity menu].
Thick paper 0 1 1
Thin paper 1 0 0
Recycled paper 1 0 1
*14 TSL control of the user paper (tray) Mode 29-4 29-3
Set the TSL control that is applicable when selecting
Normal ON control 0 0
the user paper in [Paper type] of [Utility menu]. When
All OFF 0 1
selecting "Switch over depending on the environ-
Switching over depending 1 0
ment," conduct the TSL control by switching over
on the environment
"Normal ON control"/"All OFF" according to the
humidity detected by the humidity sensor (HUMS).
*15 Selection of the transfer/separation output of the Mode 30-2 30-1 30-0
user paper (bypass)
Normal paper (Japan) 0 0 0
When selecting the bypass tray, set the transfer/sep-
Normal paper (inch) 0 0 1
aration output that is applicable when the user paper
is selected in [Specialty paper] of "Change Tray set- Normal paper (metric) 0 1 0
tings" or when it is selected in [Paper type] of [Utility Thick paper 0 1 1

menu]. Thin paper 1 0 0
Recycled paper 1 0 1
*16 TSL control of the user paper (bypass) Mode 30-4 30-3
When selecting the bypass tray, set the TSL control
Normal control 0 0
that is applicable when the user paper is selected in
All OFF 0 1
[Specialty paper] of "Change Tray settings" or when it
is selected in [Paper type] of [Utility menu]. Switching over depending 1 0
When selecting "Switch over depending on the envi- on the environment
ronment," conduct the TSL control by switching over

"Normal control"/"All OFF" according to the humidity
detected by the humidity sensor (HUMS).
*17 Switchover of the punch hole number (PU) Mode 33-1 33-0
While in the use of PU-501, set the number of punch
2 holes (Japan) 0 0
holes to be displayed on the operation board. This
3 holes (inch) 0 1
can be set regardless of the destination of the main
body. 4 holes (metric) 1 0
Default setting is 3 holes for inch and 4 holes for met- 4 holes (Sweden) 1 1
ric.
251
*18 FS-510 paper exit tray position Mode 34-3 34-2 34-1
Set the stop position of the paper exit tray.
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Not fixed 0 0 0
Tray 1 0 0 1
Tray 2 0 1 0
Tray 3 0 1 1
Folding/stitch-and-fold 1 0 0
tray (SD)
Not fixed 1 0 1
1 1 0
1 1 1
*19 Fusing temperature setting while in the selection Mode 36-3 36-2
of plain paper
Standard 0 0
When there occurs a problem (insufficient fusing,
Standard + 10 °C 0 1
large paper curl) with fusibility while in the selection of
plain paper, change the fusing set temperature.
• Countermeasure Standard – 10 °C 1 1
1) Increase the temperature: To suppress a jam
due to an insufficient fusing and the wind-up of
paper around the roller.
2) Decrease the temperature: To suppress a
paper curl and the undulation of paper.
*20 Fusing temperature setting while in the selection Mode 36-4

of thick paper, envelope, label.
Standard 0
When there occurs a problem (insufficient fusing) with
Standard + 10 °C 1
fusibility while in the selection of thick paper, envelope
and label, change the fusing set temperature. (For
countermeasure, see *19.)
*21 Fusing temperature setting while in the selection Mode 36-5

of thin paper
Standard 0
When there occurs a problem (insufficient fusing) with
Standard + 10 °C 1
fusibility while in the selection of thin paper, change
the fusing set temperature. (For countermeasure, see
*19.)
*22 Fusing temperature setting while in the selection Mode 36-7 36-6
of OHP
Standard 0 0
When there occurs a problem (insufficient fusibility
and large paper curl) with fusibility while in the selec-
Standard – 20 °C 1 0
tion of OHP, change the fusing set temperature. (For
countermeasure, see *19.) Standard – 10 °C 1 1
252
10.12.4 ISW
For particulars, see "5. FIRMWARE VERSION UP".
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(See P.95)
10.12.5 Option
Let the main body recognize the installing condition of the optional HDD and FAX.
A. Procedure

Press [System 2].
Press [Option].
3. "Option screen"
Press [Installed] or [Not Installed] to select the installation or non-installation of the HDD and FAX.
4. Press [OK].
10.12.6 Trouble Reset

After completion of the handling of a trouble related to the fusing system, release the trouble.
Note
• When a trouble related to the fusing system occurs, the software DipSW3-1 (SC latch) is set to "1"
("0" for default). This adjustment is used to return this to the default condition (normal operation).
• When an SC code is displayed on the touch panel, you cannot enter the service mode. Accord-
ingly, the following shows the method for resetting a trouble from the power-off condition.
A. Procedure
1. Turn ON the main power switch (SW1).

2. With the Utility/Counter key pressed, turn ON the power switch (SW2).
3. Press [Trouble reset] to release a trouble with [OK] displayed.
4. Turn OFF and ON the power switch (SW2).
253
10.13 List Output

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10.13.1 List output

Outputs various types of lists.
Lists that can be output are as shown below.
• Machine Management List
• Adjustment List
• Service Parameter
• Protocol Trace Last
• Protocol Trace Error
• Fax Setting List
A. Prearrangement
Set A4S (for metric) or 8.5 x 11S (for inch) size paper in one of the trays.
B. Procedure

Press [List Output].
2. "List Output screen"
Press the list to output for selection.
The list selected is output.
4. "List Output screen"
When outputting other lists, repeat steps 2 to 3.
5. Press [END].
Service Mode screen appears.
254
10.14 Test Mode
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10.14.1 Test pattern list
The following test patterns can be output.
• Full Image Halftone (No. 1)
• Gradation Pattern (No. 2)
• Beam Gap Check (No. 11)
• Line Check Pattern (No. 16)
Note
• Be sure not to output a test pattern that is not given in this service manual.
255
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No.1 Overall halftone (8-bit output)
[Check item]
• When the density is set at 70 (halftone)
When there are white stripes or black stripes, check to see if an abnormality is found with the scanner
system or process system
[Recommended sections to be checked]: Developing unit, cleaning glass, charging corona, transfer/sep-
aration corona, scanner mirror, slit glass and original glass
• When the density is set at 0 (white)
When an image fogging occurs, check the process system to see if an abnormality is found with it.
[Recommended sections to be checked]: Charging corona, and the contact of a high voltage power
source
• When the density is set at 255 (black)
When the density is thin, check the process system to see if an abnormality is found with it.
[Recommended sections to be checked]: Write unit
Test pattern
When the density is set at 70. When the density is set at 0. When the density is set at 255.
50gaf3c007na
256
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No.2 Gradation pattern
[Check item]
When fogging appears or density is thin, check the process system and the gamma correction to see if which
is defective.
Regardless of this test pattern being normal, any trouble is found with the print image, the image processing
system or scanner system is considered defective.
Test patterns
50gaf3c013na
257
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No.3 Gradation pattern (8-bit output)
[Check item]
• Check to see if the laser output of LD1/LD2 is uniform and if the gradation is reproduced without a break.
[Recommended sections to be checked]: Write unit, and LD offset adjustment
* For LD offset adjustment, see "10.4.11 LD1 Offset Adj. / LD2 Offset Adj.".
(See P.172)
Test pattern
LD1 LD2
50gaf3c008na
258
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No.5 Gradation pattern (8-bit output)
[Check item]
• Check the pattern to see if the laser output of LD1/LD2 is uniform with the gradation continuously repro-
duced.
[Recommended checkpoints]: Write unit, LD offset adjustment
* For LD offset adjustment, see "10.4.11 LD1 Offset Adj. / LD2 Offset Adj.".
(See P.172)
Test pattern
LD1 LD2
50gaf3c009na
259
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No.11 Beam check (8-bit output)
[Check item 1]
• Check to see if there is a difference in density found with the solid black pattern in the main scan and sub
scan directions.
[Recommended sections to be checked]: Charging corona, transfer/separation corona, developing unit,
and write dust-proof glass.
[Check item 2]
• Check to see if an image crawling occurs with the gradation pattern at the leading edge and/or trailing
edge of the test pattern in the sub scan direction.
[Recommended sections to be checked]: Transfer/separation corona
Test pattern
[1]
[2]
50gaf3c010na
[1] Solid black pattern [2] Gradation pattern
260
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No.16 Linearity evaluation pattern (1-bit error diffusion output)
[Check item]
Judge from this test pattern whether the scanner system or the printer system is abnormal.
Items that can be checked include main scan magnification, sub scan magnification, image skew, and leading
edge timing of the printer system. If the copy image is defective despite no abnormality being visible on the
test pattern, the scanner system is defective.
Test pattern
[1]
31mm 237mm
20mm
[1]
190mm
m
0m
28
205.7mm
28
0m
m
190mm
190mm 50gaf3c011na
[1] Edge of paper
261
10.14.2 Test pattern output

There are two methods provided for the test pattern output.
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• Output it by selecting the item of each test pattern. (Procedure A)

• Output it by specifying the test pattern number. (Procedure B)
Note
• Be sure not to output a test pattern that is not given in this service manual.
A. Procedure for a test pattern output

Press [Test Mode].
2. "Test Mode screen"
Press either of the following: [Full Image Halftone], [Gradation Pattern (No. 2)], [Gradation Pattern (No. 3)],
[Gradation Pattern (No. 5)], [Beam Gap Check] and [Line Check Pattern].
3. Screen for each pattern
When specifying any density, enter a density value through [+]/[–] keys and press [Setting].
When selecting an overall halftone, it is possible to select a halftone density by [0 (White)], [70 (Halftone)]
and [255 (Black)].
Select A3 (for metric) or 11 x 17 (for inch) paper and press the Start key.
6. Check the test pattern and press [END].
7. When outputting other test patterns, repeat steps 2 to 6.
8. Press [OK].
B. Procedure for any test pattern output

Press [Test Mode].
Press [Test pattern output mode].
3. "Test Pattern Output Mode screen"
Press [Pattern No.] and specify a test pattern number through the [+]/[–] keys.
When specifying any density, press [Density Setting], enter a density value through the [+]/[–] keys and
press [Setting].
With A3 (for metric) or 11 x 17 (for inch) paper selected, press the Start key.
6. Check the test pattern and press [END].
7. When outputting other test patterns, repeat steps 3 to 7.
8. Press [OK].
262
10.14.3 Running Mode

Conduct a continuous print operation test.
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In this mode, the following items can be selected.
• Intermittent Copy Mode

The machine shifts into the ready condition after completion of the print operation of the set copy count and
conducts the same operation after waiting for 0.5 sec.
• Paperless Running Mode

In this mode, no paper is fed and none of the paper detection/jam detection is made while in the operation. The
print operation is made nearly at the same timing as the usual operation with no transfer/separation control
made. The machine shifts into the ready condition after completion of the print operation of the set copy count
and conducts the same operation after waiting for 0.5 sec.
• Paperless Mode
With no paper fed and none of the paper detection/jam detection made, the print operation is made nearly at
the same timing as the usual operation.
• Paperless Endless Mode

The operation is made with the set copy count automatically set with no limit. Like the paperless mode, the print
operation is made nearly at the same timing as the usual operation with no paper fed and none of the paper
detection/jam detection made.
• Progress Running Mode

The combined operation of the paperless endless mode plus the scan operation and the stepped change of the
auto paper feed is made. This is not use in the field.
A. Procedure

Press [Test Mode].
Press [Running mode].
3. "Running Mode screen"
Press [Intermittent Copy] to [Paperless Endless] and select a test mode to be conducted.
4. Press the Start key to start the running test.
5. Press the Stop key to stop the running test.
6. Turn off and on the power switch (SW2) to exit the running test mode.
263
10.15 Fax setting

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For particulars of the setting, see FK-502 Service Manual.
264
10.16 Enhanced Security
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10.16.1 List of the security setting
Adjustment/setting item
Enhanced Security CE Password
Administrator Password
Administrator Feature Level Level 1
Level 2
Prohibit
CE Authentication ON
OFF
10.16.2 Start and termination of the security mode

Security setting is made on "Enhanced security screen" in the security mode.
A. Procedure

With none of the service mode items selected, press the copy count setting keys in the order shown
below.
Stop → 0 → C
2. "Enhanced Security screen"
The security mode is put in the start-up condition and the security setting is available.
When selecting either of the service mode items, the selected service mode item screen is displayed and
the security mode terminates.
265
10.16.3 CE Password
Set a password to enter the service mode.
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Note
• Be sure to avoid using as a password the name and the birth day that can be easily suspected by
other people.
• CE must not leak the password to other people.
• The CE password is valid when the CE authentication function is valid.
(See P.267)
A. Procedure

Press [CE Password].
2. "CE Password Setting screen"
Enter 8 digits of a password currently set in the alphanumeric characters and press [END]. "92729272" is
set for default.
3. Enter 8 digits of a new password in the alphanumeric characters and press [END].
4. Enter 8 digits of the re-entered password in the alphanumeric characters and press [END] to make the
setting valid with [Enhanced Security screen] displayed.
If you want to make the entered setting invalid, press [Cancel].
10.16.4 Administrator Password

Set a password to enter the administrator setting of the set-up menu.
The administrator password can also be set from the administrator setting of the set-up menu.
Note
• Be sure to avoid using as a password the name and the birth day that can be easily suspected by
other people.
A. Procedure

Press [Administrator Password].
2. "Administrator Password Setting screen"
Enter 8 digits of a new password in the alphanumeric characters and press [END]. "12345678" is set for
default.
3. Enter 8 digits of the re-entered password in the alphanumeric characters and press [END] to make the
setting valid with [Enhanced Security screen] displayed.
If you want to make the entered setting invalid, press [Cancel].
266
10.16.5 Administrator Feature Level

Set the range of the administrator feature to be displayed in Administrator Setting in the Utility menu. When the
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setting is made to [Prohibit] in this feature, the following features are not displayed.
A. Features not diaplayed
[3] Administrator setting [1] System setting [0] Standard Size setting
B. Procedure

Press [Administrator Feature Level].
2. "Administrator Feature Level Setting screen"
Select either of [Level 1]/[Level 2]/[Prohibit].
3. Press [END] to register the feature selected.
10.16.6 CE Authentication
Set the request or non-request of the password entry to enhance the security level in the service mode.
A. Procedure

Press [CE Authentication].
2. "CE Authentication screen"
Press [ON] or [OFF].
3. Press [END] to decide the setting with [Enhanced Security screen] displayed.
267
10.17 Billing Setting

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10.17.1 List of the billing setting
Adjustment/setting item
Billing Setting Counter Setting
Management Function Choice
10.17.2 Start and termination of the billing setting mode

The billing setting is made in [Billing Setting screen] in the billing setting mode.
A. Procedure

With none of the service mode items selected, press the copy count setting keys in the order shown
below.
Stop → 9
2. "Billing Setting screen"
The billing mode is put in the start-up condition and the billing setting is available.
When selecting either of the service mode items, the billing setting mode is terminated and the selected
service mode item screen is displayed.
268
10.17.3 Counter Setting

Set the counter mode of the counters of 2 types.
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• Total Counter Mode
• Large Size Counter Mode
A. Procedure

Press [Counter Setting].
2. "Counter Setting screen"
Select a count mode of the total counter in either of [Mode 1] or [Mode 2].
• Total counter count mode ([Mode 1] for the initial setting)
[Mode 1]: 1 count for each print
[Mode 2]: 2 counts depending on the paper size and the print mode.
3. Select a count mode of the large size counter from among the following items.
• Large size counter count mode ([No Count] for the initial setting)
[No Count]
[A3/11 x 17]
[A3/B4/11 x 17/81/2 x 14]
[A3/11 x 17/B4/81/2 x 14/Foolscap]
Note
• When selecting other than [No count], the count-up is as shown below in the combination of the
total counter and the counter mode.
Copy mode 1-sided copy 2-sided copy

Print paper size Other than the Specified size Other than the Specified size
specified size specified size
Count mode selection of the total counter Mode 1 Mode 2 Mode 1 Mode 2 Mode 1 Mode 2 Mode 1 Mode 2
Number of Total counter 1 1 1 2 2 2 2 4
counts Size counter 0 0 1 1 0 0 2 2
2-sided total counter 0 0 0 0 1 1 1 1
4. Press [END].
269
10.17.4 Management Function Choice

Set the installation/non-installation of the key counter and the management device.
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A. Procedure

Press [Management Function Choice].
2. "Management Function Choice screen"
Select the management device.
Note
• The initial setting is [Unset].
3. Select the message type.
4. Press [END].
270
Field Service Ver1.0 Feb.2006 11. MECHANICAL ADJUSTMENT
11. MECHANICAL ADJUSTMENT
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11.1 Mis-centering adjustment of the trays 1 and 2
This adjustment is made when there occurs a mis-centering that cannot be adjusted in the service mode.
A. Procedure
1. Pull out the tray [1].
2. If there remains any paper, remove it thoroughly.
3. When the paper guide [2] is set to the small size
position, expand it.
5. Move the paper guide [2] and adjust the center
position with the marking-off [4] as a guide.
6. Tighten the 2 screws [3].
[4] [3] [2]
[1] 50gaf3c014na
7. Set the tray with paper put in it.

8. Conduct the copy/print operation and check to
[2] see if the mis-centering between the center [1] of
the paper and the center [2] of the copied image
[3] is within a standard value (± 3 mm or less [3]).
9. When the value is not within the standard value,
[1] repeat steps 1 to 8 until the standard value can be
obtained.
50gaf3c015na
271
11. MECHANICAL ADJUSTMENT Field Service Ver1.0 Feb.2006
11.2 Mis-centering adjustment of the bypass tray

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This adjustment is made when there occurs a mis-centering that cannot be adjusted in the service mode.
A. Procedure
1. Open the bypass tray [1].
2. If paper is set, remove it.
3. When the paper guide [2] is set to the small size
position, expand it.
5. Move the paper guide [2] and adjust the center
[4] position with the marking-off [4] as a guide.
[2] [1]
[2] [3]
50gaf3c016na
7. Set paper in the bypass tray.

8. Conduct the copy/print operation and check to
[2] see if the mis-centering between the center [1] of
the paper and the center [2] of the copied image
[3] is within a standard value (± 3 mm or less [3]).
9. When the value is not within the standard value,
[1] repeat steps 1 to 8 until the standard value can be
obtained.
50gaf3c017na
272
Field Service Ver1.0 Feb.2006 12. JAM CODE
TROUBLESHOOTING
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12. JAM CODE
12.1 Jam code list
Classification Jam code Cause Resulting Correction

operation
Bypass J-1000 The vertical conveyance sensor (PS2) If there is a Pull out the paper from
During operation
does not turn ON within a specified sheet of paper the bypass tray and
period of time after the feed clutch being printed remove jammed paper
/BP (CL6) turns ON. when a jam if any.
Tray 1 J-1100 The registration sensor (PS1) does occurs, the main Open the vertical con-
not turn ON within a specified period body completes veyance door and ADU
of time after the feed clutch /1 (CL4) the paper exit and remove jammed
turns ON. before stopping paper if any.
Tray 2 J-1200 The vertical conveyance sensor (PS2) operations. Pull out the tray and
does not turn ON within a specified remove jammed paper
period of time after the feed clutch /2 if any.
(CL5) turns ON.
J-1201 The registration sensor (PS1) does
not turn ON within a specified period
of time after the vertical conveyance
sensor (PS2) turns ON.
PC-202 J-1300 The vertical conveyance sensor /3 Open the right door of
(PS117) does not turn ON a specified PC and the vertical
period of time after the paper feed conveyance door of the
motor /3 (M122) turns ON. main body and remove
PC-402 The vertical conveyance sensor (PS2) jammed paper if any.
does not turn ON a specified period Pull out the tray and
of time after the paper feed motor remove jammed paper
(M1) turns ON. if any.
PC-202 J-1301 The vertical conveyance sensor (PS2)
of the main body does not turn ON
within a specified period of time after
the vertical conveyance sensor /3
(PS117) of PC-202 turns ON.
PC-402 J-1302 The vertical conveyance sensor (PS2)
the vertical conveyance sensor (PS2)
of PC-402 turns ON.
J-1305 The paper feed sensor (PS1) does not
turn ON within a specified period of
time after the paper feed motor (M1)
turns ON.
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12. JAM CODE Field Service Ver1.0 Feb.2006

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operation
PC-402 J-1306 The paper feed sensor (PS1) does not If there is a Open the right door of
During operation
turn OFF within a specified period of sheet of paper PC and the vertical
time after the PS1 turns ON. being printed conveyance door of the
J-1307 The vertical conveyance sensor (PS2) when a jam main body and remove
does not turn ON within a specified occurs, the main jammed paper if any.
period of time after the paper feed body completes Pull out the tray and
sensor (PS1) turns ON. the paper exit remove jammed paper
J-1308 The paper feed sensor (PS2) does not before stopping if any.
turn OFF within a specified period of operations.
time after the PS2 turns ON.
J-1309 When a paper feed start signal is sent
out to PC-402 from the main body, a
recieve signal from PC-402 is not sent
out within a specified period of time
after that.
J-1311 The shift position sensor (PS11) does
of time after shift home sensor (PS12)
turns OFF.
PC-202 J-1400 The vertical conveyance sensor /4
(PS126) does not turn ON within a
specified period of time after the
paper feed motor /4 (M123) turns ON.
J-1401 The vertical conveyance sensor /3
specified period of time after the verti-
cal conveyance sensor /4 (PS126)
turns ON.
LU J-1500 The LU exit sensor (PS155) does not Open the upper door of
turn ON within a specified period of LU and the vertical
time after the feed clutch (CL151) conveyance door of the
turns ON. main body and remove
J-1501 The vertical conveyance sensor (PS2) jammed paper if any.
the LU exit sensor (PS155) turns ON.
Other J-2001 Emergency stop jam of the system The main body Remove jammed paper
J-2002 While in the print, the vertical convey- and the optional if any from optional
ance door opens. device stop device / main body.
J-2003 The ADU door is opened while in immediately.
printing.
J-2004 The ADU is opened while in printing.
PC J-2005 While in the print, the right door
opens.
274
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operation
FS J-2006 While in the print, the front door The main body Remove jammed paper
During operation
opens. and the optional if any from optional
FS-510 J-2007 While in the print, the guide plate device stop device / main body.
switch (SW4) turns OFF. immediately.
While in the up drive operation of the
tray, the shutter switch (SW2) turns
ON.
FS-511 J-2008 While in the print, FS-511 comes off
from the main body.
RU J-2009 While in the print, the front door
opens.
FS-511 J-2010 While in the print, the upper door
opens.
MT While in the print, the right door
opens.
SD While in the print, the saddle-stitching
section opens.
Conveyance J-3000 The registration sensor (PS1) does The printer sec- Open ADU and remove
not turn OFF within a specified period tion stops jammed paper if any.
of time after the registration clutch immediately.
(CL1) turns ON.
J-3100 The fusing exit sensor (PS3) does not
time after the registration clutch (CL1)
turns ON.
Fusing J-3200 The fusing exit sensor (PS3) does not
turn OFF within a specified period of
Reversing J-3300 The reverse sensor (PS27) does not
time after the fusing exit sensor (PS3)
turns ON.
J-3400 The reverse sensor (PS27) does not
Other J-5001 A print start signal is not sent out from The main body Open the right door of
the overall control board (OACB) and the optional PC, the vertical convey-
within a specified period of time after device stop ance door of the main
the registration sensor (PS1) turns immediately. body and ADU and
ON. remove jammed paper
if any.
275

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operation
DF J-6001 The DF open/close switch (SW3) The DF stops Open the open/close
During operation
turns OFF while in the DF operation. immediately. If cover and remove
J-6002 The cover open/close sensor (PS7) there is paper jammed paper if any.
turns OFF while in the DF operation. being trans-
J-6101 While in the single sided mode, the ferred or having
original feed sensor (PS6) does not been trans-
turn ON within a specified period of ferred, the main
time after the original feed motor (M1) body completes
turns ON. the paper exit
before stopping
J-6102 When feeding the first original in the
operations.
mode other than the single sided
mode, the original feed sensor (PS6)
does not turn ON within a specified
period of time after the original feed
motor (M1) turns ON.
J-6103 When feeding the second original in
the mode other than the single sided
J-6104 When feeding the third original in the
J-6105 While in the single sided mode, the
original feed sensor (PS6) does not
does not turn OFF within a specified
period of time after the PS6 turns ON.
period of time after the PS6 turns ON.
276
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operation
DF J-6108 When feeding the third original in the The DF stops Open the open/close
During operation
mode other than the single sided immediately. If cover and remove
mode, the original feed sensor (PS6) there is paper jammed paper if any.
does not turn OFF within a specified being trans-
period of time after the PS6 turns ON. ferred or having
been trans-
ferred, the main
original registration sensor (PS9) does
body completes
the paper exit
of time after the feed motor (M1) turns
before stopping
ON.
operations.
mode, the original registration feed
sensor (PS9) does not turn ON within
a specified period of time after the
feed motor (M1) turns ON.
mode, the original registration sensor
(PS9) does not turn ON within a spec-
ified period of time after the feed
ified period of time after the feed
original registration sensor (PS9) does
not turn OFF within a specified period
of time after the PS9 turns ON.
(PS9) does not turn OFF within a
specified period of time after the PS9
turns ON.
turns ON.
277

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operation
During operation
mode, the original registration sensor there is paper jammed paper if any.
(PS9) does not turn OFF within a being trans-
specified period of time after the PS9 ferred or having
turns ON. been trans-
J-6301 While in the single sided mode, the ferred, the main
original detection sensor (PS8) does body completes
not turn ON within a specified period the paper exit
of time after the original coveyance before stopping
motor (M2) turns ON. operations.
mode, the original detection sensor
ified period of time after the original
coveyance motor (M2) turns ON.
original detection sensor (PS8) does
turns ON.
turns ON.
278
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operation
During operation
mode, the original detection sensor there is paper jammed paper if any.
(PS8) does not turn OFF within a being trans-
specified period of time after the PS8 ferred or having
turns ON. been trans-
J-6501 While in the idle, the original feed sen- ferred, the main
When idling
sor (PS6) is ON. body completes
J-6502 While in the idle, the original registra- the paper exit
tion sensor (PS9) or the original before stopping
detection sensor (PS8) is ON. operations.
J-6503 While In the idle, either of the original

feed sensor (PS6), the original regis-
tration sensor (PS9) and the original
detection sensor (PS8) is ON.
J-6504 While in the idle, the original exit sen-
sor (PS10) is ON.
J-6505 While in the idle, the original registra-
tion sensor (PS6) or the original exit
sensor (PS10) is ON.
J-6506 While in the idle, any of the original
registration sensor (PS9), the original
detection sensor (PS8) or the original
exit sensor (PS10) is ON.
J-6507 While in the idle, any of the original
feed sensor (PS6), the original regis-
tration sensor (PS9), the original
detection sensor (PS8) or the original
exit sensor (PS10) is ON.
During operation
original exit sensor (PS10) does not

time after the original coveyance

mode, the original exit sensor (PS10)
period of time after the original covey-
ance motor (M2) turns ON.
period of time after the original covey-
ance motor (M2) turns ON.
279

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operation
During operation
mode, the original exit sensor (PS10) there is paper jammed paper if any.
does not turn ON within a specified being trans-
period of time after the original covey- ferred or having
ance motor (M2) turns ON. been trans-
J-6605 While in the single sided mode, the ferred, the main
original exit sensor (PS10) does not body completes
turn OFF within a specified period of the paper exit
time after the PS10 turns ON. before stopping
J-6606 When feeding the first original in the operations.
period of time after the PS10 turns
ON.
ON.
ON.
FS-510 J-7201 While in the idle, the entrance sensor FS, RU, MT, SD, Remove jammed paper
When idling
(PS4) is ON. main body stop if any from the FS/main

FS-511 While in the idle, the passage sensor immediately. body.
(PS2) of RU turns ON.
FS-510 J-7202 While in the idle, the conveyance sen-
sor (PS5) or the stacker sensor (PS8)
is ON.
FS-511 While in the idle, any of the sub tray
exit sensor (PS1), the bypass route
conveyance sensor (PS2), the inter-
mediate conveyance sensor (PS3),
the main route conveyance sensor
(PS4) or the alignment tray sensor
(PS5) is ON.
FS-510 J-7203 While in the idle, the stacker sensor
(PS8) is ON.
SD J-7204 While in the idle, the the paper exit
sensor (PS20) is ON.
280
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operation
MT J-7205 While in the idle, the conveyance sen- FS, RU, MT, SD, Remove jammed paper
When idling
sor /Up (PS9) or /Lw (PS10) is ON. main body stop if any from the FS/main
immediately. body.
FS-510 J-7216 The entrance sensor (PS4) of FS does
During operation
of time after the fusing exit sensor
(PS3) of the main body turns ON.
FS-511 The path sensor (PS2) of RU does not
time after the fusing exit sensor (PS3)
of the main body turns ON.
FS-510 J-7217 The entrance sensor (PS4) does not
The conveyance sensor (PS5) does
of time after the entrance sensor
(PS4) turns ON.
FS-511 The path sensor (PS2) of RU does not
The sub tray paper exit sensor (PS1)
of FS does not turn ON within a spec-
ified period of time after the path sen-
sor (PS2) of RU turns ON.
The main route conveyance sensor
(PS4) of FS does not turn ON within a
specified period of time after the path
sensor (PS2) of RU turns ON.
The bypass route conveyance sensor
(PS2) of FS does not turn ON within a
specified period of time after the path
sensor (PS2) of RU turns ON.
The main route conveyance sensor
turns ON.
The bypass route conveyance sensor
turns ON.
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operation
FS-511 J-7217 The intermediate conveyance sensor FS, RU, MT, SD, Remove jammed paper
During operation
(PS3) does not turn ON within a spec- main body stop if any from the FS/main
ified period of time after the main immediately. body.
route conveyance sensor (PS4) turns
ON.
The intermediate conveyance sensor
bypass route conveyance sensor
(PS2) turns ON.
FS-510 J-7218 The conveyance sensor (PS5) does
FS-511 The sub tray exit sensor (PS1) does
The intermediate conveyance sensor
turns ON.
FS-510 J-7221 After completion of stapling, the
stacker sensor (PS8) does not turn
OFF within a specified period of time
after the paper exit motor (M1) turns
ON.
FS-511 After completion of stapling, the align-
ment tray sensor (PS5) does not turn
OFF within a specified period of time
after the paper exit motor (M3) turns
ON.
SD J-7225 Folding jam
PU J-7243 Punch jam
FS-510 J-7281 The stapler motor does not return to
the home position within a specified
period of time after the stapler motor
turns ON.
FS-511 The stapler home sensor /Fr (PS22)
/Fr (M16) turns ON.
FS-511 J-7282 The stapler home sensor /Rr (PS25)
/Rr (M17) turns ON.
282
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operation
SD J-7284 The clincher motor /Fr does not return FS, RU, MT, SD, Remove jammed paper
During operation
to the home position within a speci- main body stop if any from the FS/main
fied period of time after the clincher immediately. body.
motor /Fr turns ON.
J-7285 The clincher motor /Rr does not
return to the home position within a
clincher motor /Rr turns ON.
MT J-7290 The conveyance sensor /Up (PS9) or
/Lw (PS10) of MT does not turn ON
the conveyance sensor (PS5) of FS
turns ON.
The conveyance sensor /Up (PS9) or
/Lw (PS10) do not turn OFF within a
specified period of time after PS9 or
PS10 turn ON.
Paper J-8100 The registration sensor (PS1) turns The printer sec- Open the vertical con-
When idling
feed ON while in idling. tion stops veyance door and ADU

J-8200 The vertical conveyance sensor (PS2) immediately. and remove jammed
turns ON while in idling. paper if any.
PC-202 J-8300 The vertical conveyance sensor /3 Open the right door
(PS116) turns ON while in idling. and remove jammed
PC-402 The vertical conveyance sensor (PS2) paper if any.
turns ON while in idling.
PC-202 J-8400 The vertical conveyance sensor /4
(PS126) turns ON while in idling.
LU J-8500 The LU exit sensor (PS155) turns ON Open the upper door
while in idling. and remove jammed
paper if any.
Fusing J-9000 The fusing exit sensor (PS3) turns ON Open ADU and remove
while in idling. jammed paper if any.
Reverse J-9100 The reverse sensor (PS27) turns ON
while in idling.
ADU J-9200 The ADU conveyance sensor /1
J-9300 The ADU conveyance sensor /2
J-9701 The ADU conveyance sensor /1
During operation

reverse motor (M6) turns ON for
reverse rotation.
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operation
ADU J-9702 The ADU conveyance sensor /2 The printer sec- Open ADU and remove
During operation
(PS25) does not turn ON within a tion stops jammed paper if any.
specified period of time after the ADU immediately.
conveyance sensor /1 (PS24) turns
ON.
J-9703 The registration sensor (PS1) does

of time after the ADU conveyance
sensor /2 (PS25) turns ON.
284
Field Service Ver1.0 Feb.2006 13. MALFUNCTION CODE
13. MALFUNCTION CODE
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13.1 Malfunction code list
A. Note for use
Turn OFF/ON the power switch (SW2) of the main body when releasing an abnormal condition.
B. Code list
NOTE
• For codes with "*" given in the error code column, a message "Turn off the power and turn it on
again" is displayed on the operation panel.
• For codes with no "*" given in the error code column, a message "Contact the service" is dis-
played.
Classification Code Causes Resulting Estimated abnormal parts

operation
Drive C-0201 The upper limit sensor /1 (PS6) The main body Paper lift motor /1 (M7)
Main body
does not turn ON within a speci- stops immedi- Upper limit sensor /1 (PS6)
fied period of time after the paper ately to turn OFF Printer control board (PRCB)
lift motor /1 (M7) turns ON. the main relay
C-0202 The upper limit sensor /2 (PS13) (RL1). Paper lift motor /2 (M8)
does not turn ON within a speci- Upper limit sensor /2 (PS13)
fied period of time after the paper Printer control board (PRCB)
lift motor /2 (M8) turns ON.
C-0203 The upper limit sensor /3 (PS114) Paper lift motor /3 (M124)
PC-202
does not turn ON within a speci- Upper limit sensor /3

fied period of time after the paper (PS114)
lift motor /3 (M124) turns ON. PC control board (PCCB)
C-0204 The upper limit sensor /4 (PS123) Paper lift motor /4 (M125)
does not turn ON within a speci- Upper limit sensor /4
fied period of time after the paper (PS123)
lift motor /4 (M125) turns ON. PC control board (PCCB)
C-0205 The upper limit sensor (PS152) Paper lift motor (M151)
LU
does not turn ON within a speci- Upper limit sensor (PS152)

fied period of time after the paper LU drive board (LTDB)
lift motor (M151) turns ON.
C-0206 Paper lift motor (M5) abnormality. Paper lift motor (M5)
PC-402
Shift motor (M4) abnormality. Shift motor (M4)

Shift gate motor (M3) abnormality. Shift gate motor (M3)
PC control board (PCCB)
285
13. MALFUNCTION CODE Field Service Ver1.0 Feb.2006

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operation
Drive C-0207 While in the paper feed, there The main body Pick-up solenoid /BP (SD1)
Bypass
occurs a condition twice in suc- stops immedi- Lift sensor (PS23)

cession in which the lift sensor ately to turn OFF Feed motor (M9)
(PS23) does not turn ON within a the main relay Printer control board (PRCB)
specified period of time after the (RL1).
pick-up solenoid /BP (SD1) turns
ON.
While in the power switch (SW2)
ON, there occurs a condition
twice in succession in which
PS23 does not turn OFF within a
specified period of time after SD1
turns ON.
Fan C-0301 Conveyance suction fan (FM5) Conveyance suction fan
Main body
abnor- abnormality. (FM5)

mality Printer control board (PRCB)
Commu- C-1001* Communication abnormality Overall control board (OACB)
nication between the engine control of the Printer control board (PRCB)
abnor- overall control board (OACB) and
mality that of the printer control board
(PRCB).
While in the stand-by, an FS
Ready signal cannot be detected
for a specified period of time.
FS C-1002 FS communication abnormality. FS control board (FSCB)
FS
A serial communication is unavail- Printer control board (PRCB)

able between the FS control
board (FSCB) and the printer
control board (PRCB).
FS-510 C-1003 Flash ROM abnormality. FS control board (FSCB)
A checksum error of the flash
ROM is detected.
FS-511 C-1101 Shift motor (M8) drive abnormal- Shift motor (M8)
ity. Shift home sensor (PS10)
• When starting the home posi- FS control board (FSCB)
tion movement, the shift
home sensor (PS10) does not
turn ON a specified period of
time after M8 turns ON.
• When starting the shift posi-
tion movement, PS10 does
not turn OFF a specified
period of time after M8 turns
ON.
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operation
FS FS-511 C-1102 Tray lift motor (M7) drive abnor- The main body Tray lift motor (M7)
mality. stops immedi- Main tray upper limit sensor
• While in the main tray up ately to turn OFF (PS19)
drive, the main tray upper limit the main relay FS control board (FSCB)
sensor (PS19) does not turn (RL1).
ON within a specified period
of time after M7 turns ON.
• While in the main tray down
drive, the lock signal of M7 is
detected.
• While in the M7 ON, the main
tray upper limit switch (SW2)
or the main tray lower limit
switch (SW3) turns ON.
C-1103 Alignment motor (M5) drive Alignment motor (M5)
abnormality. Alignment home sensor
• While in the alignment home (PS9)
position search, the alignment FS control board (FSCB)
turn ON within a specified
ON.
• While in the alignment opera-
tion, PS9 does not turn OFF
within a specified period of
C-1104 Paper exit roller release motor Paper exit roller release
(M13) drive abnormality. motor (M13)
• When starting the pressure Exit roller home sensor
position drive, the exit roller (PS13)
home sensor (PS13) does not FS control board (FSCB)
turn ON within a specified
ON.
• When starting the separation
position drive, PS13 does not
turn OFF within a specified
ON.
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operation
FS-511 C-1105 Intermediate conveyance roller The main body Intermediate conveyance
FS
release motor (M12) drive abnor- stops immedi- roller release motor (M12)
mality. ately to turn OFF Roller release home sensor
• When starting the pressure the main relay (PS12)
position drive, the roller (RL1). FS control board (FSCB)
release home sensor (PS12)
does not turn ON within a
specified period of time after
M12 turns ON.
• When starting the separation
position drive, PS12 does not
ON.
C-1106 Stapler movement motor (M6) Stapler movement motor
drive abnormality. (M6)
• While in the home position Stapler home sensor (PS14)
search, the stapler home sen- FS control board (FSCB)
sor (PS14) does not turn ON
• While in the 1-staple position
movement, PS14 does not
ON.
C-1107 Stapler motor /Rr (M16) drive Stapler motor /Rr (M16)
abnormality. Stapler home sensor /Rr
• The stapler home sensor /Rr (PS22)
(PS22) does not turn OFF FS control board (FSCB)
• PS22 does not turn ON within
a specified period of time
after the OFF of PS22 is
detected.
after M16 turns ON for
reverse rotation.
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operation
FS FS-511 C-1108 Stapler motor /Fr (M17) drive The main body Stapler motor /Fr (M17)
abnormality. stops immedi- Stapler home sensor /Fr
• The stapler home sensor /Fr ately to turn OFF (PS25)
(PS25) does not turn OFF the main relay FS control board (FSCB)
within a specified period of (RL1).
after the OFF of PS25 is
detected.
after M17 turns ON for
reverse rotation.
SD C-1109 Saddle stapler motor /Fr drive Saddle stapler motor /Fr
abnormality. SD control board (SDCB)
• When the saddle stapler
motor /Fr is ON, it does not
get off from the home position
time.
• After its getting off from the
home position is detected, it
does not get to the home
position within a specified
period of time.
• After the saddle stapler motor
/Fr turns ON for reverse rota-
tion, it does not get to the
home position within a speci-
fied period of time.
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operation
SD C-1110 Saddle stapler motor /Rr drive The main body Saddle stapler motor /Rr
FS
abnormality. stops immedi- SD control board (SDCB)

• When the saddle stapler ately to turn OFF
motor /Rr turns ON, it does the main relay
not get off from the home (RL1).
period of time.
• After its getting off from the
home position is detected, it
does not get to the home
period of time.
• After the saddle stapler motor
/Rr turns ON for reverse rota-
tion, it does not get to the
home position within a speci-
fied period of time.
C-1111 Paper guide motor (M13) drive Paper guide motor (M13)
abnormality. Paper guide home sensor
• When M13 turns ON for pro- (PS23)
trusion, the paper guide SD control board (SDCB)
period of time.
• When M13 turns ON for evac-
uation, PS23 does not turn
of time.
C-1112 Staple guide motor (M14) drive Staple guide motor (M14)
abnormality. Staple guide home sensor
• While in the home position (PS26)
return operation, the staple SD control board (SDCB)
guide home sensor (PS26)
M14 turns ON.
• When starting a retraction
operation, PS26 does not
ON.
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FS SD C-1113 Exit open/close motor (M9) drive The main body Exit open/close motor (M9)
abnormality. stops immedi- Saddle exit home sensor
• When starting a pressure ately to turn OFF (PS18)
contact operation, the sad- the main relay SD control board (SDCB)
dle exit home sensor (PS18) (RL1).
M9 turns ON.
• When starting a separation
ON.
C-1114 Folding motor (M10) drive abnor- Folding motor (M10)
mality. Folding roller home sensor
The folding roller home sensor (PS22)
(PS22) does not turn ON within a SD control board (SDCB)
specified period of time after M10
turns ON.
C-1115 Conveyance motor (M8) drive Conveyance motor (M8)
abnormality. SD control board (SDCB)
• Within a specified period of
time after M8 turns ON, the
ON of a motor lock signal is
detected for a prescribed
period of time in succession.
• A specified period of time
after M8 turns OFF, the OFF
of a motor lock signal is
detected for a prescribed
period of time in succession.
FS-510 C-1116 Exit roller release motor (M6) drive Exit roller release motor (M6)
abnormality. Shutter home sensor (PS16)
• When the shutter is closed, FS control board (FSCB)
the shutter home sensor
(PS16) does not turn ON
• When the shutter is open,
PS16 does not turn OFF
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operation
FS-510 C-1117 Alignment motor /Fr (M5) drive The main body Alignment motor /Fr (M5)
FS
abnormality. stops immedi- Alignment home sensor /Fr

• While in the home position ately to turn OFF (PS7)
search, the alignment home the main relay FS control board (FSCB)
sensor /Fr (PS7) does not turn (RL1).
• While in the home position
search, PS7 does not turn
OFF within a specified period
C-1118 Exit paddle solenoid (SD2) drive Exit paddle solenoid (SD2)
abnormality. Exit paddle home sensor
• While in the paddle evacua- (PS11)
tion, the exit paddle home FS control board (FSCB)
sensor (PS11) does not turn
of time after SD2 turns ON.
• While in the paper hold-down
period of time after SD turns
ON.
FS-511 C-1119 Punch motor (M11) drive abnor- Punch motor (M11)
mality. FS control board (FSCB)
The punch encoder sensor
specified period of time after M11
turns ON.
C-1120 Hole punch selector motor (M14) FS control board (FSCB)
drive abnormality (inch system Hole punch selector motor
only) (M14)
• When starting the punch 2-
hole position switch drive, the
hole punch position switch
(SW4) is not turned ON in the
the M14 is turned ON.
• When starting the punch 3-
hole position switch drive, the
SW4 is not turned OFF in the
the M14 is turned ON.
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FS PU C-1121 Punch motor (M1) drive abnor- The main body Punch motor (M1)
mality. stops immedi- Punch position sensor /1
The punch position sensors /1 ately to turn OFF (PS2)
(PS2) and /2 (PS3) do not turn the main relay Punch position sensor /2
OFF within a specified period of (RL1). (PS3)
time after M1 turns ON. FS control board (FSCB)
Image C-2001 Communication abnormality Overall control board (OACB)
Main body
process between the engine control of the Printer control board (PRCB)
commu- overall control board (OACB) and
nication that of the printer control board
abnor- (PRCB)
mality While in the stand-by, a process
Motor C-2201 Developing motor (M3) speed Developing motor (M3)
speed abnormality. Printer control board (PRCB)
abnor- While M3 is ON, an EM error sig-
mality nal has been detected 5 times in
succession within a specified
period of time.
C-2202 Drum motor (M1) speed abnor- Drum motor (M1)
mality. Printer control board (PRCB)
While M1 is ON, an EM error sig-
nal has been detected 5 times in
period of time.
Fan C-2301 Drum cooling fan (FM4) abnor- Drum cooling fan (FM4)
lock mality. Printer control board (PRCB)
abnor- While FM4 is ON, an EM error
mality signal has been detected 5 times
in succession within a specified
period of time.
C-2302 Developing suction fan motor Developing suction fan
(FM6) abnormality. motor (FM6)
While FM6 is ON, an EM error Printer control board (PRCB)
signal has been detected 5 times
period of time.
C-2303 Developing cooling fan (FM7) Developing cooling fan (FM7)
abnormality. Printer control board (PRCB)
While FM7 is ON, an EM error
signal has been detected 5 times
period of time.
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Abnor- C-2401 High machine inside temperature The main body TCR sensor (TCRS)
Main body
mality abnormality. stops immedi- Printer control board (PRCB)

around When the temperature around the ately to turn OFF
the drum drum is above 58 °C the main relay
C-2402 Erase lamp (EL) connector slip-off (RL1). Erase lamp (EL)
When EL turns ON before starting
an initial charging, EL abnormality
has been detected 15 times in
succession at prescribed intervals
after a specified period of time.
Toner C-2403 Toner bottle phase detection Toner bottle motor (M10)
bottle abnormality. Toner bottle position sensor
abnor- While in the power switch (SW2) (PS28)
mality ON, the toner bottle position sen- Printer control board (PRCB)
sor (PS28) does not turn ON
within a specified period of time
after the toner bottle motor (M10)
turns ON.
High C-2701 Charging abnormality. If there is a Charging corona
voltage An error signal is detected 5 sheet of paper High voltage unit (HV)
power times in succession at pre- being printed, Printer control board (PRCB)
source scribed intervals. the main body
abnor- completes the
mality paper exit to
stop opera-
tions. The main
relay (RL1) turns
OFF.
C-2702 Transfer lightning abnormality. The main body Transfer/separation charger
There occurs a phenomenon 5 stops immedi- High voltage unit (HV)
times in a job, in which an error ately to turn OFF Printer control board (PRCB)
signal is detected 3 times in suc- the main relay
cession at prescribed intervals. (RL1).
C-2703 Separation lightning abnormality.
There occurs a phenomenon 5
times in a job, in which an error
signal is detected 5 times in suc-
cession at prescribed intervals.
C-2801 TCR output abnormality. TCR sensor (TCRS)
When the TCR output is in Printer control board (PRCB)
excess of 3.0 V.
C-2802 TCR output abnormality.
When the TCR sensor (TCRS)
maximum output is 1.0 V or less.
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Main body High C-2803 TCR output abnormality. The main body TCR sensor (TCRS)
voltage When the output ripple voltage of stops immedi- Printer control board (PRCB)
power the TCR sensor (TCRS) is less ately to turn OFF
source than 0.5 V. the main relay
abnor- C-2804 Toner density abnormality. (RL1). Toner remaining sensor
mality When the L detection output is in (PZS)
excess of 2.6 V before the toner TCR sensor (TCRS)
remaining sensor (PZS) detects a Printer control board (PRCB)
no toner condition, toner density
does not recover even when
toner is automatically supplied.
Motor C-3201 Fusing motor (M11) speed abnor- Fusing motor (M11)
speed mality. Printer control board (PRCB)
abnor- When M11 is ON, an EM error
mality signal is detected 30 times in
period of time.
Fan C-3301 Fusing cooling fan /Fr (FM2) Fusing cooling fan /Fr (FM2)
lock abnormality. Printer control board (PRCB)
abnor- When FM2 is ON, an EM error
mality signal is detected 3 times in suc-
cession within a specified period
of time.
C-3302 Fusing cooling fan /Rr (FM8) Fusing cooling fan /Rr (FM8)
When FM8 is ON, an EM error
signal is detected 3 times in suc-
cession within a specified period
of time.
Fusing C-3501 Fusing main sensor high temper- The main body Thermistor /1 (TH1)
high ature abnormality. stops immedi- Printer control board (PRCB)
temper- The thermistor /1 (TH1) detects a ately to turn OFF
ature temperature higher than 236 °C the main relay
abnor- for more than a specified period (RL1). All the
mality of time. keys are not
C-3502 Fusing sub sensor high tempera- taken in. Thermistor /2 (TH2)
ture abnormality. Printer control board (PRCB)
The thermistor /2 (TH2) detects a
temperature higher than 236 °C
for more than a specified period
of time.
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Fusing C-3801 Fusing main sensor low tempera- The main body Thermistor /1 (TH1)
Main body
low ture abnormality. stops immedi- Printer control board (PRCB)

temper- While in the idle or in the low ately to turn OFF
ature power mode, the fusing heater the main relay
abnor- lamp /1 (L2) turns on for more (RL1). All the
mality than 12 seconds in succession. keys are not
C-3802 Fusing main sensor low tempera- taken in.
ture abnormality.
While in other than the warm-up,
the thermistor /1 (TH1) detects a
temperature lower than 130 °C
for more than 10 seconds.
C-3803 Fusing main sensor low tempera-
ture abnormality.
The detection temperature of the
thermistor /1 (TH1) does not get
to the prescribed temperature
after it starts the warm-up.
C-3804 Fusing sub sensor low tempera- Thermistor /2 (TH2)
ture abnormality. Printer control board (PRCB)
While in the idle, the fusing heater
lamp /2 (L3) turns on for more
than 12 seconds in succession.
C-3805 Fusing sub sensor low tempera-
ture abnormality.
While in other than the warm-up,
the thermistor /2 (TH2) detects a
temperature lower than 130 °C
for more than 10 seconds.
C-3806 Fusing sub sensor low tempera-
ture abnormality.
The detection temperature of the
thermistor /2 (TH2) does not get
to the prescribed temperature
after it starts the warm-up.
C-3807 Fusing main sensor high temper- Thermistor /1 (TH1)
ature abnormality (sub CPU Printer control board (PRCB)
detection)
In the sub CPU, the thermistor /1
(TH1) detects a temperature
higher than 236 °C for more than
a specified period of time.
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Main body Fusing C-3808 Fusing sub sensor high tempera- The main body Thermistor /2 (TH2)
low ture abnormality (sub CPU detec- stops immedi- Printer control board (PRCB)
temper- tion) ately to turn OFF
ature In the sub CPU, the thermistor /2 the main relay
abnor- (TH2) detects a temperature (RL1). All the
mality higher than 236 °C for more than keys are not
a specified period of time. taken in.
Fusing C-3901 Inferior contact of the thermistor Thermistor /1 (TH1)
sensor /1 (TH1) Printer control board (PRCB)
abnor- While in the warm-up condition,
mality when the thermistor /2 (TH2)
detection temperature gets to the
Ready temperature before the
TH1 detection temperature, the
TH1 detection temperature does
not get to the Ready temperature
a specified period of time after
the TH2 detection temperature
got to the Ready temperature.
C-3902 Inferior contact of the thermistor Thermistor /2 (TH2)
/2 (TH2) Printer control board (PRCB)
While in the warm-up condition,
when the thermistor /1 (TH1)
detection temperature gets to the
Ready temperature before the
TH2 detection temperature, the
TH2 detection temperature does
not get to the Ready temperature
a specified period of time after
the TH1 detection temperature
got to the Ready temperature.
C-3903 Thermistor /1 (TH1) open abnor- Thermistor /1 (TH1)
mality (sub CPU detection) Printer control board (PRCB)
In the sub CPU, the TH1 detec-
tion temperature detects a tem-
perature between -8 and 20 °C
of time.
C-3904 Thermistor /2 (TH2) open abnor- Thermistor /2 (TH2)
mality (sub CPU detection) Printer control board (PRCB)
In the sub CPU, the TH2 detec-
tion temperature detects a tem-
perature between -8 and 20 °C
of time.
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Image C-4001 Index board (INDEXB) contact The main body Index board (INDEXB)
Main body
proces- abnormality. stops immedi- Overall control board (OACB)

sing ately to turn OFF
abnor- the main relay
mality (RL1).
Motor C-4101 Polygon motor (M5) speed abnor- Polygon motor (M5)
speed mality. Printer control board (PRCB)
abnor- When M5 is ON, an error signal is
mality detected 3 times in succession
within a specified period of time.
Image C-4401 Laser drive board (LDB) abnor- Laser drive board (LDB)
proces- mality. Overall control board (OACB)
sing When an overcurrent flows for
abnor- laser output.
mality C-4701 Laser index abnormality. Index board (INDEXB)
When the cycle of the index is dif- Overall control board (OACB)
ferent from an expected value.
Commu- C-5001 Main body control board commu- Overall control board (OACB)
nication nication abnormality 1 Scanner drive board (SDB)
abnor- Communication abnormality
mality between the overall control board
(OACB) and the scanner drive
board (SDB).
C-5002 Main body control board commu- Printer control board (PRCB)
nication abnormality 2
Communication abnormality,
incoming command abnormality,
platen operation sequence
abnormality to the sub CPU in the
overall control board (OACB).
C-5003 Sub CPU A/D conversion abnor-
mality.
There is no response 2 times in
succession to the A/D conversion
request of the overall control
board (OACB).
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Main body Fan C-5301 Exhaust fan /Fr (FM3) conversion The main body Exhaust fan /Fr (FM3)
lock abnormality. stops immedi- Printer control board (PRCB)
abnor- When FM3 is ON, an error signal ately to turn OFF
mality is detected 5 times in succession the main relay
within a specified period of time. (RL1).
C-5302 Exhaust fan /Rr (FM9) conversion Exhaust fan /Rr (FM9)
When FM9 is ON, an error signal
is detected 5 times in succession
C-5303 Power supply cooling fan (FM1) Power supply cooling fan
conversion abnormality. (FM1)
When FM1 is ON, an error signal Printer control board (PRCB)
is detected 5 times in succession
OS C-5401* There occurs an OS error with the Engine section Printer control board (PRCB)
error engine control section in the power OFF.
printer control board (PRCB).
System C-5402* Time out for tuning off the power Engine section Overall control board (OACB)
control switch (SW2) power OFF. Printer control board (PRCB)
commu- Operation panel
nication display all ON.
abnor-
mality
Image C-6001 CCD board (CCDB) connection Scanner sec- CCD board (CCDB)
process abnormality. tion stops Overall control board (OACB)
commu- immediately.
nication C-6002* Communication abnormality Engine section Overall control board (OACB)
abnor- between the engine control of the power OFF. Printer control board (PRCB)
mality overall control board (OACB) and
that of the printer control board
(PRCB).
While in the stand-by, a scanner
C-6003* Communication abnormality Overall control board (OACB)
between the engine control of the Printer control board (PRCB)
overall control board (OACB) and
that of the printer control board
(PRCB).
Time out for the notice time of the
platen original size.
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operation
Scanner C-6101 While in the exposure unit initial Scanner sec- Scanner motor (M2)
Main body
abnor- search, the scanner home sensor tion stops Scanner home sensor
mality (PS30) does not turn on within a immediately. (PS30)
specified period of time. And Printer control board (PRCB)
also, while in the return scan,
PS30 does not turn on within a
specified period of time.
C-6201 Exposure lamp (L1) abnormality. Exposure lamp (L1)
A specified period of time after L1 L1 inverter (L1 INVVB)
turns on, an L1 abnormality signal Printer control board (PRCB)
is detected in succession for a
specified period of time.
Image C-6701 AOC abnormality. CCD board (CCDB)
proces- AOC counter overflow Exposure lamp (L1)
sing C-6702 AGC abnormality. L1 inverter (L1 INVVB)
abnor- AGC counter overflow Scanner motor (M2)
mality Overall control board (OACB)
Commu- C-8001 DF control board (DFCB) commu- The main body DF control board (DFCB)
DF
nication nication abnormality. stops immedi- Printer control board (PRCB)

abnor- Communication abnormality ately to turn OFF
mality between the printer control board the main relay
(PRCB) and DFCB. (RL1).
Fan C-8301 Cooling fan (FM3) abnormality. Cooling fan (FM3)
lock DF control board (DFCB)
abnor-
mality
FAX C-B001 FAX ROM checksum error FAX breakdown FK-502
FAX
board C-B002 A FAX board hardware error is

abnor- detected.
mality C-B003 A FAX file initialization abnormality
is detected.
FAX C-B110 Instance generation error or an
driver observer registration error
error C-B111 Initialization failure of the configu-
ration space
C-B112 A semaphore is obtained; release
error
C-B113 Sequence error between the
tasks on the main body side.
C-B114 Message queue control error
C-B115 Sequence error between the
main body and the FAX board
C-B116 FAX board no response (no
response after initialization)
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FAX FAX C-B117 Time out error for ACK standby FAX breakdown FK-502
driver C-B118 Undefined frame reception
error C-B119 DMA transfer error
JC C-B120 JC software error
C-B122 Device error (GA LOCAL SRAM)
C-B123 Device error (DRAM)
C-B125 Device error (GA)
C-B126 While in the interruption process-
ing, there occurs a time out error
due to no response from DC.
due to no response from CC.
due to no response from Line.
due to no response from the File
system/File Driver.
MIF C-B130 Driver software error
software C-B131 Length error of the frame received
error from the main side.
C-B132 Header error of the frame receive
from the main side.
C-B133 232C I/F sequence error
C-B134 DPRAM I/F sequence error
C-B135 DPRAM CTL/STS register abnor-
mality.
C-B136 Time out for ACK standby
C-B137 DPRAM RESET received
C-B140 MSG I/F error with JC
C-B141 I/F error with driver
I/F C-B142 Undefined command received
error C-B143 Command frame length error
C-B144 Command parameter length error
C-B145 Undefined parameter
C-B146 Command/response sequence
error
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Line C-B150 External class instance acquisi- FAX breakdown FK-502
FAX
control tion error

C-B151 Job start-up error (start-up JOB
parameter/slave job generation
error)
C-B152 Doc access error (report Buf
access error)
C-B153 Time out for a response from the
external task
C-B154 Internal Que table control error
(create/enque/deque)
1 des- C-B160 Instance generation error
tination C-B161 Time out error
control C-B162 Interface error
C-B163 Message queue control error
C-B164 A semaphore is obtained: release
error.
C-B165 Observer registration error
C-B166 Incoming resource check error
C-B167 Outgoing image information
expansion error
C-B168 Incoming image serialization error
C-B169 Quick memory data access error
Page C-B170 Internal Que table control error
control (create/enque/deque)
C-B171 Instance generation error
C-B172 Time out error
C-B173 Interface error
C-B174 A semaphore is obtained: release
error.
C-B175 Observer registration error
C-B176 TTI area cannot be secured.
C-B177 Error return from TTI_Rasterizer
C-B178 Incoming Job generation error
C-B180 Quick transfer memory data
access error
C-B181 Block Buff acquisition error
C-B182 Outgoing block image error (Req,
Restore)
C-B183 Incoming block image error (Req,
Store)
C-B184 Incoming image information stor-
age error
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FAX Page C-B185 Incoming data size logic error FAX breakdown FK-502
control (The incoming data is not a multi-
ple number of DotLine.
C-B186 Image Buff acquisition (alloc) error
C-B187 Error return from Compressor
C-B188 Band Buff control error (new
Instance/get/free)
Operation C-C103 While in the completion of the Engine section Overall control board (OACB)
ISW
panel reception from the control of the power OFF.

commu- operation panel, either of the fol-
nication lowing is detected or after starting
abnor- the transmission, the transmis-
mality sion cannot be completed within
a specified period of time.
• Data checksum error
• Communication GA gener-
ates an error vector.
Machine C-C181 The machine type mentioned in
type the software is different from the
detection machine type information given
abnor- on the main body drive board.
mality
Flash C-C182 A flash ROM checksum error of
ROM the image control board is
abnor- detected.
mality
Software C-C183 The machine type mentioned in
abnor- the software is different between
mality the overall control and the image
control.
Non- C-C284 Non-volatile memory abnormality It stops immedi- Overall control board (OACB)
Main body
volatile *1 ately. NVRAM board (NRB)

memory C-C285 Non-volatile memory abnormality
abnor- *1
mality C-C286 Non-volatile memory abnormality
*1
C-C287 Non-volatile memory abnormality
*1
C-C288 Non-volatile memory abnormality
*1
HDD C-D001 HDD initialization abnormality. Engine section HD-505
C-D002 JOB RAM retention abnormality. power OFF.
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operation
Fan C-D201 Overall control board cooling fan The main body Overall control board (OACB)
Main body
lock (FM8) abnormality. stops immedi- Overall control board cool-

abnor- ately to turn OFF ing fan (FM8)
mality the main relay
Commu- C-D203 Communication abnormality (RL1). Overall control board (OACB)
nication between the main body control IC-204
abnor- board and IC-204
mality C-D282* Communication abnormality Overall control board (OACB)
between the overall control board Scanner drive board (SDB)
(OACB) and the scanner drive
board (SDB).
When the power switch (SW2)
turns on, there is no SDB
response.
System C-E001 Message queue abnormality. Engine section Overall control board (OACB)
control C-E002 Incorrect parameters of the mes- power OFF.
commu- sage and the method
nication C-E003 Incorrect task
abnor-
C-E004 Incorrect event
mality
C-E005 Memory access abnormality.
C-E006 Header access abnormality.
C-E007 DIMM initialization abnormality.
C-E081 DRAM initialization abnormality.
C-E082* Image abnormality. If there is a
Image processing abnormality on sheet of paper
the overall control side being printed,
the main body
completes the
paper exit to
stop opera-
tions. The main
relay (RL1) turns
OFF.
C-E083* Copy sequence abnormality. Engine section
Job object pointer abnormality power OFF.
(For some reason, the acquisition
of the page management object
is unavailable.)
C-E084* Copy sequence abnormality.
Memory copy sequence abnor-
mality (the one the cause of which
cannot be identified.)
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Main body System C-E085* Copy sequence abnormality. Engine section Overall control board (OACB)
control Through copy sequence (FCOT) power OFF.
commu- abnormality (the one that the
nication cause of which cannot be identi-
abnor- fied.)
mality C-E086* Copy sequence abnormality.
The memory scanner stop is not
completed. (A stop completion
notice is not sent from the engine
side.)
C-E087* Copy sequence abnormality.
The memory printer stop is not
completed. (A stop completion
notice is not sent from the engine
side.)
C-E088* Unrecoverable error (The count is
made by C-5402.)
An error occurs when the timer is
set.
made by C-5402.)
An error occurs when the timer is
cancelled.
C-E08A* Unrecoverable error (The count is
made by C-5402.)
An abnormal operation occurs
when an interrupt copy is made
(printer user job).
C-E08B* Unrecoverable error (The count is
made by C-5402.)
(printer job 0).
C-E08C Unrecoverable error (The count is
made by C-5402.)
(printer job 1).
C-E08D* Unrecoverable error (The count is
made by C-5402.)
(FCOT print user job).
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operation
System C-E08E* Unrecoverable error (The count is Engine section Overall control board (OACB)
Main body
control made by C-5402.) power OFF.

commu- An abnormal operation occurs
nication when an interrupt copy is made
abnor- (FCOT print job).
mality C-E08F* Unrecoverable error (The count is
made by C-5402.)
(copy print user job).
made by C-5402.)
(copy print job 0).
made by C-5402.)
(copy print job 1).
made by C-5402.)
An error occurs when the task 0
is deleted with the queue 1 gen-
eration not allowed.
made by C-5402.)
An error occurs when the queue
0 is deleted with the queue 1
generation not allowed.
made by C-5402.)
n is deleted with the task n gener-
ation not allowed.
made by C-5402.)
An error occurs when the task 0
is deleted with the task 1 genera-
tion not allowed.
made by C-5402.)
0 is deleted with the task 1 gener-
ation not allowed.
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Main body System C-E097* Unrecoverable error (The count is Engine section Overall control board (OACB)
commu- An error occurs when the task n
nication is started.
abnor- C-E098* Unrecoverable error (The count is
mality made by C-5402.)
An error occurs when the task n
is deleted.
made by C-5402.)
n is deleted.
C-E09A* Unrecoverable error (The count is
made by C-5402.)
A scheduling abnormality occurs
when the FAX print cannot be
started due to a memory short-
age (queue operation abnormal-
ity).
C-E09B* Unrecoverable error (The count is
made by C-5402.)
A scheduling abnormality occurs
when the FAX print cannot be
started due to a memory short-
age (message transmission error).
C-E09C* Unrecoverable error (The count is
made by C-5402.)
A printer scheduling abnormality
occurs due to memory being full
(message transmission error)
C-E09E* Unrecoverable error (The count is
made by C-5402.)
(scanner scan user job).
C-E09F* Unrecoverable error (The count is
made by C-5402.)
(scanner mixed original scan job
0).
C-E0A0* Unrecoverable error (The count is
made by C-5402.)
(scanner z-folding scan job 0).
307

bizhub 500 / 420
operation
System C-E0A1* Unrecoverable error (The count is Engine section Overall control board (OACB)
Main body

abnor- (scanner normal scan job 0).
mality C-E0A2* Unrecoverable error (The count is
made by C-5402.)
(scanner scan job 1).
made by C-5402.)
(FAX scan user job).
made by C-5402.)
(FAX mixed original scan job 0).
made by C-5402.)
(FAX z-folding scan job 0).
made by C-5402.)
(FAX normal scan job 0).
made by C-5402.)
(FAX scan job 1).
made by C-5402.)
(FCOT scan user job).
made by C-5402.)
(FCOT scan job).
308
bizhub 500 / 420

operation
Main body System C-E0AA* Unrecoverable error (The count is Engine section Overall control board (OACB)
abnor- (copy scan user job).
mality C-E0AB* Unrecoverable error (The count is
made by C-5402.)
(copy mixed original scan job 0).
C-E0AC* Unrecoverable error (The count is
made by C-5402.)
(copy z-folding scan job 0).
C-E0AD* Unrecoverable error (The count is
made by C-5402.)
(copy normal scan job 0).
C-E0AE* Unrecoverable error (The count is
made by C-5402.)
(copy scan job 1).
C-E0AF* Unrecoverable error (The count is
made by C-5402.)
A SUSPEND occurs.
C-E0B0* Unrecoverable error (The count is
made by C-5402.)
An EXCEPTION occurs.
*1 NVRAM board (NRB) error code display priority

When two or more error codes related to NRB occur at the same time, a code with the highest prece-
dence is displayed according to the priorities shown below.
C-C287
C-C288
C-C286
C-C284
C-C285
309
C. Function to separate defective sections

For setting of DipSW that is specified for the following items, it is possible to use them with a failed section sep-
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arated. After setting DipSW, however, no abnormality detection is made on the separated section.
NOTE
• This function is employed to make temporary use of sections that are not affected. So, be sure
that this is limited only to a provisional use until a defective section is repaired.
(1) DipSW setting

Turning the main power switch (SW1) OFF and ON after setting the specified software DipSW bit allows you to
make a limited use of it until the bit setting is released next time.
Classification Malfunction Causes Control while detatched DipSW

code
Main C-0201 Paper lift motor /1 (M7) Paper feed in tray 1 is unavailable DipSW18-0
body abnormality (There remains no paper, and on the
operation panel, the tray 1 is displayed
in hatching.)
C-0202 Paper lift motor /2 (M8) Paper feed in tray 2 is unavailable DipSW18-1
abnormality (There remains no paper, and on the
in hatching.)
PC-202 C-0203 Paper lift motor /3 (M124) Paper feed in tray 3 is unavailable DipSW18-4
in hatching.)
C-0204 Paper lift motor /4 (M125) Paper feed in tray 4 is unavailable DipSW18-5
in hatching.)
LU C-0205 Paper lift motor (M151) Paper feed in LU is unavailable DipSW18-6
operation panel, LU is displayed in
hatching.)
PC-402 C-0206 Paper lift motor (M5) abnor- Paper feed in tray 3 is unavailable DipSW18-4
mality (There remains no paper, and on the
Shift motor (M4) abnormality operation panel, the tray 3 is displayed
Shift gate motor (M3) abnor- in hatching.)
mality
FK C-B001 FK-502 abnormality FAX mode is unavailable DipSW19-1
to B188
HDD C-D001 HD-505 abnormality HDD is unavailable DipSW19-3
to D002 (HD-505 is not connected)
DF C-8001 DF communication abnormal- DF mode is unavailable DipSW19-7
ity (DF connection is not recognized)
SD C-1109 SD drive abnormality SD is unavailable DipSW20-5
to 1115 (SD connection is not recognized)
310
Field Service Ver1.0 Feb.2006 14. PARTS LAYOUT DRAWING
APPENDIX
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14. PARTS LAYOUT DRAWING
14.1 Main body
14.1.1 Switch/sensor
A. Main body rear side
[4]
[3] [1] [2]
50gaf5c017na
[1] Toner bottle sensor (PS4) [3] Humidity sensor (HUMS)

[2] Toner bottle position sensor (PS28) [4] Toner remaining sensor (PZS)
311
14. PARTS LAYOUT DRAWING Field Service Ver1.0 Feb.2006
B. Main body front side

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[1]
[3]
[2]
50gaf5c018na
[1] Power switch (SW2) [3] Main power switch (SW1)

[2] Interlock switch (MS)
C. Main body upper surface
[3] [4] [1]
[2]
50gaf5c019na
[1] DF open/close switch (SW3) [3] APS timing sensor (PS31)

[2] Scanner home sensor (PS30) [4] APS sensor (PS32)
312
D. Developing section
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[1]
50gaf5c020na
[1] TCR sensor (TCRS)
E. Paper feed section

(1) Tray 1
[5] [6] [1]
[2]
[4]
[3] 50gaf5c034na
[1] Upper limit sensor /1 (PS6) [4] Paper size sensor /Rr1 (PS10)
[2] Paper empty sensor /1 (PS5) [5] Tray set sensor /1 (PS8)
[3] Paper size sensor /Fr1 (PS11) [6] Near-empty sensor /1 (PS9)
313
(2) Tray 2
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[7] [8] [1]
[2]
[3]
[6] [4]
[5] 50gaf5c035na
[1] Vertical conveyance sensor (PS2) [5] Paper size sensor /Fr2 (PS17)
[2] Feed door open/close sensor (PS7) [6] Paper size sensor /Rr2 (PS16)
[3] Paper empty sensor /2 (PS12) [7] Tray set sensor /2 (PS14)
[4] Upper limit sensor /2 (PS13) [8] Near-empty sensor /2 (PS15)
(3) Registration
[1] 50gaf5c036na
[1] Registration sensor (PS1)
314
F. Bypass tray section
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[6] [7] [1] [2]
[5] [4] [3] 50gaf5c037na
[1] Paper size VR/BP (VR1) [5] Paper size sensor /BP4 (PS22)
[2] Paper empty sensor /BP (PS18) [6] Paper size sensor /BP2 (PS20)
[3] Lift sensor (PS23) [7] Paper size sensor /BP1 (PS19)
[4] Paper size sensor /BP3 (PS21)
G. ADU section
[1]
[2]
[3]
50gaf5c038na
[1] ADU open/close sensor (PS26) [3] ADU conveyance sensor /2 (PS25)
[2] ADU conveyance sensor /1 (PS24)
315
H. Fusing section
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[1] [4]
[3] [2]
50gaf5c021na
[1] Fusing exit sensor (PS3) [3] Thermistor /1 (TH1)

[2] Thermistor /2 (TH2) [4] Thermostat (TS)
I. Reverse/paper exit section
[1]
50gaf5c039na
[1] Reverse sensor (PS27)
316
14.1.2 Load
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[11]
[10]
[9] [1]
[2]
[7]
[3]
[6] [5] [4] [8]
50gaf5c022na
[1] Toner supply motor (M4) [7] Developing motor (M3)

[2] Toner bottle motor (M10) [8] Feed motor (M9)
[3] Toner solenoid (SD5) [9] Drum motor (M1)
[4] Power supply cooling fan (FM1) [10] Fusing motor (M11)
[5] Overall control board cooling fan (FM10) [11] Scanner motor (M2)
[6] Developing cooling fan (FM7)
317
B. Main body inside

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[4]
[1]
[2]
[3]
50gaf5c023na
[1] Fusing cooling fan /Rr (FM8) [3] Drum cooling fan (FM4)
[2] Fusing cooling fan /Fr (FM2) [4] Developing suction fan (FM6)
C. Main body right side
[1]
[2]
50gaf5c024na
[1] Web solenoid (SD4) [2] Coveyance suction fan (FM5)
318
D. Write section
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[1]
50gaf5c025na
[1] Polygon motor (M5)
E. Photo conductor section
[1]
50gaf5c026na
[1] Drum claw solenoid (SD2)
319
F. Paper feed section

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(1) Tray 1
[2] [1]
50gaf5c040na
[1] Feed clutch /1 (CL4) [2] Paper lift motor /1 (M7)
(2) Tray 2
[3] [1]
[2] 50gaf5c041na
[1] Vertical conveyance clutch (CL3) [3] Paper lift motor /2 (M8)
[2] Feed clutch /2 (CL5)
320
(3) Registration
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[1]
[2]
50gaf5c042na
[1] Registration clutch (CL1) [2] Loop clutch (CL2)
G. Bypass tray section
[1]
[2] 50gaf5c043na
[1] Feed clutch /BP (CL6) [2] Pick-up solenoid /BP (SD1)
321
H. ADU section
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[1]
[2]
50gaf5c044na
[1] ADU conveyance clutch /Up (CL7) [2] ADU conveyance clutch /Lw (CL8)
I. Reverse/paper exit section
[1]
[4] [3] [2] 50gaf5c045na
[1] Reverse motor (M6) [3] Exhaust fan /Rr (FM9)

[2] Reverse solenoid (SD3) [4] Exhaust fan /Fr (FM3)
322
14.1.3 Boards and others

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[1]
[2]
[9]
[3]
[8]
[7]
[4]
[6]
[5]
50gaf5c027na
[1] L1 inverter (L1 INVB) [6] Paper size board /2 (PSB/2)

[2] Scanner drive board (SDB) [7] Paper size board /1 (PSB/1)
[3] Printer control board (PRCB) [8] Overall control board (OACB)
[4] Circuit breaker /1 (CBR1) [9] NVRAM board (NRB)
[5] Circuit breaker /2 (CBR2)
323
B. Main body front side

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[1]
50gaf5c028na
[1] Total counter (TCT)
C. Main body inside
[1]
[2]
50gaf5c029na
[1] DC power supply (DCPS) [2] Hight voltage unit (HV2)
324
D. Operation panel and main body upper surface
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[8]
[7]
[6]
[1]
[5]
[4]
[2]
[3]
50gaf5c030na
[1] CCD board (CCDB) [5] Operation board (OB)

[2] Panel key board (PKB) [6] Speaker (SP) (option)
[3] OB inverter (OB INVB) [7] Exposure lamp (L1)
[4] LCD board (LCDB) [8] L1 relay board (L1 RLB)
E. Write section
[2]
[1]
50gaf5c031na
[1] Index board (INDEXB) [2] Laser drive board (LDB)
325
F. Photo conductor section

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[2]
[1]
50gaf5c032na
[1] IDC sensor (IDCS) [2] Erase lamp (EL)
G. ADU section
[1]
50gaf5c046na
[1] Transfer exposure lamp (TSL)
326
H. Fusing section
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[2]
[1]
50gaf5c033na
[1] Fusing heater lamp /2 (L3) [2] Fusing heater lamp /1 (L2)
327
14.2 DF
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A. Front side
[1]
[2]
16eaf5c001na
[1] Pressure roller release solenoid (SD1) [2] LED board (LB)
B. Rear side
[5]
[1]
[4] [2]
[3]
16eaf5c002na
[1] Cover open/close sensor (PS7) [4] Cooling fan (FM3)

[2] Original conveyance motor (M2) [5] DF control board (DFCB)
[3] Original feed motor (M1)
328
C. Upper surface
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[7] [8] [9] [10] [11]
[6] [5] [4] [3] [2] [1]

16eaf5c003na
[1] Original size sensor /2 (PS2) [7] Original empty sensor (PS5)
[2] Stamp solenoid (SD2) [8] Original registration sensor (PS9)
[3] Original exit sensor (PS10) [9] Original size sensor /1 (PS1)
[4] Original detection sensor (PS8) [10] Original size sensor /3 (PS3)
[5] Original feed sensor (PS6) [11] Original size sensor /4 (PS4)
[6] Mix original size detection board (MOSDB)
D. Paper feed tray
[1]
[2]
16eaf5c004na
[1] Tray board (TB) [2] Original size VR (VR1)
329
14.3 PC
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14.3.1 PC-202
[21]
[20]
[19] [22]
[18] [23]
[17] [24]
[16] [25]
[15] [26]
[14]
[1]
[13]
[12]
[2]
[11]
[3]
[10]
[9] [4]
[8]
[5]
[7]
[6]
4061f5c001na
[1] Vertical conveyance sensor /4 (PS126) [14] Paper size detect board /3 (PSDB3)
[2] Paper feed sensor /4 (PS125) [15] Paper size sensor /Rr3 (PS118)
[3] Paper empty sensor /4 (PS124) [16] Paper size sensor /Fr3 (PS119)
[4] Upper limit sensor /4 (PS123) [17] Tray set sensor /3 (PS112)
[5] Vertical conveyance motor /4 (M121) [18] Near-empty sensor /3 (PS113)
[6] Paper feed motor /4 (M123) [19] Paper lift motor /3 (M124)
[7] Paper lift motor /4 (M125) [20] Paper feed motor /3 (M122)
[8] Near-empty sensor /4 (PS122) [21] Vertical conveyance motor /3 (M120)
[9] Paper size sensor /Fr4 (PS128) [22] Right door open/close sensor (PS111)
[10] Paper size sensor /Rr4 (PS127) [23] Upper limit sensor /3 (PS114)
[11] Paper size detect board /4 (PSDB4) [24] Vertical conveyance sensor /3 (PS117)
[12] Tray set sensor /4 (PS121) [25] Paper feed sensor /3 (PS116)
[13] PC control board (PCCB) [26] Paper empty sensor /3 (PS115)
330
14.3.2 PC-402
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[20]
[19] [21]
[18]
[17]
[22]
[16]
[23]
[24]
[1]
[15]
[2]
[3]
[14]
[4]
[5]
[13]
[6]
[7]
[8]
[12] [9]
[11] [10]
4061f5c201na
[1] Paper empty sensor (PS3) [13] Shift gate motor (M3)
[2] Main tray empty board (MEB) [14] Shift gate position sensor (PS14)
[3] Paper lift motor (M5) [15] Rely board (RLB)
[4] Paper lift motor encoder sensor (PS10) [16] PC control board (PCCB)
[5] Lower limit over run sensor (PS7) [17] Tray lock solenoid (SD1)
[6] Shft motor encoder sensor (PS8) [18] Tray set sensor (PS6)
[7] Shift motor (M4) [19] Paper feed motor (M1)
[8] Tray release switch (SW1) [20] Vertical conveyance motor (M2)
[9] Shift position sensor (PS11) [21] Right door open/close sensor (PS5)
[10] Lower limit sensor (PS13) [22] Vertical conveyance sensor (PS2)
[11] Sub tray empty sensor (PS9) [23] Upper limit sensor (PS4)
[12] Shift home sensor (PS12) [24] Paper feed sensor (PS1)
331
14.4 LU
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[8] [7] [10]

[11]
[12] [13]
[6]
[5]
[1]
[2]
[4] [3]
[9]
16aaf5c001na
[1] Remaining paper sensor /1 (PS154) [7] Upper limit sensor (PS152)
[2] Remaining paper sensor /2 (PS151) [8] Feed clutch (CL151)
[3] Dehumidifier heater (HTR101) [9] LU set sensor (PS156)
(Service parts setting
P/N 56AA-710# ) [10] Paper lift motor (M151)
[4] Pick-up solenoid (SD151) [11] Feed motor (M150)
[5] Paper empty sensor (PS153) [12] LU drive board (LUDB)
[6] LU exit sensor (PS155) [13] Upper door interlock switch (MS151)
332
14.5 FS
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14.5.1 FS-510
[27]
[26]
[28]
[20] [25]
[24] [29]
[21]
[23] [30]
[1]
[19] [22]
[18]
[17]
[16]
[2]
[13]
[12] [3]
[11] [4]
[10] [5]
[15] [9] [6]
[7]
[14]
[8]
4349f5c001na
[1] Registration clutch (CL1) [16] Tray lift motor (M11)

[2] Guide plate switch (SW4) [17] Lower limit sensor (PS14)
[3] Door switch (SW1) [18] Upper limit sensor (PS15)
[4] Stacker paddle solenoid (SD1) [19] Shutter switch (SW2)
[5] FS control board (FSCB) [20] Tray overrun switch (SW3)
[6] Exit motor (M1) [21] Shutter home sensor (PS16)
[7] Stapler movement motor (M7) [22] Shutter motor (M12)
[8] Alignment sensor /Fr (PS7) [23] Conveyance motor (M2)
[9] Alignment motor /Fr (M5) [24] Exit roller release motor (M6)
[10] Alignment motor /Rr (M4) [25] Alignment sensor /Rr (PS6)
[11] Exit paddle home sensor (PS11) [26] Exit roller home sensor (PS12)
[12] Stapler home sensor (PS10) [27] Conveyance sensor (PS5)
[13] Exit paddle solenoid (SD2) [28] Entrance motor (M3)
[14] Tray lift board (TLB) [29] Stacker sensor (PS8)
[15] Tray position sensor (PS3) [30] Entrance sensor (PS4)
333
14.5.2 FS-511
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A. Front side
[1]
[2]
[4]
[3] 4521f5c001na
[1] Main gate solenoid (SD2) [3] Tray lift motor (M7)
[2] Front door sensor (PS17) [4] Main tray upper limit LED (LED19)
334
B. Rear side
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[10] [11] [12] [13] [14]
[1]
[9]
[2]
[8] [3]
[7] [4]
[6]
[5]
4521f5c002na
[1] Main tray lower limit switch (SW3) [8] Bypass gate solenoid (SD1)
[2] Main tray upper limit sensor (PS19) [9] Entrance conveyance motor (M1)
[3] Paddle motor /Up (M15) [10] Conveyance motor /Up (M4)
[4] Paper exit motor (M3) [11] Conveyance motor /Lw (M2)
[5] FS control board (FSCB) [12] Paper exit roller release motor (M13)
[6] Interlock switch (SW1) [13] Main tray full sensor (PS7)
[7] Intermediate conveyance roller release [14] Paddle solenoid /Up (SD3)
motor (M12)
335
C. Punch section
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[3] [1]
[2] 4521f5c003na
[1] Punch motor (M11) [3] Punch encoder sensor (PS15)

[2] Punch clutch (CL1)
336
D. Conveyance section
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[13]
[12] [14]
[15]
[16]
[11]
[1]
[10]
[2]
[9] [3]
[4]
[8]
[5]
[6]
[7]
4521f5e001na
[1] Hole punch position switch (SW4) [9] Paddle motor /Lw (M9)
[2] Hole punch selector motor (M14) [10] Roller release home sensor (PS12)
[3] Intermediate conveyance sensor (PS3) [11] Main route conveyance sensor (PS4)
[4] Alignment tray sensor (PS5) [12] Exit roller home sensor (PS13)
[5] Main tray reset sensor (PS8) [13] Upper door sensor (PS18)
[6] Alignment home sensor (PS9) [14] Sub tray full sensor (PS6)
[7] Main tray upper limit switch (SW2) [15] Sub tray exit sensor (PS1)
[8] Alignment motor (M5) [16] Bypass route conveyance sensor (PS2)
337
E. Stapler section
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[1]
[2]
4521f5c005na
[1] Stapler home sensor (PS14) [2] Stapler moving motor (M6)
338
F. Main tray section
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[3] [1]
[2]
4521f5c006na
[1] Shift home sensor (PS10) [3] Shift motor (M8)

[2] Shift encoder sensor (PS11)
339
14.6 PU-501
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[1]
[2]
[3]
[5]
[4]
4512f5c001na
[1] Punch scraps full sensor (PS1) [4] Encoder sensor (PS4)
[2] Punch position sensor /1 (PS2) [5] Punch motor (M1)
[3] Punch position sensor /2 (PS3)
340
14.7 SD-502
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[14]
[1]
[13]
[12]
[11]
[10]
[9]
[8]
[2]
[7]
[3]
[6]
[5] [4]
4511f5c001na
[1] Folding motor (M10) [8] Tray empty sensor (PS21)

[2] Folding roller home sensor (PS22) [9] Paper guide motor (M13)
[3] SD interlock switch (SW4) [10] Exit motor encoder sensor (PS25)
[4] Staple guide home sensor (PS26) [11] Conveyance motor (M8)
[5] Paper guide home sensor (PS23) [12] Saddle exit home sensor (PS18)
[6] Exit sensor (PS20) [13] Exit open/close motor (M9)
[7] Staple guide motor (M14) [14] SD control board (SDCB)
341
14.8 MT-501
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[11] [12]
[13]
[10] [14]
[15]
[16]
[9] [1]
[2]
[3]
[8]
[7]
[6]
[4]
[5]
4510f5c001na
[1] Conveyance sensor /Up (PS9) [9] Gate solenoid /2 (SD2)

[2] Paper full sensor /1 (PS5) [10] Conveyance motor (M1)
[3] Conveyance sensor /Lw (PS10) [11] Gate solenoid /3 (SD3)
[4] Paper detection sensor /1 (PS1) [12] Right door open/close sensor (PS11)
[5] Paper detection sensor /2 (PS2) [13] Paper full sensor /4 (PS8)
[6] Paper detection sensor /3 (PS3) [14] Paper detection sensor /4 (PS4)
[7] Gate solenoid /1 (SD1) [15] Paper full sensor /3 (PS7)
[8] MT control board (MTCB) [16] Paper full sensor /2 (PS6)
342
14.9 RU-502
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[2] [1]
16faf5c001na
[1] Path sensor (PS2) [2] Door sensor (PS1)
343
14.10 JS-502
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[1]
[2]
4347f5c001na
[1] Paper full sensor (PS1) [2] Not used
344
Field Service Ver1.0 Feb.2006 15. CONNECTOR LAYOUT DRAWING
15. CONNECTOR LAYOUT DRAWING
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15.1 Main body
15.1.1 Connector in the board
A. Overall control board
44 (BN : 28 pin) 43 (BN: 20 pin) 51 (BN : 5 pin)

46 (BK : 50 pin) 50 (BN : 24 pin)
57 (BK : 9 pin) 42 (BN : 8 pin)

47 (BN : 2 pin)
41 (W : 5 pin)
58 (W : 20 pin)
52 (BN : 2 pin)
49 (BK : 36 pin) 40 (W : 4 pin)
59 (W : 24 pin)
NC
803 (BN : 6 pin)
1000 (BN : 8 pin) NC
NC 500 (BK : 44 pin)
NC 804 (BK : 20 pin)
45 (Silver Metal : 4 pin) 55 (BK : 100 pin)
48 (Silver Metal : 12 pin)
504 (BN : 144 pin)

56 (BN : 3 pin)
50gaf5c001na
345
15. CONNECTOR LAYOUT DRAWING Field Service Ver1.0 Feb.2006
B. Printer control board

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29 (BN : 28 pin) 34 (BN : 32 pin)

28 (BN : 24 pin) 27 (GY : 22 pin)
37 (W : 8 pin) 36 (W : 10 pin)
38 (BN : 20 pin)
91 (BN : 2 pin)
21 (W : 11 pin)
NC NC
35 (W : 5 pin) NC
NC
18 (BN : 12 pin)
20 (W : 6 pin)
90 (W : 8 pin)
69 (BN : 3 pin)
17 (BN : 10 pin)
25 (W : 6 pin) 24 (W : 7 pin) 16 (W : 6 pin)
11 (W : 3 pin)
26 (W : 13 pin) 23 (W : 12 pin) 39 (W : 5 pin)
12 (BK : 68 pin)
15 (BN : 17 pin) 22 (BN : 38 pin)

33 (W : 11 pin) NC
31 (BN : 34 pin) 32 (BN : 28 pin)

19 (BN : 24 pin) 30 (BN : 40 pin)
50gaf5c002na
346
C. Scanner drive board
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62 (BK : 3 pin)
63 (W : 10 pin)
65 (W : 2 pin)
64 (W : 9 pin) 61 (BN : 24 pin)

50gaf5c003na
D. CCD board
60 (BN : 50 pin)
50gaf5c004na
347
E. DC power supply
bizhub 500 / 420
10 (W : 2 pin)
9 (W : 3 pin)
1 (W : 4 pin) 4 (W : 8 pin) 5 (W : 10 pin) 6 (W : 8 pin)
2 (W : 5 pin) 3 (W : 12 pin) 7 (W : 6 pin)

50gaf5c005na
348
F. High voltage unit
bizhub 500 / 420

71 (W : 11 pin)
70 (W : 6 pin)
72 (W : 3 pin)
50gaf5c006na
G. Index board
51 (BN : 5 pin)
50gaf5c007na
349
H. L1 inverter
bizhub 500 / 420
931 (W : 4 pin) 930 (W : 3 pin)

50gaf5c008na
I. L1 relay board
97 (2 pin) 97(2 pin)
50gaf5c009na
J. Laser drive board
50 (BN : 24 pin) 50gaf5c010na
K. Operation board
2 (W : 3 pin)
56 (BK : 22 pin) 1 (BN : 28 pin)
7 (NC)
3 (BN : 4 pin)
4 (BK : 17 pin)
50gaf5c011na
350
L. OB inverter
bizhub 500 / 420

8 (BN : 3 pin) 9 (W : 4 pin)
50gaf5c012na
M. NVRAM board
1 (BN : 20 pin)
2 (BN : 24 pin) 50gaf5c013na
N. Panel key board
6 (BK : 22 pin)
50gaf5c014na
351
O. Paper size board /1, /2

bizhub 500 / 420
87,88 (W : 5 pin)
50gaf5c015na
P. Toner control sensor board
1 (W: 7 pin)
50gaf5c016na
352
15.2 DF
bizhub 500 / 420

A. DF control board (DFCB)
1 (W : 2 pin) 11 (W : 2 pin)
3 (W : 4 pin) 4 (W : 7 pin)
13 (W : N.C.)
2 (W : 13 pin)
6 (W : 12 pin)
5 (W : 11 pin)
16eaf5c005na
B. Tray board (TB)
3 (W : 3 pin) 2 (W : 12 pin)
1 (W : 7 pin)
16eaf5c006na
C. LED board (LB)
1 (W : 4 pin)
16eaf5c007na
353
15.3 PC
bizhub 500 / 420

A. PC-202
(1) PC control board (PCCB)
5 (W : 8 pin) 3 (W : 14 pin)
6 (W : 15 pin) 4 (W : 5 pin)
1 (W : 12 pin)
8 (W : 13 pin)
2 (W : 2 pin)
7 (W : 7 pin)
9 (W : 9 pin) 11 (W : 6 pin) 10 (W : 10 pin)
4061f5c002na
(2) Paper size detect board /3, /4 (PSDB3, PSDB4)
1 (W : 5 pin)
4061f5c003na
354
B. PC-402
(1) PC control board (PCCB)
bizhub 500 / 420

3 (W : 11 pin) 5 (W : 15 pin)
4 (W : 13 pin) 7 (W : 5 pin) 6 (W : 8 pin)
1 (W : 12 pin)
2 (W : 2 pin)
N.C
4061f5c202na
(2) Relay board (RLB)
1 (W : 22 pin) 2 (W : 22 pin)
4061f5c203na
(3) Main tray empty board (MEB)
1 (W : 3 pin)
4061f5c204na
355
15.4 LU
bizhub 500 / 420

A. LU drive board (LUDB)
112 (W : 12 pin)
114 (W : 4 pin)
113 (GY : 22 pin)
111 (W : 2 pin)
110 (GY : 19 pin)

16aaf5c002na
356
15.5 FS
bizhub 500 / 420

A. FS-510
(1) FS control board (FSCB)
7 (W : 5 pin) 5 (W : 3 pin) 3 (W : 10 pin)
8 (W : 2 pin)
10 (W : 3 pin)
6 (W : 7 pin) 4 (W : 4 pin) 1 (W : 6 pin)

12 (W : 11 pin)
2 (W : 8 pin)
11 (W : 6 pin)
9 (W : 7 pin)
14 (W : 9 pin)
26 (W : 2 pin)
13 (W : 10 pin)
16 (W : 11 pin) 18 (W : 6 pin) 20 (W : 10 pin)

15 (W : 8 pin)
25 (W : 5 pin)
17 (W : 7 pin) 19 (W : 4 pin)
4349f5c002na
(2) Tray lift board (TLB)
2 (W : 15 pin)
1 (W : 7 pin)
4349f5c003na
357
B. FS-511
bizhub 500 / 420
(1) FS control board (FSCB)

8 (W : 6 pin) 10 (W : 4 pin) 12 (W : N.C.)
6 (W : 2 pin)
5 (W : 4 pin)
4 (W : 2 pin)
15 (W : 8 pin)
3 (W : 2 pin)
16 (W : 6 pin)
2 (W : 2 pin)
17 (W : N.C.)
1 (W : 6 pin)
18 (W : 12 pin)
22 (W : 3 pin) 19 (W : 15 pin)
24 (W : 7 pin) 20 (W : 9 pin)
25 (W : 15 pin) 23 (W : 7 pin) 21 (W : 4 pin)
4521f5c007na
358
15.6 SD
bizhub 500 / 420

A. SD control board (SDCB)
5 (W : 4 pin) 6 (W : 3 pin) 8 (W : 7 pin)
7 (W : 8 pin)
4 (W : 9 pin)
2 (W : 3 pin) 12 (W : 5 pin) 10 (W : 10 pin)

4511f5c002na
359
15.7 MT
bizhub 500 / 420

A. MT control board (MTCB)
101 (W : 9 pin) 100 (W : 13 pin)
102 (W : 12 pin)
103 (W : 7 pin)
107 (W : 8 pin)
104 (W : 2 pin)
105 (W : 2 pin) 106 (W : 2 pin)
4510f5c002na
360
16.1 Main body
Field Service Ver1.0 Feb.2006
16. TIMING CHART
Drum motor (M1)

Fusing motor (M11)
Feed motor (M9)
Loop clutch (CL2)
P-VV (Valid)
Erase lamp (EL)

Charging (HV)
Transfer (HV)
Separation (HV)
Start key ON
A. A4, 2 single sided originals, single sided copy (1 copy), paper feed tray 1
50gaf5c047na
16. TIMING CHART
361
bizhub 500 / 420
bizhub 500 / 420
362
16. TIMING CHART
Drum motor (M1)

Fusing motor (M11)
Feed motor (M9)
Forward
Reverse motor (M6)
Reverse
Loop clutch (CL2)
Reverse solenoid (SD3)
ADU conveyance clutch /Up (CL7)
ADU conveyance clutch /Lw (CL8)
P-VV (Valid)
Reverse sensor (PS27)
ADU conveyance sensor /1 (PS24)
ADU conveyance sensor /2 (PS25)
Erase lamp (EL)

Charging (HV)
Transfer (HV)
Separation (HV)
B. A4, 3 double sided original, double sided copy (1 copy), paper feed tray 1
Start key ON
50gaf5c048na
Start key ON / 1st sheet feed start 2nd sheet feed start 2nd sheet scan start
16.2 DF
Original set 1st sheet scan start 1st sheet scan complete 2nd sheet scan complete
Original empty sensor (PS5)

ON
OFF
Original feed sensor (PS6)
ON
OFF
Original registration sensor ON
(PS9)
OFF
Original detection sensor ON
(PS8)
OFF
Original exit sensor (PS10)
ON
OFF
Pressure roller release ON
solenoid (SD1)
OFF
ON
Stamp solenoid (SD2)
A. Single sided original mode (A4, 2 sheets feed)
OFF
DSET signal
ON
OFF
ON
VD signal
OFF
ON
NEXTPAGE signal
OFF
High speed
Low speed
Original feed
motor (M1) Stop
Middle speed
High speed
Low speed
Original conveyance
Stop
motor (M2)
Low speed
High speed
16eaf5c009na
16. TIMING CHART
363
bizhub 500 / 420
bizhub 500 / 420
364
16. TIMING CHART
Reverse 2nd sheet

Start key ON / 1st sheet feed start 1st sheet front face scan complete Reverse complete 1st sheet back face scan complete complete feed start
2nd sheet exit
Original set 1st sheet front face scan start Reverse start Reverse start 1st sheet exit start complete
1st sheet back face scan start
Original empty sensor ON
(PS5)
OFF
Original feed sensor ON
(PS6)
OFF
Original registration ON
sensor (PS9) OFF
Original detection ON
sensor (PS8) OFF
Original exit sensor ON
(PS10)
OFF
solenoid (SD1) OFF
Stamp solenoid (SD2) ON
B. Double sided original mode (A4, 2 sheets feed)
OFF
DSET signal
ON
OFF
VD signal
ON
OFF
NEXTPAGE signal
ON
OFF
High speed
Original feed Low speed
motor (M1) Stop
Middle speed
High speed
Original Low speed
conveyance Stop
motor (M2) Low speed
High speed
16eaf5c010na
2nd sheet front face scan complete Reverse complete 2nd sheet back face scan complete Reverse complete 2nd sheet exit complete
2nd sheet front face scan start Reverse start Reverse start 2nd sheet exit start
2nd sheet back face scan start
Original empty sensor ON
(PS5) OFF
Original feed sensor ON
(PS6) OFF
sensor (PS9) OFF
sensor (PS8) OFF
Original exit sensor ON
(PS10) OFF
solenoid (SD1)
OFF

ON
OFF
DSET signal
ON
OFF
VD signal ON
OFF
NEXTPAGE signal ON
OFF
High speed
Original feed Low speed
motor (M1) Stop
Middle speed
High speed
Original Low speed
conveyance Stop
motor (M2) Low speed
High speed
Continued from previous page
16eaf5c011na
16. TIMING CHART
365
bizhub 500 / 420
bizhub 500 / 420
366
Start key ON / 1st sheet feed start 2nd sheet feed start 2nd sheet scan start
Original set 1st sheet scan start 1st sheet scan complete 2nd sheet scan complete
16. TIMING CHART

ON
OFF
ON
OFF
sensor (PS9)
OFF
Original detection sensor ON
(PS8)
OFF
C. FAX fine mode (A4, 2 sheets feed)

ON
OFF
solenoid (SD1)
OFF
ON
OFF
ON
DSET signal
OFF
ON
VD signal
OFF
ON
NEXTPAGE signal
OFF
High speed
Original feed motor Low speed

(M1) Stop
Middle speed
High speed
Low speed
Original conveyance
Stop
motor (M2)
Low speed
High speed
Stamp operation is executed only when "trailing edge" or "leading edge and trailing edge" specified.
16eaf5c012na
Start key ON / 1st sheet feed start Command received / 2nd sheet feed start 2nd sheet scan complete Command received
Original set 1st sheet scan start 1st sheet scan complete 2nd sheet scan start

ON
OFF

ON
OFF
sensor (PS9)
OFF
sensor (PS8)
OFF
ON
OFF
solenoid (SD1)
OFF
ON
OFF
D. FAX immediate send mode (A4, 2 sheets feed)
ON
DSET signal
OFF
ON
VD signal
OFF
ON
NEXTPAGE signal
OFF
High speed
Original feed motor Low speed

(M1) Stop
Middle speed
High speed
Low speed
Original conveyance
Stop
motor (M2)
Low speed
High speed
Stamp operation is executed only when "trailing edge" or "leading edge and trailing edge" specified.
When the communication completes normally, the trailing edge is stamped on.
16eaf5c013na
16. TIMING CHART
367
bizhub 500 / 420
bizhub 500 / 420
368
16.3 LU
16. TIMING CHART
A. A4, life size, 1-1 mode, 3 originals
LU feed motor (M150)

LU pick-up solenoid (SD151)
LU feed clutch (CL151)
PC vertical conveyance motor (M2)
Main body feed motor (M9)
Main body vertical conveyance clutch (CL3)
Main body loop clutch (CL2)
Loop Loop Loop
Main body registration clutch (CL1)
Print signal
PC vertical conveyance sensor (PS2)
Main body vertical conveyance sensor (PS2)
Main body registration sensor (PS1)
Main body fusing exit sensor (PS3)
Start key ON
16aaf5c003na
16.4.1
16.4 FS
FS-510
A. Non-sort, A4, 1 sheet setting
ON
Conveyance sensor (PS5)
OFF
Forward
Entrance motor (M3)
Stop
High speed
Conveyance motor Low speed
(M2)
Stop
Forward
Exit motor (M1)
Stop
4349f5c004na
16. TIMING CHART
369
bizhub 500 / 420
bizhub 500 / 420
370
16. TIMING CHART
Punch position sensor /1 (PS2) ON

Punch position sensor /2 (PS3) OFF
ON
Stacker sensor (PS8)
OFF
Forward
Entrance motor (M3)
Stop
High speed
Conveyance
Low speed
motor (M2)
Stop
Forward
Exit motor (M1) Stop
Reverse
ON
OFF
Forward
Punch motor (M1)
Reverse
Exit roller Forward (release)

B. 1 stapling, punch, A4, 2 originals, 2 copies setting
release Stop
motor (M6) Reverse (pressure)
Stacker paddle ON
solenoid (SD1) OFF
Forward
Alignment motor Stop
/Rr (M4)
Reverse
Forward
Alignment motor /Fr Stop
(M5)
Reverse
Stapler movement Forward
motor (M7) Stop
Forward
Stapler motor
Stop
4349f5c005na
16.4.2
FS-511
Item FS operation start signal ON

A. No-sort, 1 original, 1 copy setting
Fusing exit sensor (PS3) L

H
Entrance conveyance ON
motor (M1) OFF
ON
Conveyance motor /Up (M4)
OFF
Bypass gate solenoid (SD1) ON

OFF
ON
Main gate solenoid (SD2) OFF
Sub tray exit sensor (PS1) L

H
4521f5c008na
16. TIMING CHART
371
bizhub 500 / 420
bizhub 500 / 420
372
16. TIMING CHART
FS operation start signal ON

B. Sort, 2 originals, 2 copies setting
Item
H 1 2 1 2
motor (M1) OFF
Intermediate conveyance L 1 2 1 2
sensor (PS3) H
Shift motor (M8) ON

OFF
H Shift position
Shift home sensor (PS10)
L
Forward
Paper exit motor (M3) Stop
Reverse
4521f5c009na
FS operation start signal ON
Item
H 1 2 1 2
motor (M1) OFF
Conveyance motor /Up (M4) ON

OFF Switch back
Forward
Conveyance motor /Lw (M2) Stop
Reverse
Main route conveyance L 1 2 2
sensor (PS4) H
Bypass route conveyance H 1 1

sensor (PS2) L
Intermediate conveyance L 1 2 1 2
sensor (PS3) H
Alignment operation Alignment operation
Forward
Alignment motor (M5) Stop
C. 1 staple /Rr, A4S, 2 originals, 2 copies setting
Reverse
Paddle motor /Up (M15) ON

OFF
Paddle solenoid /Up (SD3) ON

OFF
Paddle motor /Lw (M9) ON

OFF
Forward
Paper exit motor (M3) Stop
Reverse
Conveyance to tray Conveyance to tray
Stapler moving motor (M6) ON
OFF
Staple Staple
Stapler motor /Rr (M17) ON
OFF
Release Pressure Release Pressure
Paper exit roller release ON
motor (M13) OFF
Release
Intermediate conveyance ON
roller release motor (M12) OFF
Shift Shift
Shift motor (M8) ON
OFF
4521f5c010na
16. TIMING CHART
373
bizhub 500 / 420
bizhub 500 / 420
374
16. TIMING CHART
Item FS operation start signal ON
L
H
motor (M1) OFF
ON
D. Non-sort, punch, 1 original, 1copy setting
Conveyance motor /Up (M4)

OFF
ON
Bypass gate solenoid (SD1)
OFF
Main gate solenoid (SD2)

ON
OFF
ON
Punch motor (M11)
OFF
Punch operation
ON
Punch clutch (CL1)
OFF
Sub tray exit sensor (PS1) L

H
4521f5c011na
Field Service Ver1.0 Feb.2006 17. OVERALL WIRING DIAGRAM
bizhub 500 / 420

17.1 Main body 1/4
1 2 3 4 5 6 7 8 9 10 11 12 13
A RL24V
A
RL1 POWER RL1 CNT FT20 FT21 FT22
J21-01
J13-2
Circuit breaker /1 CN9-1 AC(H)
FT23
FT24
TS
FT3 FT5 CN10-1 AC(H) BT1 Main relay Thermostat
CBR 1 AC(H)
AC DRIVE
B RL1
CR001
FT26
Fusing heater lamp /1
B
Noise filter
FT1 J21-02 J13-3
CN9-2 L2 DRIVE FT25
L2
Inlet
NF
Plug RL1 POWER RL1 CNT
CR002 Fusing heater lamp /2
FT2 J13-4 FT28
Circuit breaker /2 J21-03
L3
CN9-3 L3 DRIVE FT27
FT4 FT6 CN10-2 AC(N) BT3 Sub relay
CBR 2 AC(N)
RL2 J13-1
C CN8-1 SW IN(H)
CR003
RT4
Ǿ4
RT3
Ǿ4
C
CN8-3 SW IN(N)
FT9 FT10 CN8-4 SW OUT(N) AC(N) BT4
FT9 SW1 FT10 CN8-2 SW OUT(H)

24V 5V1 1-1
D Main power switch
AC(H) BT2 5V
12V
5V1
S.GND
1-2
1-3
D
S.GND 1-4
EN5V2 2-5
EN12V1 2-4
DCPS(1/2) NMI
12V1
S.GND
2-3
2-2
2-1
E 5V2 4-1
E
for FNS
24V 5V2 4-2
S.GND 4-3
F3 11 5-1 24V
S.GND 4-4
12 5-2 24V
F1 12V2 4-5
13 5-3 24V
S.GND 4-6
14 5-4 P.GND
F2 S.GND 4-7
15 5-5 P.GND
12V2 4-8
16 5-6 P.GND
F 17 5-7 S.GND Interlock switch
MS F
6-8 P.GND
6-7 P.GND
6-5 P.GND
6-6 P.GND
18 5-8 S.GND
SWD24V
6-4 24V
6-3 24V
6-1 24V
19 5-9 5V2
12V2(LD) 42- 8
S.GND 42- 7
S.GND 42- 6
12V2 42- 5
S.GND 42- 4
S.GND 42- 3
42- 2
42- 1
41- 5
41- 4
41- 3
41- 2
41- 1
40- 4
40- 3
40- 2
40- 1
6-2 24V
24V 7-1 5
20 5-10 5V2 J23-1 J24-1A -1B J23-3
SWD24V
24V 7-2 6
EN12V1
S.GND
EN5V2
S.GND
S.GND
12V1
/NMI
J23-2 J24-2A J24-2B J23-4
5V2
5V2
5V1
5V1
(J23:NMF)
G 63 64 3 4 1 2
G
ENPWR 31- 1
12V2(LD) 42- 9
S.GND 500- 4
S.GND 500- 3
S.GND 42- 8
S.GND 42- 6
S.GND 42- 4
S.GND 42- 3
S.GND 31- 6
EN24V 31- 3
EN5V2 31- 2
for for for
12V2 42- 5
12V1 31- 5
5V1 500- 2
5V1 500- 1
-12V 42- 7
-12V 31- 7
31- 4
42- 2
42- 1
LU DF SDB
3-1
PKB -2 80-A14 34-A1 DB3

J60: 1 - 1
J60: 2 - 2
NMI
5V2
5V2
-3 80-A13 34-A2 S.GND
-4 80-A12 34-A3 DB1
H 80-A11
80-A10
80- A9
34-A4 XSCL
34-A5 S.GND
34-A6 YD
H
44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 32
4-17
-16
-15
OB 80- A8
80- A7
80- A6
34-A7 OPTXD
34-A8 S.GND
34-A9 OPRTS
OACB(1/3)
33 -14 80- A5 34-A10 OPRXD
PC-202 34 -13 80- A4 34-A11 S.GND

-12 80- A3 34-A12 OPCTS
35
-11
LCDB LCD
36 80- A2 34-A13 DF_INT
-10
I 37 -9 80- A1 34-A14 APS_INT
I
or 38 -8
for DCPS
24V 62: 1 - 1 63 -7 80-B14 34-B1 DB2

62: 2 - 2 39
P.GND 64
-6 80-B13 34-B2 S.GND
62: 3 - 3 40 -5
41 -4 80-B12 34-B3 DB0
62: 4 - 4 80-B11 34-B4 LP
-3
PC-402
42
LU-201 43
-2
-1
80-B10
80- B9
80- B8
80- B7
34-B5 S.GND
34-B6 LCDENB
34-B7 RST
34-B8 S.GND
Battery
J Backlight
80- B6
80- B5
34-B9 OPINT
34-B10 /FAX_RING CN52
J
2-2 INV ON
2-3 S.GND
80- B4 34-B11 5V
80- B3 34-B12 5V
2-1 5V
80- B2 34-B13 /SYS_STOP
(CN2)
58-1 F8.DRV
58-2 F8.LCK
80- B1 34-B14 /UTY
58-3 GND
for ENGINE 9-1 FL HOT
300:B11- B11
21 FS_TXD -4 FL GND
300:B10- B10 47-1 MONIT
22 S.GND (CN8)
300:B9 - B9
K 300:B8 - B8
300:B7 - B7
23
24
NC
FS_RTS
OB INVB 8- 3
-2
47-2 S.GND
K
FS-510 300:B6 - B6
300:B5 - B5
300:B4 - B4
25
26
27
28
S.GND
FS_RXD
NC
S.GND
-1
300:B3 - B3
or 300:B2 - B2
300:B1 - B1
29
30
31
FS_CTS
S.GND
S.GND
514: 1 - 2
SP FM10
L 300:A10- A10
for DCPS
24V2
PSWB SW2 514: 2 - 1
L
FS-511
11
300:A9 - A9
300:A8 - A8
300:A7 - A7
300:A6 - A6
12
13
14
15
24V2
24V2
P.GND
P.GND
OPERATION UNIT Speaker
OACB cooling fan
+RU-502 300:A5 - A5
300:A4 - A4
300:A3 - A3
300:A2 - A2
16
19
20
P.GND
5V2
5V2
17 S.GND
300:A1 - A1
18 S.GND
M 300:A11- A11
M
1 2 3 4 5 6 7 8 9 10 11 12 13
17. OVERALL WIRING DIAGRAM Field Service Ver1.0 Feb.2006
bizhub 500 / 420
Main Body location list

Symbol Part name Location
CBR1 Circuit breaker /1 3-B
CBR2 Circuit breaker /2 3-C
DCPS DC power supply 4-A
FM10 Overall control board cooling fan 12-K
L2 Fusing heater lamp /1 11-B
L3 Fusing heater lamp /2 11-B
LCD LCD 6-H
LCDB LCD board 6-H
MS Interlock switch 8-F
NF Noise filter 4-B
OACB Overall control board 11-F
OB Operation board 8-G
OB INVB OB inverter 6-K
PKB Panel key board 6-G
PSWB Power switch board 8-L
RL1 Main relay 6-B
RL2 Sub relay 6-B
SP Speaker 11-L
SW1 Main power switch 3-D
SW2 Power switch 9-L
TS Thermostat 11-B
— FS-510 3-K
— FS-511 3-K
— LU-201 1-I
— PC-202 3-H
— PC-402 3-H
— RU-502 3-K
— Inlet 2-B
— Backlight 6-J
— Battery 12-I
— Plug 2-B
I
L
F
K
E
B
A
H
D
C
14
14
17.2 Main body 2/4
15
15
CN500
IC-204
HD-505
16
16
J50: A1 - A12
50-A12 432-A1 /ENB1
J50: A2 - A11
-A11 -A2 /ALM1
J50: A3 - A10
-A10 -A3 /BIAS1
J50: A4 - A9
- A9 -A4 /S/H1
J50: A5 - A8
- A8 -A5 S.GND
J50: A6 - A7
- A7 -A6 LD+5V
J50: A7 - A6 46- 1 60- 1 S.GND
- A6 -A7 LD+5V
J50: A8 - A5 46- 2 - 2 TG
- A5 -A8 +5VRN
J50: A9 - A4 46- 3 - 3 CLAMP
- A4 -A9 S.GND
J50:A10 - A3 46- 4 - 4 ACLAMP
- A3 -A10 -VIDEO2
J50:A11 - A2 46- 5 - 5 PRD_KEEP
- A2 -A11 +VIDEO2
J50:A12 - A1 46- 6 - 6 GND
- A1 -A12 S.GND
17
17
46- 7 - 7 GMD
J50: B1 - B12 46- 8 - 8 +TCK
50-B12 432-B1 LOAD
J50: B2 - B11 46- 9 - 9 -TCK
-B11 -B2 DACLK
J50: B3 - B10 46-10 -10 S.GND
-B10 -B3 DI
J50: B4 - B9
LDB
- B9 -B4 S.GND 46-11 -11 S.GND
J50: B5 - B8 46-12 -12 +RCK
- B8 -B5 /ALM2
J50: B6 - B7 46-13
- B7 -B6 /BIAS2
J50: B7 - B6 46-14 -14 GND
- B6 -B7 /S/H2
J50: B8 - B5 46-15 -15 GND
- B5 -B8 /ALMRST
J50: B9 - B4 46-16 -16 +IN_CLK
- B4 -B9 S.GND
J50:B10 - B3 46-17
- B3 -B10 -VIDEO1
J50:B11 - B2 46-18 -18 GND
- B2 -B11 +VIDEO1
J50:B12 - B1 46-19 -19 GND
- B1 -B12 S.GND
46-20 -20 SCLK
18
18
46-21 -21 *SEN

CN35
46-22 -22 SDI

46-23 -23 SDO
46-24 -24 S.GND
46-25 -25 S.GND
46-26
J52: 5 - 1
51-1 431- 5 +5V 46-27 -27 +AD_D0
J52: 4 - 2
-2 431- 4 S.GND 46-28 -28 S.GND
J52: 3 - 3
-3
SC-502
431- 3 /HSENSE 46-29 -29 S.GND
J52: 2 - 4
-4 431- 2 S.GND 46-30 -30 -AD_D1
J52: 1 - 5
-5 431- 1 /INDPR 46-31 -31 +AD_D1
46-32 -32 S.GND
CCDB
46-33 -33 S.GND

46-34
Memory Board
46-35 -35 +OUT_CLK
19
19
49- 1 STROBE 46-36 -36 S.GND
INDEXB
- 2 DATA0 46-37 -37 S.GND
- 3 DATA1
- 4 DATA2 46-38 -38 ADRST
- 5 DATA3
- 6 DATA4 46-39 -39 APR
- 7 DATA5 46-40 -40 S.GND
- 8 DATA6
- 9 DATA7 46-41 -41 +5V
-10 ACK
-11 BUSY 46-42 -42 +5V
-12 PERROR 46-43 -43 +5V
-13 SLCT
-14 AUTOFD 46-44 -44 +5V
-15 N.C.
-16 GND 46-45 -45 S.GND
-17 GND 46-46 -46 +12V
-18 PERIHERAL
-19 GND 46-47 -47 +12V
-20 GND
-19 GND 46-48 -48 +12V
-22 GND 46-49 -49 +12V
-23 GND
20
20
-24 GND 46-50 -50 S.GND

-25 GND
-26 GND
-27 GND
-28 GND
-29 GND
-30 HLOGIC
-31 INIT
-32 FAULT
-33 GND
-34 N.C.
-35 N.C.
-36 SELECTIN
45-4
45-3
45-2
45-1
- 9 RI
NRB
- 8 CTS
- 7 RTS
- 3 TXD
- 4 DTR
- 6 DSR
- 2 RXD
- 5 GND
21
21
57- 1 DCD
VDD
GND
-Data
+Data
USB
OACB(2/3)
CSRC I/F
22
22
-B50 LINESEL
-B49 CLKEN
-B48 3.3V
-B47 +12V
-B46 RST#
-B45 3.3V
-B44 CNT#
-B43 GND
-B42 PME#
-B41 GND
-B40 AD30
-B39 3.3V
-B38 AD28
-B37 AD26
-B36 AD24
-B35 IDSEL
-B34 GND
-B33 AD22
-B32 AD20
-B31 PAR
-B30 AD18
-B29 AD16
-B28 GND
-B27 FRAME#
-B26 TRDY#
-B25 STOP#
-B24 3.3V
-B23 DEVSEL#
-B22 GND
-B21 AD15
-B20 AD13
-B19 AD11
-B18 GND
-B17 AD9
-B16 C/BE#0
-B15 +5V(stby)
-B14 AD6
-B13 AD4
-B12 AD2
-B11 AD0
-B10 +5V(stby)
-B 9 +5V(main)
-B 8 SBDP1
-B 7 SBDM1
-B 6 GND
-B 5 SBDP2
-B 4 SBDM2
-B 3 +5V(main)
-B 2 IORST1
55-B 1 +5V(main)
-A50 INTA#
-A49 MONITOR
-A48 GND
-A47 GND
-A46 CLK
-A45 GND
-A44 REQ#
-A43 3.3V
-A42 AD31
-A41 AD29
-A40 GND
-A39 AD27
-A38 AD25
-A37 GND
-A36 C/BE#3
-A35 AD23
-A34 GND
-A33 AD21
-A32 AD19
-A31 GND
-A30 AD17
-A29 C/BE#2
-A28 IRDY#
-A27 GND
-A26 GND
-A25 SERR#
-A24 GND
-A23 PERR#
-A22 C/BE#1
-A21 AD14
-A20 GND
-A19 AD12
-A18 AD10
-A17 GND
-A16 AD8
-A15 AD7
-A14 +5V(STBY)
-A13 AD5
-A12 GND
-A11 AD3
-A10 +5V(STBY)
-A 9 AD1
-A 8 GND
-A 7 GND
-A 6 WAKEUP
-A 5 GND
-A 4 GND
-A 3 +5V(main)
-A 2 GND
55-A 1 +12V
(CN55:FX2)
CN55 Board to Board Connector(100pin)

23
23
Crimp
Symbol
Connector
24
24
Relay connector
Faston
25
25
MK-708+FK-502
26
26
L
F
K
E
B
A
H
D
C
M
bizhub 500 / 420

bizhub 500 / 420

CCDB CCD board 17-B
INDEXB Index board 18-K
LDB Laser drive board 16-K
NRB NVRAM board 20-F
— FK-502 23-E
— HD-505 15-F
— IC-204 15-G
— MK-708 23-E
— SC-502 17-G
Z
T
Y
X
V
S
P
U
R
N
Q
O
W
24V2 20- 1
5 6
24V2 20- 2 RL24V
5V-1 27-A11 5V P.GND 20- 3 7-6 P.GND
S.G-2
1
1
27-A10 S.GND P.GND 20- 4 7-5 P.GND 24V

CONT-3 27-A9 /DRM_ON(DO/L) P.GND 20- 5 7-4 P.GND
CLK-4 27-A8 DRM_CLK 24V1 20- 6
CW/CCW-5 27-A7 F_MTYPE F4
Drum motor LD-6 27-A6 /DRAM_LCK(DI/H) 24V2 21- 11
M1
H/L-7 27-A5 DRM_GAIN 5V 21- 10 3-1 5V2
17.3 Main body 3/4
P.G-8 27-A4 P.GND 5V 21- 9 3-2 5V2

P.G-9 27-A3 P.GND S.GND 21- 8 3-3 S.GND
24V-10 27-A2 24V S.GND 21- 7 3-4 S.GND
24V-11 27-A1 24V 12V2 21- 6 3-5 12V2
/EN24V2 21- 5 3-6 EN24V

/HEATER1_CNT 21- 4 3-7 L2CONT
5V-1 27-B1 5V /HEATER2_CNT 21- 3 3-8 L3CONT
S.G-2 27-B2 F_MTYPE HEATER2_CNT2 21- 2 3-9 L3CONT2
CONT-3 27-B3 FIXM_ON(DO/L) /RELAY_CNT 21- 1 3-10 RLCONT
2
2
CLK-4 27-B4 FIXM_CLK J62-4 3-11 RL_PGND

CW/CCW-5 27-B5 S.GND J62-3 3-12 RL_PWR
Fusing motor LD-6 27-B6 /FIXM_LCK(DI/H)
H/L-7
M11
27-B7 FIXM_GAIN
P.G-8 27-B8 P.GND
P.G-9 27-B9 P.GND
DCPS(2/2)
24V-10 27-B10 24V2 Charging

24V-11 27-B11 24V2
Charging
FT35
24V1 16- 1 70- 6
P.GND 16- 2 70- 5
(DO/L)/BIAS1 16- 3 70- 4 Grid biass
(AO/2-8V)B_SIG 16- 4 70- 3
5V-1 32-A14 5V
FT40
S.G-2 32-A13 S.GND
P.GND 16- 5 70- 2
To developing bias
3
3
CONT-3 32-A12 /DEV_ON(DO/L) J17-7 J17-12 70- 1 J16-20

CLK-4 32-A11 DEV_CLK 24V2 16- 6 72- 5
J25-1 J25-5
CW/CCW-5 FT31 FT32 FT33
Developing motor LD-6 32-A9 /DEVM_LCK
M3
H/L-7 32-A8 DEVM_GAIN
72- 1 J16-11
P.G-8 32-A7 P.GND
P.G-9 32-A6 P.GND (DI/L)/S_FB 15-1 71-11 FT30
24V-10 32-A5 24V2 (AO/4-10V) SDC_SIG 15-2 71-10
24V-11
HV
26-A4 24V2 (AO/4-10V) SAC_SIG 15-3 71- 9
To guide plate bias
(DO/L)/S_CONT 15-4 71- 8

(DI/L)/T_FB 15-5 71- 7
911: 3 - 1 (AO/4-10V) T_SIG 15-6 71- 6
32-A3 GND
911: 2 - 2 (DO/L) /T_CONT 15-7 71- 5 FT38 FT39
Power supply cooling fan 32-A2 /F1.LCK(DI/H)
911: 1 - 3 (DI/L)/C_FB 15-8 71- 4
FM1
32-A1 F1.DRV
(AO/4-10V) GRID_SIG 15-9 71- 3
4
4
(AO/4-10V) CHG_SIG 15-10 71- 2

(DO/L)/C_CONT 15-11 71- 1
FT36 FT37
Separation
917: 3 - 2
32-B14 GND
917: 2 - 3
Developing cooling fan 32-B13 /F7.LCK(DI/H)
917: 1 - 4
FM7
32-B12 F7.DRV
914: 3 - 1
Transfer
/F4.DRV 15-12
914: 2 - 2
(DI/H) /F4.LCK 15-13 Drum cooling fan
914: 1 - 3
FM4
5V-1 32-B11 5V P.GND 15-14

S.G-2 32-B10 S.GND
CONT-3 32-B9 FEED_ON(DO/L)
CLK-4 32-B8 FEEDM_CLK
5
5
CW/CCW-5 916: 3 - 1
/F6.DRV 15-15
Feed motor LD-6 32-B6 N.C. 916: 2 - 2
(DI/H) /F6.LCK 15-16 Developing suction fan
M9
H/L-7 32-B5 FEED_GAIN 916: 1 - 3
FM6
P.GND 15-17
P.G-8 32-B4 P.GND
P.G-9 32-B3 P.GND
24V-10 32-B2 24V2
24V-11 32-B1 24V2
J12: 7 - 1 J13:A4 - A1 980:1 - 1
(AI/0-5V) TH1.S 34-A1 Thermistor /1
J12: 6 - 2 J13:A3 - A2 980:2 - 2
S.GND 34-A2
TH1
-3 J15: 1 - 13 J12: 5 - 3 J13:A2 - A3 980:3 - 3

31-A1 5V_R (AI/0-5V) TH2.S 34-A3
Paper size sensor -2 J15: 2 - 12 J12: 4 - 4 J13:A1 - A4 980:4 - 4 Thermistor /2
31-A2 S.GND S.GND 34-A4
TH2
/BP4 J15: 3 - 11
B
972-1
PS22
31-A3 MULTI_SIZE4(MULTI)
6
6
Ǿ3
RT3
931: 1 - 2 J15: 4 - 10 J12: 3 - 5 J13:B4 - B1 J18: 3 - 1 -3
Pick-up solenoid 31-A4 24V2 5V_R 34-A5
931: 2 - 1 J15: 5 - 9 J12: 2 - 6 J13:B3 - B2 J18: 2 - 2 -2 Fusing exit sensor
S.GND 34-A6
SD1
/BP 31-A5 MULTI_PICKUP_SD_DRV(MULTI)
J12: 1 - 7 J13:B2 - B3 J18: 1 - 3 953-1
PS3
(DI/H?) FIX_PS 34-A7

-3 36: 1 - 3 J15: 6 - 8
31-A6 S.GND J05:3 - 1 -3
-2 36: 2 - 2 J15: 7 - 7 S.GND 34-A8
Paper size VR/BP 31-A7 MULTI_WIDTH_PS(MULTI) J05:2 - 2 -2
985-1 36: 3 - 1 J15: 8 - 6 /T_LEVEL(DI) 34-A9 Toner remaining sensor
VR1
Ǿ3
31-A8 5V
RT3
J05:1 - 3 987-1
PZS
TLEV_5V 34-A10
-3 J15: 9 - 5
31-A9 5V_R 903:6 - 1
-2 J15:10 - 4 TNR_A 34-A11
Lift sensor 31-A10 S.GND 903:5 - 2
973-1 J15:11 - 3 TNR_AB 34-A12
PS23
31-A11 MULTI_POSITION_PS 903:4 - 3
J15:12 - 2 TNR_B 34-A13
31-A12 MULTI_SET 903:3 - 4 Toner supply motor
J15:13 - 1 TNR_BB 34-A14
M4
31-A13 S.GND 903:2 - 5
7
7
24V2 34-A15
903:1 - 6
(J35:CT 2PIN)
24V2 34-A16
923: 1 - 2 J35: 1 - 4
31-A14 24V2 905:6 - 1
Vertical conveyance clutch 923: 2 - 1 J35: 2 - 3 BTLM_A 34-B1
CL3
31-A15 V_FEED_CL_DRV 905:5 - 2
BTLM_AB 34-B2
905:4 - 3
925: 1 - 2 J35: 3 - 2 BTLM_B 34-B3
31-A16 24V2 905:3 - 4 Toner bottle motor
Feed clutch /2 925: 2 - 1 J35: 4 - 1 BTLM_AB 34-B4
M10
905:2 - 5
CL5
31-A17 TRAY2_FEED_CL_DRV(LOWER)
24V2 34-B5
905:1 - 6
24V2 34-B6
-3 J03: 1 -14 24V2 34-B7 J29:2 - 1 934:2 - 1

31-B1 5V_R
-2 J03: 2 -13 J29:1 - 2 934:1 - 2 Web solenoid
SD4
ADU conveyance sensor /1 31-B2 S.GND WEB_SD_DRV 34-B8
PS24
974-1 J03: 3 -12
31-B3 DUP_PS1
935:2 - 1
8
8
-3 J03: 4 -11 24V2 34-B9

31-B4 5V_R 935:1 - 2 Toner solenoid
B
SD5
ADU conveyance -2 J03: 5 -10 TNR_SD_DRV 34-B10

sensor /2 31-A5 S.GND
Ǿ3
PS25
RT3
975-1 J03: 6 - 9
31-B6 DUP_PS2
J28: 6 - 1
-3 J03: 7 - 8 /F2.DRV 34-B11
31-A7 5V_R J28: 5 - 2 911: 2 - 2
ADU open -2 J03: 8 - 7 /F2.LCK(DI/H) 34-B12 Fusing cooling fan/Fr
31-A8 S.GND J28: 4 - 3 911: 1 - 3
FM2
/close sensor P.GND 34-B13

PS26
976-1 J03: 9 - 6
31-B9 DUP_COVER
927: 1 - 2 J03:10 - 5
Ǿ3
RT3
ADU conveyance 31-B10 24V2
927: 2 - 1 J03:11 - 4
CL7
clutch /Up 31-B11 DUP_CL1_DRV J28: 3 - 4 911: 3 - 1

/F2.DRV 34-B14
J28: 2 - 5 911: 2 - 2
/F8.LCK(DI/H) 34-B15 Fusing cooling fan/Rr
928: 1 - 2 J03:12 - 3 J28: 1 - 6 911: 1 - 3
PRCB(1/2)
FM8
31-B12 24V2 P.GND 34-B16

ADU conveyance clutch /Lw 928: 2 - 1 J03:13 - 2
CL8
31-B13 DUP_CL2_DRV
9
9
J03:14 - 1
31-B14 N.C.
915: 1 - 3 J33: 1 - 3
31-B15 F5.DRV
915: 2 - 2 J33: 2 - 2
Coveyance suction fan 31-B16 P.GND
915: 3 - 1 J33: 3 - 1 J16-2 J11: 7 - 1
FM5
31-B17 /F5.LCK(DI/H) 5V 33-1 988-7

J16-3 J11: 6 - 2
DRUM_TH 33-2 -6
J16-4 J11: 5 - 3
12V 33-3 -5
J16-5 J11: 4 - 4
TNRIF 33-4 -4
J16-6 J11: 3 - 5
TNOUT1 33-5 -3
IDCS
J16-7 J11: 2 - 6
IDC sensor
939-2 J07: 1 - 8 TNOUT2 33-6 -2

30-A1 24V2 J16-8 J11: 1 - 7
Total counter 939-1 J07: 2 - 7 S.GND 33-7 -1
TCT
30-A2 TC_DRV
J16-15 932:2 - 1
-3 J04: 1 - 6 J07: 3 - 6 CLAW_SD_DRV 33-8
30-A3 5V_R J16-16 932:1 - 2 Drum claw solenoid
SD2
-2 J04: 2 - 5 J07: 4 - 5 24V2 33-9

10
10
Paper empty sensor /1 30-A4 S.GND

955-1 J04: 3 - 4 J07: 5 - 4
PS5
30-A5 TRAY1_EMPTY_PS(UPPER)
J16-12 937:2 - 1
24V2 33-10
J16-18 937:1 - 2 Erase lamp
EL
-3 J04: 4 - 3 J07: 6 - 3 PCL_DRV 33-11

30-A6 5V_R
-2 J04: 5 - 2 J07: 7 - 2
Upper limit sensor /1 30-A7 S.GND
956-1 J04: 6 - 1 J07: 8 - 1
PS6
30-A8 TRAY1_FULL_PS(UPPER)
24V2 35-1
35-2
-3 J08: 1 - 12 /KEY.SIG 35-2
30-A9 5V_R 35-3
Paper empty sensor /2 -2 J08: 2 - 11 S.GND 35-3
30-A10 S.GND
962-1 J08: 3 - 10 KC.DRV 35-4
PS12
30-A11 TRAY2_EMPTY_PS(LOWER)
P.GND 35-5
-3 J08: 4 - 9
11
11
30-A12 5V_R
Upper limit sensor /2 -2 J08: 5 - 8
30-A13 S.GND
963-1 J08: 6 - 7 /M1 36-1
PS13
30-A14 TRAY2_FULL_PS(LOWER)
/PF 36-2
/PS0 36-3
-3 J08: 7 - 6 /PS1 36-4
30-A15 5V_R
-2 J08: 8 - 5 /PS2 36-5
Vertical conveyance sensor 30-A16 S.GND
952-1 J08: 9 - 4
PS2
30-A17 V_FEED_PS /PS3 36-6

/SIDE 36-7
-3 J08:10 - 3 /CPF0 36-8
Coin vendor/2
30-A18 5V_R
Feed door -2 J08:11 - 2 /CPF1 36-9
30-A19 S.GND
open/close sensor 957-1 J08:12 - 1 P.GND 36-10
PS7
30-A20 SIDE DOOR
TXD 37-1
989-1 J17-2 J14: 1 - 4
30-B1 TDS_CONT S.GND 37-2
-2 J17-3 J14: 2 - 3
12
12
30-B2 12V CTS 37-3

-3 J17-9 J14: 3 - 2
TCR sensor 30-B3 TDS_SIG RXD 37-4
-4 J17-5 J14: 4 - 1
30-B4 S.GND NC 37-5
TCRS
-5
RTS 37-6
S.GND 37-7
5V 37-8
924: 1 - 2
30-B5 24V2
Feed clutch /1 924: 2 - 1
CL4
30-B6 TRAY1_FEED_CL_DRV(UPPER)
-3 J27: 1 - 3
30-B7 5V_R
Paper empty sensor /BP -2 J27: 2 - 2
30-B8 S.GND
968-1 J27: 3 - 1
PS18
30-B9 MULTI_EMPTY_PS
13
13
-3 J10: 1 - 11
30-B10 5V_R
paper size sensor /BP1 -2 J10: 2 - 10
30-B11 S.GND
969-1 J10: 3 - 9
PS19
30-B12 MULTI_SIZE1
Z
T
Y
X
V
S
P
U
R
N
Q
O
W
bizhub 500 / 420

bizhub 500 / 420

CL3 Vertical conveyance clutch 7-Y
CL4 Feed clutch /1 12-Y
CL5 Feed clutch /2 7-Y
CL7 ADU conveyance clutch /Up 9-Y
CL8 ADU conveyance clutch /Lw 9-Y
EL Erase lamp 10-Q
FM1 Power supply cooling fan 4-X
FM2 Fusing cooling fan /Fr 8-Q
FM4 Drum cooling fan 5-Q
FM5 Coveyance suction fan 9-X
FM6 Developing suction fan 5-Q
FM7 Developing cooling fan 4-X
FM8 Fusing cooling fan /Rr 9-Q
HV Hight voltage unit 3-Q
IDCS IDC sensor 9-Q
M1 Drum motor 1-X
M3 Developing motor 3-X
M4 Toner supply motor 7-R
M9 Feed motor 5-X
M10 Toner bottle motor 7-R
M11 Fusing motor 2-X
PRCB Printer control board 1-T
PS2 Vertical conveyance sensor 11-Y
PS3 Fusing exit sensor 6-Q
PS5 Paper empty sensor /1 10-Y
PS6 Upper limit sensor /1 10-Y
PS7 Feed door open/close sensor 12-Y
PS12 Paper empty sensor /2 11-Y
PS13 Upper limit sensor /2 11-Y
PS18 Paper empty sensor /BP 13-Y
PS19 Paper size sensor /BP1 13-Y
PS23 Lift sensor 7-Y
PS24 ADU conveyance sensor /1 8-Y
PS25 ADU conveyance sensor /2 8-Y
PS26 ADU open/close sensor 8-Y
PZS Toner remaining sensor 6-Q
SD1 Pick-up solenoid /BP 6-Y
SD2 Drum claw solenoid 10-Q
SD4 Web solenoid 8-R
SD5 Toner solenoid 8-R
TCRS TCR sensor 12-Y
TCT Total counter 10-Y
TH1 Thermistor /1 6-Q
TH2 Thermistor /2 6-Q
VR1 Paper size VR /BP 6-Y
— DF-607 14-O
— Guide plate bias 3-P
— Grid 3-Q
— Developing 3-O
— Coin vendor /2 11-Q
— Charging 3-Q
— Transfer 4-P
— Separation 4-P
Z
T
Y
X
V
S
P
U
R
N
Q
O
W
-3 J10: 4 - 8
30-B13 5V_R
-2 J10: 5 - 7
Paper size sensor /BP2 30-B14 S.GND
970-1 J10: 6 - 6
PS20
30-B15 MULTI_SIZE2
201A: 1- 10
N.C. 17-10
14
14
201A: 2- 9
-3 J10: 7 - 5
ADF_RXD 17-9
30-B16 5V_R 201A: 3- 8
-2 J10: 8 - 4
N.C. 17-8
Paper size sensor /BP3 30-B17 S.GND 201A: 4- 7
971-1 J10: 9 - 3
ADF_TXD 17-7
201A: 5- 6
PS21
30-B18 MULTI_SIZE3 N.C. 17-6
201A: 6- 5
N.C. 17-5
17.4 Main body 4/4
201A: 7- 4
926: 1 - 2 J10:10 - 2 ADFOPEN 17-4
30-B19 24V2 201A: 8- 3
Feed clutch /BP 926: 2 - 1 J10:11 - 1 N.C. 17-3
CL6
30-B20 MULTI_FEED_CL_DRV(MULTI) 201A: 9- 2
N.C. 17-2
201A:10- 1
N.C. 17-1
201B: 1- 12
-3
ADS_BUSY 18-12
23-A1 5V_R 201B: 2- 11
-2
ADF_VV 18-11
Near-emptysensor/1 23-A2 S.GND 201B: 3- 10
959-1
ADF_DSET 18-10
PS9
23-A3 NEAR_EMPTY_PS(UPPER) 201B: 4- 9
ADF_SIZE1 18-9
201B: 5- 8
15
15
ADF_SIZE2 18-8
201B: 6- 7
-3
ADF_SIZE3 18-7
23-A4 5V_R 201B: 7- 6
ADF_NEXTPAGE 18-6
DF-607
Tray set sensor /1 -2 201B: 8- 5
23-A5 S.GND N.C. 18-5
958-1
PS8
23-A6 CASETTE_SET(UPPER) 201B: 9- 4
ADF_EMPTY_PS 18-4
201B:10- 3
5V1 18-3
201B:11- 2 200: 1 - 1 20: 1 - 1
-3
ADF_READY 18-2 24V 3
23-A7 5V_R 201B:12- 1 200: 4 - 4 20: 2 - 2
-2
SGND 18-1 P.GND 4
for DCPS
Paper size sensor /Rr1 23-A8 S.GND

960-1
PS10
23-A9 WIDTH_PS1(UPPER)
-3
23-A10 5V_R
-2 62-1 U
Paper size sensor /Fr1 23-A11 S.GND
961-1 Scanner motor -2 V
M2
PS11
23-A12 WIDTH_PS2(UPPER)
16
16
-3 W
-5 24-A1 FD_SIZE1(UPPER) 980-3 63-1 S.GND

-4 24-A2 FD_SIZE2(UPPER) Scanner home sensor -2 63-2 OPT_HOME
Paper size board /1
PS30
-3 24-A3 FD_SIZE3(UPPER) -1 63-3 5V2
-2 24-A4 FD_SIZE4(UPPER)
97-1 24-A5 S.GND 981-3 63-4 5V1
PSB/1
APS timing sensor -2 63-5 S.GND
PS31
-1 63-6 TIMING1
907- 2
24-A6 24V2 97-3 96-1 930-1 L.V. 931-4 63-7 24V
Paper lift motor /1 907- 1
M7
24-A7 LIFT_UP_M_DRV(UPPER) 97-1 96-3 -3 H.V. -3 63-8 LAMP_ON/OFF
L1 RLB -2 63-9 LAMP_EM
17
17
L1
-1 63-10 P.GND
L1 relay board L1 inverter
L1 INVB
-3
25-A1 5V_R
-2
Near-emptysensor/2 25-A2 S.GND Exposure lamp
965-1 (J22:CT)
PS15
25-A3 NEAR_EMPTY_PS(LOWER)
J22: 1 - 2
930-2 64-1 ADF_CLOSE_SIG
DF open/close switch J22: 2 - 1
-1
SW3
-3
64-2 S.GND
25-A4 5V_R
-2
Tray set sensor /2 25-A5 S.GND
964-1 -4
PS14
25-A6 CASETTE_SET(LOWER) 64-3 KC_24V
936B-1 -3
64-4 KC.DRV
936B-2 -2
-3 64-5 /KEY.SIG
26-A1 5V_R 985A-1
-2 64-6 S.GND
26-A2 S.GND
Key counter
Paper size sensor /Rr2 966-1 982-3 64-7 APS_5V
PS16
26-A3 WIDTH_PS1(LOWER)
18
18
APS sensor -2 64-8 APS_DATA1

PS32
SDB
-1 64-9 S.GND
-3
26-A4 5V_R
-2
Paper size sensor /Fr2 26-A5 S.GND KC_24V 28-A1 61- A12
967-1
PS17
26-A6 WIDTH_PS2(LOWER) APS_SIG_IN 28-A2 61- A11
APS_5V 28-A3 61- A10
S_DA_DATA 28-A4 61- A9
OPM_EN 28-A5 61- A8
-5 26-A7 FD_SIZE1(LOWER) S.GND 28-A6 61- A7
-4 26-A8 FD_SIZE2(LOWER) OPM_CLK 28-A7 61- A6
Paper size board /2 -3 26-A9 FD_SIZE3(LOWER) OPM_MODE_C 28-A8 61- A5
-2 26-A10 FD_SIZE4(LOWER) DF_CLOSE_SIG 28-A9 61- A4
98-1 26-A11 S.GND XENON_EM 28-A10 61- A3
PSB/2
S.GND 28-A11 61- A2
19
19
HPPS_IN 28-A12 61- A1

APS_TIM_IN 28-B1 61- B12
J03: 7 - 5
26-A12 24V2 5V1 28-B2 61- B11
Paper lift motor /2 908- 1
M8
26-A13 LIFT_UP_M_DRV(LOWER) XENON_ON 28-B3 61- B10
5V2 28-B4 61- B9
5V2 28-B5 61- B8
OPM_DIR 28-B6 61- B7
OPM_MODE_B 28-B7 61- B6
986-4 J09 1 - 4 OPM_MODE_A 28-B8
22-B1 N.C. 61- B5
-3 J09 2 - 3 S_DA_LATCH 28-B9
22-B2 S.GND 61- B4
Humidity sensor -2 J09 3 - 2 S_DA_CLK 28-B10
22-B3 HUMS_SIG 61- B3
-1 J09 4 - 1 65- 2 P.GND 2
HUMS
22-B4 5V /KC_DRV 28-B11 61- B2
KCSIG_IN 28-B12 65- 1 24V2 1
61- B1
for DCPS
921: 1 - 2 J39: 1 - 7
22-B5 24V2
20
20
Registration clutch 921: 2 - 1 J39: 2 - 6
CL1
22-B8 RESIST_CL_DRV
922: 1 - 2 J01: 1 - 5
22-B7 24V2
Loop clutch 922: 2 - 1 J01: 2 - 4 B_VV 38-1 43-20
CL2
48-5 CT
22-B6 LOOP_CL_DRV
48-8 FG
48-7 NC
48-2 TX-
48-6 RX-
48-1 TX+
48-4 RX+
48-3 RX+
TONYY 38-2 43-19

48-9 VDD1
48-11 LED2
48-10 LED1
48-12 VDD2
P_VV 38-3 43-18

-3 J01: 3 - 3 S_VV 38-4 43-17
22-B9 S.GND LAN
-2 J01: 4 - 2 EE_VV 38-5 43-16
Registration sensor 22-B10 RESI.PS(DI/H)
PRCB(2/2)
951-1 J01: 5 - 1 S.GND 38-6 43-15
PS1
22-B11 5V
/EG_RTS 38-7 43-14
EG_TXD 38-8 43-13
BK
J54: - 6 /EG_CTS 38-9 43-12
22-B12 5V_R
Ǿ3
RT3
J54: - 5
22-B13 S.GND EG_RXD 38-10 43-11
21
21
J54: - 4
S.GND 38-11 43-10
S.GND 38-12 43- 9
J54: - 3 5V1 38-13 43- 8
22-B15 5V_R
J54: - 2 S.GND 38-14 43- 7
22-B16 S.GND
J54: - 1 /EG_RST 38-15 43- 6
Ǿ3
RT3
BK
APS_TIM_IN 38-16 43- 5
938:2 - 1 J02: 1 - 2
NMI_SIG 38-17 43- 4
22-B18 TSL_DRV FIX_OK_IN 38-18 43- 3
Transfer exposure lamp 1-2 J02: 2 - 1
TSL
OACB(3/3)
22-B19 P.GND DDF_VV 38-19 43- 2

ADF_EMPTY_PS 38-20 43- 1
BK
Ǿ3
RT3
J63: 1 - 19
22-A1 S.GND
J63: 2 - 18
22-A2 LT_TRAY_UP_M_ON
22
22
J63: 3 - 17
22-A3 LU_CLOSE_IN
J63: 4 - 16
22-A4 LU_FEED_M_H/L
J63: 5 - 15
22-A5 LU_FEED__M_CLK
J63: 6 - 14
22-A6 LU_FEED_M_ON
J63: 7 - 13
Ǿ3
22-A7 LU_SD_DRIVE
RT3
BK
J63: 8 - 12
22-A8 LU_CL_DRIVE J31: 8 - 1
J63: 9 - 11 JOB_TRAY_SET 29-A1
22-A9 LU_JAM_IN J31: 7 - 2
J63:10 - 10 S.GND 29-A2
22-A10 LU_FULL_PS_IN
J63:11 - 9
22-A11 LU_EMPTY_PS_IN J31: 6 - 3
J63:12 - 8 5V_R 29-A3
22-A12 LU_SET1_IN J31: 5 - 4
J63:13 - 7 S.GND 29-A4
22-A13 LU_SET2_IN J31: 4 - 5
J63:14 - 6 JOB_TRAY_EMPTY_PS 29-A5
22-A14 LU_SET_IN
J63:15 - 5
22-A15 LU_TYPE_IN J31: 3 - 6
J63:16 - 4
JS-502
5V_R 29-A6
22-A16 5V J31: 2 - 7
J63:17 - 3 S.GND 29-A7
EMPTY PS FULL PS
23
23
22-A17 5V J31: 1 - 8
JOB TRAY JOB TRAY
J63:18 - 2 JOB_TRAY_FULL_PS 29-A8

22-A18 S.GND
J63:19 - 1
44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62
22-A19 S.GND
J30: 6 - 1 913: 3 - 1
/F3.DRV 29-A9
(J51:CT) J30: 5 - 2 913: 2 - 2
P.GND 29-A10 Exhaust fan /Fr
J51:5 - 1 J30: 4 - 3 913: 1 - 3
FM3
-5 24V1(POLYGON) 39-1 /F3.LCK(DI/H) 29-A11

J51:4 - 2
-4 P.GND 39-2
J51:3 - 3
Polygon motor -3 /PLY.ON 39-3
M5
J51:2 - 4 J30: 3 - 4 919: 3 - 1

-2 /PLY.LCK 39-4 /F9.DRV 29-A12
J51:1 - 5 J30: 2 - 5 919: 2 - 2
904-1 PLY.CLK 39-5 P.GND 29-A13 Exhaust fan /Rr
919: 1 - 3
FM9
J30: 1 - 6
/F9.LCK(DI/H) 29-A14
J61 : 1 - 12
19-A1 LCC_FLM
J61 : 2 - 11 J32:11 - 1 906-4
24
19-A2 S.GND
24
REVERSE_M_XB 29-B1
J61 : 3 - 10 J32:10 - 2 -3
19-A3 S.GND REVERSE_M_B 29-B2 Reverse motor
J61 : 4 - 9 J32: 9 - 3 -2
19-A4 5V2 REVERSE_M_XA 29-B3
M6
J61 : 5 - 8 J32: 8 - 4 -1
19-A5 5V2 REVERSE_M_A 29-B4
J61 : 6 - 7
19-A6 LCC_RTS
J61 : 7 - 6
19-A7 LCC_RXD 24V2 29-B5 J32: 7 - 5 933:2 - 1
J61 : 8 - 5
19-A8 LCC_TXD REVERSE_SD 29-B6 J32: 6 - 6 933:1 - 2 Reverse solenoid
SD3
J61 : 9 - 4
for DB/LCC UNIT
19-A9 LCC_CLK
J61 :10 - 3
19-A10 N.C.
J61 :11 - 2 J32: 5 - 7 -3
19-A11 P.GND 5V_R 29-B7
REVERSE UNIT
J61 :12 - 1 J32: 4 - 8 -2

32 33 34 35 36 37 38 39 40 41 42 43
19-A12 P.GND S.GND 29-B8 Reverse sensor

J32: 3 - 9 977-1
PS27
REVERSE_PS 29-B9
J32: 2 - 10
19-B1 FS_TXD REVERSE_UNIT_SET 29-B10
J32: 1 - 11
19-B2 S.GND S.GND 29-B11
25
25
19-B3 N.C
19-B4 FS_RTS
J06:3 - 1 -3
19-B5 S.GND 5V_R 29-B12
J06:2 - 2 -2
19-B6 FS_RXD S.GND 29-B13 Toner bottle sensor
J06:1 - 3 954-1
PS4
19-B7 N.C TNRB.PS(DI/H) 29-B14

For Finisher
19-B8 S.GND
19-B9 FS_CTS
19-B10 S.GND
J48:3 - 1 -3
21 22 23 24 25 26 27 28 29 30 31
19-B11 S.GND 5V_R 69-1

15-B12 N.C J48:2 - 2 -2
S.GND 69-2 Toner bottle position sensor
J48:1 - 3 978-1
PS28
TNRB.PS(DI/H) 69-3
J64-2
26
26
11-1 DH_REM
J64-1
11-3 24V
for DH
11-2 NC
Z
T
Y
X
V
S
P
U
R
N
Q
O
W
bizhub 500 / 420

bizhub 500 / 420

CL1 Registration clutch 20-Y
CL2 Loop clutch 20-Y
CL6 Feed clutch /BP 14-Y
FM3 Exhaust fan /Fr 23-Q
FM9 Exhaust fan /Rr 24-Q
HUMS Humidity sensor 20-Y
KCT Key counter 18-R
L1 Exposure lamp 17-S
L1 INVB L1 inverter 17-Q
L1 RLB L1 relay board 17-R
M2 Scanner motor 16-Q
M5 Polygon motor 23-X
M6 Reverse motor 24-Q
M7 Paper lift motor /1 17-Y
M8 Paper lift motor /2 19-Y
PS1 Registration sensor 21-Y
PS4 Toner bottle sensor 25-R
PS8 Tray set sensor /1 15-Y
PS9 Near-empty sensor /1 15-Y
PS10 Paper size sensor /Rr1 16-Y
PS11 Paper size sensor /Fr1 16-Y
PS14 Tray set sensor /2 18-Y
PS15 Near-empty sensor /2 17-Y
PS16 Paper size sensor /Rr2 18-Y
PS17 Paper size sensor /Fr2 18-Y
PS27 Reverse sensor 25-Q
PS28 Toner bottle position sensor 26-R
PS30 Scanner home sensor 16-Q
PS31 APS timing sensor 17-Q
PS32 APS sensor 18-Q
PSB/1 Paper size board /1 16-Y
PSB/2 Paper size board /2 19-Y
SD3 Reverse solenoid 24-Q
SDB Scanner drive board 16-N
SW3 DF open/close switch 17-Q
TSL Transfer exposure lamp 22-Y
— JS-502 22-Q
17.5 DF
Original registration sensor
PS9
CN15
Original detection sensor
PS8
PS9 ON
Original exit sensor

PS8 ON
PS10
PS10 ON
CN16
Cover open/close sensor PS7 ON
PS7 CN14
MOSDB
SD2
SD2
PS2 ON
DFCB
LB
PS6 ON
Original empty sensor

PS5
Pressure roller release

Original feed sensor SD1
SD1
solenoid
PS6
Original size FM3

Cooling fan
FM3
PS1
sensor/1
Original size
PS3
sensor/3
Original conveyance motor
M2
PS1 ON
Original size
PS3 ON PS1 ON PS1 ON
PS4
sensor/4 PS3 ON PS3 ON

CN18
PS4 ON PS4 ON
PS4 ON PS2 ON PS2 ON
CN17
Original size
TB
PS2 ON VR ON VR ON
PS2
sensor/2 Original feed motor

M1
VR ON
Original size VR
CN19
bizhub 500 / 420

bizhub 500 / 420
DF-607 location list

DFCB DF control board 3-D
FM3 Cooling fan 5-B
LB LED board 5-B
M1 Original feed motor 6-B
M2 Original conveyance motor 6-B
MOSDB Mix Original size detection board 5-F
PS1 Original size sensor /1 6-H
PS5 Original empty sensor 5-G
PS6 Original feed sensor 5-G
PS7 Cover open/close sensor 4-G
PS8 Original detection sensor 3-G
PS9 Original registration sensor 3-G
PS10 Original exit sensor 3-G
SD1 Pressure roller release solenoid 5-B
SD2 Stamp solenoid 5-B
TB Tray board 6-F
VR1 Original size VR 6-H
I
F
E
B
A
H
D
C
G
17.6.1
17.6 PC
PC-202
1
1
2
2
3
3
Upper limit sensor /3

PS114
Paper empty sensor /3

PS115
Paper lift motor /4
M125
Paper feed sensor /3
PS116
Near-emptysensor/4
PS122
Vertical conveyance sensor /3
PS117
PSDB4
4
4
PSDB4
Paper size detect board /4 Right door open/close sensor
PS111
Paper feed motor /3

M122
Tray set sensor/4
PS121
Vertical conveyance motor /3
M120
Paper size sensor /Fr4

PS128
Near-emptysensor /3
PS113
Paper size sensor /Rr4

PS127
5
5
Paper lift motor /3

M124
PCCB
Lift sensor /4 Paper size sensor /Rr3

PS123
PS118
Paper empty sensor /4 Paper size sensor /Fr3

PS124
PS119
Paper feed sensor /4 Tray set sensor/3

PS125
PS112
6
6
Vertical conveyance sensor /4 PSDB3

PS126
PSDB3
Paper size detect board /3
Upper limit sensor /4

M123
Vertical conveyance motor /4

M121
7
7
8
8
Crimp
Symbol
Connector
9
9
Relay connector
Faston
I
F
E
B
A
H
D
C
G
bizhub 500 / 420

bizhub 500 / 420
PC-202 location list

M120 Vertical conveyance motor /3 4-C
M121 Vertical conveyance motor /4 7-G
M122 Paper feed motor /3 4-C
M123 Paper feed motor /4 6-G
M124 Paper lift motor /3 5-C
M125 Paper lift motor /4 3-G
PCCB PC control board 3-D
PS111 Right door open/close sensor 4-C
PS112 Tray set sensor/3 6-C
PS113 Near-empty sensor /3 5-C
PS114 Upper limit sensor /3 3-C
PS115 Paper empty sensor /3 3-C
PS116 Paper feed sensor /3 3-C
PS117 Vertical conveyance sensor /3 4-C
PS118 Paper size sensor /Rr3 5-C
PS119 Paper size sensor /Fr3 5-C
PS121 Tray set sensor /4 4-G
PS122 Near-empty sensor /4 4-G
PS123 Upper limit sensor /4 5-G
PS124 Paper empty sensor /4 5-G
PS125 Paper feed sensor /4 6-G
PS126 Vertical conveyance sensor /4 6-G
PS127 Paper size sensor /Rr4 5-G
PS128 Paper size sensor /Fr4 5-G
PSDB3 Paper size detect board /3 6-C
PSDB4 Paper size detect board /4 4-G
I
F
E
B
A
H
D
C
G
17.6.2
PC-402
1
1
2
2
RLB
Tray release switch
SW1
3
3
Lower limit sensor
PS13
Shift home sensor
PS12
Shift position sensor
PS11
MEB
MEB
4
4
Main tray empty board
RLB
Paper lift motor encoder sensor
PS10
Sub tray empty sensor

PS9
Shft motor encoder sensor

PS8
5
5
Lower limit over run sensor

PS7
Paper lift motor

M5
Shift motor
M4
PCCB
Shift gate motor

M3
6
6
Shift gate position sensor

PS14
Right door open/close sensor

PS5
Upper limit sensor

PS4
Paper empty sensor

PS3
Vertical conveyance sensor

PS2
7
7
Paper feed sensor

PS1
Vertical conveyance motor

M2
Paper feed motor

M1
Tray lock solenoid

SD1
8
8
Tray set sensor

PS6
Crimp
Symbol
Connector
9
9
Relay connector
Faston
I
F
E
B
A
H
D
C
G
bizhub 500 / 420

bizhub 500 / 420
PC-402 location list

M1 Paper feed motor 8-C
M2 Vertical conveyance motor 7-C
M3 Shift gate motor 6-G
M4 Shift motor 6-G
M5 Paper lift motor 5-G
MEB Main tray empty board 4-G
PCCB PC control board 3-A
PS1 Paper feed sensor 7-C
PS2 Vertical conveyance sensor 7-C
PS3 Paper empty sensor 7-C
PS4 Upper limit sensor 6-C
PS6 Tray set sensor 8-C
PS7 Lower limit over run sensor 5-G
PS8 Shft motor encoder sensor 5-G
PS9 Sub tray empty sensor 5-G
PS10 Paper lift motor encoder sensor 4-G
PS11 Shift position sensor 4-G
PS12 Shift home sensor 3-G
PS13 Lower limit sensor 3-G
PS14 Shift gate position sensor 6-G
RLB Rely board 4-B
SD1 Tray lock solenoid 8-C
SW1 Tray release switch 3-G
17.7 LU
bizhub 500 / 420

1 2 3 4 5 6 7 8 9
A A
Dehumidifier heater
OPTIONAL
HTR101
114-3 24V
J121-1 J121-2
114-2 P_GND
B NC (2pin) B
MS
151
FT102 (4pin)
114-4 24V Upper door interlock switch
FT101 (1pin)
114-1 T5M_24V
121- 1
112-1 T5M_24V
112-2 T5M_ON
121- 2 M151 Paper lift motor
J62- 1 24V 111- 1 24V 112-3 P_GND
C J62- 2 PGND
J62- 3 24V
111- 2 PGND
C
J62- 4 RL_POWER 112-4 24V 120-11
112-5 24V -10
112-6 P_GND -9
112-7 P_GND -8
112-8 LUM_HL -7
(LD)
112-9 LUM_FR
-6
-5
M150 Feed motor
112-10 LUM_CLK -4
D J63-19 SGND 110- 1 SGND
112-11 LUM_ON
112-12 SGND
-3
-2
D
J63-18 SGND 110- 2 SGND
112-13 5V -1
J63-17 5V2 110- 3 5V2
J63-16 5V2 110- 4 5V2
J63-15 LU_TYPE 110- 5 LU_TYPE
J63-14 T5_SET_PS 110- 6 T5_SET_PS
J63-13 T5_SET2 110- 7 T5_SET2
J82: 5- 1 J84: 2 - 1
J63-12 T5_SET1 110- 8 T5_SET1 113- A1 24V
J82: 4- 2 J84: 1 - 2 SD151 Pick-up solenoid
J63-11 T5_ZERO_PS 110- 9 T5_ZERO_PS 113- A2 T5SD_DRV
E J63-10 T5_FULL_PS
J63- 9 LU_JAM_PS
110-10 T5_FULL_PS
110-11 LU_JAM_PS J82: 3- 3 127- 3
E
110-12 LU_CL_ON 113- A3 S_GND
J63- 8 LU_CL_ON J82: 2- 4 -2
113- A4 LCT_JAM PS155 LU exit sensor
J63- 7 T5_SD_ON 110-13 T5_SD_ON J82: 1- 5 -1
113- A5 5V
J63- 6 LUM_ON 110-14 LUM_ON
J63- 5 LUM_CLK 110-15 LUM_CLK
J83: 6- 1 125- 3
J63- 4 LUM_HL 110-16 LUM_HL 113- A6 S_GND
J83: 5- 2 -2 Upper limit sensor
J63- 3 T5_CLOSE 110-17 T5_CLOSE 113- A7 T5_FULL PS152
J83: 4- 3 -1
J63- 2 T5_UPM_ON 110-18 T5_UPM_ON 113- A8 5V
F J63- 1 SGND 110-19 SGND

113- A9 S_GND
J83: 3- 4 124- 3 F
J83: 2- 5 -2
113-A10 T5_ZERO PS153 Paper empty sensor
J83: 1- 6 -1
113-A11 5V
126- 3
113- B1 S_GND
-2
113- B2 T5_SET1 PS154 Remaining paper sensor/1
-1
113- B3 5V
G 113- B4 S_GND
122- 3
G
-2
113- B5 T5_SET2 PS151 Remaining paper sensor/2
-1
113- B6 5V
129- 3
113- B7 S_GND
-2
113- B8 LU_SET PS156 LU set sensor
-1
Main body 113- B9 5V
H J85: 2 - 1
H
Symbol
113-B10 LUCL_DRV
J85: 1 - 2 CL151 Feed clutch
113-B11 24V
LUDB
Connector Faston
I Crimp Relay connector I
1 2 3 4 5 6 7 8 9
bizhub 500 / 420
LU-201 location list

CL151 Feed clutch 7-H
HTR101 Dehumidifier heater 7-A
LUDB LU drive board 4-A
M150 Feed motor 7-C
M151 Paper lift motor 7-C
MS151 Upper door interlock switch 7-B
PS151 Remaining paper sensor /2 7-G
PS152 Upper limit sensor 7-F
PS153 Paper empty sensor 7-F
PS154 Remaining paper sensor /1 7-G
PS155 LU exit sensor 7-E
PS156 LU set sensor 7-H
SD151 Pick-up solenoid 7-E
17.8 FS
bizhub 500 / 420

17.8.1 FS-510/PU-501
1 2 3 4 5 6 7 8 9
SW4 Guide plate switch
SD-502/MT-501
A (Option) PS5
Conveyance sensor A
Exit roller home sensor
PS12
SD1 Stacker paddle solenoid
M6 Exit roller release motor

B B
Entrance sensor
PS4
CL1 Registration clutch
M3 Entrance motor
C SW1
SD2 Exit paddle solenoid C
Door switch
FSCB M2 Conveyance motor
PS11 Exit paddle home sensor
Stapler home sensor
Punch Unit Setting 2nd Detection
Punch Unit Setting 3rd Detection

Punch Unit Setting 1st Detection
PS10
D D
Staple Needle Empty Detect Sensor
SD-502/MT-501 Staple Selfpriming Detect Sensor
Staple Home Detect Sensor
(Option)
GND
GND
GND
Chopper Unit Setting Detection
GND
M1 Exit motor
E PU-501(Option) E
M7 Stapler movement motor
Punch scraps full sensor

PS1 Stacker sensor
PS8
Punch position sensor 1

PS2 Alignment sensor/Fr
PS7
F Punch position sensor 2

PS3
F
PS6 Alignment sensor/Rr
Encoder sensor M5 Alignment motor/Fr

PS4
Punch motor M1 M4 Alignment motor/Rr
G M11 Tray lift motor G

SW3 Tray overrun switch
M12 Shutter motor
SW2 Shutter switch
H Shutter home sensor

Symbol H
PS16
PS14
Lower limit sensor
Upper limit sensor

Connector Faston
PS15
Crimp Relay connector
I TLB I
PS3
Tray position sensor
1 2 3 4 5 6 7 8 9
bizhub 500 / 420
FS-510 location list PU-501 location list

Symbol Part name Location Symbol Part name Location
CL1 Registration clutch 7-B M1 Punch motor 3-G
FSCB FS control board 3-B PS1 Punch scraps full sensor 3-E
M1 Exit motor 7-E PS2 Punch position sensor /1 3-F
M2 Conveyance motor 7-C PS3 Punch position sensor /2 3-F
M3 Entrance motor 7-C PS4 Encoder sensor 3-F
M4 Alignment motor /Rr 7-G
M5 Alignment motor /Fr 7-F
M6 Exit roller release motor 7-B
M7 Stapler movement motor 7-E
M11 Tray lift motor 7-G
M12 Shutter motor 7-G
PS3 Tray position sensor 7-I
PS4 Entrance sensor 7-B
PS5 Conveyance sensor 7-A
PS6 Alignment sensor /Rr 7-F
PS7 Alignment sensor /Fr 7-F
PS8 Stacker sensor 7-E
PS10 Stapler home sensor 7-D
PS11 Exit paddle home sensor 7-C
PS12 Exit roller home sensor 7-A
PS14 Lower limit sensor 7-H
PS15 Upper limit sensor 7-I
PS16 Shutter home sensor 7-H
SD1 Stacker paddle solenoid 7-A
SD2 Exit paddle solenoid 7-C
SW1 Door switch 2-C
SW2 Shutter switch 7-H
SW3 Tray overrun switch 7-G
SW4 Guide plate switch 7-A
TLB Tray lift board 5-H
17.8.2 FS-511
bizhub 500 / 420

1 2 3 4 5 6 7 8 9
SW4 Hole punch position switch
W W
Intermediate conveyance W W
M12 Stapler moving motor M6 Hole punch Only for inch
roller release motor B
B M14 destination
A selector motor
A
CL1 Punch clutch
Paper exit motor M3
Conveyance motor/Lw M2
M9 Paddle motor/Lw
Conveyance motor/Up M4
Punch encoder sensor
PS15
Entrance conveyance M5 Alignment motor

B motor M1
B
PS2 Path sensor (RU-502)
PS1
Door sensor (RU-502)
C Punch motor M11

C
RU-502
Sift motor M8
M13 Paper exit roller release motor
Tray lift motor M7 SD3 Paddle solenoid

D D
M15 Paddle motor/Up
SW3
Main tray lower limit switch
Main tray upper limit switch

SW2 FSCB SD1 Bypass gate solenoid
E SD2 Main gate solenoid

E
PWB-E_GL
SW1
Interlock switch PWB-E_GL
LED19 Main tray upper limit LED
F CN200C
PS18 Upper door sensor
F
RU-502 Front door sensor
PS17
CN201B
Sub tray full sensor

PS6
Sub tray exit sensor

G PS1
G
PWD-F_GL
PWD-F
Bypass route conveyance sensor
PS2
PS7 Main tray full sensor

Sift encoder sensor Intermediate conveyance sensor
PS11 PS3
H Sift home sensor PS10

PS12 Roller release home sensor PS13
Exit roller home sensor
H
Main route conveyance sensor
Symbol
PS4
Main tray reset sensor PS8
PWD-F
Alignment home sensor PS19 Main tray upper limit sensor
Faston
PS9
Connector
PWD-F_GL
I Crimp Relay connector

I
Alignment tray sensor PS5
PS14 Stapler home sensor
1 2 3 4 5 6 7 8 9
bizhub 500 / 420
FS-511 location list

CL1 Punch clutch 7-A
FSCB FS control board 2-B
LED19 Main tray upper limit LED 7-E
M1 Entrance conveyance motor 4-B
M2 Conveyance motor /Lw 4-A
M3 Paper exit motor 2-A
M4 Conveyance motor /Up 4-B
M5 Alignment motor 5-B
M6 Stapler moving motor 4-A
M7 Tray lift motor 2-D
M8 Shift motor 2-C
M9 Paddle motor /Lw 5-A
M11 Punch motor 2-C
M12 Intermediate conveyance roller release motor 2-A
M13 Paper exit roller release motor 8-D
M14 Hole punch selector motor (Inch area only) 7-A
M15 Paddle motor /Up 8-D
M16 Stapler motor /Rr 4-H
M17 Stapler motor /Fr 4-H
PS1 Sub tray exit sensor 8-G
PS1 Door sensor (RU-502) 8-B
PS2 Bypass route conveyance sensor 8-G
PS2 Path sensor (RU-502) 8-B
PS3 Intermediate conveyance sensor 6-H
PS4 Main route conveyance sensor 6-H
PS5 Alignment tray sensor 2-I
PS6 Sub tray full sensor 8-F
PS7 Main tray full sensor 8-G
PS8 Main tray reset sensor 2-H
PS9 Alignment home sensor 2-I
PS10 Shift home sensor 2-H
PS11 Shift encoder sensor 2-H
PS12 Roller release home sensor 6-H
PS13 Exit roller home sensor 8-H
PS14 Stapler home sensor 6-I
PS15 Punch encoder sensor 7-B
PS17 Front door sensor 7-F
PS18 Upper door sensor 8-F
PS19 Main tray upper limit sensor 6-I
PS20 Staple empty sensor /Rr 4-H
PS21 Stapler ready sensor /Rr 4-H
PS22 Stapler home sensor /Rr 4-H
PS23 Staple empty sensor /Fr 4-H
PS24 Stapler ready sensor /Fr 4-H
PS25 Stapler home sensor /Fr 4-H
SD1 Bypass gate solenoid 8-E
SD2 Main gate solenoid 8-E
SD3 Paddle solenoid 8-D
SW1 Interlock switch 2-E
SW2 Main tray upper limit switch 2-E
SW3 Main tray lower limit switch 2-D
SW4 Hole punch position switch (Inch area only) 7-A
I
F
E
B
A
H
D
C
G
17.9 SD
1
1
2
2
3
3
Tray empty sensor

PS21
Saddle exit home sensor

PS18
Exit sensor
PS20
4
4
Paper guide home sensor

PS23
Staiple guide home senso

PS26
Exit motor encoder sensor

PS25
SDCB
5
5
SD interlock switch
SW4
Staple guide motor

M14
6
6
Exit open/close motor

M9
Paper guide motor

M13
Conveyance motor
M8
FS-510
7
7
Folding roller home sensor

PS22
Folding motor
M10
8
8
Crimp
Symbol
Connector
9
9
Relay connector
Faston
I
F
E
B
A
H
D
C
G
bizhub 500 / 420

bizhub 500 / 420
SD-502 location list

M8 Conveyance motor 6-G
M9 Exit open/close motor 6-G
M10 Folding motor 8-D
M13 Paper guide motor 6-G
M14 Staple guide motor 6-G
PS18 Saddle exit home sensor 4-B
PS20 Exit sensor 4-B
PS21 Tray empty sensor 3-B
PS22 Folding roller home sensor 7-D
PS23 Paper guide home sensor 4-B
PS25 Exit motor encoder sensor 4-B
PS26 Staiple guide home sensor 4-B
SDCB SD control board 3-C
SW4 SD interlock switch 5-G
I
F
E
B
A
H
D
C
G
17.10 MT
1
1
2
2
3
3
Gate solenoid /3
SD3
Conveyance motor
M1
4
4
Conveyance sensor /Up

PS9
Gate solenoid /2 Paper full sensor /2

PS6
SD2
Paper detection sensor/3

PS3
5
5

PS1
MTCB
Conveyance sensor /Lw

PS10
Paper full sensor/1

PS5
Gate solenoid /1
SD1

PS2
6
6
Paper full sensor/3

PS7

PS4
FS-510
Paper full sensor/4

PS8
Right door open/close sensor

PS11
7
7
8
8
Crimp
Symbol
Connector
9
9
Relay connector
Faston
I
F
E
B
A
H
D
C
G
bizhub 500 / 420

bizhub 500 / 420
MT-501 location list

M1 Conveyance motor 4-C
MTCB MT control board 3-D
PS1 Paper detection sensor /1 5-C
PS5 Paper full sensor /1 5-C
PS9 Conveyance sensor /Up 4-C
PS10 Conveyance sensor /Lw 5-C
SD1 Gate solenoid /1 6-G
SD2 Gate solenoid /2 4-G
SD3 Gate solenoid /3 3-C
DF-607
2006.02
Ver. 1.0
Revision history
Revision mark:
ing page.
NOTE

Field Service Ver. 1.0 Feb. 2006
CONTENTS
DF-607
DF-607
OUTLINE
MAINTENANCE
OUTLINE
2. PERIODIC CHECK..................................................................................................5
2.1 Maintenance procedure ........................................................................................5
2.1.1 Replacing the Pick-up Roller and Feed Roller...............................................5
2.1.2 Replacing the Separation Roller....................................................................6
2.1.3 Cleaning of the Pick-up Roller, Feed Roller and Separation Roller...............7
2.1.4 Cleaning of Miscellaneous Rolls ...................................................................8
MAINTENANCE
2.1.5 Cleaning of Miscellaneous Rollers ................................................................9
2.1.6 Cleaning of the Scanning Guide..................................................................11
2.1.7 Cleaning of the Reflective Sensor Section ..................................................12
3. OTHER ..................................................................................................................13
3.1 Disassembly/Adjustment prohibited items ..........................................................13
ADJUSTMENT/SETTING
3.2 Disassembling and assembling list .....................................................................14
3.3 Disassembling and assembling procedure .........................................................14
3.3.1 Cover /Fr, Cover /Rr and Original Feed Tray Cover /Lw ..............................14
3.3.2 DF Control Board (DFCB) ...........................................................................15
3.3.3 Original Size VR (VR1)................................................................................15
3.3.4 Complete Stamp Unit 2 ...............................................................................17
3.3.5 Replacing the Replace Stamp 2..................................................................18
ADJUSTMENT/SETTING
4. MECHANICAL ADJUSTMENT..............................................................................19
4.1 Leading Edge Skew Adjustment .........................................................................19
i
DF-607
OUTLINE
MAINTENANCE
Blank Page
ADJUSTMENT/SETTING
ii
Field Service Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS
OUTLINE
DF-607
A. Type
Name Reverse Automatic Document Feeder

Paper Feed Paper Feed from top of stack
Type Turnover Switch back system
Paper Exit Straight exit system
OUTLINE
Installation Screw cramp to the main unit
Document Loading Left image side up
B. Functions
Modes 1-Sided Mode / 2-Sided Mode
C. Paper type
1-Sided Mode
Standard Mode 35 to 128 g/m2 (9.25 to 34 lbs)
50 to 128 g/m2 (13.25 to 34 lbs)
Mixed Original Detection
1-Sided / 2-Sided Mode
Type of Document Mode
50 to 128 g/m2 (13.25 to 34 lbs)
Plain Paper
1-Sided Mode
FAX Mode 35 to 128 g/m2 (9.25 to 34 lbs)
50 to 128 g/m2 (13.25 to 34 lbs)
Inch area
A3, A4S, A4, B4, B5S, B5
Detectable Document 11 x 17, 81/2 x 14, 81/2 x 11S, 81/2 x 11, 81/2 x 51/2S, 81/2 x 51/2
Size*1 Metric area
A3, A4S, A4, A5S, A5, B4, B5S, B5, B6S
11 x 17, 81/2 x 11S, 81/2 x 11
Capacity 80 sheets (80 g/m2) or load height of 11 mm or less.
*1: For the Combined Original Detection Mode, Refer to the Mixed Original Detection Enabled
Size Combination Table.
1
1. PRODUCT SPECIFICATIONS Field Service Ver. 1.0 Feb. 2006
D. Paper feed prohibited originals

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

Feed failure, damage to the original, or drive failure
Original that is stapled or clipped.
due to clip clogging
Book original Feed failure, damage to the original, or drive failure
Original weighing less than 35g/m2 or 128g/m2
Feed failure
or more
Torn original Feed failure, damaged sheet
OUTLINE
Highly curled original (15 mm or more) Original misfeed due to dog-ear or skew
OHP transparencies Feed failure
Label Sheet Feed failure
Offset master Feed failure
Sheets clipped or notched Damaged sheet
Sheets patched Patched part folded or torn sheet
E. Paper feed not guaranteed originals

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

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

For Metric
DF-607
A3 A4 B4S B5 A4S A5 B5S A5
Other A3 U { — — — — — —
originals A4 { U — — — — — —
B4S ~ ~ U { — — — —
B5 ~ ~ { U — — — —
A4S ~ ~ ~ ~ U { — —
OUTLINE
A5 ~ ~ ~ ~ { U — —
B5S X X ~ ~ ~ ~ U —
A5S X X X X X X X U
For Inch

11 x 17 81/2 x 11 81/2 x 14 81/2 x 11S 51/2 x 81/2 51/2 x 81/2 S
Other 11 x 17 U { — — — —
originals 81/2 x 11 { U — — — —
81/2 x 14 ~ ~ U { { —
81/2 x 11S ~ ~ { U { —
51/2 x 81/2 ~ ~ { { U —
51/2 x 81/2S X X X X X U
G. Maintenance

H. Machine data
Power Requirements 24V DC ± 10% (supplied from the main body)

Max. Power
48 W or less
Consumption
I. Operating environment
Temperature 10 to 30°C
Humidity 10 to 80% RH (with no condensation)
NOTE
• These specifications are subject to change without notice.
3
DF-607
OUTLINE
Blank Page
4
Field Service Ver. 1.0 Feb. 2006 2. PERIODIC CHECK
MAINTENANCE
2. PERIODIC CHECK
DF-607
2.1 Maintenance procedure
NOTE
• The alcohol described in the cleaning procedure of Maintenance represents the iso-
propyl alcohol.
2.1.1 Replacing the Pick-up Roller and Feed Roller

• Pick-up Roller: Every 500,000 prints (Actual replacement cycle: Every 200,000 faces)
B. Procedure
1. Open the Open/Close Cover [1].
MAINTENANCE
[1]
16eaf2c001na
2. Remove two screws [2], and remove the

cover [3].
[3]
[2]
16eaf2c002na
[5] 3. Remove two C-clips [4], and remove the

Pick-up Roller Assy [5].
[4]
16eaf2c003na
5
2. PERIODIC CHECK Field Service Ver. 1.0 Feb. 2006
4. Remove two levers [6].

[12]
[13] 5. Remove five C-rings [7].
6. Remove the arm /Fr [8].
DF-607
[7]
7. Remove the belt [9].
[13] [9] 8. Remove the Pick-up Roller Shaft [11]
from the Arm /Rr [10].
[12]
[11] 9. Remove the 2 Spacers [12] from the
Pick-up Roller Shaft.
[6]
10. Remove two Pick-up Rollers [13].
[7] NOTE
• Be sure to take note of the direction of
[8]
the pick-up roller when installing it.
[10]
16eaf2c004na
[14] 11. Remove the C-ring [14], and remove the

gear [15] and the bushing [17].
[17]
12. Remove two pins [16].
[15]
13. Remove the Feed Roller [18].
[16] NOTE
MAINTENANCE
• Use care not to lose the pin.
[18] 16eaf2c005na
2.1.2 Replacing the Separation Roller

• Separation Roller: Every 500,000 prints (Actual replacement cycle: Every 200,000 faces)
B. Procedure
[1]
16eaf2c006na
2. Hold the [2] sections in the figure, and

[2]
remove the cover [3].
[3]
[2] 16eaf2c007na
6
3. Remove the Separation Roller Assy [4].

[4] NOTE
• Use care not to lose the spring at the
DF-607
bottom side of the Separation Roller
Assy.
16eaf2c008na
4. While opening up the holder [5], remove

the Separation Roller Shaft [6].
NOTE
• Opening the holder too much can
break the holder.
[5] [6]
16eaf2c009na
MAINTENANCE
5. Remove the Separation Roller [7] from
the Separation Roller Shaft.
[7]
16eaf2c010na
2.1.3 Cleaning of the Pick-up Roller, Feed Roller and Separation Roller
A. Periodic cleaning parts/cycle
• Pick-up Roller: Every 250,000 prints (Actual replacement cycle: Every 50,000 faces)
• Feed Roller: Every 250,000 prints (Actual replacement cycle: Every 50,000 faces)
• Separation Roller: Every 250,000 prints (Actual replacement cycle: Every 50,000 faces)
B. Procedure
[1]
16eaf2c011na
7
2. Using a soft cloth dampened with alco-

hol, wipe the Pick-up Roller [2], Feed
Roller [3] and Separation Roller [4].
DF-607
[3]
[4]
[2] 16eaf2c012na
2.1.4 Cleaning of Miscellaneous Rolls

• Miscellaneous Rolls: Every 250,000 prints (Actual replacement cycle: Every 50,000 faces)
B. Procedure
[2] 2. Using a soft cloth dampened with alco-
hol, wipe the roll [2].
MAINTENANCE
16eaf2c013na
3. Lift up the Original Feed Tray [3].

[3]
[4]
16eaf2c014na
[5] 5. Open the DF.

6. Remove the Platen Guide [5].
16eaf2c015na
8

DF-607
[6]
[6]
16eaf2c016na
2.1.5 Cleaning of Miscellaneous Rollers

• Miscellaneous Rollers: Every 250,000 prints (Actual replacement cycle: Every 50,000 faces)
MAINTENANCE
B. Procedure
hol, wipe the roller [2].
[2]
[1]
16eaf2c017na
3. Lift up the Original Feed Tray [3].

[3]
16eaf2c018na
5. Remove the Cover /Fr and Cover /Rr.

[5]
(See P.14)
6. Disconnect eight connectors [5] on the
DF Control Board (DFCB).
[5]
[5] 16eaf2c019na
9
7. Remove the lever [6].

DF-607
[6]
16eaf2c020na

MAINTENANCE
[7]
16eaf2c021na
10
9. Remove seven screws [8], and remove

[8]
[8] the Paper Feed Unit [9].
DF-607
[9]
MAINTENANCE
16eaf2c022na

[10]
[10]
16eaf2c023na
2.1.6 Cleaning of the Scanning Guide

A. Periodic cleaning part/cycle
• Scanning Guide: Every 250,000 prints (Actual replacement cycle: Every 50,000 faces)
B. Procedure
1. Open the DF.
[1] hol, wipe the Scanning Guide [1].
16eaf2c024na
11
2.1.7 Cleaning of the Reflective Sensor Section

A. Periodic cleaning part/cycle
DF-607
• Reflective Sensor: Every 250,000 prints (Actual replacement cycle: Every 50,000 faces)
B. Procedure
1. Clean the Original Size Sensor /2 (PS2)
[1] [1] using a brush or other similar tools.
16eaf2c025na
MAINTENANCE
12
Field Service Ver. 1.0 Feb. 2006 3. OTHER
3. OTHER
3.1 Disassembly/Adjustment prohibited items
DF-607
A. Screws to which blue paint or green paint is applied
• Blue paint or green paint is applied to some screws to prevent them from coming
loose.
• As a general rule, screws to which blue paint or green paint is applied should not be
removed or loosened.
B. Red-painted screws
• Do not remove or loosen any of the red-painted screws in the field. It should also be
noted that, when two or more screws are used for a single part, only one representa-
tive screw may be marked with the red paint.
C. Variable Resistors on Board
NOTE
• Do not turn the variable resistors on boards for which no adjusting instructions are
given in ADJUSTMENT/SETTING.
MAINTENANCE
D. Removal of Boards
Caution
• When removing a circuit board or other electrical component, refer to “SAFETY AND
IMPORTANT WARNING ITEMS” and follow the corresponding removal procedures.
• The removal procedures given in the following omit the removal of connectors and
screws securing the circuit board support or circuit board.
• When it is absolutely necessary to touch the ICs and other electrical components on
the board, be sure to ground your body.
13
3. OTHER Field Service Ver. 1.0 Feb. 2006
3.2 Disassembling and assembling list

DF-607
No. Section Part name Ref.Page

1 Cover /Fr P.14
2 Cover Cover /Rr P.14
4 Original Feed Tray Cover /Lw P.14
5 DF Control Board (DFCB) P.15
Board and etc.
6 Original Size VR (VR1) P.15
7 Complete Stamp Unit 2 P.17
Others
8 Replace Stamp 2 P.18
3.3 Disassembling and assembling procedure

3.3.1 Cover /Fr, Cover /Rr and Original Feed Tray Cover /Lw
[3]
MAINTENANCE
[9]
[4]
[5] [7]
[2]
[6]
[8]
[1]
16eaf2c026na
1. Remove two screws [1], and remove the Cover /Fr [2].
2. Remove the 2 Screws [3] and raise the Original Feed Tray. Open DF to release the Lock
Claws (at 2 places) and then remove the Cover /Rr [4].
3. Remove the screw [5] and the washer [6], and remove the stopper [7].
4. Lift up the Original Feed Tray.
5. Remove four screws [8], and remove the Original Feed Tray Cover /Lw [9].
14
3.3.2 DF Control Board (DFCB)
[1]
1. Turn OFF the Main Power Switch
DF-607
(SW1).
2. Remove the Cover /Rr.
(See P.14)
[1] 3. Disconnect all the connectors on the DF
Control Board (DFCB).
4. Remove three screws [1], and then
[2] remove the DFCB [2].
16eaf2c027na
NOTE
• When DFCB is replaced, be sure to conduct the back-up data initialization, the origi-
nal width detection adjustment and the rewrite of the firmware.
3.3.3 Original Size VR (VR1)
A. Removal Procedure
[1] 1. Turn OFF the Main Power Switch
[2]
MAINTENANCE
(SW1).
2. Remove the Original Feed Tray Cover
[3] /Lw.
[2]
(See P.14)
3. Disconnect the connector [1].
4. Remove two screws [2] and the mount-
16eaf2c028na ing plate [3].
5. Remove the gear [4].

[4]
16eaf2c029na
[5] 6. Remove the nut [5] and the washer [6],

and remove the Original Size VR (VR1)
[7].
[6]
[7] 16eaf2c030na
15
B. Reinstallation Procedure
[1]
1. Close the Side Edge Stop [1] of the
Original Feed Tray.
DF-607
NOTE
• Be sure to perform document width
detection adjustment after replacing
the Original Size VR (VR1).
(See P.212 "10.8 ADF" in Field Service
16eaf2c031na bizhub 500 / 420 main body.)
2. Use the nut [2] and the washer [3] to

[2] install the VR1 [4].
[3] NOTE
• Align the protrusion of the VR1 and the
cutout of the mounting plate.
[4]
16eaf2c032na
MAINTENANCE
3. Turn the protrusion of the VR1 [5] coun-

terclockwise until it stops.
[5]
16eaf2c033na
4. Reinstall the gear [6].

[6] NOTE
• Note the mounting position of the gear
and the VR1.
16eaf2c034na
5. Connect the connector [7].

[8] [7] 6. Use two screws [8] to install the VR1 [9].
NOTE
• Install the gear and rack gear by align-
[10] [11]
ing the arrows [10] and [11].
[8]
[9] 16eaf2c035na
7. Install the Original Feed Tray Cover /Lw and turn ON the Main Power Switch (SW1).
16
NOTE
• When VR1 is replaced, be sure to conduct the back-up data initialization and the orig-
inal width detection adjustment.
DF-607
3.3.4 Complete Stamp Unit 2
2. Open the Processing Guide [2].
[2]
[1]
16eaf2c036na
3. Remove the screw [3] and the cover [4].

[3]
[4]
MAINTENANCE
16eaf2c037na
[5] 4. Remove the screw [5] and disconnect

the connector [6], and remove the Com-
plete Stamp Unit 2 [7].
[6]
[7]
16eaf2c038na
17
3.3.5 Replacing the Replace Stamp 2

DF-607
2. Open the Processing Guide [2].

[2]
[1]
16eaf2c039na
3. Remove the stamp.

[4]
4. Reinstall the new Replace Stamp 2 [3].
[3]
NOTE
• Align the protrusion [4] of the stamp to
the crevice [5] of the holder.
5. Close the Processing Guide.
[5]
6. Close the Open/Close Cover.
MAINTENANCE
16eaf2c040na
18
Field Service Ver. 1.0 Feb. 2006 4. MECHANICAL ADJUSTMENT
ADJUSTMENT/SETTING
DF-607
4.1 Leading Edge Skew Adjustment
1. Load the test chart [1] in the DF and
[1] make one 1-sided copy five consecutive
times.
16eaf3c001na
2. Fold each of the sample copies as illus-

trated and check for any deviation.
Specifications: 0 ± 3.0 mm
3. If the deviation does not fall within the
specified range, perform the following
adjustment procedure.
16eaf3c002na
4. Open the DF.
ADJUSTMENT/SETTING
5. Loosen the decorative screw [2] and the
nut [3] in the back to the right.
[2] [3]
16eaf3c003na
6. If there is a deviation as shown on the

figure, turn the screw counterclockwise
to adjust it.
16eaf3c004na
19
4. MECHANICAL ADJUSTMENT Field Service Ver. 1.0 Feb. 2006
7. If there is a deviation as shown on the

figure, turn the screw clockwise to
adjust it.
DF-607
8. After the adjustment procedure has

been completed, tighten the decorative
screw and the nut which has been loos-
ened in step 5.
16eaf3c005na
ADJUSTMENT/SETTING
20
PC-202
( 500 / 420)
2006.02
Ver. 1.0
Revision history
Revision mark:
ing page.
NOTE

CONTENTS
PC-202
PC-202
OUTLINE
MAINTENANCE
OUTLINE
2. PERIODIC CHECK..................................................................................................3
2.1.1 Replacing the Separation Roller Assy...........................................................3
2.1.2 Replacing the Feed Roller.............................................................................4
2.1.3 Replacing the Pick-up Roller .........................................................................7
3. OTHER ....................................................................................................................9
MAINTENANCE
3.1 Disassembly/Adjustment prohibited items ............................................................9
3.2 Disassembling, assembling and cleaning list......................................................10
3.2.1 Disassembling and assembling list .............................................................10
3.2.2 Cleaning list.................................................................................................10
ADJUSTMENT/SETTING
3.3.1 Right Door/Rear Right Cover/Lower Right Cover/Front Right Cover...........11
3.3.2 Rear Cover ..................................................................................................11
3.4 Cleaning procedure.............................................................................................12
3.4.1 Separation Roller.........................................................................................12
3.4.2 Feed Roller..................................................................................................13
3.4.3 Pick-up Roller ..............................................................................................13
3.4.4 Vertical Conveyance Roller .........................................................................13
ADJUSTMENT/SETTING
4.1 Mis-centering adjustment of the Trays 3 and 4 ...................................................15
i
PC-202
OUTLINE
MAINTENANCE
Blank Page
ADJUSTMENT/SETTING
ii
OUTLINE
PC-202
A. Type
Name 2 way Paper Take-Up Cabinet

Type Front loading type 2 way paper take-up device
OUTLINE
B. Paper type

Metric: A3, B4, A4, A4S, B5, A5S, 11 × 17, 81/2 × 11, 81/2 × 11S, Foolscap
Paper Size
Inch: 11 × 17, 81/2 × 14, 81/2 × 11, 81/2 × 11S, 51/2 × 81/2S, A3, A4, A4S, Foolscap
Capacity
C. Maintenance



NOTE
1
PC-202
OUTLINE
Blank Page
2
MAINTENANCE
2. PERIODIC CHECK
PC-202
2.1.1 Replacing the Separation Roller Assy
• Separation Roller Assy: Every 750,000 prints (Actual replacement cycle: Every 300,000
prints)
NOTE
• Replace the Separation Roller Assy, Feed Roller and Pick-up Roller at the same time.
B. Procedure
1. Remove the Right Door.
[2] (See P.11)
2. Remove two screws [1] and remove the
Jam Access Cover [2].
MAINTENANCE
[1] 4061f2c001na

[4] Separation Roller Mounting Plate Assy
[4].
[3]
4061f2c002na
4. Remove two C-rings [5] and the shaft

[7] [6], and remove the Separation Roller
[5] [6] Fixing Plate Assy [7].
NOTE
• Be careful not to lose spring at this
time.
[5]
4061f2c003na
3
5. Remove the C-ring [8], the Guide [9],

[10] and remove the Separation Roller Assy
[9]
[10].
PC-202
6. Repeat steps 1 to 5 similarly for the Tray

4.
[8]
4061f2c004na
NOTE
• When installing the Separation Roller
Mounting Plate Assy, be sure to fix the
holder with screws while holding it
down.
4061f2c005na
MAINTENANCE
2.1.2 Replacing the Feed Roller

• Feed Roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints)
NOTE
B. Procedure
1. Remove the Rear Right Cover. (Remove
[2] [1] the Right Lower Cover for Tray 4.)
(See P.11)
2. Remove the Tray.
3. Remove the Separation Roller Mounting
Plate Assy.
(See P.3)
4. Disconnect the connector [1] (Tray 3),
two connectors [2] (Tray 4) and remove
the harness from two wire saddles.
NOTE
• Be careful not to confuse the connec-
4061f2c006na tor of the Tray 3 with the connectors of
the Tray 4.
4
5. Remove four screws [3] and remove the

[4]
Paper Feed Unit [4].
PC-202
[3]
[3] 4061f2c007na

Mounting Frame [6] for the Separation
Roller Mounting Plate Assy.
[5]
[6]
MAINTENANCE
4061f2c008na

Feed Roller Cover [8].
[8]
[7]
4061f2c009na
8. Remove the C-ring [9] and remove the

bearing [10].
[9] [10]
4061f2c010na
5
9. Shift the Shaft Assy [11] in the orienta-

[11] tion as shown on the left, and remove
the C-ring [12] and the gear [13].
PC-202
[13]
[12]
4061f2c011na
10. Remove the C-ring [14], the bearing

MAINTENANCE
[15], and remove the shaft Assy [16].

[16]
[15]
[14]
4061f2c012na
11. Remove two C-rings [17] and the bear-

[17] [19] [17] ing [18], and remove the Pick-up Roller
Fixing Plate Assy [19].
[18]
4061f2c013na

[20] Feed Roller [21].
13. Repeat steps 1 to 12 similarly for the
Tray 4.
[21]
4061f2c014na
6
2.1.3 Replacing the Pick-up Roller

PC-202
• Pick-up Roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints)
NOTE
B. Procedure
1. Remove the Rear Right Cover. (Remove
[1] the Right Lower Cover for Tray 4.)
(See P.11)
2. Remove the Tray.
Plate Assy.
(See P.3)
4. Disconnect the connector [1] and
remove the harness from two wire sad-
dles.
MAINTENANCE
4061f2c015na

[3]
Paper Feed Unit [3].
[2]
[2] 4061f2c016na

Separation Roller Mounting Plate Assy
[5] together with frame.
[4]
[5]
4061f2c017na
7

PC-202
[7]
[6]
4061f2c018na
8. Remove two C-rings [8], two bearings

[8]
[9], and remove the Pick-up Roller Assy
[10].
[9]
MAINTENANCE
[9]
[10] 4061f2c019na

[11] Pick-up Roller [12].
10. Repeat steps 1 to 9 similarly for the tray
4.
[12]
4061f2c020na
8
3. OTHER
PC-202
loose.
NOTE
MAINTENANCE
CAUTION
9
3.2 Disassembling, assembling and cleaning list

3.2.1 Disassembling and assembling list
PC-202
No Section Part name Ref. page

1 Right Door See P.11
2 Rear Right Cover See P.11
3 Covers Lower Right Cover See P.11
4 Front Right Cover See P.11
5 Rear Cover See P.11
3.2.2 Cleaning list

1 Separation Roller See P.12
2 Feed Roller See P.13
Paper feed section
3 Pick-up Roller See P.13
MAINTENANCE
4 Vertical Conveyance Roller See P.13
10

3.3.1 Right Door/Rear Right Cover/Lower Right Cover/Front Right Cover
PC-202
[1] 1. Open the Right Door [1].
[3] 2. Remove the Right Door [1].
[2]
Rear Right Cover [3].
Lower Right Cover [5].
Front Right Cover [7].
[4]
[5]
[7] [6] 4061f2c021na
3.3.2 Rear Cover
MAINTENANCE
[1]
Rear Cover [2].
[2]
[1] 4061f2c022na
11
3.4 Cleaning procedure

NOTE
PC-202
• The alcohol described in the cleaning procedure represents the isopropyl alcohol.
3.4.1 Separation Roller

A. Periodically cleaning cycle
• Separation Roller: Every 250,000 prints
B. Procedure
[2] (See P.11)
Jam Access Cover [2].
[1] 4061f2c023na
MAINTENANCE

[4] Paper Separation Roller Mounting Plate
Assy [4].
[3]
4061f2c024na

hol, wipe the Separation Roller [5].
[5]
4.
4061f2c025na
12
3.4.2 Feed Roller

PC-202
• Feed Roller: Every 250,000 prints
B. Procedure
1. Remove the Tray 3.
[1] 2. Remove the Separation Roller Mounting
Plate Assy.
(See P.12)
hol, wipe the Feed Roller [1] clean of
dirt.
4.
4061f2c026na
3.4.3 Pick-up Roller
MAINTENANCE
• Pick-up Roller: Every 250,000 prints
B. Procedure
1. Remove the Tray 3.
Plate Assy.
(See P.12)
hol, wipe the Pick-up Roller [1].
4.
4061f2c027na
3.4.4 Vertical Conveyance Roller

• Vertical Conveyance Roller: Every 250,000 prints
B. Procedure
1. Open the Right Door.
hol, wipe the Vertical Conveyance Roller
[1].
[1]
4061f2c028na
13
PC-202
MAINTENANCE
Blank Page
14
ADJUSTMENT/SETTING
PC-202
4.1 Mis-centering adjustment of the Trays 3 and 4
Conduct this adjustment when a mis-centering occurs that cannot be adjusted in the service
mode.
A. Procedure
1. Pull out the Tray [1].
2. If there remains any paper, remove it
thoroughly.
4. Move the Paper Guide [3] and adjust the
center position with the marking-off [4]
as a guide.
[3] [4] [2]
ADJUSTMENT/SETTING
[1] 4061f3c001na
6. Set the Tray with paper put it in.

7. Conduct the copy/print operation and
[2] check to see if the mis-centering
between the center [1] of the paper and
[3] the center [2] of the copied image is
within a standard value (± 3 mm or less
[1] [3]).
8. When the value is not within the stan-
dard value, repeat steps 1 to 7 until the
standard value can be obtained.
4061f3c002na
15
PC-202
Blank Page
ADJUSTMENT/SETTING
16
PC-402
( 500 / 420)
2006.02
Ver. 1.0
Revision history
Revision mark:
ing page.
NOTE

CONTENTS
PC-402
PC-402
OUTLINE
1. PRODUCT SPECIFICATION...................................................................................1
MAINTENANCE
OUTLINE
2. PERIODIC CHECK..................................................................................................3
2.1.1 Replacing the Separation Roller Assy...........................................................3
2.1.2 Replacing the Feed Roller.............................................................................4
2.1.3 Replacing the Pick-up Roller .........................................................................7
3. OTHER ....................................................................................................................9
MAINTENANCE
3.2 Disassembling, assembling and cleaning list......................................................10
3.2.1 Disassembling and assembling list .............................................................10
3.2.2 Cleaning list.................................................................................................10
ADJUSTMENT/SETTING
3.3.1 Right Door/Rear Right Cover/Lower Right Cover/Front Right Cover...........11
3.3.2 Rear Cover ..................................................................................................11
3.3.3 Tray..............................................................................................................12
3.3.4 Wire .............................................................................................................13
3.4 Cleaning procedure.............................................................................................16
3.4.1 Separation Roller.........................................................................................16
3.4.2 Feed Roller..................................................................................................16
3.4.3 Pick-up Roller ..............................................................................................17
3.4.4 Vertical Conveyance Roller .........................................................................17
ADJUSTMENT/SETTING
4.1 Mis-centering adjustment....................................................................................19
4.2 Shifter Movement Timing Belt Adjustment ..........................................................21
i
PC-402
OUTLINE
MAINTENANCE
Blank Page
ADJUSTMENT/SETTING
ii
Field Service Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATION
OUTLINE
PC-402
A. Type
Name 2500 sheets paper feed cabinet

Type Front loading type LCC
OUTLINE
B. Paper type

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



NOTE
1
1. PRODUCT SPECIFICATION Field Service Ver. 1.0 Feb. 2006
PC-402
OUTLINE
Blank Page
2
MAINTENANCE
2. PERIODIC CHECK
PC-402
2.1.1 Replacing the Separation Roller Assy
• Separation Roller Assy: Every 750,000 prints (Actual replacement cycle: Every 300,000
prints)
NOTE
B. Procedure
[2]
(See P.11)
[2].
MAINTENANCE
[1]
4061f2c201na
3. Remove two C-rings [3] and the shaft

[5] [4], and remove the Separation Roller
[3] [4] Fixing Plate Assy [5].
NOTE
• Be careful not to lose spring at this
time.
[3]
4061f2c202na
4. Remove the C-ring [6], the Guide [7],

[8] and remove the Separation Roller Assy
[8].
[7]
[6]
4061f2c203na
3
NOTE
• When installing the Separation Roller
Mounting Plate Assy, be sure to fix the
PC-402
holder with screws while holding it

down.
4061f2c204na
2.1.2 Replacing the Feed Roller

• Feed Roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints)
NOTE
B. Procedure
1. Remove the Rear Cover and the Rear
MAINTENANCE
[1]
Right Cover.
(See P.11)
2. Remove the Tray.
Plate Assy.
(See P.3)
4. Disconnect the connector [1] from the
PC Control Board (PCCB).
4061f2c205na

[3] Paper Feed Unit [3].
[2]
[2]
4061f2c206na
4

Mounting Frame [5] for the Separation
Roller Mounting Plate Assy.
PC-402
[4]
[5]
4061f2c207na

[7]
[6]
MAINTENANCE
4061f2c208na
8. Remove two C-rings [8] and remove the

bearing [9].
[8]
[9]
4061f2c209na
5
9. Shift the Shaft Assy [10] in the orienta-

tion as shown on the left, and remove
[10] the C-ring [11] and the gear [12].
PC-402
10. Remove the Shaft Assy [10].
[12]
[11]
4061f2c210na
MAINTENANCE
11. Remove two C-rings [13] and the bear-

[15] [13] ing [14], and remove the Pick-up Roller
[13] Fixing Plate Assy [15].
[14]
4061f2c211na

[16] Feed Roller [17].
[17]
4061f2c212na
6
2.1.3 Replacing the Pick-up Roller

A. Periodic replaced part/cycle
PC-402
• Pick-up Roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints)
NOTE
B. Procedure
1. Remove the Rear Cover and the Rear
[1]
Right Cover.
(See P.11)
2. Remove the Tray.
Plate Assy.
(See P.3)
4. Disconnect the connector [1] from the
PC Control Board (PCCB).
MAINTENANCE
4061f2c213na
5. Remove four screws [2] and the Paper

[3] Feed Unit [3].
[2]
[2]
4061f2c214na

[5] together with frame.
[4]
[5]
4061f2c215na
7

Paper Feed Roller Cover [7].
PC-402
[7]
[6]
4061f2c216na
8. Remove two C-rings [8], two bearings

[8] [9], and the Pick-up Roller Assy [10].
[8]
[9]
[9]
MAINTENANCE
[10]
4061f2c217na

[11] Pick-up Roller [12].
[12]
4061f2c218na
8
3. OTHER
PC-402
loose.
NOTE
MAINTENANCE
CAUTION
9
3.2 Disassembling, assembling and cleaning list

3.2.1 Disassembling and assembling list
PC-402

1 Right Door P.11
2 Rear Right Cover P.11
3 Cover Lower Right Cover P.11
4 Front Right Cover P.11
5 Rear Cover P.11
6 Tray P.12
Tray section
7 Wire P.13
3.2.2 Cleaning list

1 Separation Roller P.16
MAINTENANCE
2 Feed Roller P.16

Paper feed section
3 Pick-up Roller P.17
4 Vertical Conveyance Roller P.17
10

3.3.1 Right Door/Rear Right Cover/Lower Right Cover/Front Right Cover
PC-402
1. Open the Right Door [1].
[1]
[3] 2. Remove the Right Door [1].
[2]
Rear Right Cover [3].
Lower Right Cover [5].
Front Right Cover [7].
[4]
[5]
[7] [6] 4061f2c219na
3.3.2 Rear Cover
MAINTENANCE
Rear Cover [2].
[2]
[1] 4061f2c220na
11
3.3.3 Tray
1. Press the Tray Release Key [1] and slide

PC-402
[3] out the Tray [2].

2. Remove the paper.
3. Remove four screws [3] and slide out
the Tray [2].
[2]
[3] [1] 4061f2c221na
4. Remove two screws [4], the connector

[4] [5], and remove the Relay Board (RLB)
[6].
5. Remove the Tray.
NOTE
• When removing the RLB, take care not
to drop the Tray from the guide rail.
MAINTENANCE
[5]
[6]
4061f2c222na
CAUTION
• To prevent injuries, press the guide rail
[7] inside the machine.
[7]
4061f2c223na
12
3.3.4 Wire
1. Remove the Tray.
PC-402
[3] [1] (See P.12)
Front Cover Assy [2].
3. Unplug the connector [3].
[1]
[2]
4061f2c224na
[4]
4. Remove two screws [4] and the Inner
Cover Assy [5].
NOTE
• Do not peel off pulley protective mylar
sheet.
MAINTENANCE
[5]
[4]
4061f2c225na

Driver Cover [7].
[7]
[6]
4061f2c226na
6. Remove three screws [8] and remove

[9] the Driver Mounting Plate Assy [9].
[8]
4061f2c227na
13
NOTE
• When assembling, be sure to engage
rib of gear 1 [10] with concave section
PC-402
of gear 2 [11].
[10]
[11]
4061f2c228na

[13]
the Reinforcement Plate Assy [13].
[12]
[12]
MAINTENANCE
4061f2c229na
8. Remove two C-clips [14].

[15] 9. Remove four Pulley Covers [15].
[16] 10. Unhook four pulleys [16].
[15]
[15]
[16]
[14]
[15]
[14]
4061f2c230na
11. Remove the Ground Plate [17].

[18]
12. Remove four Cable Holders [18] and
[18] remove the Main Tray [19].
[19] NOTE
• Take care not to bend the wires.
[18]
[18]
[17]
4061f2c231na
14
13. Remove four screws [20] and remove

[21]
the Side Guide Assy /Rr [21].
PC-402
[20]
[20]
4061f2c232na
14. Remove four screws [22] and remove

[23] [22]
the Side Guide Assy /Fr [23].
MAINTENANCE
[22]
4061f2c233na
15. Remove three C-rings [24], the bearing

[24] [27]
[25], and two gears [26].
16. Remove the Wire Pulley Assy [27].
[25]
[26]
[24]
4061f2c234na
17. Remove two C-rings [28] and the Wire

[28] [29] Pulley [29].
NOTE
• Take care not to lose fixing pins.
• When reinstalling the Wire Pulley,
check that the direction of the wire
[29]
coming from both wire pulleys are the
[28] same.
• Install so that cut parts [30] at both
ends of shaft face up.
[30]
4061f2c235na
15
3.4 Cleaning procedure

NOTE
PC-402
• The alcohol described in the cleaning procedure represents the isopropyl alcohol.
3.4.1 Separation Roller

• Separation Roller: Every 250,000 prints
B. Procedure
[2] (See P.11)
Paper Separation Roller Mounting Plate
Assy [2].
MAINTENANCE
[1]
4061f2c236na

hol, wipe the Separation Roller [3].
[3]
4061f2c237na
3.4.2 Feed Roller

• Feed Roller: Every 250,000 prints
B. Procedure
1. Remove the Tray.
Plate Assy.
(See P.16)
hol, wipe the Feed Roller [1].
4061f2c238na
16
3.4.3 Pick-up Roller

PC-402
• Pick-Up Roller: Every 250,000 prints
B. Procedure
1. Remove the Tray.
Plate Assy.
(See P.16)
hol, wipe the Pick-up Roller [1].
4061f2c239na
3.4.4 Vertical Conveyance Roller
MAINTENANCE
• Vertical Conveyance Roller: Every 250,000 prints
B. Procedure
hol, wipe the Vertical Conveyance Roller
[1].
4061f2c240na
17
PC-402
MAINTENANCE
Blank Page
18
ADJUSTMENT/SETTING
PC-402
4.1 Mis-centering adjustment
Conduct this adjustment when a mis-centering occurs that cannot be adjusted in the service
mode.
1. Press the Tray Release Key [1] and slide

out the Tray [2].
[2]
[1]
4061f3c201na

[4]
3. Loosen the adjustment screw [3] and
[3]
turn screw D [4].
NOTE
• Do not damage the passage surface of
the Right Door.
ADJUSTMENT/SETTING
4061f3c202na
• When moving the center of the paper to

the rear side, rotate the screw D counter-
clockwise.
4061f3c203na
• When moving the center of the paper to

the front side, rotate the screw D clock-
wise.
4061f3c204na
19
4. Close the Right Door and set the Tray.

5. Conduct the copy/print operation and
[2] check to see if the mis-centering
PC-402
between the center [1] of the paper and

[3] the center [2] of the copied image is
within a standard value (± 3 mm or less
[1] [3]).
6. When the value is not within the stan-
dard value, repeat steps 1 to 5 until the
standard value can be obtained.
4061f3c209na 7. Slide out the Tray and tighten the adjust-
ment screw.
ADJUSTMENT/SETTING
20
4.2 Shifter Movement Timing Belt Adjustment

1. Slide out the Tray and remove it.
PC-402
[2] 2. Lift the Main Tray [1], and remove two
[1] screws [2] fixing the Shift Tray.
NOTE
• When reinstalling, take care not to
unfasten the wire of the Main Tray.
4061f3c205na

[4]
Shifter [4].
[3]
4061f3c206na
4. Push the tab [6] of the Shift Tray [5] as

[5] shown on the left and release the lock.
5. Remove the Sub Tray [5].
ADJUSTMENT/SETTING
[6]
4061f3c207na
6. Loosen the screw [7] as shown to the

left and move it in the direction of the
arrow.
7. After moving the Shifter, tighten the
screw [7].
[7]
4061f3c208na
21
PC-402
Blank Page
ADJUSTMENT/SETTING
22
LU-201
2006.02
Ver. 1.0
Revision history
Revision mark:
ing page.
NOTE

CONTENTS
LU-201
LU-201
OUTLINE
MAINTENANCE
2. PERIODIC CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Maintenance procedure of the paper feed section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.1 Replacing the pick-up rubber and the feed rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.2 Replacing the separation roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 Disassembling and assembling list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Disassembling and assembling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2.1 Removal and reinstallation of the right cover, the front cover and the rear cover. . . . . . . . . . . . 11
3.2.2 Replacing the wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ADJUSTMENT/SETTING
4. MECHANICAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1 Adjusting the tilt of the lift plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
i
LU-201
Blank page
ii
Field Service Ver1.0 Feb.2006 1. PRODUCT SPECIFICATION
OUTLINE
LU-201
A. Type
Type Side mount type large volume paper feed tray
B. Functions
Maximum tray capacity 2,000 sheets (80 g/m2)
C. Type of paper
Paper type *1 Plain paper, recycled paper, high quality paper of 60 to 105 g/m2
Paper size A4, 81/2 x 11
*1 Recommended paper
Plain paper Inch: Hammermill Tidal MP (20 lbs)
Metric: Konica Profi (80 g/m2), Konica Minolta Original (80 g/m2)
Recycled paper Inch: Weyehaeuser Recycled Laser Copy (20 lbs)
D. Maintenance
Maintenance Same as the main body

Machine service life Same as the main body
E. Machine data
Power source 24/5V DC (supplied from the main body)

Power consumption 30 W or less (internal heater is not used)
Temperature Same as the main body

Humidity Same as the main body
Note
1
1. PRODUCT SPECIFICATION Field Service Ver1.0 Feb.2006
LU-201
Blank page
2
MAINTENANCE
LU-201
2. PERIODIC CHECK
2.1 Maintenance procedure of the paper feed section
Caution
• When connected to the main body, make sure that the power cord of the main body is unplugged
from the power outlet.
2.1.1 Replacing the pick-up rubber and the feed rubber

• Pick-up rubber: Every 500,000 prints (Actual replacement cycle: Every 200,000 prints)
• Feed rubber: Every 500,000 prints (Actual replacement cycle: Every 200,000 prints)
B. Procedure
1. Open the upper door [1].
[1]
2. Remove the C-clips [2], 1 each, and release the 2
bearings [3].
3. Remove the paper feed roller unit [4].
[2] [3] [3] [2]
[4] 16aaf2c001na
3
Note
• When installing the paper feed roller unit, be
sure to insert the shaft [1] into the ring of the
LU-201
[3]
actuator [2].
[4] • When installing the paper feed roller unit, be
sure to install it so that the hook [3] comes
above the lift-up shaft [4].
• When installing the paper feed roller unit, be
sure to insert the shaft [5] securely into the
coupling [6].
[2] [6] [1] [5]
16aaf2c002na
4
4. Remove the C-clip [1] and then remove the actua-

[8]
tor [2].
5. Remove the C-clip [3] and then remove the bear-
LU-201
ing [4].
6. Pull out the shaft [5] in the arrow-marked direction
[6] and remove the feed roller [7].
[6] [2]
[5] [7] [4] [3] [1] 16aaf2c003na
7. Remove the feed rubber [2] from the paper feed

[3] roller [1].
Note
• Be sure to install the feed rubber [2] so that
the paint mark [3] comes in the opposite
direction of the gear [4].
• When setting the feed rubber, apply alcohol
on the inside of the feed rubber. By doing so,
the feed rubber can be set more easily.
[4] [2] [1] 16aaf2c004na
5
8. Remove the screw [1] and then remove the han-

[4] [5]
dle [3] from the roller mounting plate [2].
9. Remove the screw [4] and then remove the bear-
LU-201
ing holder [5] from the roller mounting plate [2].
[2] [3] [1] 16aaf2c005na
10. Remove the bearing [1] and then remove the pick-
[3] [1]
up roller [3] from the shaft [2].
[2] 16aaf2c006na
11. Remove the pick-up rubber [2] from the pick-up

roller [1].
Note
• When setting the pick-up rubber, apply alco-
hol on the inside of the pick-up rubber. By
doing so, the pick-up rubber can be set more
easily.

steps in reverse.
[2] [1]
16aaf2c007na
6
2.1.2 Replacing the separation roller

• Separation rubber: Every 500,000 prints (Actual replacement cycle: Every 200,000 prints)
LU-201
B. Procedure
1. Pull out LU from the main body.
[1] 2. Open the upper door [1].
3. Lift up the paper feed roller unit [2].
guide plate [4].
[2]
[4] [3] 16aaf2c008na
5. Remove the 2 screws [1] and then remove the left

[1]
cover [2].
[2] 16aaf2c009na
7

[1] [3] [2]
Note
LU-201
• When installing the separation roller assy, be

sure to set the upper section of the claw [2] at
the center of the marking-off [3] of the plate.
In this way, the separation roller assy can be
horizontally positioned.
16aaf2c010na
7. Release the lock lever [1] and remove the separa-

[1]
tion roller assy [2].
[2] 16aaf2c011na
8
8. Pull out the shaft [2] while pressing the lever [1]
[3] [2] and remove the separation roller [3].
LU-201
[1] 16aaf2c012na
9. Remove the separation rubber [2] from the sepa-

[4] [2] [1]
ration roller [1].
Note
• Be sure to install the separation rubber [2] so
that the paint mark [3] comes in the opposite
direction of the projection [4].
• When setting the separation rubber, apply
alcohol on the inside of the separation rubber.
By doing so, the separation rubber can be set
more easily.

[3] steps in reverse.
16aaf2c013na
9
3. OTHERS
LU-201
Note
• This list shows the explanation of the disassembly and reassembly of the parts which are consid-
ered necessary to replace (other than periodically replaced parts). However, these parts except for
the covers are not required to be disassembled while in normal service operations.
• For the method of replacing the periodically replaced parts, see "2.1 Maintenance procedure of
the paper feed section".
(See P.3)

1 Cover Right cover P.11
Front cover P.11
Rear cover P.11
2 Tray section Wire A P.14
Wire B P.14
Wire C P.14
Wire D P.14
10
LU-201
Caution
• When connected to the main body, make sure that the power cord of the main body is unplugged
from the power outlet.
3.2.1 Removal and reinstallation of the right cover, the front cover and the rear cover
A. Procedure
1. Pull out LU from the main body side.
[1] [2] 2. Open the upper door [1].
right cover [3].
Note
• When installing the right cover [3], be sure to
take note of the direction of the 2 casters [4].
[3]
[4] 16aaf2c014na
11

[1] 5. Remove the 2 screws [2] and then remove the
front cover [3].
LU-201
[3] [2] 16aaf2c015na

[3] [1]
7. Remove the screw [2] and then remove the auxil-
iary cover /Rr [3].
[2] 16aaf2c016na
12

[3]
cable cover [2].
LU-201
rear cover [4].
steps in reverse.
[4] [3]
[2]
[1] 16aaf2c017na
13
3.2.2 Replacing the wires

The length of the wires
Wire /A: 707.2 mm
LU-201
Wire /B: 585.7 mm

Wire /C: 558.7 mm
Wire /D: 680.2 mm
Auxiliary wire: 706.3 mm
Detection wire: 609.6 mm
A. Removing the wire

1. Remove the right cover, the front cover and the
[6] [5] rear cover.
(See P.11)
[3]
2. Remove the connectors [1] and [2], and pull out
the wiring harness [4] from the hole [3].
3. Remove the 2 connectors [5] and the connector
[1]
[6].
[4]
[2]
16aaf2c018na
14
4. Remove the 5 connectors [2] from the LU drive

board (LUDB) [1].
[2]
LU-201
[2]
[1]
16aaf2c019na
5. Remove the 6 screws [1] and then remove the LU

[1] drive board unit [2].
[1] [2] [1]
16aaf2c020na
15
Note
[1] [2] • When removing the LU drive board unit, the
bearings [1] and [2] may come off and fall. Be
LU-201
careful that they do not get lost.

• On the inside of the gear [3], the spacer [4] is
provided. Be careful that it does not get lost.
[4] [3]
16aaf2c021na

[2]
paper lift motor (M151) [2].
[1] 16aaf2c022na
16

[2] [1] motor mounting plate [2].
LU-201
[1] 16aaf2c023na
8. Remove the E-ring [1], and remove the wire stop-

per [2].
[6] [8]
9. Remove the assist wire [4] from the spring [3].
[7]
Note
• Be careful that the lift plate [5] comes down
by its own weight.
10. Peel off the seal [7] from the detection reel [6].
11. Rotate the detection reel [6] clockwise as seen
from the rear side, and remove the detection wire
[8] from the reel.
C
D
B
A
[3] [5]
[4]
[2]
[1]
16aaf2c024na
17
12. Remove the 2 E-rings [1] and the 2 wire stoppers

[2].
[2] [2]
13. Remove the 4 E-rings [4] and remove the 4 upper
LU-201
[1] [1]
pulleys [5].
C
D
[5] [4]
[5]
[4]
16aaf2c025na
14. Remove the E-ring [1] and the drive pulley [2],
then remove the auxiliary wire [3], the wire A [4]
and the wire B [5].
15. Remove the E-ring [6] and the drive pulley [7],
C then remove the detection wire [8], the wire D [9]
D and the wire C [10].
B
A
[4] A [5] [10] D [9]

[3] [8]
B C
[2] [7]
[1] [6]
16aaf2c026na
18
B. Stringing wires
1. Pass the wire A [1], the wire B [2], the wire C [3]
and the wire D [4] through the lift plate [5].
LU-201
[6] [7] [6] [14] [15] [15]
B C 2. Run the wire A [6] and the wire B [7] through the 2
A A D D
upper pulleys [8] and the 2 lower pulleys [9], and
then through the adjustment part [10].
3. Tighten the 2 upper pulleys [8] with the 2 E-rings
[11] [8] [11] [8] [16] [17] [16] [17] [11].
4. Install the wire stopper [12] to each of the 2 lower
pulleys [9] in the direction as shown in the draw-
ing. And then fasten it with the 2 E-Rings [13].
5. Run the wire C [14] and the wire D [15] through
[4]
C the groove of the pulley [16].
[10] 6. Tighten the 2 pulleys [16] with each of the E-ring
D
[3] [17].
B
A
[2]
[1] [5]
[9] [9]
[12] [12]
[13] [13]
16aaf2c027na
7. After putting the auxiliary wire [1], the wire A [2]

and the wire B [3] into the holes in the front sec-
tion of the drive shaft [4], install the drive pulley [5]
and tighten it with the E-ring [6].
C 8. After putting the detection wire [7], the wire D [8]
D and the wire C [9] into the holes in the rear section
of the drive shaft [4], install the drive pulley [10]
B and tighten it with the E-ring [11].
A
[2] A [3] [9] D [8]

[1] [7]
B C
[5] [10]
[6] [11]
[4] [4]
16aaf2c028na
19
9. Hold the drive pulley [1] and the drive pulley [2]
[7] with both hands and rotate them counterclock-
[9] wise as seen from the front side until there are no
LU-201
[10] slacks found in the wires A, B, C, and D.

10. Rotate the coupling shaft [3] on the rear side to lift
[3]
the lift plate [4] to the upper limit.
[2]
Note
• Be sure to wind the wires from the inside of
C the LU to the outside.
[1]
D • At this time, the auxiliary wire [5] and the
detection wire [11] should not have been
B
wound around the drive pulleys [6] and [12].
A
[4]
11. Wind the auxiliary wire [5] about half turn counter-
[5] [8] clockwise around the drive pulley [6].
12. Wind the auxiliary wire [5] about 1.5 turn clock-
wise around the pulley [7] and install it to the
spring [8].
13. Install the wire stopper [9] to the pulley [7] in the
[6] [5] [11] [12] direction as shown in the drawing, and tighten it
16aaf2c029na with the E-ring [10].
14. With the lift plate [4] lifted fully up to the upper
limit, wind the detection wire [11] about half turn
clockwise around the drive pulley [12].
15. Set the wire attaching notch [2] at the right above
[2] position with no tension applied on the detection
reel [1], and wind the detection wire [3] a full turn
counterclockwise around the detection reel [1]
starting at the top side.
Note
• Be sure to wind the wire from the inside of the
LU to the outside.
[1] [4] [3]
16aaf2c030na
16. Rotate the detection reel [1] clockwise to apply
tension. After rotating about 3/4 turn, install the
detection wire [3].
17. Stick the seal [4] to the detection reel [1].
18. Follow Steps 1 to 10 in “A. Removing the wire” in
reverse order.
Note
• After finishing wire replacement, move the lift
plate up and down to confirm that it moves
smoothly.
• Make sure that the wires do not cross each
other, or a wire does not run on another wire.
• After installing the wires, adjust the tilt of the
lift plate.
(See P.21)
20
ADJUSTMENT/SETTING
LU-201
4.1 Adjusting the tilt of the lift plate
When the lift plate is tilted, paper may not be fed correctly. Adjust the lift plate so that it becomes parallel to the
paper feed roller shaft. When replacing the wire, be sure to conduct this adjustment.
A. Procedure
1. Remove the right cover and the front cover.
(See P.11)
[1] 16aaf3c001na
21

[2] [5] 4. Stand the scale [3] on the upper surface of the lift
plate [2].
LU-201
5. Move and adjust the wire adjusting member [6] so

that the distance from each of the upper surfaces
of the panels /Fr [4] and /Rr [5] to the upper sur-
face of the lift plate become identical.
6. After completion of the adjustment, tighten up the
screw [7] securely.
[1] [3]
[4] [7] [6]
16aaf3c002na
22
FS-510/PU-501/
OT-601
2006.02
Ver. 1.0
Revision history
Revision mark:
ing page.
NOTE

FS-510/PU-501/OT-601
CONTENTS
FS-510/PU-501/OT-601
OUTLINE
1.1 FS-510 ..................................................................................................................1
1.2 PU-501..................................................................................................................3
OUTLINE
1.3 OT-601 ..................................................................................................................4
MAINTENANCE
2. PERIODIC CHECK..................................................................................................5
2.1.1 Cleaning of the Roller and Roll......................................................................5
MAINTENANCE
3. OTHER ....................................................................................................................7
3.2 Disassembling and assembling list .......................................................................8
3.3 Disassembling and assembling procedure ...........................................................9
3.3.1 Conveyance Front Cover /Up, /Rt, /Lw ..........................................................9
3.3.2 Conveyance Upper Cover .............................................................................9
ADJUSTMENT/SETTING
3.3.3 Front Door ...................................................................................................10
3.3.4 Conveyance Front Cover /Lt ........................................................................10
3.3.5 Paper Exit Front Cover, Rear Cover, Connector Cover ...............................11
3.3.6 Tray /2..........................................................................................................12
3.3.7 OT ...............................................................................................................12
3.3.8 Tray /1..........................................................................................................12
3.3.9 Lift Tray ........................................................................................................13
3.3.10 Conveyance Unit .........................................................................................13
3.3.11 Stapler .........................................................................................................14
3.3.12 PU ...............................................................................................................15
3.3.13 Stacker Paddle Drive Clutch Assy ...............................................................16
3.3.14 Paper Holding Paddle Drive Clutch Assy ....................................................17
ADJUSTMENT/SETTING
4.1 Staple Position Adjustment .................................................................................21
4.2 Adjustment of the Installation Position of the Shutter Drive Gear .......................22
4.3 Punch Mis-centering Adjustment (PU-501).........................................................23
i
ADJUSTMENT/SETTING MAINTENANCE OUTLINE FS-510/PU-501/OT-601
ii
Blank Page
OUTLINE
FS-510/PU-501/OT-601
1.1 FS-510
A. Type
Name Multi tray finisher built into the main body

OUTLINE
Consumables Staples (5,000 staples/cartridge)
B. Functions
Modes Non sort, sort, group, sort staple, and punch (when PU-501 is mounted)
C. Paper type
(1) Non sort

Tray /1 200 sheets
Metric:
A4S, 81/2 x 11S 1000
A3, B4, A4, A4S, B5,
Plain paper 50 to 90 g/m2 or less sheets
B5S, A5, A5S, B6S Tray /2
11 x 17, 81/2 x 11, B4, 81/2 x 14 500
81/2 x 11S, Foolscap or greater sheets
Thick paper 91 to 210 g/m2
Inch:
OHP transparencies -
11 x 17, 81/2 x 14,
Translucent paper 81/2 x 11, 81/2 x 11S, -
20 sheets
Envelope 51/2 x 81/2S -
A3, A4, A4S, A5S,
Label -
Foolscap
Letterhead -
(2) Sort/Group

A3, B4, A4, A4S, B5,
B5S, A5
11 x 17, 81/2 x 11, A4S, 81/2 x 11S 1000
81/2 x 11S, Foolscap or less sheets

Inch: Tray /2
11 x 17, 81/2 x 14,
81/2 x 11, 81/2 x 11S, B4, 81/2 x 14 500
A3, A4, A4S, A5S,
Foolscap
1
FS-510/PU-501/OT-601
(3) Sort Staple

A3, B4, A4, A4S, B5,
B5S, A5, A5S, B6S
11 x 17, 81/2 x 14, A4S, 81/2 x 11S 1000
81/2 x 11, 81/2 x 11S, or less sheets
Foolscap
Inch: Tray /2
11 x 17, 81/2 x 14,
OUTLINE
81/2 x 11, 81/2 x 11S, B4, 81/2 x 14 500

A3, A4, A4S, A5S,
Foolscap
D. Stapling
Staple Filling Mode Dedicated Staple Cartridge (5000 staples)

Staple Detection Available (Nearly Empty: 20 remaining staples)
Front: Diagonal 45° 1 point *1 A3, B4, A4, B5
Rear: Diagonal 45° 1 point *1 11 x 17, 81/2 x 11
Front: Parallel 1 point A4S, B5S, A5
Stapling Position
Rear: Parallel 1 point 81/2 x 14, 81/2 x 11S, 51/2 x 81/2S
A3, B4, A4, A4S, B5, B5S, A5
Side: Parallel 2 point
11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S
*1: Diagonal 30° for B5 and B4
E. Maintenance

F. Machine specifications
Power Requirements 24/5V DC (supplied from the main body)

G. Operating environment

2
FS-510/PU-501/OT-601
1.2 PU-501
A. Type
Type FS built-in type punching operation device

Metric:
A3, B4, A4, A4S, B5, B5S
11 x 17, 81/2 x 11, 81/2 x 11S, Foolscap
Paper Size Inch:

2 holes: 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S
OUTLINE
3 holes: 11 x 17, 81/2 x 11
A3, A4
Paper Type Plain Paper (60 to 130 g/m2), Recycled Paper (60 to 130 g/m2)
Metric: 4 holes, Swedish 4 holes (φ 6.5 mm)
Punch Hole
Inch: 2 and 3 holes (can be switched) (φ 8 mm)
Number of Stored Metric (4 holes): For 1,500 sheets of paper (80 g/m2)
Punch Wastes Inch (2, 3 holes): For 1,000 sheets of paper (20 lbs)
B. Maintenance

Power Requirements 24/5V DC (Supplied from FS)


3
FS-510/PU-501/OT-601
1.3 OT-601
A. Type
Type Additional Tray to FS

Mode Non sort, sort, group, and sort staple
Number of Bins 1 bin
B. Paper Type
OUTLINE
Mode Size Type Capacity

Metric: Plain Paper, Recycled Paper
200 sheets
A3, B4, A4, A4S, B5, (56 to 90 g/m2,15 to 24 lb)
B5S, A5, A5S, B6S
OHP transparencies
11 x 17, 81/2 x 11,
81/2 x 11S, Foolscap Thick paper
Non sort (91 to 210 g/m2)
Inch:
11 x 17, 81/2 x 14, Special Envelope 20 sheets
81/2 x 11, 81/2 x 11S, Label paper
51/2 x 81/2S
Letterhead
A3, A4, A4S, A5S,
Foolscap Translucent paper
Metric:
A3, B4, A4, A4S, B5,
Sort / group B5S, A5 200 sheets
11 x 17, 81/2 x 11,
Plain Paper, Recycled paper
Inch: (56 to 90 g/m2)
11 x 17, 81/2 x 14,
81/2 x 11, 81/2 x 11S,
Sort staple 200 sheets or 20 copies
51/2 x 81/2S
A3, A4, A4S, A5S,
Foolscap
C. Maintenance



NOTE
4
MAINTENANCE
FS-510/PU-501/OT-601
2. PERIODIC CHECK
NOTE
propyl alcohol.
2.1.1 Cleaning of the Roller and Roll

1. Remove the Lift Tray.
(See P.13)
2. Remove the Conveyance Unit.
(See P.13)
3. Remove the Conveyance Top Cover.
(See P.9)
MAINTENANCE
[1] [1]
hol, wipe the roller and roll [1].
[1]
4349f2c001na
5. Lower Processing Guide FN1 [2].

[2]
4349f2c002na
7. Remove Punch Scraps Box FN3.1 [4].

(only when PU is installed)
[4]
4349f2c003na
5
FS-510/PU-501/OT-601
8. Lower Processing Guide FN-3 [5].

[5]
4349f2c004na
10. Lower Processing Guide FN-4 [7].

[8]
[7]
4349f2c005na
MAINTENANCE
12. While turning Processing Knob FN-5

[10] [9], wipe the roller [10] using a soft cloth
dampened with alcohol.
[9]
4349f2c006na

[11] hol, wipe the roller [11].
[11]
4349f2c007na
6
FS-510/PU-501/OT-601
3. OTHER
loose.
NOTE
MAINTENANCE
Caution
7
FS-510/PU-501/OT-601

1 Conveyance Front Cover /Up P.9
2 Conveyance Upper Cover P.9
3 Conveyance Front Cover /Rt P.9
4 Front Door P.10
5 Conveyance Front Cover /Lw P.9
6 Conveyance Front Cover /Lt P.10
Cover
7 Paper Exit Front Cover P.11
8 Tray /2 P.12
9 OT (Option) P.12
10 Tray /1 P.12
11 Connector Cover P.11
12 Paper Exit Rear Cover P.11
13 Lift Tray P.13
MAINTENANCE
14 Conveyance Unit P.13

Unit
15 Stapler Unit P.14
16 PU (Option) P.15
17 Stacker Paddle Drive Clutch Assy P.16
Others
18 Paper Holding Paddle Drive Clutch Assy P.17
8
FS-510/PU-501/OT-601
3.3.1 Conveyance Front Cover /Up, /Rt, /Lw
1. Open the Front Door.

2. Unhook the tab, and remove the Con-
veyance Front Cover /Up [1].
[1]
4349f2c008na

Conveyance Front Cover /Rt [3].
[2]
MAINTENANCE
[3]
4349f2c009na

Conveyance Front Cover /Lw [5].
NOTE
[5] • At reinstallation, first fit the claw [6]
into position.
[6]
[4] 4349f2c010na
3.3.2 Conveyance Upper Cover
1. Remove four screws [1], and remove the

[1] Conveyance Upper Cover [2].
[2]
[1]
4349f2c011na
9
FS-510/PU-501/OT-601
3.3.3 Front Door
1. Open the Front Door [1].

[5] [4] [3] [2] 2. Remove the screw [2], and remove the
stopper [3].
3. Loosen two screws [4].
4. Slide up the Fulcrum /Up [5] and
remove the Front Door.
5. Reinstall the above parts following the
removal steps in reverse.
MAINTENANCE
[1] [3]
4349f2c036na
3.3.4 Conveyance Front Cover /Lt
1. Remove three screws [1], and remove

the Conveyance Front Cover /Lt [2].
[2]
[1]
4349f2c014na
10
FS-510/PU-501/OT-601
3.3.5 Paper Exit Front Cover, Rear Cover, Connector Cover
1. Remove the Front Door.

(See P.10)
2. Remove the Conveyance Front Cover
/Lt.
(See P.10)
Paper Exit Front Cover [2].
[1] [2] 4349f2c037na
4. Remove the screw [3], and remove the

[3] [4]
Connector Cover [4].
MAINTENANCE
the Paper Exit Rear Cover [6].
[5] 6. Reinstall the above parts following the
[6]
[5]
4349f2c038na
11
FS-510/PU-501/OT-601
3.3.6 Tray /2

[2]
Tray /2 [2].
[1] 4349f2c016na
3.3.7 OT
[2]
MAINTENANCE
OT [2].
[1] 4625f2c001na
3.3.8 Tray /1

[2] Tray /1 [2].
[1] 4349f2c017na
12
FS-510/PU-501/OT-601
3.3.9 Lift Tray
NOTE
• When removing the Lift Tray, be sure to bring the Tray down to the bottom.
• If the OT is installed, remove it in advance.
[1] 1. Remove the Front Door.

[1] (See P.10)
/Lt.
(See P.10)
3. Disconnect three connectors [1].
ground wire.
[2] 4349f2c019na 5. Remove the Tray /1, Tray /2 and OT.
(See P.12)
6. Remove six screws [3], and lift the Lift

[4] Tray [4] upward and off from the Con-
veyance Unit.
MAINTENANCE
NOTE
• The removal of the upper 2 screws [3]
[3] [3] is not available when the Lift Tray is
not brought down to the bottom.
4349f2c020na
3.3.10 Conveyance Unit

(See P.13)
2. Remove the Front Door.
(See P.10)
3. While holding down the lock release
button [1], remove the Conveyance Unit
[2] [1]
[2].
4349f2c021na
13
FS-510/PU-501/OT-601
3.3.11 Stapler

2. Turn the knob [1], and move the stapler
[3] forward.
3. Remove the Staple Cartridge.
[1] cover [3].
[2]
4349f2c022na
5. Disconnect two connectors [4].
[4]
MAINTENANCE
4349f2c023na

[6] Stapler Unit [6].
[5]
4349f2c024na

Stapler [8].
[8]
[7]
4349f2c025na
14
FS-510/PU-501/OT-601
3.3.12 PU

[1] (See P.13)
(See P.13)
3. Remove the Conveyance Upper Cover.
(See P.9)
[2] /Lw.
4512f2c001na (See P.9)
Reinforcement Plate [2].
6. Disconnect two connectors [3].
[3]
MAINTENANCE
4512f2c002na

[7] [6]
PU [7].
[6]
4512f2c003na
8. Remove nine screws [8], and the Punch

[8]
[8] Unit [9].
[8]
[9]
[8]
4512f2c004na
15
FS-510/PU-501/OT-601
3.3.13 Stacker Paddle Drive Clutch Assy
(See P.13)
(See P.13)
[1] 3. Remove the Conveyance Upper Cover.
(See P.9)
4. Remove the E-ring [1].
4349f2c026na
5. Loosen two hexagonal socket head

screws [2], and remove the Stacker
Paddle Drive Clutch Assy [3].
[3]
[2]
MAINTENANCE
4349f2c027na
[3] 1. Check that the 2-mm hole [2] of the
[1]
stacker paddle drive shaft [1] and the
cutout of the frame [3] are aligned and
[2]
install the Stacker Paddle Drive Clutch
Assy [4].
2. Refer to the figure and check the paddle
position [5].
3. Hook the Solenoid Flapper [7] to the
claw [6] of the Stacker Paddle Drive
Clutch Assy [4].
4. Attach the E-ring and reinstall the
Stacker Paddle Drive Clutch Assy.
5. Adjust the spacing between the E-ring
[5] and the Stacker Paddle Drive Clutch
Assy to 0.2 mm and tighten two hexago-
nal socket head screws.
[4]
[7]
[6] 4349f2c028na
16
FS-510/PU-501/OT-601
3.3.14 Paper Holding Paddle Drive Clutch Assy
[1] 1. Remove the Lift Tray.
(See P.13)
(See P.13)
[2] 3. Remove the Conveyance Upper Cover.
(See P.9)
4. Remove the C-ring [1].
4349f2c029na 5. Remove the bearing [2].
6. Loosen two hexagonal socket head

[4] [3] screws [3], and remove the Paper Hold-
ing Paddle Drive Clutch Assy [4].
MAINTENANCE
4349f2c030na
[1] 1. Reinstall the Paper Holding Paddle
Drive Clutch Assy [1].
4349f2c031na
17
FS-510/PU-501/OT-601
Precaution for Reinstallation
[3] [4] [5]
[2]
[1]
MAINTENANCE
4349f2c032na
[1] Solenoid Flapper [4] Paper Holding Paddle Drive Clutch Assy
[2] 107 ± 3mm [5] Paper Holding Paddle
[3] Paper Holding Paddle
2. Install the bearing [2].
[2]
4349f2c033na
3. Hook the Solenoid Flapper [4] to the

claw [3] of the Paper Holding Paddle
Drive Clutch Assy.
NOTE
• Install the Paper Holding Paddle Drive
Clutch Assy with the side having a
[3] wider spacing between the claws fac-
[4]
ing upward.
4349f2c034na
18
FS-510/PU-501/OT-601
4. Attach the C-ring and press the Paper
[5] [6]
Holding Paddle Drive Clutch Assy [6] to
the bearing [5].
5. Adjust the spacing [7] between the
bushing [5] and the Paper Holding Pad-
dle Drive Clutch Assy [6] to 0.2 mm and
tighten two hexagonal socket head
[7] screws.
4349f2c035na
MAINTENANCE
19
FS-510/PU-501/OT-601
MAINTENANCE
Blank Page
20
ADJUSTMENT/SETTING
FS-510/PU-501/OT-601
4.1 Staple Position Adjustment
1. Set the staple and make a print.
B [1]
2. Check the staple position of the paper.
A
• Slant one point Staple [1]
C
D (Paper Width: 216 to 297 mm)
279 to 297 mm: 45°,
B5, B4: 30°
Measurement Adjustment
Specification
position range
A, C 4.4 mm —
B, D 12.1 mm +1 to –2mm
A [2]
• Parallel one point Staple [2]
B (Paper Width: 182 to 216 mm)
Measurement Adjustment
Specification
position range
A 4.5 mm —
B 6 mm +1 to –2mm
• Parallel two points Staple [3]
ADJUSTMENT/SETTING
[3]
C Measurement Adjustment
Specification
position range
D
C, F 6 mm +1 to –2mm
D Y —
E
E X —
Y = (paper width–X–11) / 2
X = A3, A4: 137 mm
F 4349f3c001na
B4, B5: 114 mm
A4S: 190 mm
B5S: 162 mm
11 x 17, 81/2 x 11: 119.4 mm
81/2 x 11S: 196 mm
Substitute above into the equation.
3. If the staple position is misaligned,

adjust with the following procedure.
21
FS-510/PU-501/OT-601

5. Turn the knob [1], and move the stapler
[3] forward.
6. Loosen the screw [2], and remove the
cover [3].
[1]
[2]
4349f3c002na
7. Loosen two adjustment screws [2] and

move the Stapler Unit [3] in the direction
of the arrow to make the adjustment.
8. Make another print and check the staple
position.
[5]
[4]
4349f3c003na
4.2 Adjustment of the Installation Position of the Shutter Drive Gear

1. Set three gears.
[2]
NOTE
[1] [1] • Set the gears so that the marks on
ADJUSTMENT/SETTING
Gears 1 and 3 [1] are aligned with the

rib of Gear 2 [2] as shown on the right.
4349f3c004na
22
FS-510/PU-501/OT-601
4.3 Punch Mis-centering Adjustment (PU-501)
1. Set the copier into the Punch mode and
make a 1-sided print from a 1-sided
original.
2. Fold the output paper in half and check
whether the punch hole positions are
aligned.
4512f3c001na
Specification: 0 ± 2 mm
3. If the punch hole position is misaligned,
adjust with the following procedure.

/Lw.
(See P.9)
[2] 5. Loosen the adjustment screw [1], and
[1] move the Punch Unit [2] forward or
backward to make the adjustment.
6. Make another print and check the punch
displacement.
4512f3c002na
ADJUSTMENT/SETTING
23
FS-510/PU-501/OT-601
Blank Page
ADJUSTMENT/SETTING
24
FS-511/RU-502
2006.02
Ver. 1.0
Revision history
Revision mark:
ing page.
NOTE

CONTENTS
FS-511/RU-502
FS-511/RU-502
OUTLINE
1.1 FS-511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 RU-502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MAINTENANCE
2. OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Disassembling and assembling list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Disassembling and assembling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2.1 Removal/reinstallation of the upper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2.2 Removal/reinstallation of the front cover /Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2.3 Removal/reinstallation of the front cover /Lw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2.4 Removal/reinstallation of the rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.5 Removal/reinstallation of the punch unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2.6 Replacing the stapler unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ADJUSTMENT/SETTING
3. MECHANICAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 Output check mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1.1 Switches provided inside the board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1.2 Output check mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2 Adjusting the punch hole position in the vertical direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Adjusting the solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3.1 Adjustment of the bypass gate solenoid (SD1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3.2 Adjustment of the main gate solenoid (SD2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.4 Adjusting the belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.4.1 Adjustment of the timing belt of the conveyance motor /Up (M4) . . . . . . . . . . . . . . . . . . . . . . . 28
3.4.2 Adjustment of the timing belt of the conveyance motor /Lw (M2) . . . . . . . . . . . . . . . . . . . . . . . 29
3.4.3 Adjustment of the timing belt of the paper exit motor (M3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.5 Adjusting the tray upper surface detection position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.6 Adjusting the tray overload detection level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
i
FS-511/RU-502
Blank page
ii
OUTLINE
FS-511/RU-502
1.1 FS-511
A. Type
Type Multi staple finisher

Installation Floor-mounted type
Document alignment Center
Consumables Staples
B. Functions
Mode Normal Non-sort, sort, group, sort-staple

Punch Non-sort-punch, sort-punch, group-punch,
sort-staple-punch
C. Type of paper
• Maximum load capacity: (80 g/m2) when loaded with paper of the same size.
(1) Straight
sheets stapled
Plain paper A3, B4, A4, A4S, B5, 60 to 90 g/m2 250 sheets Sub tray —
Recycled paper B5S, A5S, and B6S
Thick paper 51/2 x 81/2S, 81/2 x 11, 91 to 130 g/m2 20 sheets
81/2 x 11S, 81/2 x 14,
Thin paper 50 to 59 g/m2
11 x 17
OHP —
transparencies
Label
Envelope
Label sheet
Letterhead
1
(2) Non-sort, sort, group

FS-511/RU-502
sheets stapled
Plain paper A3, B4, A4, A4S, B5, 50 to 130 g/m2 3000 sheets Main tray —
Thick paper 81/2 x 11, 81/2 x 11S, 1500 sheets
81/2 x 14, 11 x 17 (B4 or larger)
Thin paper
(3) Sort-staple, group-staple
sheets stapled
Plain paper A3, B4, A4, A4S, B5, 60 to 90 g/m2 3000 sheets Main tray 50 sheets
81/2 x 11, 81/2 x 11S, 1500 sheets
81/2 x 14, 11 x 17 (B4 or larger)
(4) Punch
a. Metric/Swedish
sheets stapled
Plain paper A3, B4, A4, A4S, B5, 60 to 90 g/m2 — Main tray —
Recycled paper B5S Sub tray
b. Inch 2 holes
sheets stapled
Plain paper 81/2 x 11S, 81/2 x 14 60 to 90 g/m2 — Main tray —
c. Inch 3 holes
sheets stapled
Plain paper 81/2 x 11S, 11 x 17 60 to 90 g/m2 — Main tray —
2
D. Stapling
FS-511/RU-502
Staple filling method Dedicated staple cartridge (5000 staples)
Staple detection Available (near empty: 20 remaining staples)
Staple position *1 Rear: Diagonal 45° 1 point Metric: A3, B4, A4, B5
Front: Diagonal 45° 1 point Inch: 81/2 x 11, 11 x 17
Rear: Diagonal 28° 1 point Metric: B4, B5
Front: Diagonal 28° 1 point Inch: —
Rear: Parallel 1 point Metric: A4S, B5S
Front: Parallel 1 point Inch: 81/2 x 11S, 81/2 x 14
Side: 2 points A4, A4S, A3, B5, B5S, B4, 81/2 x 11, 81/2 x 11S,
81/2 x 14, 11 x 17
Manual staple None
*1 In case of the 1-staple mode, conduct a parallel and a skew adjustment according to the length in the
main scan direction.
Parallel: main scan direction 182 to 216 mm
Diagonal: main scan direction 216 to 297 mm
E. Punch
No. of holes Inch: 2 holes, 3 holes

Metric: 4 holes
Punch scraps full detection None
F. Maintenance

G. Machine data
Power source 24V DC ± 10 % (supplied from the main body)

Power consumption 64 W or less
Weight 39.2 kg
H. Operating environment
Note
3
1.2 RU-502
FS-511/RU-502
A. Type
Type Roller method relay conveyance unit
B. Functions
Conveyance Paper conveyance from the main body to FS
C. Type of paper
Paper size Same as the main body.

Paper type Same as the main body.
Amount of curling b = 10 mm or less
(5 sheets)
h
16fat1c001na
D. Maintenance

E. Machine data
Power source 5.1V DC ± 5 % (supplied from FS)

Dimensions 474.5 (W) x 469.5 (D) x 254.4 (H) mm
Note
4
MAINTENANCE
FS-511/RU-502
2. OTHERS
1 Cover Upper cover P.6
2 Front cover /Up P.8
3 Front cover /Lw P.9
4 Rear cover P.10
5 Punch section Punch unit P.11
6 Staple section Stapler unit P.13
5

FS-511/RU-502
2.2.1 Removal/reinstallation of the upper cover

A. Procedure
1. Remove the sub tray [1].
[1]
4521f2c004na
6

FS-511/RU-502
4. Loosen 2 screws [4].
5. Loosen the screw [5] and remove the upper cover
[6].
steps in reverse.
[3] [2]
[4] [6] [5]
4521f2c005na
7
2.2.2 Removal/reinstallation of the front cover /Up

A. Procedure
FS-511/RU-502

[1]
2. Loosen 2 screws [2] and remove the front cover
/Up [3].
steps in reverse.
[2]
[3] 4521f2c006na
8
2.2.3 Removal/reinstallation of the front cover /Lw

A. Procedure
FS-511/RU-502
1. Loosen 2 screws [1] and remove the front cover
[1] /Lw [2].
steps in reverse.
[2] 4521f2c007na
9
2.2.4 Removal/reinstallation of the rear cover

A. Procedure
FS-511/RU-502
1. Remove the screw [1] and loosen the screw [2].

[1] 2. Loosen 2 screws [3] and remove the rear cover
[4].
steps in reverse.
[2] [3]
[4] 4521f2c008na
10
2.2.5 Removal/reinstallation of the punch unit

A. Installation of the Swedish punch kit G
FS-511/RU-502
When installing the Swedish punch kit G, be sure to remove the existing punch unit and follow the procedure
given below.
B. Procedure
1. Remove the upper cover.
(See P.6)
3. Remove the screws [2] and [3]. After sliding the
punch unit [4] in the arrow-marked direction [5],
remove it in the arrow-marked direction [6].
Note
• The screw [2] is provided with the spacer [7]
and the washer [8]. Be careful that they do not
get lost.
[6] [1] [5]
[3] [4]
[2][7][8] 4521f2c009na
11
Note
[9] [13] [14]
FS-511/RU-502
• When installing the punch unit, be sure to set

the gear [9] of the main body to the gear [10]
of the punch unit, and then insert the shaft
[11] into the hole [12] of FS.
• When engaging the gears, be sure to engage
them so that the gear flange [13] of the main
body comes inside the gear flange [14] of the
punch unit.

steps in reverse.
[10] [12] [11] 4521f2c010na
12
2.2.6 Replacing the stapler unit

A. Procedure
FS-511/RU-502
1. Open the punch scraps box holder [1].
[1]
4521f2c001na
2. Rotate the dial [1] in the arrow-marked direction

[5]
[2] to expand the intervals of the stapler units /Fr
[3] and /Rr [4].
Note
• After replacing the stapler units /Fr and /Rr,
be sure to return these intervals to their origi-
nal widths.
3. While pressing both sides [6] of each of the sta-

pler unit covers [5], remove 2 stapler unit covers.
Note
• For each FS unit, 2 stapler units are provided.
[6]
When replacing these 2 stapler units, they are
replaced at the same time. So, be sure to
remove both the covers.
[3] [1] [2] [4] 4521f2c002na
13
4. Remove 2 connectors [6].

[10] [6] 5. Remove the screw [7] and then remove the
FS-511/RU-502

6. Remove the screw [9] and then remove the sta-
pler unit /Rr [10].
7. Remove 2 connectors [11].
9. Remove the screw [14] and then remove the sta-
pler unit /Fr [15].
[7][8] [9]
[15] [12][13]
[14] [11] 4521f2c003na
14
10. Remove 2 screws [16] and then remove the plate

[16] [17] [17], 1 each, from each of the stapler units.
FS-511/RU-502
steps in reverse.
4521f2c029na
15
FS-511/RU-502
Blank page
16
ADJUSTMENT/SETTING
FS-511/RU-502
3.1 Output check mode
3.1.1 Switches provided inside the board
Test switch [1] Dipswitch used for the mode setting of the output check mode. (All settings
are off in the initial condition.)
Output check switch /1 [2] Used to execute the output check mode.
Output check switch /2 [3]
LED1 to 4 [4] Display the conditions while in the output check mode.
[1] [3] [2] [4]

4521f3c001na
17
3.1.2 Output check mode

A. Setting of the output check mode.
FS-511/RU-502
(1) Procedure for setting
Note
• Before executing the output check mode, be sure to remove the upper cover, the front cover /Up
and the rear cover of FS in advance.
(See P.6, P.8, P.10)
• When removing the covers of FS, be sure to block the light that strikes on the front door sensor
(PS17) and the upper door sensor (PS18).
1. Turn OFF the power switch (SW2) of the main

body.
2. Switch the test switch [1] to the output check
mode.
(See P.19)
3. Turn ON SW2.
4. The output check mode is set.
[1] 4521f3c002na
18
(2) Method for release

1. Turn OFF the power switch (SW2) of the main
FS-511/RU-502
body.
2. Set the test switch [1] to the initial condition (all
OFF).
3. Turn ON SW2.
[1] 4521f3c003na
B. Types of the output check modes
Output check mode Test switch LED1 to 4

1 2 3 4 1 2 3 4
Sub tray paper exit mode ON OFF OFF OFF z { { {
Main tray paper exit mode OFF ON OFF OFF { z { {
Alignment tray paper exit mode ON ON OFF OFF z z { {
Shift operation mode ON OFF ON OFF z { z {
Alignment plate operation mode OFF ON ON OFF { z z {
Stapler unit CD movement mode ON ON ON OFF z z z {
Paper exit roller release mode OFF OFF OFF ON { { { z
Intermediate conveyance roller ON OFF OFF ON z { { z
release mode
Main tray operation mode OFF ON OFF ON { z { z
Punch hole operation mode ON ON OFF ON z z { z
Sensor output check mode ON OFF ON ON The sensor conditions are displayed.
z : Blink { : Off
19
C. Operation of each of the output check modes

(1) Sub tray paper exit mode
FS-511/RU-502
Output check switch /1 : ON The motor and the solenoid turn ON.
• Entrance conveyance motor (M1)
• Conveyance motor /Up (M4)
• Bypass gate solenoid (SD1)
• Main gate solenoid (SD2)
Output check switch /2 : ON The motor and the solenoid turn OFF.
• Main gate solenoid (SD2)
(2) Main tray paper exit mode
Output check switch /1 : ON The motor turns ON.

• Conveyance motor /Lw (M2)
• Paper exit motor (M3)
• Shift motor (M8)
Output check switch /2 : ON The motor turns OFF.

• Shift motor (M8)
(3) Alignment tray paper exit mode
Output check switch /1 : ON The motor and the solenoid turn ON.
• Paddle motor /Up (M15)
• Paper exit roller release motor (M13)
Output check switch /2 : ON The motor and the solenoid turn OFF.
• Paddle motor /Up (M15)
• Paper exit roller release motor (M13)
20
(4) Shift operation mode
FS-511/RU-502
Output check switch /1 : ON
The main tray shifts to the front side.

• The shift motor (M8) turns ON.
The main tray shifts to the rear side.

• The shift motor (M8) turns ON.
(5) Alignment plate operation mode
The alignment plate moves to the home position for

the 1st time.
The alignment plate moves to the A4 alignment posi-

tion for the 2nd time.
The alignment plate moves to the 81/2 x 11 alignment

position for the 3rd time.
The alignment plate moves to the A4S alignment

position for the 4th time.
The alignment plate moves to the 81/2 x 11S alignment

position for the 5th time.
(6) Stapler unit CD moving mode
The stapler unit moves to the home position for the

1st time.
The stapler unit moves to the A4 corner for the 2nd

time.
21
(7) Paper exit roller release mode

FS-511/RU-502

The paper exit roller is in the pressure/release opera-
tion
(8) Intermediate conveyance roller release mode
The intermediate conveyance roller is pressured.
The intermediate conveyance roller is released.
(9) Main tray operation mode

The main tray goes up until the light of the main tray
upper limit LED (LED19) is blocked.

The main tray goes down until the main tray upper
limit sensor (PS19) receives the light.
(10) Punch hole operation mode
The punch motor (M11) drives.
The punch clutch (CL1) turns ON.
The punch motor (M11) stops.
22
(11) Sensor output check mode
FS-511/RU-502
Sensor Status LED
1 2 3 4
Main tray upper limit sensor (PS19) Light pass through { { { z
Intermediate conveyance sensor (PS3) Light blocked { { z {
Bypass route conveyance sensor (PS2) Light blocked { z { {
Main route conveyance sensor (PS4) Light blocked z { { {
z : On { : Off
23
3.2 Adjusting the punch hole position in the vertical direction

FS-511/RU-502
A. Procedure
1. Set the punch hole mode, and make a copy in the
single sided original -> single sided print mode.
2. Fold the copy exited into two and check the posi-
tion of the punch holes to see if the discrepancy
"A" [1] is 2 mm or less.
3. When "A" is in excess of 2 mm, adjust the punch
hole position in the vertical direction.
[1]
4521f3c004na
24

[6] [5] [2]
5. Loosen the screw [3] and move the handle [4] in
FS-511/RU-502
the arrow-marked direction [5] to adjust the posi-
tion of the punch unit [6].
6. Repeat steps 1 and 2 and check the punch holes
to see if the discrepancy "A" is 2 mm or less.
7. When "A" is in excess of 2 mm, repeat steps 3 to
6 until "A" gets inside 2 mm.
[4]
[3] 4521f3c005na
25
3.3 Adjusting the solenoid

FS-511/RU-502
3.3.1 Adjustment of the bypass gate solenoid (SD1)

A. Procedure
(See P.6)
2. Remove the rear cover.
(See P.10)
4. Move the bypass gate solenoid (SD1) [2] in the
arrow-marked direction [3] and tighten the screw
[1] when the length of "A" [4] comes to the speci-
fied value.
Specified value "A" = 4.4 mm
[1] [2] [3] [4]
4521f3c006na
26
3.3.2 Adjustment of the main gate solenoid (SD2)

A. Procedure
FS-511/RU-502
[1] [2] (See P.6)
2. Remove the front cover /Up.
(See P.8)
4. Move the main gate solenoid (SD2) [2] and tighten
the 2 screws [1] when the length of "A" [3] comes
to the specified value.
Note
• With the plunger of SD2 pressed in the arrow-
marked direction [4] in advance, be sure to
[4] [3]
adjust the clearance with no play.
Specified value "A" = 3.6 mm
4521f3c007na
27
3.4 Adjusting the belt tension

FS-511/RU-502
3.4.1 Adjustment of the timing belt of the conveyance motor /Up (M4)
A. Procedure
[2]
(See P.6)
[4]
2. Remove the rear cover.
(See P.10)
4. Press the timing belt at the center section [2] with
a spring balance [3] from above. And when the
[3] amount of the deflection [4] comes to 4 mm,
tighten 2 screws [1] at the position in which the
scale of the spring balance points to the specified
value "A."
Specified value "A" = 200 ± 100 gf
[1]
4521f3c008na
28
3.4.2 Adjustment of the timing belt of the conveyance motor /Lw (M2)
A. Procedure
FS-511/RU-502
[2] [4] [3] (See P.6)
2. Remove the rear cover /Up.
(See P.10)
4. Pull the square hole [3] provided on the convey-
ance motor /Lw mounting plate [2] with the spring
balance [4] and tighten 2 screws [1] at the position
in which the scale of the spring balance points to
the specified value "A."
Specified value "A" = 800 ± 50 gf
[1]
4521f3c009na
29
3.4.3 Adjustment of the timing belt of the paper exit motor (M3)
A. Procedure
FS-511/RU-502
1. Loosen the screw [1] and 2 screws [2].

[2] [3] [1] 2. Tighten the screw [1] and 2 screws [2] at the posi-
tion [5] in which the external form of the screw [1]
[5] and that of the oblong hole [4] provided on the
paper exit motor mounting plate [3] coincide each
other.
[4] [1]
4521f3c010na
30
3.5 Adjusting the tray upper surface detection position
FS-511/RU-502
This adjustment is made when replacing the FS control board (FSCB), or the main tray upper limit LED (LED19)
or the main tray upper limit sensor (PS19).
A. Procedure
1. Set the output check mode "Sensor output check
mode."
(See P.17)
2. Rotate VR1 [1] provided on the FS control board
(FSCB) up to the limit counterclockwise.
[1] 4521f3c011na
3. Place the paper [3] on the main tray [2] to block

[4] [3] the light of the main tray upper limit LED (LED19)
[4].
[2] 4521f3c012na
31
4. Check to see if LED4 [5] on FSCB turns OFF from

ON. If it is left ON, rotate VR1 [1] slowly clockwise
FS-511/RU-502
and stop the rotation of VR1 at the position in

which LED4 turns OFF.
[5]
[1] 4521f3c013na
32
3.6 Adjusting the tray overload detection level
FS-511/RU-502
This adjustment is made when replacing the FS control board (FSCB) or replacing the tray lift motor (M7).
A. Procedure
1. Set the output check mode "Main tray operation
[1]
mode."
(See P.17)
2. Rotate VR2 [1] on the FS control board (FSCB)
counterclockwise up to the limit.
4521f3c014na
33
3. Place the paper [3] to block the light of the main

[2] [3] tray upper limit LED (LED19) [2].
FS-511/RU-502
4521f3c015na
4. Press the output check switch /2 [4] to bring

down the main tray.
[4] 4521f3c016na
34
5. Load 1500 sheets of A3 paper (80 g/m2) on the

[1] main tray.
FS-511/RU-502
6. Remove the paper that was put in step 3 to block
the light and let the light of LED19 pass through.
Note
• When letting the light of LED19 pass through,
the main tray starts to go up. Be sure to con-
duct the following steps 7 and 8 while in the
up drive of the main tray.
7. While in the up drive of the main tray, rotate VR2

[1] on FSCB clockwise.
LED3 [5] on FSCB turns ON.
[5] 4521f3c017na
35
8. When LED3 [5] on FSCB turns ON, rotate VR2 [1]

[1] counterclockwise, and stop VR2 at the position in
FS-511/RU-502
which LED3 changes to OFF from ON.
[5] 4521f3c018na
36
SD-502
( 500 / 420)
2006.02
Ver. 1.0
Revision history
Revision mark:
ing page.
NOTE

CONTENTS
SD-502
SD-502
OUTLINE
MAINTENANCE
OUTLINE
2. PERIODIC CHECK..................................................................................................3
2.1.1 Cleaning of the Rollers and Rolls ..................................................................3
3. OTHER ....................................................................................................................4
MAINTENANCE
3.3.1 Paper Output Tray/Front Cover......................................................................5
3.3.2 Rear Cover ....................................................................................................6
3.3.3 Upper Cover ..................................................................................................6
3.3.4 Saddle Unit....................................................................................................7
ADJUSTMENT/SETTING
3.3.5 Folding Unit ...................................................................................................8
3.3.6 Stapler Unit....................................................................................................9
3.3.7 Paper Guide Motor (M13)............................................................................14
3.3.8 Folding Roller ..............................................................................................16
ADJUSTMENT/SETTING
4.1 Fold Skew Adjustment ........................................................................................23
4.2 Center Staple Skew Adjustment .........................................................................24
i
SD-502
OUTLINE
MAINTENANCE
Blank Page
ADJUSTMENT/SETTING
ii
OUTLINE
SD-502
A. Type
Type FS built-in saddle-stitching device

Center parallel two points
Stapling Function
No. of sheets to be stapled together: 2 to 15
OUTLINE
Consumables Staples (2000 staples/cartridge)
B. Paper type
Type Plain Paper 56 to 90 g/m2

Metric: A3, B4, A4S, B5S
Size
Inch: 11 x 17, 81/2 × 11S
Capacity 200 sheets or 20 copies
C. Maintenance

Power Requirements 24/5V DC (supplied from FS)


NOTE
1
SD-502
OUTLINE
Blank Page
2
MAINTENANCE
2. PERIODIC CHECK
SD-502
NOTE
propyl alcohol.
2.1.1 Cleaning of the Rollers and Rolls

• Various Rollers: Every 250,000 prints
• Various Rolls: Every 250,000 prints

[1] hol, wipe the roller [1] and roll [2].
MAINTENANCE
[2]
[2]
4511f2c001na
2. Remove the Folding Unit.

(See P.8)

[4]
hol, wipe the roller [3] and roll [4].
[3]
4511f2c002na
3
3. OTHER
SD-502

loose.
NOTE
MAINTENANCE
Caution
4
SD-502
1 Paper Output Tray Paper Output Tray P.5
2 Front Cover P.5
3 Cover Upper Cover P.6
4 Rear Cover P.6
5 Saddle Unit P.7
6 Unit Folding Unit P.8
7 Stapler Unit P.9
8 Paper Guide Motor (M13) P.14
Others
9 Folding Roller P.16

3.3.1 Paper Output Tray/Front Cover
MAINTENANCE
[3]
[1]
[2]
4511f2c004na
1. Align the cutout and remove the Paper Output Tray [1].
2. Remove two screws [2], and remove the Front Cover [3].
5
3.3.2 Rear Cover

SD-502
[2]
[1]
4511f2c005na
MAINTENANCE
1. Remove two screws [1], and remove the Rear Cover [2].
3.3.3 Upper Cover

1. Remove the Front Cover.
(See P.5)
2. Remove the Rear Cover.
(See P.6)

[1] Upper Cover [2].
[1]
[2]
4511f2c006na
6
3.3.4 Saddle Unit
SD-502
Connector Cover [2].
[1]
[2] 4511f2c007na
[4]
[3]
3. Unplug two connectors [5].
[5]
MAINTENANCE
4511f2c008na

Front Cover /Lw [7].
[7]
[6]
4511f2c009na
5. Pull the lock release lever [8], and open

[8] [9] the Saddle Unit.
4511f2c010na
7
7. Remove two screws [10], and remove

[11]
the Saddle Unit [11].
SD-502
[10] 4511f2c011na
3.3.5 Folding Unit

1. Remove the Saddle Unit.
(See P.7)
(See P.13 in "Field Service FS-510/PU-501/OT-601")
3. Remove the Horizontal Conveyance Unit.
(See P.13 in "Field Service FS-510/PU-501/OT-601")
MAINTENANCE

[1]
Horizontal Conveyance Upper Cover [2].
[2]
[1]
4511f2c012na

[3]
Reinforcement Plate [4].
[4]
4511f2c013na

Horizontal Conveyance Front Cover /Lw
[6].
NOTE
[6]
• At reinstallation, first fit the claw [7]
into position.
[7]
[5] 4511f2c014na
8
7. Unplug the connector [8].

[8]
SD-502
4511f2c015na

[9] Folding Unit [10].
[10]
[9]
4511f2c016na
MAINTENANCE
3.3.6 Stapler Unit
(See P.7)
2. Remove the Paper Output Tray.
(See P.5)
(See P.5)
(See P.6)
5. Remove the Upper Cover.
(See P.6)

[4] ground terminal [2].
holder [4].
[3]
[1]
[3] [2]
4511f2c017na
8. Release the lock release lever [5], and

[6] slide the Saddle Unit Mounting Plate [6].
9. Remove the screw [7] and the washer
[8], and remove the Saddle Unit Mount-
ing Plate [6].
[7]
[5] [8]
4511f2c018na
9
10. Remove the harness clamp [6] from the

Metal Plate.
11. Remove the wiring harness from the
SD-502
harness clamp [6].
[6]
4511f2c019na
12. Unplug four connectors [7].

[7] [11] [10] 13. Remove the C-ring [8], and remove the
bearing [9].
14. Remove five screws [10], and remove
the Drive Unit [11].
[7]
MAINTENANCE
[10] [9]
[8]
[10]
4511f2c020na
15. Remove the harness clamp [12], and

[13]
unplug the connector [13].
[12]
4511f2c021na
16. Remove two screws [14] and two

[15]
screws [15].
[14]
4511f2c022na
10
17. Remove the Tray [16].
SD-502
[16]
4511f2c023na
18. Unplug all the connectors on the SD

Control Board (SDCB) [17].
[17] 19. Remove the Board support, and then
remove the SDCB.
MAINTENANCE
4511f2c024na

lock release lever [19].
[19]
[18]
4511f2c025na
[20]
21. Remove eight screws [20], and remove
the Lower Cover [21].
[20]
[21]
[20]
[20] 4511f2c026na
11
[22] 22. Remove the harness clamp and unplug

the connector.
23. Remove three screws [22], and remove
SD-502
the Clincher /1 [23].
[23] 4511f2c027na
24. Remove the Staple Cartridge /1 [24].
[24]
MAINTENANCE
4511f2c028na
25. Remove four screws [25], unplug the

connector, and remove the Stapler /1
[26] [26].
NOTE
[25]
• To replace Clincher /2 and Stapler /2,
repeat steps 22 to 25.
4511f2c029na
Precaution for Clincher Reinstallation

• When the Clincher is installed, the position of the Stapler and the Clincher will be
misaligned. Be sure to perform the following adjustment.
1. Use three screws [1] to temporary fix

[1] the Clincher [2].
2. Install the Staple Cartridge.
[2] 4511f2c030na
12
[3]
3. Loosen three screws [3] of the stopper.
4. Loosen three screws [4] of the Clincher.
SD-502
[4]
[3]
4511f2c031na
5. Aligning the protrusions of the jig [6]

with the recesses in the Staple Car-
tridge [5], fit the jig to the Stapler.
NOTE
• Make sure that the protrusions of the
[6]
jig properly rest in the recesses.
[6]
[5]
4511f2c032na
MAINTENANCE
6. Turn the gear [7] of the Clincher and
[7] [9] then slide the Clincher so that the pro-
trusion of the Clincher [9] fits into the
recess in the jig [8].
[8]
4511f2c033na
7. Tighten six screws [10].

[10] NOTE
• Turn the gear again and check to see
that the protrusion of the Clincher
smoothly fits into the recess in the jig.
8. Turn the gear and remove the jig.
[10]
4511f2c034na
13
3.3.7 Paper Guide Motor (M13)

SD-502
(See P.7)
2. Remove the Paper Output Tray.
(See P.5)
(See P.5)
(See P.6)
5. Remove the Upper Cover.
(See P.6)

[4] ground terminal [2].
holder [4].
[3]
MAINTENANCE
[1]
[3] [2]
4511f2c035na
8. Release the lock release lever [5], and

[6] slide the Saddle Unit Mounting Plate [6].
9. Remove the screw [7] and the washer
[8], and remove the Saddle Unit Mount-
ing Plate [6].
[7]
[5] [8]
4511f2c036na

lock release lever [10].
[10]
[9]
4511f2c037na
14
11. Remove eight screws [11], and remove

[11] the Lower Cover [12].
SD-502
[11]
[12]
[11]
[11]
4511f2c038na
12. Remove the wire saddle [13], and

unplug two connectors [14].
[13]
MAINTENANCE
[14]
4511f2c039na

Paper Guide Motor Assy [16].
[16]
[15]
4511f2c040na
14. Remove two C-rings [17].

[17] 15. Remove two bearings [18], and remove
[18] the Clutch Gear Assy [19].
[19]
[17]
4511f2c041na

[20] [20] M13 [21].
[21]
4511f2c042na
15
Precaution for M13 Reinstallation

SD-502
[2]
[1]
[4]
[3]
4511f2c043na
1. Press the two Paper Guides [1] in and check that they touch the stopper [2] simulta-
MAINTENANCE
neously.
2. Check that pins [4] can be inserted through the positioning holes [3] (3 holes) of the Paper
Guide Sensor Assy.
3. Use two screws to secure M13.
3.3.8 Folding Roller

1. Remove the Folding Unit.
(See P.8)
2. Remove four screws [1] and two

[1]
springs, and remove the Upper Plate
[2].
[2]
[1] 4511f2c044na

[4] guide plate [4].
[3]
4511f2c045na
16

[6]
Folding Blade Assy [6].
SD-502
[5]
4511f2c046na
NOTE
• Install the Folding Blade Assy in the
direction shown in the left figure.
[B] [A] [A] Front
[B] Rear
MAINTENANCE
4511f2c047na
5. Remove three C-rings [7], and remove

three gears [8].
[7]
[8]
4511f2c048na
NOTE
• Install the gears so that the mark [9]
are aligned to the position shown in
the left figure.
[9]
4511f2c049na
17
6. Remove three C-rings [10], and remove

[11] [10] two bearings [11].
7. Remove the bearing [12].
SD-502
[12]
4511f2c050na

the Rear Holder [14].
[14]
MAINTENANCE
[13]
4511f2c051na
9. Remove the gear [15] of Folding Roller

[16] /Rt, and remove the Lower Guide Plate
[16].
[15]
4511f2c052na
NOTE
[19]
• When installing the gear [17] to the
Lower Guide Plate [18], insert the gear
[18] [17] at an angle and take care not to
[17]
break the claws [19].
• Install the Lower Guide Plate as shown
on the left.
4511f2c053na
18

[21] 11. Remove two C-rings [21], and remove
[20]
the Folding Roller A [22], B [23] and C
SD-502
[22] [24].
[24]
[23]
4511f2c054na
12. Remove the gear [25] of Folding Roller

[26] /Lt, and remove the Lower Guide Plate
[26].
MAINTENANCE
[25]
4511f2c055na
NOTE
[29]
• When installing the gear [27] to the
Lower Guide Plate [28], insert the gear
[28] [27] at an angle and take care not to
[27]
break the claws [29].
• Install the Lower Guide Plate as shown
on the left.
4511f2c056na

[31] 14. Remove two C-rings [31], and remove
[30]
the Folding Roller A [32], B [33] and C
[32] [34].
[34]
[33]
4511f2c057na
19
NOTE
[36] • When installing the Folding Rollers A,
B and C, be sure to align the direction
SD-502
of the mark [35] of the gear with the

direction in which the screw [36] is
tightened.
MAINTENANCE
[35]
4511f2c059na
20
15. Reinstall the above parts following the

[38] [37]
NOTE
SD-502
• When installing the Folding Rollers /Rt
and /Lt, be sure to install them so that
the mark [37] of the Roller Gear /Rt
provided on the front of the Folding
Unit comes one tooth above the mark
[38] of the Roller Gear /Lt.
• When installing the Folding rollers /Rt
the gear of the Guide Gear /Lt [40]
comes one tooth above the gear of the
Guide Gear /Rt [41] as seen from the
direction of the arrow mark [39].
• When installing the Folding Rollers /Rt
[39] the mark [43] of the Guide Gear /Rt and
the mark [44] of the Sector Gear get
MAINTENANCE
aligned with each other as seen from
[42] the direction of the arrow mark [42].
[41] [40]
[43]
[44]
4511f2c060na
21
SD-502
MAINTENANCE
Blank Page
22
ADJUSTMENT/SETTING
SD-502
4.1 Fold Skew Adjustment
NOTE
Make this adjustment after any of the following procedures has been performed.
• When the Folding Unit has been replaced.
• When skew occurs in the crease.
1. Enter the Half-fold mode and make a copy. (A3 or 11 x 17 Size)
2. Fold the output paper along the crease

A [2].
3. Fold the output paper and measure the
[1] width A of the paper.
Specification: 0 ± 1.5 mm
[2] 4. If the fold position is skewed as shown
on the left, make the following adjust-
ment.
[3]
4511f3c001na [1] Center
[2] Crease
[3] Exit direction
5. Open the Front Door, loosen the adjust-

ment screw [4], and move the Folding
ADJUSTMENT/SETTING
Unit to the left to make the adjustment.
Graduated in 1 mm divisions
• If the fold position is skewed opposite to
the figure of step 4, move the Folding Unit
to the right to make the adjustment.
6. Make another copy and check the fold
[4] position.
4511f3c002na
23
4.2 Center Staple Skew Adjustment

NOTE
SD-502
Make this adjustment after any of the following procedures has been performed.
• When Staple Unit 1 or 2 has been replaced.
• When skew occurs in the position of the center staple.
1. Set to Fold & Staple mode and make a

A
copy. Measure the width A of the paper.
Specification: 0 ± 1.5 mm
2. If the staple position is skewed as
shown on the left, make the following
adjustment.
[1] [1] Exit direction

4511f3c003na
3. Release the lock release lever [2] of the

[4] Saddle Unit.
4. Loosen the adjustment screw [3] and
[3] move the lock member [4] to the left to
make the adjustment.
• If the staple position is skewed opposite
to the figure of step 2, move the lock
member to the right to make the adjust-
ment.
5. Make another copy and check the staple
ADJUSTMENT/SETTING
position.
[2]
4511f3c004na
24
MT-501
( 500 / 420)
2006.02
Ver. 1.0
Revision history
Revision mark:
ing page.
NOTE

CONTENTS
MT-501
MT-501
OUTLINE
MAINTENANCE
OUTLINE
2. PERIODIC CHECK..................................................................................................3
2.1.1 Cleaning of the Roller and Roll......................................................................3
3. OTHER ....................................................................................................................4
MAINTENANCE
3.3.1 Rear Cover/Right Door ..................................................................................5
3.3.2 Front Cover/Upper Cover/Paper Output Tray.................................................5
i
MT-501
OUTLINE
MAINTENANCE
Blank Page
ii
OUTLINE
MT-501
A. Type
Type 4 bins Mailbin (available only for printing from PC)

Number of Bins 4 bins
Number of Sheets
125 sheets (80 g/m2)
Stored per Bin
OUTLINE
Storable Paper Plain Paper (56 to 90 g/m2)
Metric: A4, B5, 81/2 x 11
Storable Paper Size
Inch: 81/2 x 11, 51/2 x 81/2S
B. Maintenance

Power Requirements 24V DC (supplied from FS)

Weight Approx. 8 kg

NOTE
1
MT-501
OUTLINE
Blank Page
2
MAINTENANCE
2. PERIODIC CHECK
MT-501
NOTE
propyl alcohol.
2.1.1 Cleaning of the Roller and Roll

• Various Rollers: Every 250,000 prints
• Various Rolls: Every 250,000 prints
B. Procedure
[1]
hol, wipe the rollers [1] and rolls [2].
MAINTENANCE
[1]
[1]
[2]
[2]
4510f2c001na
3
3. OTHER
MT-501

loose.
NOTE
MAINTENANCE
NOTE
4
MT-501
No. Section Part name Ref. page
1 Rear Cover P.5
2 Front Cover P.5
Cover
3 Upper Cover P.5
4 Right Door P.5
5 Paper Output Tray Paper Output Tray P.5

3.3.1 Rear Cover/Right Door
[5] [2] 1. Remove the screw [1] and remove the

Rear Cover [2].
2. Remove the screw [3], the stopper [4],
and remove the Right Door [5].
MAINTENANCE
[3] [4] [1] 4510f2c002na
3.3.2 Front Cover/Upper Cover/Paper Output Tray
[3] [2]
1. Remove the screw [1] and remove the
Front Cover [2].
(See P.5)
3. Remove the Upper Cover [3].
4. Remove the Paper Output Trays [4].
[4] [1] 4510f2c003na
5
MT-501
MAINTENANCE
Blank Page
6
JS-502
( 500 / 420)
2006.02
Ver. 1.0
Revision history
Revision mark:
ing page.
NOTE

CONTENTS
JS-502
JS-502
OUTLINE
MAINTENANCE
OUTLINE
2. OTHER ....................................................................................................................3
2.3.1 Upper Cover ..................................................................................................4
MAINTENANCE
i
JS-502
OUTLINE
MAINTENANCE
Blank Page
ii
OUTLINE
JS-502
A. Type
Name Job Separator

Type Expansion tray
OUTLINE
B. Paper type
Exit Tray Size Type Capacity

Inch: 11 x 17, 81/2 x 14, Plain Paper (56 to 90 g/m2) 250 sheets
81/2 x 11, 81/2 x 11S,
OHP transparencies
51/2 x 81/2S
Tray 1 A3, A4, A4S, A5S, Thick paper (91 to 210g/m2)
(Main 8 x 13
Envelope
Body Metric: A3, B4, A4, A4S, B5, Special 20 sheets
Tray) B5S, A5S Label
11 x 17, 81/2 x 11,
81/2 x 11S, 8 x 13 Letterhead
Inch:
11 x 17, 81/2 x 14,
81/2 x 11, 81/2 x 11S,
Tray 2
51/2 x 81/2S Plain Paper (56 to 90 g/m2) 100 sheets
(Job Tray)
Metric: A3, B4, A4, A4S, B5,
B5S, A5S
C. Maintenance
Maintenance None
Power Requirements 5V DC ± 5 % (supplied from the main body)


NOTE
1
JS-502
OUTLINE
Blank Page
2
MAINTENANCE
2. OTHER
JS-502
loose.
NOTE
MAINTENANCE
Caution
3

JS-502

1 Cover Upper Cover See P.4

2.3.1 Upper Cover
[1]
[2]
MAINTENANCE
4347f2c001na
1. Remove two screws [1], and remove the Upper Cover [2].
4
IC-204
2006.02
Ver. 1.0
Revision history
Revision mark:
page.
NOTE

Field Service Ver1.0 February.2006 CONTENTS
CONTENTS
IC-204
IC-204
OUTLINE
MAINTENANCE
2. FIRMWARE VERSION UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. DISASSEMBLY / REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Removal / Installation of Printer key control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ADJUSTMENT / SETTING
4. SERVICE MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5. Starting and Finishing the Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TROUBLESHOOTING
6. TROUBLESHOOTING THE PRINTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.1 Troubleshooting of the print controller and copier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7. Data Capture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
i
CONTENTS Field Service Ver1.0 February.2006
IC-204
Blank Page
ii
Field Service Ver1.0 February.2006 1. PRODUCT SPECIFICATIONS
OUTLINE
IC-204
A. Type
Type: Built-in box type for the KONICA MINOLTA Printer/Copier
B. Functions
Resolution 600 x 600 dpi

Gradation binary
Blank area PCL6: 4.23mm (left, right, top and bottom without variation)
PCL5e: 4.23mm (left, right, top and bottom without variation)
PS: 4.23mm (left, right, top and bottom without variation)
Printable Area 292.77 x 427.57mm (The maximum paper size)
No. of Print 1 to 999
Continuous Print Speed bizhub 500: 50 ppm (A4, 8.5 x 11) / (600 x 600 dpi)
bizhub 420: 42 ppm (A4, 8.5 x 11) / (600 x 600 dpi)
Printer Description Language PCL5e/PCL6/PostScript3 (compatible)
Compliant OS Windows 98SE/Me
Windows NT 4.0 (Service Pack 6a or more)
Windows 2000 (Service Pack 4 or more)
Windows XP (Service Pack 1 or more)
Windows XP x64 Edition
Windows Server 2003
Windows Server 2003 x64 Editions
Mac OS 9.x
Mac OS X v10.2/v10.3/v10.4
Printer Driver PCL printer driver for Windows 98SE/Me/NT 4.0/2000/XP/Server
2003 (XP/Server 2003 includes the x64 Edition (PS).)
PS printer driver for Windows
PS printer driver for Windows/Macintosh
No driver for PCL5e
Network Functions
Printing Method SMB (Windows), Pserver (IPX/SPX), lpd/lpr (TCP/IP for Windows NT
4.0/2000), lpd/lpr (TCP/IP for UNIX), IPP (TCP/IP), AppleTalk (Ether-
Talk), NPrinter/RPrinter (IPX/SPX), RAW (Port 9100; extensible up to 6
ports)
Dedicated Utilities EMS Plug-in
NDPS Gateway
Direct Print
C. Paper
Paper Size Same as copier

Paper Type Same as copier
Paper Weight Same as copier
1
1. PRODUCT SPECIFICATIONS Field Service Ver1.0 February.2006
D. Maintenance and Life
Maintenance Same as copier

IC-204
Machine Service Life Same as copier
E. Machine Data
System Memory Same as copier

Host Interface Ethernet, Serial (RS-232C/USB), Parallel (IEEE1284)
Hard Disk Drive 40 GB (supporting HD-505)
Power Same as copier
Network Function
Network Interface Ethernet (100 Base-TX/10-Base-T)
Frame Type IEEE 802.2/802.3/Ethernet II/IEEE802.3 SNMP
Ethernet Connection 100 Base-TX/10-Base-T
Network Connector RJ-45
LED Green LED 2
F. Operating Environment
Temperature Same as copier

Humidity Same as copier
2
Field Service Ver1.0 February.2006 2. FIRMWARE VERSION UP
MAINTENANCE
IC-204
2. FIRMWARE VERSION UP
Firmware for IC-204 is contained in the copier firmware (MFP Controller).
With the updating of MFP controller version, the version of the IC-204 firmware is also updated.
Firmware’s version is upgraded by ISW.

See “5. FIRMWARE VERSION UP” in the Field Service for the main body.
3
3. DISASSEMBLY / REASSEMBLY Field Service Ver1.0 February.2006
3. DISASSEMBLY / REASSEMBLY
IC-204
Caution
• Assembly should be made in reverse order of disassembly unless otherwise noted.
Precautions against static electricity.

• Keep the image controller in an antistatic bag while transporting it or storing it.
• When working in places where static electricity tends to accumulate, such as on a carpet, dis-
charge electricity from your body by touching any metallic portion before handling the image con-
troller.
• Do not touch the contacts on the image controller with your hands, as that may result in poor con-
ductivity.
• Do not physically damage the image controller by dropping it, bending it, etc.
3.1 Tools Required

• Standard screwdriver
Caution
• Be sure to unplug the power cable, not only to turn the copier off, before attempting to make ser-
vicing.
Caution
• Before engaging in Disassembly/Reassembly, check to make sure that all the cables are
unplugged from the copier.
• There may be occasions when boards are damaged if no appropriate grounding measures are
taken. Wear a wrist strap or others during servicing.
• Disassembly/Reassembly should be made on cushioning materials.
4
Field Service Ver1.0 February.2006 3. DISASSEMBLY / REASSEMBLY
3.2 Removal / Installation of Printer key control board

1. Turn the Sub and Main power switches OFF of
IC-204
the main body, and unplug the power cord from
the outlet.
2. Remove the back cover(6 screws).
Back cover
3. Remove the board cover(4 screws).
Board cover
4. Remove the image controller in the location with

the IC204 mark on the system control board.
NOTE
• You should be careful not to damage the
board.
Align concave
areas
• Remove the image controller pulling it per-
pendicularly to the system control board.
• Align the concave area on the left side of the
image controller and the concave area on left
Image controller
side of the slot in the system control board
when installing.
• Assembly should be made in reverse order
from disassembly.
5
3. DISASSEMBLY / REASSEMBLY Field Service Ver1.0 February.2006
IC-204
Blank Page
6
Field Service Ver1.0 February.2006 4. SERVICE MODE
ADJUSTMENT / SETTING
IC-204
4. SERVICE MODE
In the service mode, various adjustments / settings are available.
See “10. SERVICE MODE” in Field Service for the main body.
5. Starting and Finishing the Service Mode

1. Confirm that the normal Copy Mode screen is on the display.
2. Press the [Utility/Counter] button.
[MetaCount/Utility] screen appears.
3. Press the [Details] key.
[MetaCount] screen appears.
4. Press the keypad in the following order.
Stop -> 0 -> 0 -> Stop -> 0 -> 1
[Service Mode menu] screen appears.
NOTE
• If the CE password has been provided, you should enter the password to enter the service mode.
5. Press the key of items to be set.
Setting screen of each item appears.
6. Set items as required and press the [OK] key after completion.
Setting is accepted and the [Service Mode menu] screen returns.
7. Press the [Exit] key.
Normal Copy Mode screen returns.
7
5. Starting and Finishing the Service Mode Field Service Ver1.0 February.2006
IC-204
Blank Page
8
Field Service Ver1.0 February.2006 6. TROUBLESHOOTING THE PRINTING SYSTEM
TROUBLESHOOTING
IC-204
6. TROUBLESHOOTING THE PRINTING SYSTEM
This table lists information about the symptoms, possible causes, and remedies for problems that may occur
with the printing system (combination of the print controller and copier). It is intended to help engineers find
information as quickly as possible, and provide basic solutions.
Caution
• See the “Copier Service Manual” for information about Error Cord List.
6.1 Troubleshooting of the print controller and copier
Symptoms Causes Actions

“Warming up” does not disappear. Copier is in trouble. Locate the cause of trouble of the
copier.
Printout is defective, or nothing can be The system board or some Put the copier in service mode and per-
printed. boards of the copier are form test. If it operates properly, system
defective. board may be failure.
Print controller does not start. The printer key control Check the connector of the controller
board is inactive. board. Replace the system board as
Or printer key control necessary.
board is not installed.
Software of the print con- Reinstall the software of the print con-
troller is defective. troller.
Test print can be produced but not from The parallel port, USB port Check the cables (internal/external).
the parallel port, USB port. has something wrong or Perform test using a data generator or
the cable is wrong or, the a well-proven PC/I/O cable. Replace
problem is on the com- the system board as necessary.
puter side.
Test print can be produced and all ports Some software error has Print controller’s software or application
are good, but user jobs cannot be printed. happened. program has something wrong. Save
the file, which failed to be printed, in the
disk and analyze the problem by suit-
able means.
9
7. Data Capture Field Service Ver1.0 February.2006
7. Data Capture
If any fault is caused in relation with the printer, acquire the print job data for the fault analysis.
IC-204
Capture data of up to 5 jobs can be saved. When new data is saved, oldest one is deleted.
Caution
To enable this function, following conditions should be met.
• Hard disk should have been installed in the main body printer (copier).
• [Administrator Setting] - [Security Setting] - [Security Details] - [Print Data Capture] should be set
to [Allow].
• [Administrator Setting] - [Network Setting] - [FTP Setting] - [FTP Server] should be set to [ON].
1. Activate the service mode.

• (Refer to the steps 1 through 7 of "ADJUSTMENT
/ SETTING, 5. Starting and Finishing the Service
Mode".)
2. Press [System2] - [Data Capture] and select
[ON]. Selecting [ON] saves the job data transmit-
ted from PC in the copier hard disk.
3. Confirm the IP address of the copier.
4. Connect the Windows PC and copier with the
Ethernet cable.
5. Activate the command prompt, specify the IP
address of the copier and activate the FTP.
6. Enter User and Password.

• User: capture
• Password: sysadm
7. Display the list of files which can be captured

with the [ls] or [dir] command.
10
Field Service Ver1.0 February.2006 7. Data Capture
8. Set the file transfer mode to binary transfer with

the [binary] command.
IC-204
9. Transfer the data to be captured to PC with the
[get] or [mget] command.
10. Exit from the command prompt.
NOTE
• If you set [Administrator Setting] - [Security
Setting] - [Security Details] - [Print Data Cap-
ture] to [Restrict] after acquiring the capture
data, the job data saved in the hard disk will
be deleted.
11
7. Data Capture Field Service Ver1.0 February.2006
IC-204
Blank Page
12
© 2006 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.
Printed in Japan
Use of this manual should be strictly supervised to avoid
NN50GAPE1-0900
disclosure of confidential information.

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SERVICE MANUAL Theory of Operation

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

bizhub 500 / 420 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 using the

:Prohibition when using the

:Direction when using 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

Connection to Power Supply

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.

Power Plug and Cord

• 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

• The area around the fixing unit is hot.

Work Performed with the Product Powered On

• Take every care when servicing with the external cover

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

• Check wiring for squeezing and any other damage.

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

• Check electrode units such as a charging corona unit for

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

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

• Check the interlock switch and actuator for loosening and

Handling of Service Materials

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

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

• When using any solvent, ventilate the room well.

INDICATION OF WARNING ON THE MACHINE

MEASURES TO TAKE IN CASE OF

<Theory of Operation section>

OUTLINE: System configuration, product specifications,

<Field service section>

OUTLINE: System configuration, and product specifications

(1) IC board: Standard printer

C. Electrical parts and signals

Classification Load symbol Ex. of signal name Description

D. Paper feed direction

Paper size Feed direction Notation