Bizhub751 601TheoryOfOperation

SERVICE MANUAL Theory of Operation
751/601
2010.03
Ver. 2.0
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-13
IMPORTANT NOTICE ..............................................................................................S-13
INDICATION OF WARNING ON THE MACHINE .....................................................S-14
MEASURES TO TAKE IN CASE OF AN ACCIDENT ....................................................S-17
Legal restrictions on copying .......................................................................................... C-1
Composition of the service manual ................................................................................. C-2
Notation of the service manual ....................................................................................... C-3
bizhub 751/601
OUTLINE ........................................................................................................................ 1
COMPOSITION/OPERATION ........................................................................................ 9
* For particulars, see the contents of the main body.
DF-614
OUTLINE ........................................................................................................................ 1
COMPOSITION/OPERATION ...................................................................................... 11
* For particulars, see the contents of DF-614.
LU-405/406
OUTLINE ........................................................................................................................ 1
* For particulars, see the contents of LU-405/406.
SF-602
OUTLINE ........................................................................................................................ 1
* For particulars, see the contents of SF-602.
FS-524/525/610
OUTLINE ........................................................................................................................ 1
COMPOSITION/OPERATION ...................................................................................... 11
* For particulars, see the contents of FS-524/525/610.
i
PI-504
OUTLINE ........................................................................................................................ 1
COMPOSITION/OPERATION........................................................................................ 5
* For particulars, see the contents of PI-504.
PK-502
OUTLINE ........................................................................................................................ 1
* For particulars, see the contents of PK-502.
PK-503/504/505
OUTLINE ........................................................................................................................ 1
* For particulars, see the contents of PK-503/504/505.
ZU-604/605
OUTLINE ........................................................................................................................ 1
* For particulars, see the contents of ZU-604/605.
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.)

Safety will not be assured, leading to a risk of fire and
injury.
Making any modification to the product unless instructed

by KMBT
Using parts not specified by KMBT
S-2
[2] POWER PLUG SELECTION

In some countries or areas, the power plug provided with the product may not fit wall outlet
used in the area. In that case, it is obligation of customer engineer (hereafter called the CE)
to attach appropriate power plug or power cord set in order to connect the product to the
supply.
Power Cord Set or Power Plug
WARNING
Use power supply cord set which meets the following
criteria:
AC230V
- provided with a plug having configuration intended for
the connection to wall outlet appropriate for the prod-
uct's rated voltage and current, and
- the plug has pin/terminal(s) for grounding, and
- provided with three-conductor cable having enough cur-
rent capacity, and
AC208V 240V
- the cord set meets regulatory requirements for the area.
Use of inadequate cord set leads to fire or electric shock.
Attach power plug which meets the following criteria:
- having configuration intended for the connection to wall
outlet appropriate for the product's rated voltage and
current, and
- the plug has pin/terminal(s) for grounding, and
- meets regulatory requirements for the area.
Use of inadequate cord set leads to the product connect-
ing to inadequate power supply (voltage, current capac-
ity, 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,
grounding), and may result in fire or electric shock.
If proper wall outlet is not available, advice the customer
to contact qualified electrician for the installation.
Plug the power cord into the dedicated wall outlet with a
capacity greater than the maximum power consumption.
If excessive current flows in the wall outlet, fire may
result.
If two or more power cords can be plugged into the wall

outlet, the total load must not exceed the rating of the wall
outlet.
If excessive current flows in the wall outlet, fire may
result.
Make sure the power cord is plugged in the wall outlet

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

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

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

Overheating may occur there, leading to a risk of fire.
S-5
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 vol-
atile 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
3. Servicing
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
When taking a report of problems from a user, check each
part and repair properly.
A risk of product trouble, injury, and fire exists.
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.
The laser light can enter your eye, leading to a risk of
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 instal-
lation 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
Handling of Consumables
WARNING
Never throw the used cartridge and toner into fire.
You may be burned due to dust explosion.
Handling of Service Materials
CAUTION
Unplug the power cord from the wall outlet.
Isopropyl alcohol and acetone are highly flammable and
must be handled with care. A risk of fire exists.
Do not replace the cover or turn the product ON before

any solvent remnants on the cleaned parts have fully
evaporated.
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.
4. Fuse
Fuse
CAUTION
CAUTION
Double pole / neutral fusing
ATTENTION
Double ple / Fusible sur le neutre
S-11
5. Used Batteries Precautions
Handling of batteries
CAUTION
ALL Areas
CAUTION
Danger of explosion if battery is incorrectly replaced.
Replace only with the same or equivalent type recommended by the manufacturer.
Dispose of used batteries according to the manufacturers instructions.
Germany
VORSICHT!
Explosionsgefahr bei unsachgemem Austausch der Batterie.
Ersatz nur durch denselben oder einen vom Hersteller empfohlenen gleichwertigen
Typ.
Entsorgung gebrauchter Batterien nach Angaben des Herstellers.
France
ATTENTION
Il y a danger dexplosion sil y a remplacement incorrect de la batterie.
Remplacer uniquement avec une batterie du mme type ou dun type quivalent
recommand par le constructeur.
Mettre au rebut les batteries usages conformment aux instructions du fabricant.
Denmark
ADVARSEL!
Lithiumbatteri - Eksplosionsfare ved fejlagtig hndtering.
Udskiftning m kun ske med batteri af samme fabrikat og type.
Levr det brugte batteri tilbage til leverandren.
Finland, Sweden
VAROlTUS
Paristo voi rjht, jos se on virheellisesti asennettu.
Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin.
Hvit kytetty paristo valmistajan ohjeiden mukaisesti.
VARNING
Explosionsfara vid felaktigt batteribyte.
Anvnd samma batterityp eller en ekvivalent typ som rekommenderas av apparat-
tillverkaren.
Kassera anvnt batteri enligt fabrikantens instruktion.
Norway
ADVARSEL
Eksplosjonsfare ved feilaktig skifte av batteri.
Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten.
Brukte batterier kasseres i henhold til fabrikantens instruksjoner.
S-12
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-13
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.
For metric area:
a0pnp0e001ca
S-14
SAFETY INFORMATION
For inch area:
a0pnp0e002ca
S-15
SAFETY INFORMATION
a0pnp0e003ca
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-16
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-17
MEASURES TO TAKE IN CASE OF AN ACCIDENT
Blank page
S-18
Legal restrictions on copying
Certain types of originals must never be copied with the purpose or intent to pass copies of
such originals off as the originals.
The following is not a complete list, but is meant to be used as a guide to responsible copy-
ing.
<Financial Instruments>
Personal checks
Travelers checks
Money orders
Certificates of deposit
Bonds or other certificates of indebtedness
Stock certificates
<Legal Originals>
Food stamps
Postage stamps (canceled or uncanceled)
Checks or drafts drawn by government agencies
Internal revenue stamps (canceled or uncanceled)
Passports
Immigration papers
Motor vehicle licenses and titles
House and property titles and deeds
<General>
Identification cards, badges, or insignias
Copyrighted works without permission of the copyright owner
In addition, it is prohibited under any circumstances to copy domestic or foreign currencies,

or works of art without permission of the copyright owner.
When in doubt about the nature of an original, consult with legal counsel.
Detail
In order to prohibit the illegal reproduction of certain originals, such as paper currency, this
machine is equipped with a counterfeit prevention feature.
Due to the counterfeit prevention feature that this machine is equipped with, images may
be distorted.
C-1
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-2
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 751/601: Main body
(3) PS-502 PostScript3 Option: PS3 Option
(4) Microsoft Windows 95: Windows 95
Microsoft Windows 98: Windows 98
Microsoft Windows Me: Windows Me
Microsoft Windows NT 4.0: Windows NT 4.0 or Windows NT
Microsoft Windows 2000: Windows 2000
Microsoft Windows XP: Windows XP
Microsoft Windows Vista: Windows Vista
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-3
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-4
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-5
Blank page
C-6
751/601
Main body
2010.03
Ver. 2.0
Revision history
After publication of this service manual, the parts and mechanism may be subject to change for
improvement of their performance.
Therefore, the descriptions given in this service manual may not coincide with the actual machine.
When any change has been made to the descriptions in the service manual, a revised version will be
issued with a revision mark added as required.
Revision mark:
To indicate clearly a section revised, 1 is shown at the left margin of the revised section.
The number inside 1 represents the number of times the revision has been made.
To indicate clearly a page that contains the revision, 1 is shown near the page number of the
corresponding page.
NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.
2010/03 2.0 1 Revision due to the addition of a new optional unit (LK)
2008/11 1.0 Issue of the first edition
Date Service manual Ver. Revision mark Descriptions of revision
Theory of Operation Ver.2.0 Mar. 2010 CONTENTS
CONTENTS
bizhub 751/601
bizhub 751/601
OUTLINE
1. SYSTEM CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. PRODUCT SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. UNIT CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
COMPOSITION/OPERATION
5. OVERALL CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.1 Time chart when the power is turned ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.2 Control block diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6. SCANNER SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.3.1 Scan/exposure lamp control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.3.2 Original size detection control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.3.3 AE control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.3.4 Image processing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7. WRITE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.2.1 Laser beam path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.2.2 Write control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.2.3 Polygon control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.2.4 Image stabilization control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8. PHOTO CONDUCTOR SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.2.1 Drum drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.2.2 Drum claw drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.3.1 Image creation control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.3.2 Drum claw control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.3.3 Cooling around the drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9. CHARGING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9.3.1 Charging control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9.3.2 Wire cleaning control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9.3.3 Erase lamp control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10. TRANSFER/SEPARATION SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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CONTENTS Theory of Operation Ver.2.0 Mar. 2010
10.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
bizhub 751/601
10.3.1 Transfer guide control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

10.3.2 Transfer/separation control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10.3.3 Transfer exposure lamp control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10.3.4 Wire cleaning control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11. DEVELOPING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
11.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
11.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
11.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
11.3.1 Conveyance of developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
11.3.2 Developing bias . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
11.3.3 Developing suction control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
12. TONER SUPPLY SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
12.3.1 Toner remaining detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
12.3.2 Toner supply control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
12.3.3 Toner conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
13. CLEANING/TONER RECYCLE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
13.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
13.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
13.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
13.3.1 Toner guide roller control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
13.3.2 Other controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
14. PAPER FEED SECTION (trays 1 and 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
14.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
14.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
14.2.1 Paper feed drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
14.2.2 Tray lift drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
14.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
14.3.1 Up/down control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
14.3.2 Paper feed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
14.3.3 Paper empty detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
14.3.4 Remaining paper detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
14.3.5 Horizontal conveyance control (tray 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
15. PAPER FEED SECTION (trays 3 and 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
15.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
15.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
15.2.1 Paper feed drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
15.2.2 Tray lift drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
15.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
15.3.1 Up/down control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
15.3.3 Paper size detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
15.3.5 Remaining paper detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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Theory of Operation Ver.2.0 Mar. 2010 CONTENTS
15.3.6 Dehumidification heater control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

16. BYPASS TRAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
bizhub 751/601
16.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
16.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
16.2.1 Paper feed drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
16.2.2 Tray lift drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
16.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
16.3.1 Up/down control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
16.3.5 Remaining paper detection control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
17. VERTICAL CONVEYANCE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
17.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
17.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
17.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
17.3.1 Conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
18. REGISTRATION SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
18.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
18.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
18.2.1 Registration drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
18.2.2 Loop roller drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
18.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
18.3.1 Loop control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
18.3.2 Paper mis-centering correction control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
19. HORIZONTAL CONVEYANCE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
19.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
19.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
19.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
19.3.2 Thick paper support mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
20. ADU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
20.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
20.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
20.2.1 ADU conveyance roller drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
20.2.2 ADU reverse roller drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
20.2.3 ADU pre-registration roller drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
20.2.4 Reverse/exit roller drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
20.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
21. FUSING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
21.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
21.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
21.2.1 Fusing drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
21.2.2 Cleaning web drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
21.2.3 Reverse/exit switching gate drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
21.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
21.3.1 Web solenoid control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
21.3.2 Fusing temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
21.3.3 Protection against abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
iii
CONTENTS Theory of Operation Ver.2.0 Mar. 2010
21.3.4 Fusing conveyance mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

22. REVERSE/EXIT SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
bizhub 751/601
22.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
22.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
22.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
23. INTERFACE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
23.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
23.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
24. IMAGE STABILIZATION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
24.1 Outline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
24.2 Operation flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
24.2.1 Image stabilization control flow when the power switch (SW2) is ON . . . . . . . . . . . . . . . . . . . . 89
24.2.2 Image stabilization control flow while in the print and after completion of the print. . . . . . . . . . . 91
25. IMAGE PROCESSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
25.1 Image processing in the scanner section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
25.1.1 Shading correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
25.1.2 AE processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
25.1.3 Area discrimination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
25.1.4 Brightness/density conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
25.1.5 Filter/magnification and contraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
25.1.6 Density gamma (conversion). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
25.1.7 Tilt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
25.1.8 Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
25.1.9 Storage of image data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
25.2 Image processing in the write section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
25.2.1 Elongation/rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
25.2.2 1dotPWM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
25.2.3 Frequency conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
26. OTHERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
26.1 Fan control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
26.1.1 Composition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
26.1.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
26.2 Counter control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
26.2.1 Composition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
26.2.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
26.3 Parts that operate when the power switch is turned ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
26.3.1 Parts that operate when the power cord is plugged into the power outlet. . . . . . . . . . . . . . . . 106
26.3.2 Parts that operate when the main power switch (SW1) is turned ON . . . . . . . . . . . . . . . . . . . 107
26.3.3 Parts that operate when the power switch (SW2) is turned ON . . . . . . . . . . . . . . . . . . . . . . . . 108
26.4 Authentication unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
26.4.1 Authentication unit (Biometric type) (AU-101) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
26.4.2 Authentication unit (IC card type: AU-201) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
iv
Theory of Operation Ver.2.0 Mar. 2010 1. SYSTEM CONFIGURATION
OUTLINE
bizhub 501/421/361
1. SYSTEM CONFIGURATION
A. System configuration
[7] [24]
[22] [23]
[12]
[8]
[13] [14]
[21] [15]
[16]
[2] [17]
[9] [18]
[20] [1] [19]
[7]
[8]
[3]
[10]
[6]
[7] [4]
[8]
[5]
[11] a0pnt1c001cb
[1] Main body [13] Authentication unit (Biometric type) (AU-101) *1

[2] Reverse automatic document feeder (DF-614) [14] Authentication unit (IC card type) ( AU-201) *1
[3] Large capacity unit (LU-405) [15] Working table (WT-504)
[4] Large capacity unit (LU-406) [16] Local interface kit (EK-703)
[5] Shift tray (SF-602) [17] Image controller (IC-208)
[6] Z-folding unit (ZU-604/ZU-605) [18] Security kit (SC-506)
[7] Post inserter (PI-504) [19] Upgrade kit (UK-202)
[8] Punch kit (PK-502/PK-503/PK-504/PK-505) [20] Output tray (OT-505)
[9] Finisher (Flat staple type) (FS-524) [21] Hard disk (HD-510)
[10] Finisher (Flat staple type) (FS-525) [22] FAX kit (FK-502)
[11] Finisher (Saddle stitch type) (FS-610) [23] Mount kit (MK-716)
[12] Key counter [24] i-Option (LK-101/102/103) *2
*1 HD-510 is required to use the authentication unit.

*2 Upgrade kit (UK-202) and hard disk (HD-510) are needed for using i-option.
1 1
1. SYSTEM CONFIGURATION Theory of Operation Ver.2.0 Mar. 2010
B. Configuration for optional device connection

bizhub 501/421/361
NOTE
Any combination other than those listed below is not available.
No. Paper feeding Combinations for finishing AC power to be

option connected
1 LU-405/406 or FS-524/525/610 *2
None *1
2 LU-405/406 or SF-602
None *1
3 LU-405/406 or FS-524/525/610 *2 PI-504
None *1
4 LU-405/406 or FS-524/525/610 *2 PK-502/503/504/505 *3
None *1
5 LU-405/406 or FS-524/525/610 *2 PI-504 PK-502/503/504/505*3
None *1
6 LU-405/406 or ZU-604/605 *4 FS-524/525/610 *2 External
None *1 (ZU-604/605)
7 LU-405/406 or ZU-604/605 *4 FS-524/525/610 *2 PI-504 External
None *1 (ZU-604/605)
8 LU-405/406 or ZU-604 *5 FS-524/525/610 *2 PI-504 PK-504 *5 External
None *1 (ZU-604)
9 LU-405/406 or ZU-605 *5 FS-524/525/610 *2 PI-504 PK-502/503/505 *5 External
None *1 (ZU-605)
*1 Either one of LU-405, LU-406 or no paper feeding option can be selected.

*2 Either one of FS-524, FS-525 or FS-610 can be selected.
*3 Either one of PK-502, PK-503, PK-504 or PK-505 can be selected.
*4 Either one of ZU-604 or ZU-605 can be selected.
*5 Paper fed from PI-504 is punched by PK-502/503/504/505. And paper fed from main body is punched by
ZU-604/605.
2
Theory of Operation Ver.2.0 Mar. 2010 2. PRODUCT SPECIFICATIONS
2. PRODUCT SPECIFICATIONS
bizhub 501/421/361
A. Type
Type Console type (floor-mount type)

Copying method Indirect electrostatic method
Original stand Fixed
Original alignment Left rear standard
Photosensitive material OPC
Sensitizing method Laser writing
Paper feed trays Four trays (1,500 sheets x1, 1,000 sheets x 1, 500 sheets x 2: 80 g/m2)
Bypass feed (100 sheet x 1: 80 g/m2)
LU-405 (4,000 sheet x 1: 80 g/m2) *1
LU-406 (4,000 sheet x 1: 80 g/m2) *1
*1 LU-405 and LU-406 are optional.
B. Functions
Original Sheet, book, solid object

Max. original size A3 or 11 x 17
Copy size Trays 1 and 2 Inch: 81/2 x 11, 51/2 x 81/2, A4, B5, A5
Metric: A4, B5, A5, 81/2 x 11, 51/2 x 81/2, 16K
Trays 3 and 4 Inch: 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2
A3, B4, A4, B5, B5S
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13,
wide paper, custom size (Max. 314 mm x 458 mm)
Metric: A3, B4, A4, A4S, B5, B5S, A5
11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13, 8K, 16K, 16KS,
Bypass feed Inch: 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2,
51/2 x 81/2S
A3, B4, A4, B5, B5S
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13, wide paper,
custom size (Max. 314 mm x 458 mm), Tab paper
Metric: A3, B4, A4, A4S, B5, B5S, A5, A5S, A6S
11 x 17, 81/2 x 14, 81/2 x 11, 51/2 x 81/2
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13,
8K, 16K, 16KS,
wide paper (Max. 314 mm x 458 mm), Tab paper
ADU Inch: 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2,
51/2 x 81/2S
A3, B4, A4, B5, B5S
8 x 13, 81/8 x 131/4, 81/4 x 13, 81/2 x 13
Metric: A3, B4, A4, A4S, B5, B5S, A5, A5S, A6S
11 x 17, 81/2 x 14, 81/2 x 11, 51/2 x 81/2
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
8K, 16K, 16KS,
wide paper (Max. 314 mm x 458 mm)
3
2. PRODUCT SPECIFICATIONS Theory of Operation Ver.2.0 Mar. 2010
Magnification Fixed magnification Inch: x 1.000, x 1.214, x 1.294, x 1.545, x 2.000,

bizhub 501/421/361
x 0.785, x 0.772, x 0.647, x 0.500

Metric: x 1.000, x 1.154, x 1.224, x 1.414, x 2.000,
x 0.866, x 0.816, x 0.707, x 0.500
Special magnifica- x 0.930 (can be changed between x 0.900 and x 0.999)
tion setting
Optional magnifica- 3 types
tion setting
Zoom magnification x 0.250 to x 4.000 (at the step of 0.1%)
Vertical magnification x 0.250 to x 4.000 (at the step of 0.1%)
Horizontal magnification x 0.250 to x 4.000 (at the step of 0.1%)
Warm-up time 751 Less than 300 sec. (at temperature of 20C, at rated volt-
age)
601 Less than 270 sec. (at temperature of 20C, at rated volt-
age)
First copy out time 751 inch: Less than 3.0 sec.
Metric: Less than 2.9 sec.
601 inch: Less than 3.5 sec.
Metric: Less than 3.3 sec.
Continuous copy speed 751 75 copies/min. (for A4/81/2 x 11)
601 60 copies/min. (for A4/81/2 x 11)
Continuous copy count Up to 9,999 sheets
Original density selection Auto density selection, manual (9 steps), optional density (9 steps)
Resolution Scan 600 dpi x 600 dpi
Write 600 dpi x 600 dpi
Image memory Standard *1 1 GB
Interface section RJ45 Ethernet, Serial port (RS232-C), Serial port (USB TypeA x 3),
Serial port (USB TypeB) *2, RJ-11 *3
*1 The increase of the memory is impossible.

*2 When EK-703 is installed.
*3 When MK-716 and FK-502 are installed. (FK-502 x 2 for 2 lines)
1 4
Theory of Operation Ver.2.0 Mar. 2010 2. PRODUCT SPECIFICATIONS
C. Type of paper
bizhub 501/421/361
Plain paper *1 High quality and recycle paper of 60 to 90 g/m2
Special paper *2 Bypass feed only OHP paper, label paper *3, blueprint master paper *3,
tab paper
Thin paper of 50 g/m2 to 59 g/m2
All trays Thick paper of 91 g/m2 to 200 g/m2
*1 Standard specified paper
Inch: Hammermill Tidal MP (75 g/m2), Hammermill Bond, Domtar Recycled Copy
Metric: Konica Minolta Profi (80 g/m2), Konica Minolta Original (80 g/m2),
Nautilus (80 g/m2), Classic white 70
*2 Special paper/recommended paper
Thick paper: Inch: HM-Cover (65lb), HM-Laser Print (32lb)
Metric: RDEREY200 (200 g/m2), Xerox colotech (200 g/m2)
Thin paper: Inch: Domtar16lb
Metric: Clair Mail (60 g/m2)
Label paper: Inch: AVERY 5160, 5352
Metric: AVERY DPS24
OHP: Inch: 3M CG3700
Metric: Folex overhead X-500, 3M CG3700
Tab paper: Inch: AVERY 7103 (81/2 x 11)
Metric: RX 3R90947 (A4)
*3 Label paper and blue print master are loaded and fed one sheet at a time.
D. Maintenance
Maintenance Every 250,000 prints
E. Machine data
Power source Inch: 120V AC 10% 60Hz, Metric: 220-240V AC 10% 50Hz
Power consumption: Inch: 1920W or less, Metric: 2000W or less
Weight Approx. 225 kg
Dimensions Main body + DF-614 650mm (W) x 791mm (D) x 1,140mm (H) *1
886mm (W) x 859mm (D) x 1,140mm (H) *2
Main body + DF-614 1,877mm (W) x 791mm (D) x 1,140mm (H) *1
+ FS-524 (or FS-
525) + LU-405
*1 The operation panel is not included

*2 The operation panel is included
F. Operating environment
Temperature 10 to 30C
Humidity 10 to 80% RH
NOTE
The information herein may be subject to change for improvement without notice.
5
3. UNIT CONFIGURATION Theory of Operation Ver.2.0 Mar. 2010
3. UNIT CONFIGURATION
bizhub 501/421/361
[16]
[15] [17]
[14] [1]
[2]
[3]
[13]
[4]
[12]
[5]
[11] [6]
[7]
[10]
[9] [8] 57aat1c002na
[1] Photo conductor section [10] Paper feed section (trays 3, 4)

[2] Toner supply section [11] Paper feed section (trays 1, 2)
[3] Developing unit [12] Paper reverse/exit section
[4] Registration section [13] Fusing section
[5] Bypass tray [14] Cleaning/toner recycle section
[6] Horizontal conveyance section [15] Charging section
[7] Vertical conveyance section [16] Scanner section
[8] Transfer/separation section [17] Writing section
[9] ADU
6
Theory of Operation Ver.2.0 Mar. 2010 4. PAPER PATH
4. PAPER PATH
bizhub 501/421/361
[7] [8] [9] [10] [11]
[6] [5] [4] [3] [2] [1] 57aat1c003na
[1] Tray 1 paper feed [7] Straight paper exit

[2] Tray 2 paper feed [8] ADU paper feed
[3] Tray 4 paper feed [9] Registration conveyance
[4] Tray 3 paper feed [10] Bypass feed
[5] Reverse conveyance [11] LU paper feed
[6] Reverse paper exit
7
4. PAPER PATH Theory of Operation Ver.2.0 Mar. 2010
bizhub 501/421/361
Blank page
8
Theory of Operation Ver.2.0 Mar. 2010 5. OVERALL CONFIGURATION
bizhub 751/601
5. OVERALL CONFIGURATION
5.1 Time chart when the power is turned ON
[1] [3] [4] [2] [5] [6]
Time (sec)
Item 0 30 60 90 120 150 180
Forward
Scanner motor (M1)
Reverse
Exposure lamp (L1)
Fusing heater lamp /1, /2 (L2, L3)

Fusing heater lamp /3 (L4)
Maximum density correction
Gamma correction
Fusing motor (M4)
Drum motor (M2)
Developing motor (M3)
Polygon motor (M15)
Laser (LDB)
Charging cleaning Forward

motor (M14)
Reverse
Forward
Transfer/separation
cleaning motor (M10)
Reverse
Transfer/separation cleaning home sensor (PS52)
Transfer/separation cleaning limit sensor (PS53)
Paper lift motor /1 (M16)

Upper limit sensor /1 (PS2)

57aat2e001na
9
5. OVERALL CONFIGURATION Theory of Operation Ver.2.0 Mar. 2010
bizhub 751/601
[1] Power switch (SW2) ON [4] Home position search/shading correction

[2] Thermistors /1 (TH1) and /2 (TH2) get to the [5] Image stabilization control
specified temperature [6] Warm-up completed
[3] OS start-up completed
Note
Each operation varies with the software DIPSW setting in the service mode and the environmental
conditions.
The power is turned ON with DF closed.
The power is turned ON with the tray lift plate brought down.
10
Theory of Operation Ver.2.0 Mar. 2010 5. OVERALL CONFIGURATION
5.2 Control block diagram
bizhub 751/601
CCD CF HDD USB RS232C LAN PCI PWB
I/F I/F I/F I/F
OACB
Write
Section
M FM CL SD PS
PRCB
SDB ADUDB HV
M SD CL
APS DF LU FS/SF
[7] [6] [5] [4] [3] [2] [1]

57aat2c085nb
[1] Image bus [5] Other buses

[2] Parallel bus [6] Individual signal line
[3] Clock synchronization serial bus [7] SATA
[4] UART bus
11
6. SCANNER SECTION Theory of Operation Ver.2.0 Mar. 2010
6. SCANNER SECTION
bizhub 751/601
6.1 Composition
Shading correction plate Exposure unit Mirror unit CCD unit
a0pnt2c001ca
6.2 Drive
[3] [4] [5]
[2] [1] 57aat2c002na
[1] Scanner wire /Fr [4] Scanner wire /Rr

[2] V-mirror unit [5] Exposure unit
[3] Scanner motor (M11)
12
Theory of Operation Ver.2.0 Mar. 2010 6. SCANNER SECTION
6.3 Operation
bizhub 751/601
6.3.1 Scan/exposure lamp control
A. Operation when the power is turned ON
The home position varies depending on whether DF is open or closed. When DF is open, the home position is at
the platen APS read position and when it is closed, the DF read position becomes the home position. When the
power is turned ON, a search is made with the APS read position as the home position regardless of whether
DF is open or not.
While the power switch (SW2) is ON, the exposure unit conducts the home position search and the shading cor-
rection.
(1) Home position search

The home position search varies depending on whether the scanner home sensor (PS61) [2] is turned ON or
OFF.
Home position search when the scanner home sensor (PS61) is turned OFF
[2] [1]
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[1] Position at which the platen APS is read [2] Scanner home sensor (PS61)
Home position search when the scanner home sensor (PS61) is turned ON
[2] [1]
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[1] Position at which the platen APS is read [2] Scanner home sensor (PS61)
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(2) Shading correction

After completion of the home position search [4], the exposure unit conducts shading corrections. For shading
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corrections, there are the following types of corrections: white correction 1 [5], white correction 2 [6], and black
correction [7]. For the shading correction at the time of the power ON, these corrections are carried out in a
series of operations. And after completion of the corrections, the exposure unit returns to the position at which
the platen APS is read [1]. When DF is open, the exposure unit stands by at the APS read position. And when it
is closed, however, the unit conducts the home position search to the position [3] at which DF is read.
[3] [2] [1]
[4]
[5]
[6]
[7]
[9]
[10]
[8]
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[1] Position at which the platen APS is read [6] White correction 2
[2] Scanner home sensor (PS61) [7] Black correction
[3] Position at which DF is read [8] Home position search when DF is closed
[4] Completion of the home position search [9] Exposure lamp (L1) on
[5] White correction 1 [10] Movement of the exposure unit
14
B. Operation when the start key is turned ON

The operation when the start key is turned ON varies depending on whether DF is open or closed. In either
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operation, the shading correction is carried out first. However, unlike the operation when the power is turned
ON, the exposure unit proceeds to the original read operation with the exposure lamp (L1) left on, and therefore,
the black correction is not conducted.
(1) When the platen is in use (when DF is open)

When the platen is in use and the start key is turned ON, the operation varies depending on whether AE is
selected or not.
While in the AE copy

When the start key is turned ON [3] while in the AE copy, the exposure unit conducts the white correction 1 [4]
and the white correction 2 [5] before the AE scan [6] is made. And then the exposure scan [7] is carried out.
After completion of the exposure scan, the home position search [8] is made.
[2] [1]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
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[1] Position at which the platen APS is read [6] AE scan

[2] Scanner home sensor (PS61) [7] Exposure scan
[3] Start key ON [8] Home position search
[4] White correction 1 [9] Exposure lamp (L1) on
15
While in the manual copy

When the start key is turned ON [3] while in the manual copy, the exposure unit conducts the white correction 1
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[4] and the white correction 2 [5] before the exposure scan [6] is made. After completion of the exposure scan,
the home position search [7] is carried out.
[2] [1]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
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[1] Position at which the platen APS is read [6] Exposure scan
[2] Scanner home sensor (PS61) [7] Home position search
[3] Start key ON [8] Exposure lamp (L1) on
[5] White correction 2
16
(2) When DF is in use (when DF is closed)

When the start key is turned ON [4], the exposure unit conducts the white correction 1 [5] and the white correc-
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tion 2 [6] before moving to the original read position [3]. The same operation is made when AE is selected. The
exposure unit stops at the original read position to read the original [7]. After completion of reading of the origi-
nal, the exposure unit conducts the home position search [8] to the position at which the platen APS is read [1].
And then, it also conducts the home position search [9] to the position at which DF is read [3].
[3] [2] [1]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11] 57aat2c008na
[1] Position at which the platen APS is read [8] Home position search
[2] Scanner home sensor (PS61) (position at which the platen APS is read)
[3] Position at which DF is read [9] Home position search
[4] Start key ON (position at which DF is read)
[5] White correction 1 [10] Exposure lamp (L1) on
[7] Original is read
17
6.3.2 Original size detection control

A. Detection method
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The detection method of the original size varies with the DF mode and the platen mode.
(1) DF mode
Refer to DF-614.
(2) Platen mode

In the main scan direction
Read is made by the CCD sensor.
In the sub scan direction
Detection is made by the combination of the APS sensors /1 (PS63), /2 (PS64) and /3 (PS65) that turn ON
and OFF.
Original size PS65 PS63 PS64

ON/OFF ON/OFF ON/OFF
Minimum size OFF OFF OFF
B5S ON OFF OFF
B5 OFF OFF OFF
B4 ON ON ON
A4S ON ON OFF
A4 OFF OFF OFF
A3 ON ON ON
81/2 x 11S ON OFF OFF
81/2 x 11 OFF OFF OFF
81/2 x 14 ON ON ON
11 x 17 ON ON ON
B. Detection timing
The detection timing of the original size varies with the DF mode and the platen mode.
(1) DF mode
Refer to the DF-614.
(2) Platen mode

When the APS timing sensor (PS51) turns on with the DF closed, the exposure lamp (L1) turns ON and the CCD
sensor and the APS sensor /1 (PS63), /2 (PS64) and /3 (PS65) detect the original size.
18
6.3.3 AE control
When AE is selected, the density level of the original is detected to adjust it automatically to an appropriate den-
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sity. The sampling area of the original density in the AE control varies with the platen mode and the DF mode.
(1) AE sampling area in the platen mode

While in the normal copy
[2]
[2]
[1] 57aat2c009na
[1] 30 mm [2] 10 mm
While in the auto erasure outside the original mode

Entire original area detected by the original area discrimination scan (pre-scan)
(2) AE sampling area in the DF mode
[3]
[3]
[2] [1]
57aat2c010na
[1] 2 mm [3] 10 mm
[2] 2 mm
6.3.4 Image processing

There are following items for the image processing. For particulars, refer to "25. IMAGE PROCESSING." for
details. (Refer to P.94)
AOC (Auto offset control)
AGC (Auto gain control)
Shading correction
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7. WRITE SECTION Theory of Operation Ver.2.0 Mar. 2010
7. WRITE SECTION
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7.1 Composition
Index board
Collimator lens unit (INDEXB)
Laser drive
board (LDB)
CY2 lens
CY1 lens
f lens
Polygon mirror
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7.2 Operation
7.2.1 Laser beam path
[8]
[7] [1]
[6]
[5]
[4] [2]
[3]
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[1] Write mirror [5] Polygon mirror

[2] CY2 lens [6] CY1 lens
[3] Drum [7] Collimator lens
[4] f lens [8] Laser diode
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Theory of Operation Ver.2.0 Mar. 2010 7. WRITE SECTION
7.2.2 Write control

To prevent the mis-centering of written images, the INDEX signal detected by the index board (INDEXB) is used
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to decide a reference position for writing in the direction of the drum shaft (main scan direction) and control the
starting position of the laser irradiation on the drum according to the paper edge detected by the centering sen-
sor (PS66).
7.2.3 Polygon control

The polygon mirror is driven by the polygon motor (M15) and the number of its rotations changes according to
the process speed that varies with the type of paper.
A. In the case of bizhub 751
Type of paper Process speed No. of rotations

Regular 357 mm/s 42165.35 rpm
Thick paper 178.5 mm/s 42165.35 rpm (Note)
Note
The number of rotations of the polygon mirror for the thick paper is the same as that for the regu-
lar paper. However, to comply with the reduction in the process speed (to as much as 50%), every
other plane of the six reflection planes of the polygon mirror is used to scan the laser beam.
B. In the case of bizhub 601
Type of paper Process speed No. of rotations

Regular 300 mm/s 35433.07 rpm
Thick paper 178.5 mm/s 42165.35 rpm (Note)
Note
The number of rotations of the polygon mirror for the thick paper is faster than that for the regular
paper. However, to comply with the reduction in the process speed, every other plane of the six
reflection planes of the polygon mirror is used to scan the laser beam.
7.2.4 Image stabilization control

There are following items for the image stabilization control. For particulars, refer to "24. IMAGE STABILIZATION
CONTROL." for details. (Refer to P.89)
MPC (Maximum power control)
APC (Auto power control)
Dot diameter adjustment control
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8. PHOTO CONDUCTOR SECTION Theory of Operation Ver.2.0 Mar. 2010
8. PHOTO CONDUCTOR SECTION

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8.1 Composition
Drum Toner control sensor board (TCSB)
Suction duct Drum claw

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Theory of Operation Ver.2.0 Mar. 2010 8. PHOTO CONDUCTOR SECTION
8.2 Drive
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8.2.1 Drum drive
[5] [6]
[1]
[4] [2]
[3] 57aat2c014na
[1] Toner guide roller (TGR) [4] Separation guide plate assembly
[2] Toner conveyance screw [5] Drum
[3] Drum motor (M2) [6] Toner recycle clutch (CL14)/toner convey-
ance screw
8.2.2 Drum claw drive
[1] [2] [3]
[5] [4]
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[1] Drum claw oscillation cam [4] Separation guide plate assembly
[2] Drum claw solenoid (SD1) [5] Gear (drive input for oscillation)
[3] Drum claw
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8.3 Operation
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8.3.1 Image creation control

When the print start signal turns ON [1], various types of motors turn ON to make each of the units operative. At
this time, the erase lamp (EL) also turns ON to start to neutralize [2] the drum. And a specified period of time
after this signal is sent, a high voltage impression is made on the charging [3], the developing bias [4], the trans-
fer guide [5] and the toner guide roller (TGR) [7] to form images on the drum surface by the laser irradiation and
the developing.
In parallel with the operation above, a specified period of time after completion of the formation of a loop on the
paper [6] supplied in the registration roller section, a drum ready signal [8] is generated. With this as a starting
point, the registration clutch (CL1) turns ON. When CL1 turns on, the drive force of the registration motor (M5) is
transmitted to the registration roller to start the registration conveyance [9] of the 1st sheet of paper that has
formed the loop. At this time, when the paper is fed from the trays 1 to 4, LU or ADU (only while in the double
sided copy mood), the loop motor (M6) that drives the loop roller and the ADU pre-registration roller changes the
line speed into a low speed to assist [10] the loop.
With this conveyance, the paper edge sensor (PS43) detects the leading edge of the paper and turns ON [11].
And a specified period of time after that, it turns on successively the transfer exposure lamp [12], the high volt-
age impression ON the separation [13] and the transfer [14], and the drum claw solenoid [15]. In due course of
time, the paper passes through the drum and at this time, the images formed on the drum are transferred to the
paper, and then finally the paper is separated from the drum.
A series of these operations is realized by the continuous conveyance of paper, and when PS43 detects the
trailing edge of paper and it turns OFF [16], each of the operations is also turned OFF a specified period of time
after that. However, while in the print of two or more sheets of paper, some of the operations continue for a
specified period of time after PS43 detects the trailing edge of the last sheet of paper and turns OFF [21].
Paper the transfer of which has been completed is conveyed to the fusing section through the conveyance sec-
tion. M5 and the fusing motor (M4) that have a bearing on the drive in this conveyance path continue to operate
until the paper exit sensor (PS37) detects the trailing edge of the last paper and turns OFF [22].
[1] [2] [3][4] [5] [6] [8] [9] [10] [13] [14] [17] [18] [19] [20]
Drum motor (M2)

Developing motor (M3)
Fusing motor (M4)
Registration motor (M5)
Loop motor (M6) H

L
Registration clutch (CL1)

Erase lamp (EL)
Charging
Transfer
Separation
Developing bias
Transfer guide
Toner guide roller (TGR)
Transfer exposure lamp (TSL)
Drum claw solenoid (SD1)
Loop sensor (PS36)

Registration sensor (PS44)
Paper edge sensor (PS43)
Paper exit sensor (PS37)
[7] [11] [12] [15] [16] [21] [22] 57aat2c086na
[17] Drum Ready signal of the last sheet of paper [21] Detection of the trailing edge of the last
[18] Loop assist of the last sheet of paper sheet of paper by PS43
[19] Registration conveyance of the last sheet of paper [22] Detection of the trailing edge of the last
[20] High voltage impression for the transfer of sheet of paper by PS37
the 1st sheet of paper
* Refer to the descriptions in the text for the items [1] through [16].
24
Theory of Operation Ver.2.0 Mar. 2010 8. PHOTO CONDUCTOR SECTION
8.3.2 Drum claw control

A. Purpose
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To prevent the occurrence of a drum wrap jam, 3 drum claws are employed to prevent the drum from being
wrapped with the paper. The contact and the release of contact of the drum claws onto the drum is made by
turning on and off the drum claw solenoid (SD1).
B. Oscillating operation
To prevent the paper from getting soiled in certain areas and the drum from being damaged, the drum claw con-
ducts the oscillation of about 8 mm on the drum surface.
There is a projection on the rear side of the separation guide plate assembly to which the drum claw is installed.
A cam provided on the gear presses this projection to push the separation guide plate assembly to the front
side. When the cam is released by the rotation of the gear, the separation guide plate assembly is brought back
to its former position by the spring. Repeating this operation oscillates the drum claws.
8.3.3 Cooling around the drum

The duct [3] is provided in the main scan direction of the drum [4] to exhaust heat and ozone around the drum
by the developing suction fan (FM4) [1]. To prevent toner and dust contained in the exhaust from escaping into
the environment, the developing suction filter is provided between the developing suction fan [FM4] and the
duct. And also, the developing cooling fan (FM12) is employed to cool down the underside of the developing
unit to improve the performance of the developer.
[4]
[5]
[1]
[3]
[2] 57aat2c016na
[1] Developing suction fan (FM4) [4] Drum

[2] Developing suction filter [5] Developing cooling fan (FM12)
[3] Duct
25

There are following items for the image stabilization control. For particulars, refer to "24. IMAGE STABILIZATION
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CONTROL." for details. (Refer to P.89)

Environmental decision control
Maximum density control
Gamma correction control
A. Environmental decision control

The temperature of the environment in which the main body is installed is detected by the thermistor provided
on the toner control sensor board (TCSB), and the environmental humidity is detected by the humidity sensor
mounted on the back of the main body. Data thus detected are used as information to keep the image quality at
a fixed level. For particulars, refer to "24. IMAGE STABILIZATION CONTROL." for details. (Refer to P.89)
(1) Detection timing

When the prescribed conditions are met with the power switch (SW2) ON.
26
Theory of Operation Ver.2.0 Mar. 2010 9. CHARGING SECTION
9. CHARGING SECTION
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9.1 Composition
Charge cleaning
Charge cleaning block /Up Charge wire
block /Lw
Charge control plate
Erase lamp (EL)
Erase lamp (EL) Back plate

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9.2 Drive
[5]
[4] [3] [2] [1] 57aat2c018na
[1] Charge cleaning block /Lw [4] Charge control plate

[2] Charge cleaning block /Up [5] Charge cleaning motor (M14)
[3] Charge wire
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9. CHARGING SECTION Theory of Operation Ver.2.0 Mar. 2010
9.3 Operation
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9.3.1 Charging control

A. Charge wire
The high voltage unit (HV) pressurizes 24V DC to impress a minus (-) DC voltage to the charging wire for dis-
charge.
Charging output range: -600 A to -1200 A
B. Charge grid
To make the discharge of the charging wire uniform, a minus (-) high voltage is impress from the high voltage unit
(HV) to the charging grid.
Charging grid voltage output range: -500 V to -1000 V
9.3.2 Wire cleaning control

A. Purpose
The wire is cleaned periodically to prevent the deterioration of the discharge characteristics caused by soil
adhered to the charging wire.
B. Timing
While in the print, executes after completion of a job for every specified number of prints.
When the environmental condition meets the prescribed condition, executes according to the predeter-
mined condition.
Note
When the environmental condition meets the specified condition with the power on, no cleaning is
made.
While in the print, the cleaning operation varies with the setting of the software DIPSW in the ser-
vice mode. For particulars, refer to "24. IMAGE STABILIZATION CONTROL." for details. (Refer to
P.89)
9.3.3 Erase lamp control

A. Purpose
To neutralize the residual potential on the drum surface and make the potential on the drum surface uniform, the
erase lamp (EL) is illuminated on the drum before charging.
B. Timing for the erase lamp to be turned on

A start signal turns ON the erase lamp (EL), and it is turned OFF a specified period of time after the last paper is
detected by the paper leading edge sensor (PS43).
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Theory of Operation Ver.2.0 Mar. 2010 10. TRANSFER/SEPARATION SECTION
10. TRANSFER/SEPARATION SECTION
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10.1 Composition
Separation cleaning Transfer cleaning Transfer charge wire

assembly assembly
Transfer guide plate
Wire guide /2 Wire guide /1
Back plate Separation charge wire
Transfer exposure lamp (TSL) 57aat2c019na
10.2 Drive
[3]
[2] [1]
57aat2c020na
[1] Transfer/separation cleaning motor (M10) [3] Transfer cleaning assembly and separation
[2] Transfer charge wire and separation charge cleaning assembly
wire
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10. TRANSFER/SEPARATION SECTION Theory of Operation Ver.2.0 Mar. 2010
10.3 Operation
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10.3.1 Transfer guide control

A. Purpose
To prevent the transfer guide from getting soiled, a minus (-) DC voltage is impressed from the high voltage unit
(HV).
Impressed voltage: -500 V
B. Timing
The impression of voltage onto the transfer guide plate is turned ON a specified period of time after a start signal
is sent, and it is turned OFF a specified period of time after the trailing edge of the last paper is detected by the
paper leading edge sensor (PS43).
10.3.2 Transfer/separation control

A. Transfer
The high voltage unit (HV) pressurizes 24V DC to impress a plus (+) DC voltage onto the transfer wire for dis-
charge.
Transfer DC output range: 50 A to 600 A
B. Separation
For separation, an AC high voltage and a minus (-) DC voltage are used. The high voltage unit (HV) impresses 2
separation wires for discharge.
Separation AC output range: 4 kV to 5.7 kV
Separation DC output range: 0 A to -400 A
10.3.3 Transfer exposure lamp control

A. Purpose
The transfer exposure lamp (TSL) is turned on to secure the transferability and to prevent the reverse charge to
the drum.
B. Timing
The transfer exposure lamp turns ON a specified period of time after the paper leading edge sensor (PS43) in
the registration section turns ON, and it turns OFF a specified period of time after PS43 detect the trailing edge
of the paper.
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Theory of Operation Ver.2.0 Mar. 2010 10. TRANSFER/SEPARATION SECTION
10.3.4 Wire cleaning control

A. Purpose
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To prevent the deterioration of the discharge characteristics caused by soil adhered to the transfer wire and the
separation wire, the wire is cleaned periodically.
B. Timing
While in the print, executes after completion of a job for every specified number of prints.
When the environmental condition meets the prescribed condition, executes according to the predeter-
mined condition.
Note
When the environmental condition meets the specified condition with the power on, no cleaning is
made.
While in the print, the cleaning operation varies with the setting of the software DIPSW in the ser-
vice mode. For particulars, refer to "24. IMAGE STABILIZATION CONTROL." for details. (Refer to
P.89)
C. Cleaning operation
The home position of the cleaning member is provided on the front side of the machine. It operates as shown
below.
[1] [2]
[3]
[4]
[5]
[6]
57aat2c021na
[1] Transfer/separation cleaning limit sensor [3] Cleaning (going)

(PS53) [4] Cleaning (returning)
[2] Transfer/separation cleaning home sensor [5] Home search (going)
(PS52) [6] Home search (returning)
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11. DEVELOPING UNIT Theory of Operation Ver.2.0 Mar. 2010
11. DEVELOPING UNIT

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11.1 Composition
Developer Developer regulation blade
Agitator plate 57aat2c022na
11.2 Drive
[5] [6] [7]
[4] [3] [2] [1]
57aat2c023na
[1] Gear for the agitator screw [5] Coupling for developing drive
[2] Gear for the agitator plate [6] Developing input gear
[3] Gear for the developing roller [7] Developing idler gear
[4] Developing motor (M3)
32
Theory of Operation Ver.2.0 Mar. 2010 11. DEVELOPING UNIT
11.3 Operation
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11.3.1 Conveyance of developer
Developer in the developing unit is supplied to the developing roller [3] by the agitator plate [2]. And developer
that adheres to the developing roller is kept at a fixed thickness by the developer regulation blade [5]. Developer
that remains on the developing roller is returned to the agitator screw [1].
.
[4] [5]
[3] [2] [1] 57aat2c024na
[1] Agitator screw [4] Drum

[2] Agitator plate [5] Developer regulation blade
[3] Developing roller
11.3.2 Developing bias

A. Purpose
During developing, a developing bias voltage is impressed onto the developing roller [1] so that toner is ready to
adhere to the drum. A developing bias voltage is sent from the high voltage unit (HV) to the developing bias con-
tact [4] to be supplied to the developing roller [1] from the developing bias spring /Rr [3] through the bearing [2].
[4] [3] [2] [1] 57aat2c025na
[1] Developing roller [3] Developing bias spring /Rr

[2] Bearing [4] Developing bias contact
B. Timing
To prevent unnecessary carriers from adhering to the drum, the developing bias turns ON a specified period of
time after a print start signal is sent, and it turns OFF a specified period of time after the trailing edge of the last
paper is detected by the paper leading edge sensor (PS43).
33
11. DEVELOPING UNIT Theory of Operation Ver.2.0 Mar. 2010
11.3.3 Developing suction control

A. Purpose
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The developing suction fan (FM4) exhausts heat around the drum and the developing roller to suck in toner scat-
tered around by the rotation of the developing roller and improve the durability of developer. For the exhaust
path, refer to "8.3.3 Cooling around the drum." for details. (Refer to P.25)
B. Developing suction fan control

The developing suction fan (FM4) turns ON when the drum motor (M2) turns ON, and it turns OFF when the M2
turns OFF.

A. Toner concentration control
The toner concentration control detects the patch density in the latent image and the developed image created
under a fixed condition and controls either the number of rotations of the developing roller or the toner supply
time depending on the findings obtained by comparing it to the reference value. For particulars, refer to "24.
IMAGE STABILIZATION CONTROL." for details. (Refer to P.89)
(1) Execution timing

Once every specified number of prints after the power switch (SW2) is turned ON.
B. Maximum density control

The maximum density control is a control in which the patch in the latent images written under a fixed condition
is developed while changing the number of rotations of the developing roller to obtain the number of rotation of
the developing roller the density of which is the same as the reference density. For particular, refer to "24. IMAGE
STABILIZATION CONTROL." for details. (Refer to P.89)

While in the print, executed after completion of a job under the specified condition (the number of prints,
and developing theta).
Note
Not executed when the environmental condition meets the specified condition with the power
switch ON.
C. Gamma correction control

The gamma correction control detects the patch density in the latent image and the developed image created
under a fixed condition to correct the amount of laser beam while in the write depending on the findings
obtained by comparing the patch density with the reference density. For particular, refer to "24. IMAGE STABILI-
ZATION CONTROL." for details. (Refer to P.89)

While in the print, executed after completion of a job under the specified condition (the number of prints,
and developing theta).
Note
Not executed when the environmental condition meets the specified condition with the power
switch ON.
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Theory of Operation Ver.2.0 Mar. 2010 12. TONER SUPPLY SECTION
12. TONER SUPPLY SECTION
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12.1 Composition
Toner bottle
Toner hopper Agitator plate Toner remaining sensor (PZS) 57aat2e002na
12.2 Drive
[6]
[7]
[5]
[3]
[2]
[4] [1] [1]
57aat2e003na
[1] Front [5] Toner bottle motor (M13)

[2] Toner supply motor (M12) [6] Toner bottle
[3] Toner conveyance screw [7] Toner conveyance screw
[4] Rear
35
12. TONER SUPPLY SECTION Theory of Operation Ver.2.0 Mar. 2010
12.3 Operation
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12.3.1 Toner remaining detection control

A. Toner remaining detection control
The toner remaining in the toner hopper is detected by the toner remaining sensor (PZS). When the toner
remaining in the toner hopper gets below the specified amount, a toner supply signal is output to the printer
control board (PRCB). This signal is transmitted to the operation board /1 (PWB1) through the overall control
board (OACB). As a result, PWB1 displays a message on LCD on the LCD board (LCDB).
B. Detection timing
When the power switch (SW2) is ON.
When the front doors /Lt and /Rt are opened and closed.
When the drum motor (M2) starts to rotate.
When the toner supply door is opened and closed.
12.3.2 Toner supply control

A. Purpose
When it is determined that the toner supply is required as a result of the toner concentration control, toner is
supplied. For the toner concentration control, refer to "24. IMAGE STABILIZATION CONTROL." for details.
(Refer to P.89)
B. Operation
When the toner supply is required as a result of the toner concentration control, the toner supply motor (M12)
turns ON to supply toner from the toner hopper to the developing unit.
C. Timing
Toner is supplied when the trailing edge of paper in printing is detected. And the toner supply time varies
depending on the result of the toner concentration control and the paper size. This is normally controlled
between 0 to 1.49 sec. The table shown below shows the relationship between the paper size and the toner
supply time.
Paper size Toner supply time (sec.)

A3 1.42
B4 1.24
8 x 13 1.14
A4 0.71
B5 0.60
B5S 0.89
A5 0.50
11 x 17 1.49
81/2 x 14 1.21
81/2 x 11 0.71
51/2 x 81/2 0.46
36
Theory of Operation Ver.2.0 Mar. 2010 12. TONER SUPPLY SECTION
12.3.3 Toner conveyance control

A. Purpose
bizhub 751/601
To convey toner in the toner bottle to the toner hopper.
B. Operation
The toner bottle set to the toner supply section is rotated when the toner bottle motor (M13) turns ON. When the
toner bottle rotates, toner is guided to the exit [1] of the bottle along the spiral groove carved on the surface of
the toner bottle. When the exit of the bottle turns to the bottom, toner flows into the toner hopper [2].
[1]
D C
B
A
[3]
D C
B
[2]
A 57aat2e004na
[1] Exit of the bottle [3] Rotate by 90

[2] Into the toner hopper
37
13. CLEANING/TONER RECYCLE SECTION Theory of Operation Ver.2.0 Mar. 2010
13. CLEANING/TONER RECYCLE SECTION

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13.1 Composition
Toner recycle pipe Cleaning blade Toner guide roller (TGR)
57aat2c029na
13.2 Drive
[4] [5] [1]
[3] [2] 57aat2c030na
[1] Drum [4] Toner recycle clutch (CL14) /

[2] Toner conveyance screw toner conveyance screw
[3] Drum motor (M2) [5] Toner guide roller (TGR)
38
Theory of Operation Ver.2.0 Mar. 2010 13. CLEANING/TONER RECYCLE SECTION
13.3 Operation
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13.3.1 Toner guide roller control
A. Operation
To improve the cleaning performance of toner, a fixed voltage is impressed on the toner guide roller (TGR) [1]. A
voltage impressed on the TGR is sent to the cleaner power supply shaft /Rr [3] from the high power unit (HV) to
be supplied to TGR [1] through the power supply pin [2].
Toner guide roller (TGR) output range: 0 to 50 A
[3] [2] [1] 57aat2c031na
[1] Toner guide roller (TGR) [3] Cleaner power supply shaft /Rr
[2] Power supply pin
B. Timing
The impression of a voltage on the toner guide roller (TGR) turns ON a specified period of time after the start sig-
nal is output, and it turns OFF a specified period of time after the trailing edge of the last paper is detected by
the paper leading edge sensor (PS43).
13.3.2 Other controls

Blade set mode
As an operation conducted after replacing the cleaning blade for the maintenance purpose, there is a blade set
mode in the service mode. Executing the blade set mode prevents the curling-up of the cleaning blade by clean-
ing the drum with the cleaning blade after letting toner adhere to the drum.

A. Black belt creation control
In order to stabilize the cleaning blade pressure while in the low coverage, and to prevent the trampling of paper
dust, the laser is turned ON to create black band patters on the drum. For particular, refer to "24. IMAGE STABI-
LIZATION CONTROL." for details. (Refer to P.89)
B. Execution timing
Once every 3 prints. However, this can be changed by the software DIPSW in the service mode. For particular,
refer to "10.9.1 Software DIPSW setting" in Field Service.
39
14. PAPER FEED SECTION (trays 1 and 2) Theory of Operation Ver.2.0 Mar. 2010
14. PAPER FEED SECTION (trays 1 and 2)

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14.1 Composition
Horizontal conveyance section Pre-registration roller
Tray /1 Lift plate Tray /2 Pick-up roller Feed roller Separation roller
Feed roller Pre-registration roller Horizontal conveyance section

Pick-up roller
Pre-registration
roller
Feed roller
Separation roller
Separation roller Lift plate Lift plate Tray /2
Tray /1 Pick-up roller
57aat2c032na
40
Theory of Operation Ver.2.0 Mar. 2010 14. PAPER FEED SECTION (trays 1 and 2)
14.2 Drive
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14.2.1 Paper feed drive
[11] [12] [13] [14] [15] [16]
[5] [6] [7] [8] [9] [10]
[17]
[1]
[4] [3] [2] 57aat2c033na
[1] Paper feed motor (M1) [10] Pre-registration clutch /1 (CL4), /2 (CL6)
[2] Separation clutch /1 (CL21), /2 (CL22) [11] Coupling shaft /1
[3] Separation roller [12] Belt
[4] Tray 1 and 2 [13] Horizontal conveyance roller /Lt
[5] Pick-up roller [14] Horizontal conveyance clutch /Lt (CL15)
[6] Feed roller [15] Horizontal conveyance clutch /Rt (CL16)
[7] Paper feed clutch /1 (CL3), /2 (CL5) [16] Horizontal conveyance roller /Rt
[8] Coupling [17] Coupling shaft /2
[9] Pre-registration roller
41
14.2.2 Tray lift drive

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[5]
[1]
[4] [2]
[3]
57aat2c034na
[1] Paper lift motor /1 (M16) [4] Lift wire

[2] Paper lift motor /2 (M17) [5] Lift plate
[3] Lift wire
42
14.3 Operation
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14.3.1 Up/down control
A. Up operation
The paper lift motors /1 (M16) and /2 (M17) cause the lift wires to be taken up by the pulley to raise the lift plate.
B. Down operation
When the tray is pulled out, the coupling shaft [2] of the tray is disengaged from the coupling gear [4] of the
paper lift motors /1 (M16) and /2 (M17) [3]. This bring up the lift plate [1] to release the drive force of the M16 or
M17 and the lift plate goes down by its own weight.
[3] [4]
[1]
[2] 57aat2c035na
[1] Lift plate [3] Paper lift motor /1 (M16), /2 (M17)

[2] Coupling shaft [4] Coupling gear
C. Operation timing
When the tray is set, the paper lift motors /1 (M16) and /2 (M17) turn ON to bring up the lift plate. When the lift
plate goes up and the upper most paper on the plate turns ON the upper limit sensors /1 (PS2) and /2 (PS8),
M16 and M17 turn OFF to stop the up operation.
While in the print operation, when PS2 and PS8 are turned OFF from ON by the paper feed operation, M16 and
M17 turn ON again to raise the lift plate. When PS2 and PS8 are turned ON again by this operation, M16 and
M17 turn OFF to stop the up operation.
43
14.3.2 Paper feed control

A. Pick-up control
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The up operation of the lift plate causes the paper and the pick-up roller come into contact. At this time, the
pick-up roller pressurizes the paper by its own weight.
When the print start signal [1] turns ON [2] the paper feed clutches /1 (CL3) and /2 (CL5), the pick-up roller that
pressurized the paper is rotated by the rotational drive that is transmitted from the paper feed motor (M1) to pick
up the paper and convey it to the feed roller. The feed roller rotates together with the pick-up roller and the paper
is conveyed to the pre-registration roller. When the paper feed sensors /1 (PS1) and /2 (PS7) positioned short of
the pre-registration roller turn ON [3], the CL3 and CL5 turn OFF [4] a specified period of time after this to stop
the rotation of the feed roller and the pick-up roller.
When the 1st sheet of paper passes through PS1 and PS7 and they turn OFF [5], CL3 and CL5 turn ON [6]
again to pick up the 2nd sheet of paper.
[1] [2] [4] [6]
Paper feed motor (M1)
Paper feed clutches /1, /2 (CL3, 5)
Paper feed sensors /1, /2 (PS1, 7)
[3] [5] 57aat2c036na
[1] Print start signal [4] Completion of the feed of the 1st sheet of paper
[2] Pick-up of the 1st sheet of paper [5] Detection of the trailing edge of the 1st sheet of paper
[3] Detection of the leading edge of the 1st [6] Pick-up of the 2nd sheet of paper
sheet of paper
44
B. Separation mechanism
The separation roller [4] is driven in the direction opposite [2] to the paper conveyance [10] through the torque
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limiter [1]. However, it is pressed against the feed roller [8] by the working pressure generated by the pressure [9]
of the spring [3] and the torque of the torque limiter. This working pressure of the feed roller, the separation roller
and the torque limiter becomes a limit torque for the double feed prevention of paper.
When no paper is conveyed or when only one sheet of paper is convey between the separation roller and the
feed roller, the frictional force is greater than the limit torque and the separation roller is driven by the feed roller
to be rotated [5].
When 2 or more sheets of paper are conveyed between the separation roller and the feed roller, the limit torque
is greater than the frictional force of these sheets of paper and the separation roller rotates in the reverse direc-
tion [2] to push back the lower paper [7] in contact with the separation roller in the direction [6] of the tray, thus
separating the paper. And, the separation clutch is provided on the same shaft of the torque limiter, and to
reduce the load of the torque limiter on the paper feed motor (M1), it turns ON only when paper is being fed.
[8] [9] [10]
[7] [6] [5]
[4]
[3] [2] [1] 57aat2c037na
[1] Torque limiter [6] To the tray

[2] Rotation in the direction for separation [7] 2nd sheet of paper
[3] Spring [8] Feed roller
[4] Separation roller [9] Pressure
[5] Driven for rotation [10] Paper conveyance direction
45
C. Paper loop mechanism

Paper that passed through the feed roller [5] and the separation roller [3] is sent out to the pre-registration roller
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[7]. The paper thus sent out presses the actuator [1] to turn ON the paper feed sensors /1 (PS1) and /2 (PS7) [6].
By stopping the paper feed roller a specified period of time after PS1 and PS7 turn ON, the paper forms a loop
[2] short of the pre-registration roller to correct the skew of paper.
[4] [5] [6] [7]
[1]
[3] [2] 57aat2c038na
[1] Actuator [5] Feed roller

[2] Paper loop [6] Paper feed sensors 1/ (PS1), /2 (PS7)
[3] Separation roller [7] Pre-registration roller
[4] Pick-up roller
D. Pre-registration control
The pre-registration roller is driven by the paper feed motor (M1) through the pre-registration clutches /1 (CL4)
and /2 (CL6). Turning ON and OFF the CL4 and CL6 transmits and shuts off the drive force to rotate and stop
the motor.
From the moment when the paper feed sensors /1 (PS1) and / (PS7) turn ON [2] until the paper feed clutches /1
(CL3) and /2 (CL5) turn OFF [3] while in the pick-up control, CL4 and CL6 turn OFF and the pre-registration roller
stops. In this way, the paper thus conveyed from the feed roller hits against the pre-registration roller and a loop
is formed to correct the skew of paper.
After formation of the loop, CL4 and CL6 turn ON [4] a specified period of time after a print start signal [1] is out-
put to rotate the pre-registration roller for pre-registration. At the same time, CL3 and CL5 turn ON [5] for a short
period of time to rotate the feed roller and assist the conveyance until the pre-registration roller nips the paper
securely.
When the 1st sheet of paper passes through PS1 and PS7 and they turn OFF [6], CL4 and CL6 also turn off to
complete the pre-registration of the 1st sheet of paper. This timing becomes a starting point for the pick-up of
the 2nd sheet of paper [7] and the control of the pre-registration [8].
46
[1] [3] [4] [5] [7] [8]
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Paper feed clutches /1, /2 (CL3, 5)
Pre-registration clutches /1, /2 (CL4, 6)
Separation clutches /1, /2 (CL21, 22)
Paper feed sensors /1, /2 (PS1, 7)
[2] [6] 57aat2c039na
[1] Print start signal [5] Assist of the conveyance of the 1st sheet of paper
[2] Detection of the leading edge of the 1st [6] Detection of the trailing edge of the 1st
sheet of paper sheet of paper
[3] Formation of the loop of the 1st sheet of paper [7] Pick-up of the 2nd sheet of paper
[4] Pre-registration of the 1st sheet of paper [8] Pre-registration of the 2nd sheet of paper
14.3.3 Paper empty detection control

The paper empty detection in the tray is made by the paper empty sensors /1 (PS3) and /2 (PS9).
14.3.4 Remaining paper detection control

The remaining paper in the tray is detected according to the time required for the lift plate to be brought up by
the paper lift motors /1 (M16) and /2 (M17) when the tray is set. The time required for this up operation (operat-
ing time of M16 and M17) is stored in the printer control board (PRCB) and the remaining paper after that is
detected by subtracting a value shown on the paper feed counter.
The paper remaining thus detected is shown on the operation panel in 5 steps.
14.3.5 Horizontal conveyance control (tray 1)

Paper fed from the tray 1 is conveyed to the vertical conveyance section through the horizontal conveyance sec-
tion.
The horizontal conveyance rollers /Lt and /Rt are driven by the paper feed motor (M1) through each of the hori-
zontal conveyance clutches /Lt (CL15) and /Rt (CL16).
When the pre-registration of the 1st sheet of paper is made, CL15 turns ON a specified period of time after the
print start signal [1] is sent. In this manner, the horizontal conveyance roller /Lt rotates [2] to convey the paper
sent out by the pre-registration roller to the horizontal conveyance roller /Rt. When the horizontal conveyance
sensor /Rt (PS6) detects the leading edge of the paper and turns ON [3], the horizontal conveyance roller /Rt
rotates a specified period of time after that to convey [4] the paper to the vertical conveyance section. CL16
turns OFF [5] a specified period of time after PS6 detects the trailing edge of the paper, and then it turns OFF a
specified period of time after that to complete the horizontal conveyance. The conveyance [7] of the 2nd sheet
and the succeeding sheets of paper is made when CL16 turns ON a specified period of time after the drum
ready signal [6] is sent.
47
[1] [2] [4] [6] [7]

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Horizontal conveyance clutch /Lt (CL15)
Horizontal conveyance clutch /Rt (CL16)
Horizontal conveyance sensor /Lt (PS5)
Horizontal conveyance sensor /Rt (PS6)
[3] [5] 57aat2c040na
[1] Print start signal [5] Detection of the trailing edge of the 1st sheet of paper
[2] Rotation of the horizontal conveyance roller /Lt [6] Drum ready signal
[3] Detection of the leading edge of the 1st [7] Rotation of the horizontal conveyance roller
sheet of paper /Rt for the 2nd sheet of paper
[4] Rotation of the horizontal conveyance roller
/Rt for the 1st sheet of paper
48
15. PAPER FEED SECTION (trays 3 and 4)
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15.1 Composition
Pick-up roller Pre-registration roller
Lift plate
Dehumidification Dehumidification Feed roller Separation roller

57aat2c041na
heater /1 (HTR1) heater /2 (HTR2)
49
15.2 Drive
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[8] [9] [10] [11] [12] [13]
[1]
[2]
[7] [6] [5] [3]
[4] 57aat2c042na
[1] Coupling shaft /3 [8] Pick-up roller

[2] Belt [9] Feed roller
[3] Coupling shaft /4 [10] Paper feed clutch /3 (CL7), /4 (CL9)
[4] Paper feed motor (M1) [11] Coupling
[5] Separation clutch /3 (CL17), /4 (CL18) [12] Pre-registration roller
[6] Separation roller [13] Pre-registration clutch /3 (CL8), /4 (CL10)
[7] Trays 3 and 4
50
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[5]
[4]
[1]
[2]
[3] 57aat2c043na
[1] Paper lift motor /3 (M18) [4] Lift plate

[2] Paper lift motor /4 (M19) [5] Lift wire
[3] Lift wire
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15.3 Operation
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A. Up operation
The paper lift motors /3 (M18) and /4 (M19) cause the lift wires to be taken up by the pulley to raise the lift plate.
B. Down operation
When the tray is pulled out, the coupling shaft [2] of the tray is disengaged from the coupling gear [4] of the
paper lift motors /3 (M18) and /4 (M19) [3]. This brings up the lift plate [1] to release the drive force of the M16 or
M17 and the lift plate goes down by its own weight.
[3] [4]
[1]
[2] 57aat2c044na
[1] Lift plate [3] Paper lift motor /3 (M18), /4 (M19)

[2] Coupling shaft [4] Coupling gear
C. Operation timing
When the tray is set, the paper lift motors /3 (M18) and /4 (M19) turn ON to bring up the lift plate. When the lift
plate goes up and the upper most paper on the plate turns ON the upper limit sensors /3 (PS14) and /4 (PS20),
M18 and M19 turn OFF to stop the up operation.
While in the print operation, when PS14 and PS20 are turned OFF from ON by the paper feed operation, M18
and M19 turn on again to raise the lift plate. When PS14 and PS20 are turned ON again by this operation, M18
and M20 turn OFF to stop the up operation.

Refer to "14.3.2 Paper feed control." for details. (Refer to P.44)
52
15.3.3 Paper size detection control

A. Size detection in the main scan direction
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The size detection of paper in the main scan direction is made according to the position of the guide plate con-
nected to the paper size VR/1 (VR3) and /2 (VR4).
B. Size detection in the sub scan direction

The size detection of paper is made by the combination of the paper size sensors /Fr1 (PS17) and /Fr2 (PS23)
and the paper size sensors /Rr1 (PS18) and /Rr2 (PS24) that turn ON and OFF.
Original size PS17, PS23 PS18, PS24

ON/OFF ON/OFF
81/2 x 11 or less OFF OFF
A4S to B5S ON OFF
8 x 13 or more ON ON

The paper empty detection in the tray is made by the paper empty sensors /3 (PS15) and /4 (PS21).

The remaining paper in the tray is detected according to the time required for the lift plate to be brought up by
the paper lift motors /3 (M18) and /4 (M19) when the tray is set. The time required for this up operation (operat-
ing time of M18 and M19) is stored in the printer control board (PRCB) and the remaining paper after that is
detected by subtracting a value shown on the paper feed counter.
The paper remaining thus detected is shown on the operation panel in 5 steps.
15.3.6 Dehumidification heater control

A. Purpose
To keep the humidity in the tray at a fixed state, the dehumidification heaters /1 (HTR1) and /2 (HTR2) are pro-
vided.
B. Operation timing
The dehumidification heaters /1 (HTR1) and 2 (HTR2) operate when the dehumidification heater switch (SW3) is
ON and the power switch (SW2) is OFF.
53
16. BYPASS TRAY Theory of Operation Ver.2.0 Mar. 2010
16. BYPASS TRAY

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16.1 Composition
Paper feed roller Pick-up roller
Separation roller
Lift plate
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54
Theory of Operation Ver.2.0 Mar. 2010 16. BYPASS TRAY
16.2 Drive
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[4] [5]
[1]
[3] [2] 57aat2c046na
[1] Separation roller [4] Paper feed roller

[2] Belt [5] Pick-up roller
[3] Loop motor (M6)
[2]
[1]
57aat2c047na
[1] Lift plate [2] Bypass tray lift motor (M20)
55
16.3 Operation
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A. Up operation
The bypass tray lift motor (M20) drives the fan-shaped gear to bring up the lift plate.
B. Down operation
The bypass tray lift motor (M20) drives the fan-shaped gear to bring down the lift plate.
C. Operation timing
(1) Up operation
A print start signal rotates the bypass tray lift motor (M20) in the normal direction to bring up the lift plate. When
the lift plate goes up and the upper most paper on the lift plate turns ON the upper limit sensor/bypass (PS34),
M20 turns OFF to stop the up operation.
When PS34 is turned OFF from ON by the paper feed operation, M20 turns ON again to bring up the lift plate.
When PS34 is turned ON by this operation, M20 turns OFF to stop the up operation.
(2) Down operation

When there remains no paper in the bypass tray and the paper empty sensor/bypass (PS33) turns OFF, the
bypass tray lift motor (M20) rotates in the reverse direction to bring down the lift plate. When the lift plate goes
down and the lower limit sensor/bypass (PS35) turns ON, M20 turns OFF to stop the down operation.

A. Size detection in the main scan direction
The size detection of paper in the main scan direction is made according to the position of the guide plate con-
nected to the paper size VR/BP (VR5).
B. Size detection in the sub scan direction

The size detection of paper is made by the combination of the paper size sensors /Fr3 (PS31) and the paper
size sensors /Rr3 (PS32) that turn ON and OFF.
Paper size PS31 PS32

ON/OFF ON/OFF
81/2 x 11 or less OFF OFF
A4S to B5S ON OFF
8 x 13 or more ON ON
56
Theory of Operation Ver.2.0 Mar. 2010 16. BYPASS TRAY

A. Pick-up control
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The up operation of the lift plate causes the paper and the pick-up roller to come into contact. At this time, the
pick-up roller pressurizes the paper by its own weight.
When a print start signal [1] turns ON [2] the loop motor (M6), the pick-up roller that pressurized the paper
rotates and pick up the paper to convey it to the paper feed roller. The feed roller rotates together with the pick-
up roller and the paper is conveyed to the registration roller. When the registration sensor (PS44) provided short
of the registration roller turn ON [3], M6 turns OFF [4] a specified period of time after that to stop the rotation of
the feed roller and the pick-up roller.
When the 1st sheet of paper passes through PS44 and they turn OFF [5], M6 turns ON [6] again to pick up the
2nd sheet of paper.
[1] [2] [4] [6]
Loop motor (M6)
[3] [5] 57aat2c048na
[1] Print start signal [4] Completion of the feed of the 1st sheet of paper
[2] Pick-up of the 1st sheet of paper [5] Detection of the trailing edge of the 1st sheet of paper
[3] Detection of the leading edge of the [6] Pick-up of the 2nd sheet of paper
1st sheet of paper
57
The separation roller [4] is driven in the direction opposite [1] to the paper conveyance [8] through the torque lim-
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iter [6]. However, it is pressed against the feed roller [10] by the working pressure generated by the pressure [9]
of the spring [5] and the torque of the torque limiter. This working pressure of the feed roller, the separation roller
and the torque limiter becomes a limit torque for the double feed prevention of paper. When no paper is con-
veyed or when only one sheet of paper is convey between the separation roller and the feed roller, the frictional
pressure is greater than the limit torque and the separation roller is driven by the feed roller to be rotated [3].
When 2 or more sheets of paper are conveyed between the separation roller and the feed roller, the limit torque
is greater than the frictional force of these sheets of paper and the separation roller rotates in the reverse direc-
tion [7] to push back the lower paper [2] in contact with the separation roller in the tray direction [1], and the
paper is thus separated.
[10]
[9]
[2] [1]
[8]
[7] [6] [5] [4] [3] 57aat2c049na
[1] To the tray [6] Torque limiter

[2] 2nd sheet of paper [7] Rotation in the direction for separation
[3] Driven for rotation [8] Paper conveyance direction
[4] Separation roller [9] Pressurization of the separation roller
[5] Spring [10] Feed roller

The paper empty detection in the tray is made by the paper empty sensor/bypass (PS33).

When the paper empty sensor/bypass (PS33) turns OFF, a warning that there is no paper loaded on the bypass
tray is displayed on the operation panel.
58
Theory of Operation Ver.2.0 Mar. 2010 17. VERTICAL CONVEYANCE SECTION
17. VERTICAL CONVEYANCE SECTION
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17.1 Composition
Vertical conveyance sensor /1 (PS25)
Vertical conveyance roller /1

Vertical conveyance door
Vertical conveyance roller /2

Vertical conveyance roller /3 Vertical conveyance sensor /4 (PS28)
57aat2c050na
59
17. VERTICAL CONVEYANCE SECTION Theory of Operation Ver.2.0 Mar. 2010
17.2 Drive
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[1]
[2]
[3]
[4]
[5]
[6]
[7] 57aat2c051na
[1] Vertical conveyance roller /1 [5] Belt

[2] Vertical conveyance clutch /1 (CL11) [6] Vertical conveyance roller /3
[3] Vertical conveyance clutch /2 (CL12) [7] Paper feed motor (M1)
[4] Vertical conveyance roller /2
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17.3 Operation
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17.3.1 Conveyance control
A. Outline of the operation
In the vertical conveyance section, the vertical conveyance roller /1, /2 and /3 conveys paper supplied from the
trays 2, 3 and 4 to the loop roller. Paper fed from the tray 1 is also conveyed to the loop roller through the vertical
conveyance section. However, the drive of this paper is made by the conveyance rollers /1 and /2 with the verti-
cal conveyance roller having nothing to do with the conveyance drive.
B. Vertical conveyance of the tray 1 paper

Paper sent out from the horizontal conveyance section is conveyed to the loop roller through the upper most
section of the vertical conveyance section. The vertical conveyance sensor /1 (PS25) is provided on the convey-
ance path to detect a jam. While in the vertical conveyance from the trays 2, 3 and 4, PS25 is also used to
detect a jam.
C. Vertical conveyance of the tray 2 paper

When the paper feed operation turns ON [2] the paper feed sensor /2 (PS7), the vertical conveyance clutch /1
(CL11) is turned ON to transmit the drive force of the paper feed motor (M1) to the vertical conveyance roller /1.
In this manner, the paper sent out by the pre-registration roller of the tray 2 is conveyed [3] to the loop roller by
the vertical conveyance roller /1. When the registration sensor (PS44) detects the leading edge of the paper and
turns ON [4], CL11 turns OFF a specified period of time after that to complete the vertical conveyance of the 1st
sheet of paper. The conveyance [7] of the 2nd sheet and the succeeding sheets of paper is made by turning ON
[6] CL11 a specified period of time after the drum ready signal [5] is sent.
[1] [3] [5] [6] [7]
Vertical conveyance clutch /1 (CL11)
Paper feed sensor /2 (PS7)
[2] [4] [8] 57aat2c052na
[1] Print start signal [5] Drum ready signal

[2] Detection of the leading edge of the 1st [6] Start of the vertical conveyance of the 2nd
[3] Rotation of the vertical conveyance roller /1 [7] Rotation of the vertical conveyance roller /1
for the 1st sheet of paper for the 2nd sheet of paper
[4] Detection of the leading edge of the 1st [8] Detection of the leading edge of the 2nd
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17. VERTICAL CONVEYANCE SECTION Theory of Operation Ver.2.0 Mar. 2010
D. Vertical conveyance of the tray 3 paper

(1) Conveyance of small size paper
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The vertical conveyance clutch /2 (CL12) turns ON [2] a specified period of time after a print start signal [1] is
sent. In this manner, CL12 transmits the drive force of the paper feed motor (M1) to the vertical conveyance
roller /2. Paper sent out from the pre-registration roller of the tray 3 is conveyed to the vertical conveyance roller
/1 by the vertical conveyance roller /2 after passing through the vertical conveyance sensor /3 (PS27). When the
vertical conveyance sensor /2 (PS26) detects the leading edge of paper and turns ON [3], the vertical convey-
ance clutch /1 (CL11) turns ON to transmit the drive force of M1 to the vertical conveyance roller /1. In this way,
the paper is conveyed from the vertical conveyance roller /1 to the loop roller. When the registration sensor
(PS44) detects the leading edge of the paper and turns ON [5], CL11 turns OFF a specified period of time after
that to complete the vertical conveyance [4] of the 1st sheet of paper.
While in the paper feed of the 2nd sheet and the succeeding sheets of paper, CL12 turns OFF at once when
PS26 turns ON and stops once at the vertical conveyance section. And then, a specified period of time after a
drum ready signal [6] is sent, CL11 and CL12 turn ON [7] to convey the paper to the loop roller.
[1] [2] [4] [6] [7] [8]
[3] [5] [9] 57aat2c053na

[2] Rotation of the vertical conveyance roller /2 [7] Start of the vertical conveyance of the 2nd
[3] Detection of the leading edge of the 1st sheet of paper
sheet of paper [8] Rotation of the vertical conveyance roller /1
[4] Rotation of the vertical conveyance roller /1 for the 2nd sheet of paper
for the 1st sheet of paper [9] Detection of the leading edge of the 2nd
[5] Detection of the leading edge of the 1st sheet of paper
sheet of paper
62
(2) Conveyance of large size paper

The vertical conveyance of the 1st sheet of paper is the same as the conveyance of the small size paper. How-
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ever, in the same manner as with the vertical conveyance clutch /1 (CL11), the vertical conveyance clutch /2
(CL12) turns OFF a specified period of time after the registration sensor (PS44) detects the leading edge of the
paper and turns ON [5].
While in the paper feed of the 2nd sheet and succeeding sheets of paper, CL12 turns ON a specified period of
time after a drum ready signal [6] and the vertical conveyance roller /2 conveys [7] the 2nd sheet of paper to the
vertical conveyance roller /1. In this manner, when vertical conveyance sensor /2 (PS26) detects the leading
edge of the paper and turns ON [8], CL12 turns OFF to stand by for paper at the position short of PS26. And a
specified period of time after a drum ready signal is sent, CL11 and CL12 turn ON to resume the vertical con-
veyance [9] of the end sheet of paper.
[1] [2] [4] [6] [7] [9]
[3] [5] [8] [10] 57aat2c054na

[2] Rotation of the vertical conveyance roller /2 [7] Rotation of the vertical conveyance roller /2
[3] Detection of the leading edge of the 1st for the 2nd sheet of paper
sheet of paper [8] Detection of the leading edge of the 2nd
[4] Rotation of the vertical conveyance roller /1 sheet of paper
for the 1st sheet of paper [9] Rotation of the vertical conveyance roller /1
[5] Detection of the leading edge of the 1st for the 2nd sheet of paper
sheet of paper [10] Detection of the leading edge of the 2nd
sheet of paper
E. Vertical conveyance of the tray 4 paper

(1) Conveyance of small size paper
Same as "(1) Conveyance of small size paper" of "D. Vertical conveyance of the tray 3 paper." However, the ver-
tical conveyance clutch /2 (CL12) turns ON a specified period of time after the vertical conveyance sensor /4
(PS28) turns ON.
(2) Conveyance of large size paper

Same as "(2) Conveyance of large size paper" of "D. Vertical conveyance of the tray 3 paper." However, while in
the conveyance of the 1 sheet of paper, the vertical conveyance clutch /2 (CL12) turns ON a specified period of
time after the vertical conveyance sensor /4 (PS28) turns ON.
63
18. REGISTRATION SECTION Theory of Operation Ver.2.0 Mar. 2010
18. REGISTRATION SECTION

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18.1 Composition
Pre-transfer roller /Up Pre-transfer roller /Lw
Centering sensor (PS66) Registration roller

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64
Theory of Operation Ver.2.0 Mar. 2010 18. REGISTRATION SECTION
18.2 Drive
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18.2.1 Registration drive
[6]
[1]
[5]
[4]
[2]
[3] 57aat2c056na
[1] Registration clutch /1 (CL1) [4] Registration roller

[2] Front [5] Pre-transfer roller /Lw
[3] Registration motor (M5) [6] Pre-transfer roller /Up
18.2.2 Loop roller drive
[1]
[3] [2] 57aat2c057na
[1] Loop roller [3] Loop motor (M6)

[2] Belt
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18.3 Operation
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18.3.1 Loop control

A. Registration path
When paper supplied from the trays 1 to 4 [2], LU [1], the bypass tray [14] and ADU [5] hits against the registra-
tion roller [7], a loop [12] is formed until the roller provided just in front of the registration roller on each convey-
ance path turns OFF. And a paper skew is adjusted by this loop.
The rollers provided just in front of the registration rollers on each of the conveyance paths are as shown below:
Trays 1 to 4: Loop roller [3]
LU: Loop roller [3]
Bypass tray: Feed roller [13] for bypass feed
ADU: ADU pre-registration roller [4]
Each of these rollers is driven by the loop motor (M6) and the paper loop is controlled by the registration sensor
(PS44) [6] provided just in front of M6 and the registration roller.
[9] [10] [11] [12] [13] [14]
[8]
[7] [6]
[5] [4] [3] [2] [1] 57aat2c058na
[1] LU paper conveyance path [8] Pre-transfer roller /Lw

[2] Trays 1 to 4 paper conveyance path [9] Drum
[3] Loop roller [10] Pre-transfer roller /Up
[4] ADU pre-registration roller [11] Paper edge sensor (PS43)
[5] ADU paper conveyance path [12] Loop
[6] Registration sensor (PS44) [13] Feed roller for the bypass tray
[7] Registration roller [14] Bypass tray paper conveyance path
66
Theory of Operation Ver.2.0 Mar. 2010 18. REGISTRATION SECTION
B. Registration operation
(1) While in the paper feed from the trays 1 to 4, LU and ADU
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A specified period of time after the print start signal [1] is sent, the loop motor (M6) turns ON to drive [2] the loop
roller and the ADU pre-registration roller at a high process speed. The registration sensor (PS44) detects the
leading edge of paper conveyed from each of the rollers and turns ON [3]. And a specified period of time after
that, M6 turns OFF. At this time, the paper is conveyed for a specified period of time after it hits against the reg-
istration roller and a loop [4] is formed to correct the skew of the paper.
When a drum ready signal [5] is generated, the registration clutch (CL1) turns ON to transmit the drive force of
the registration motor (M5) to the registration roller. At the same time, M6 also turns ON. However, the process
speed is the same low speed as that of the registration roller to drive each of the rollers. In this way, the registra-
tion [8] of the paper is made by the registration roller while receiving a loop assist [6] from each of the rollers. And
the moment the print start signal is sent, M5 turns ON and drive the pre-transfer rollers /Up and /Lw at all times.
Paper sent out from the registration roller is conveyed to the drum by these rollers.
When, the registration let the loop sensor (PS36) or ADU pre-registration sensor (PS50) detect the trailing edge
of paper and turns OFF [7], M6 changes the rotation from low speed to high speed to feed [9] the next paper.
And when PS44 detects the trailing edge of paper and turns OFF [10], M6 and CL1 also turns OFF a specified
period of time after that to complete the registration operation.
[1] [2] [4] [5] [6] [8] [9]
Loop motor High speed

(M6)
Low speed
Loop sensor (PS36)

ADU pre-registration sensor (PS50)
[3] [7] [10] 57aat2c059na
[1] Print start signal [6] Loop assist

[2] High speed drive of the loop roller/ADU pre- [7] Detection of the trailing edge of paper
registration roller [8] Registration
[3] Detection of the leading edge of paper [9] Paper feed of the next paper
[4] Loop [10] Detection of the trailing edge of paper
[5] Drum ready signal
(2) While in the paper feed from the bypass tray

While in the paper feed from the bypass tray, the loop motor (M6) drives the feed roller at the process speed for
the bypass tray. The registration operation is the same as that of "(1) While in the paper feed from the trays 1 to
4, LU and ADU." However, to comply with the paper feed of special paper, no loop assist is made.
And while in the postcard mode and the thick paper mode, the process speed varies with the registration roller
and the pre-transfer rollers /Up and /Lw that are driven by the registration motor (M5).
67
18.3.2 Paper mis-centering correction control

To detect the mis-centering of paper after the registration, the paper leading edge sensor (PS43) and the center-
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ing sensor (PS66) are provided at the exit of the registration roller. PS43 detects the positional information in the
sub scan direction and PS66 detects it in the main scan direction. The positional information obtained by these
sensors is processed at the image processing section and adjusted prior to writing so that the image data cor-
responds to the position.
68
Theory of Operation Ver.2.0 Mar. 2010 19. HORIZONTAL CONVEYANCE SECTION
19. HORIZONTAL CONVEYANCE SECTION
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19.1 Composition
Transfer/sepa-
ration suction
Thick paper support belt fan (FM3)
Conveyance belt
57aat2c060na
19.2 Drive
[4]
[3]
[1]
[2] 57aat2c061na
[1] Registration motor (M5) [3] Thick paper support belt

[2] Front [4] Conveyance belt
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19. HORIZONTAL CONVEYANCE SECTION Theory of Operation Ver.2.0 Mar. 2010
19.3 Operation
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A. Conveyance suction
The duct [3] provided at the center of the conveyance section sucks paper passing through the conveyance
section to convey it. The suction opening [4] is provided at the lower section of each conveyance belt [2] and the
suction is made by the transfer/separation suction fan (FM3) [1] connected to the duct.
[1]
[4]
[2]
[3]
57aat2c062na
[1] Transfer/separation suction fan (FM3) [3] Duct

[2] Conveyance belt [4] Suction opening
70
Theory of Operation Ver.2.0 Mar. 2010 19. HORIZONTAL CONVEYANCE SECTION
B. Duct path
The duct [3] in the conveyance section [2] is connected to the transfer/separation suction fan (FM3) [1] at the
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lower section of the conveyance section. FM3 sucks through the duct and discharges the exhaust into the main
body.
[1]
[3]
[2]
57aat2c063na
[1] Transfer/separation suction fan (FM3) [3] Duct

[2] Conveyance section
C. Fan control
The transfer/separation suction fan (FM3) turns ON and OFF in accord with the ON and OFF operation of the
drum motor (M2).
71
19. HORIZONTAL CONVEYANCE SECTION Theory of Operation Ver.2.0 Mar. 2010
19.3.2 Thick paper support mechanism

In order to support the conveyance of the thick paper, the thick paper support belt [11] is provided. The thick
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paper support belt is normally [3] set at the same position in height as the conveyance belt [2]. When the set
lever [5] is changed over to the thick paper mode side [4] by the manual operation, the edge of the thick paper
support belt is raised. In this way, the drive force can be transmitted to the trailing edge of paper while in the
conveyance of the thick paper.
[1]
[5]
[2]
[4]
[3] 57aat2c064na
[1] Thick paper support belt [4] Position in the thick paper mode
[2] Conveyance belt [5] Set lever
[3] Normal position
72
Theory of Operation Ver.2.0 Mar. 2010 20. ADU
20. ADU
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20.1 Composition
ADU conveyance roller /1 ADU conveyance roller /2
Reverse/exit
gate ADU
pre-registration
Reverse/exit roller roller
ADU gate ADU conveyance roller /4
ADU reverse roller ADU conveyance roller /3

57aat2c065na
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20. ADU Theory of Operation Ver.2.0 Mar. 2010
20.2 Drive
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20.2.1 ADU conveyance roller drive
[8]
[7]
[6]
[1]
[5]
[2]
[3]
[4] 57aat2c066na
[1] Registration motor (M5) [5] ADU conveyance roller /1

[2] ADU deceleration clutch (CL2) [6] ADU conveyance roller /2
[3] ADU conveyance clutch (CL13) [7] ADU conveyance roller /3
[4] Front [8] ADU conveyance roller /4
20.2.2 ADU reverse roller drive
[3]
[2]
[1]
57aat2c067na
[1] Front [3] ADU reverse roller

[2] ADU reverse motor (M9)
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20.2.3 ADU pre-registration roller drive
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[2] [1] 57aat2c068na
[1] ADU pre-registration roller [2] Loop motor (M6)
20.2.4 Reverse/exit roller drive
[1]
[3]
[2]
57aat2c069na
[1] Reverse/exit roller [3] Reverse/exit motor (M8)

[2] Front
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20. ADU Theory of Operation Ver.2.0 Mar. 2010
20.3 Operation
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A. Conveyance path
While in the double sided print mode, paper that has been printed on the front side passes through the reverse/
exit switching gate [5], and then it is conveyed to the ADU reverse roller [1] through the underside of the reverse/
exit gate [4], the reverse/exit roller [3] and the ADU gate [2].
When the reverse/exit sensor (PS46) [7] detects the trailing edge of paper, the ADU reverse roller rotates in the
reverse direction to send back the paper. At this time, the ADU gate is closed and the paper passes through the
upper side of this gate to be conveyed to the ADU conveyance roller /1 [6]. In this way, the paper is turned over
without being stacked in the ADU. The paper thus turned over is conveyed to the ADU pre-registration roller [12]
by the ADU conveyance rollers /1, /2 [8], /3 [9] and /4 [10].
[5] [6] [7] [8] [9] [10] [11] [12]
[4]
[3]
[2] [1] 57aat2c070na
[1] ADU reverse roller [7] Reverse/exit sensor (PS46)

[2] ADU gate [8] ADU conveyance roller /2
[3] Reverse/exit roller [9] ADU conveyance roller /3
[4] Reverse/exit gate [10] ADU conveyance roller /4
[5] Reverse/exit switching gate [11] ADU pre-registration sensor (PS50)
[6] ADU conveyance roller /1 [12] ADU pre-registration roller
76
B. Pre-registration control
In the double sided print mode, when the ADU pre-registration sensor (PS50) detects the leading edge of paper
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and turns ON [2], the ADU deceleration clutch (CL2) turns OFF a specified period of time after this to shut off the
drive force of the registration motor (M5) that has been transmitted to the ADU pre-registration roller 13 and 14.
At this time, the loop motor (M6) that drives the ADU pre-registration roller is turned OFF. In this way, the paper
hits against the ADU pre-registration roller to form a loop. And the skew of the paper is corrected by this loop.
[1] [3]
ADU deceleration clutch (CL2)
Loop motor (M6)
ADU pre-registration sensor (PS50)
[2] 57aat2c071na
[1] Conveyance of the rear side of paper [3] Loop

[2] Detection of the leading edge of paper
77
21. FUSING SECTION Theory of Operation Ver.2.0 Mar. 2010
21. FUSING SECTION

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21.1 Composition
Fusing roller /Up Fusing claw /Up
Fusing roller /Lw Fusing heater

lamp /2 (L3)
Fusing heater
lamp /1 (L2)
Decurler roller Cleaning web Fusing heater lamp /3 (L4)
Fusing claw /Lw

57aat2e005na
78
Theory of Operation Ver.2.0 Mar. 2010 21. FUSING SECTION
21.2 Drive
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21.2.1 Fusing drive
[5] [6]
[4]
[3] [2] [1] 57aat2e006na
[1] Fusing motor (M4) [4] Fusing exit roller

[2] Fusing roller /Lw [5] Fusing roller /Up
[3] Decurler roller [6] Fusing input gear
21.2.2 Cleaning web drive
[5] [1]
[2]
[4]
[3]
57aat2e007na
[1] Web solenoid (SD2) [4] Cleaning web wind-up shaft

[2] Ratchet mechanism [5] Cleaning web unwinding shaft
[3] Front
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21.2.3 Reverse/exit switching gate drive

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[1]
[2]
57aat2c087na
[1] Reverse/exit switching gate [2] Reverse/exit solenoid
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21.3 Operation
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21.3.1 Web solenoid control
A. Cleaning web mechanism
Turning ON and OFF the web solenoid (SD2) [1] rotates in the ratchet mechanism section [2]. The drive force
thus generated is transmitted to the cleaning web wind-up shaft [3] through the gear to wind up the cleaning
web. The cleaning web contains silicone oil and the pressure roller [4] allows it to come into contact with the fus-
ing roller /Up to clean the roller surface. The feed per revolution of the cleaning web is about 0.04 to 0.05 mm/
print.
[1]
[5]
[4]
[2]
[3]
57aat2e008na
[1] Web solenoid (SD2) [4] Pressure roller

[2] Ratchet mechanism [5] Cleaning web unwinding shaft
[3] Cleaning web wind-up shaft
B. Operation timing
The web solenoid (SD2) turns ON and OFF based on the turning ON of the fusing exit sensor (PS30) when the
paper passes through it. However, in order to make the wind-up amount of the cleaning web per print at a fixed
rate, the number of prints is changed, which operates according to the print count value by cleaning web parts
that are required to be replaced. The following shows the count value of the cleaning web and the number of
operations of the SD2.
Count value of the cleaning web Number of operations of SD2

1 to 350,000 Operates according to the prescribed table values.
350,000 or more * Stops.
* Be sure to replace the cleaning web at the number of 250,000 prints. The performance of the cleaning web
is not necessarily guaranteed up to 350,000 prints.
81
21.3.2 Fusing temperature control

The heating of the fusing roller /Up is made by the fusing heater lamp/1 (L2) and /2(L3) and the heating of the
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fusing roller /Lw by the heater lamp/3 (L4).

The surface temperature of the fusing roller /Up is detected by the thermistors /1 (TH1) [2] and /2 (TH2) [1]. Tem-
perature of the fusing roller/Lw is not specifically detected. For TH1 of these thermistors, an NC sensor superior
in the speed of detection is employed.
The printer control board (PRCB) controls the fusing temperature as the DC power source/1 (DCPS1) turns L2
and L3 ON or OFF based on the surface temperature of the fusing roller/Up detected by TH1.
[1] [2]
57aat2e009na
[1] Thermistor /2 (TH2) [2] Thermistor /1 (TH1)
A. Warm-up
While in the warm-up, the fusing heater lamp/1 (L2), /2 (L3), and /3 (L4) are turned ON. They are turned OFF
when the fusing roller/Up surface temperature reaches the specified value. However, L2, L3 and L4 are not
turned ON at the same time to prevent flickering.
B. While in the print or while in the stand-by

The setting temperature of the fusing roller /Up varies with the type of paper, its size, the print mode or other
conditions. A control is made by turning on and off the fusing heater lamp /1 (L2) and /2 (L3) so that a prescribed
temperature can be obtained at all times. However, L2, L3 and L4 are not turned ON at the same time to prevent
flickering.
C. Power save mode

There are 2 modes available for the power save mode: sleep mode and low power mode. In the sleep mode, the
power is not supplied to the fusing heater lamp/1 (L2), /2 (L3) and /3 (L4). In the low power mode, a control is
made by turning L2, L3 and L4 ON/OFF so that the temperature is kept at a prescribed set temperature lower
than that seen while in the stand-by mode. However, L2, L3 and L4 are not turned ON at the same time to pre-
vent flickering.
82
21.3.3 Protection against abnormality

When the temperature detected by the thermostats /3 (TS3) [1] gets to 180 7C, the AC power line to the fus-
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ing heater lamp/1 (L2) and /2 (L3) is cut off to turn off L2 and L3. When the temperature to detect the thermostat
/4 (TS4) [2] reaches 110 10C, the AC power line to the fusing heater lamp/3 (L4) is cut off to turn L4 OFF. The
thermistors /1 (TH1) [4] and /2 (TH2) [3] detect the temperature of the fusing roller/Up at the center and on both
ends at a specified interval. When an abnormal temperature is detected, the power supply to L2, L3 and L4 is
turned off with a trouble cord displayed on the operation panel. For details of the abnormality detected, refer to
the trouble codes.
[3] [4] [1]
[2]
57aat2e010na
[1] Thermostat /3 (TS3) [3] Thermistor /2 (TH2)

[2] Thermostat /4 (TS4) [4] Thermistor /1 (TH1)
RL1
CBR1 TS3
L2
AC
L3 drive
section
TS4
L4 RL1
CBR2
DCPS1
TH1 AC RL
Control control drive
section section section
TH2
ADUDB PRCB
57aat2e011na
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21.3.4 Fusing conveyance mechanism

A. Decurler roller
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Paper guided by the reverse/exit switching gate [4] passes through between the decurler roller [2] and the
restriction shaft [3] for decurl.
[4]
[3]
[2] [1] 57aat2c088na
[1] Fusing exit roller [3] Restriction shaft

[2] Decurler roller [4] Reverse/exit switching gate
B. Reverse/exit switching gate

The reverse/exit switching gate is driven by the reverse/exit solenoid (SD7) to switch over the exit path for paper
sent out from the fusing exit roller.
84
Theory of Operation Ver.2.0 Mar. 2010 22. REVERSE/EXIT SECTION
22. REVERSE/EXIT SECTION
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22.1 Composition
Reverse/exit switching gate

Paper exit conveyance roller Main body paper
exit roller
Main body paper exit roller
Reverse/exit Fusing
Paper exit conveyance roller gate Decurler exit roller
roller a0pnt2c004ca
22.2 Drive
[3] [1]
[2]
57aat2c073na
[1] Paper exit motor (M7) [3] Main body paper exit roller
[2] Paper exit conveyance roller
85
22. REVERSE/EXIT SECTION Theory of Operation Ver.2.0 Mar. 2010
22.3 Operation
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A. Reverse/exit switching gate
The reverse/exit switching gate is turned ON and OFF by the reverse/exit solenoid (SD7) to switch the convey-
ance path for paper exited from the fusing exit roller over to either the straight paper exit or the reverse paper
exit.
B. Conveyance path
(1) Straight paper exit
While in the straight paper exit, the reverse/exit switching gate [2] is closed when the reverse/exit solenoid (SD7)
turns ON. So, paper exited from the fusing exit roller [1] is conveyed to the main body paper exit roller [3] pass-
ing over the reverse/exit switching gate.
[3]
[2]
[1] 57aat2c074na
[1] Fusing exit roller [3] Main body paper exit roller
[2] Reverse/exit switching gate
86
Theory of Operation Ver.2.0 Mar. 2010 22. REVERSE/EXIT SECTION
(2) Reverse paper exit

While in the reverse paper exit and the ADU paper feed, the reverse/exit switching gate [9] is opened when the
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reverse/exit solenoid (SD7) turns OFF. Paper exited from the fusing exit roller [2] is conveyed to the reverse/exit
gate [6] of ADU by the decurler roller [3] passing through the underside of the reverse/exit switching gate. The
reverse/exit gate is normally closed. However, the elasticity of paper opens it to convey the paper to the reverse/
exit roller [4] and the ADU reverse roller [1]. While in the ADU paper exit, paper is conveyed until the trailing edge
of paper passes through the reverse/exit roller.
When the paper reverse sensor (PS42) [5] detects the trailing edge of paper and turns OFF, the reverse/exit roller
and the ADU reverse roller rotate in reverse to send the paper back to the reverse/exit gate side. At this time, the
reverse/exit gate is closed and the paper is conveyed to the paper exit conveyance roller [7] side, not to the
decurler side. In this way, the paper is turned over to be exited from the main body paper exit roller [8].
[9]
[8]
[7]
[2]
[3]
[6]
[5] [4] [1]
57aat2c075na
[1] ADU reverse roller [6] Reverse/exit gate

[2] Fusing exit roller [7] Paper exit conveyance roller
[3] Decurler roller [8] Main body paper exit roller
[4] Reverse/exit roller [9] Reverse/exit switching gate
[5] Paper reverse sensor (PS42)
87
23. INTERFACE SECTION Theory of Operation Ver.2.0 Mar. 2010
23. INTERFACE SECTION

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23.1 Composition
Service port
CF card slot
USB port /4
(USB TypeB)
RJ45 Ethernet
connector
USB port /1
(USB TypeA)
USB port /2
(USB TypeA)
USB port /3 Serial port
(USB TypeA) (RS-232C)
a0pnt2c002ca
23.2 Specifications
Item Specifications
Serial port (RS-232C) For CS Remote Care
CF card slot System management for CF card
CF card stored the following programs and the datas
1. MFP controller program (Firmware)
2. The datas (Utility/Administrator Setting Data, Des-
tination Storage Data, CS Remote Care Setting
Data, All History Data) that initialized in the [Sys-
tem 1]-[Initialization] of the service mode
3. HDD serial number
4. HDD model type
RJ45 Ethernet connector Network connection, Internet for ISW
USB port /1 (USB TypeA) USB ISW, For authentication device (Biometric type: AU-
USB port /2 (USB TypeA) 101 or IC card type: AU-201)
USB port /3 (USB TypeA) Scan to USB, USB for print
USB port /4 (USB TypeB) For the local connection when installed EK-703
(Option)
Service port For the production adjustment
This is not used in the field
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Theory of Operation Ver.2.0 Mar. 2010 24. IMAGE STABILIZATION CONTROL
24. IMAGE STABILIZATION CONTROL
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24.1 Outline
In order to realize the top quality print images at all times, this machine conducts various types of control for
image stabilization. The operation of the image stabilization control varies depending on whether the power
switch (SW2) is turned ON and the print is in operation.
24.2 Operation flow

24.2.1 Image stabilization control flow when the power switch (SW2) is ON
The following shows the operation flow of the image stabilization control when the power switch (SW2) is turned
ON. However, this flow indicates an example in bizhub 751 in which the warm-up is made for 180 sec. in the
prescribed environment.
Power on F. Environmental decision
A. Charge cleaning
B. Pre-rotation of the drum
C. MPC/APC
D. Maximum density correction
E. Gamma correction
Note
Depending on the environmental condition, the cleaning of the charge and the transfer/separation
charge is made. Charge cleaning cycle varies with the number of prints set of the DIPSW2-4 and
2-5.
A. Charge cleaning
When the specified conditions are met upon the power ON, the charge and transfer/separation charge are
cleaned.
B. Pre-rotation of drum control

(1) Purpose
To prevent the drum charge leak such as an image flow while in the high humidity.
When left at a low or normal humidity, to prevent an uneven density due to the difference in sensitivity
between the areas facing the cleaner and developing unit of the drum and other areas.

When the environmental condition at the time of the power switch (SW2) being turned ON meets the pre-
scribed condition, rotate the drum for a specified period of time after starting the OS.
89
24. IMAGE STABILIZATION CONTROL Theory of Operation Ver.2.0 Mar. 2010
C. Maximum density correction

(1) Purpose
bizhub 751/601
According to "24.2.2 Image stabilization control flow while in the print and after completion of the print."

After completion of the preliminary rotation of the drum
D. Gamma correction
(1) Purpose
According to "24.2.2 Image stabilization control flow while in the print and after completion of the print."

After completion of the maximum density adjustment
E. Environmental decision control

(1) Purpose
To detect the ambient temperature and humidity and feed back the findings to the various types of controls to
maintain the image at a fixed quality.
(2) Method
The temperature sensor is provided on the toner control sensor board (TCSB) and the humidity sensor (HUM)
provided at the bottom of the printer control board (PRCB).

With the power switch (SW2) ON, when the time the machine is left unused after SW2 was turned OFF last time
is more than the specified period of time and the fusing temperature meets the prescribed condition, the envi-
ronmental condition is decided based on the measurement values of the sensors.
90
24.2.2 Image stabilization control flow while in the print and after completion of the print.
The following shows the flow of the image stabilization controls taken while in the print and after completion of
bizhub 751/601
the print.
Print start signal
Start of signal
B. Black belt creation control
b a
End of print
C. Charge cleaning D. Dot diameter correction control
E. Maximum density control
F. Gamma correction control
Stand-by
a: After completion of the last job for each specified prints and when the developing theta gets to
the reference value.
b: After completion of the last job other than the above.

(1) Method
Develop a toner patch on the drum once for every 6 prints after the power switch (SW2) turns ON, and read
the patch density with the maximum density sensor.
When the patch density is lower than the reference value, the operation varies depending on the developing
theta (developing roller line speed/drum line speed).
a. When the developing theta is lower than the reference value: Increase the number of rotations of the
developing roller for control according to the patch density.
b. When the developing theta is at the reference value: Drive the toner supply motor (M12) only for the
period of time calculated based on the patch density and the paper size to replenish toner.
91
24. IMAGE STABILIZATION CONTROL Theory of Operation Ver.2.0 Mar. 2010
B. Black belt creation control

(1) Purpose
bizhub 751/601
To stabilize the load on the cleaning blade, coat the entire drum image area with toner before cleaning the clean-
ing blade.
(2) Method
Create a black belt of 0.5 mm or 1.25 mm in width on the drum corresponding to the position about 13 mm
from the leading edge of the preceding paper.
The creation of the black band is controlled to be switched automatically between 0.5mm and 1.25mm.
Only in the case that the drum running time is less than the predetermined time or the drum motor (M2)
runs continually for more than the predetermined time, the black band is created 1.25mm in width and it is
created 0.5mm in other cases. Furthermore, it is changed to the control that always creates with 0.5mm in
width by DIPSW12-5.

Create once for every 3 prints.
The execution timing can be changed with DIPSW12-0.
C. Charge cleaning
When the print count after the previous cleaning has exceeded the specified value upon the power switch
(SW2) ON.
Cleaning is executed after completion of a job for every specified number of print count during the printing
operation.
D. Dot diameter correction control

(1) Purpose
To prevent the laser 1 dot diameter from changing due to the write system being stained or the change in the
developing performance, and to obtain a stable image quality for a long period of time.
(2) Method
Create multiple dot pattern patches of a fixed density on the drum by changing the laser power value. At
this time, create the patches while changing the MPC value with the laser PWM maximum.
Read this dot pattern patch with the gamma sensor and store as the MPC value the laser power value
obtained when the sensor output gets to the prescribed value. Until the next adjustment, use this setting as
the MPC value.

Execute each time the prescribed number of prints is made in the PM counter and after completion of the job
when the developing theta gets to the reference value.
92
E. Maximum density control

(1) Purpose
bizhub 751/601
To maintain the image at a fixed maximum density without being negatively affected by the environmental condi-
tion and the number of prints.
(2) Method
Create multiple toner patches on the drum while changing the rotation of the developing roller. At this time,
create patches with the laser exposure time per dot (laser PWM) maximum.
Read this patch with the maximum density sensor and store the number of rotations of the developing roller
when the sensor output gets to the prescribed value, and use this number of rotations to create the image.

Execute each time the prescribed number of prints is made in the PM counter and after completion of the job
when the developing theta gets to the reference value.
F. Gamma correction control

(1) Purpose
To maintain the image at a fixed gradation without being negatively affected by the environmental condition and
the number of prints.
(2) Method
Create multiple toner patches on the drum while changing the laser PWM. At this time, create patches with
the number of rotations of the developing roller decided at the maximum density control.
Read this patch with the gamma sensor and create a gamma curve by calculation.

Executed after completion of the job each time the specified number of prints are made in the PM counter
and also when the developing theta gets to the reference value.
93
25. IMAGE PROCESSING Theory of Operation Ver.2.0 Mar. 2010
25. IMAGE PROCESSING

bizhub 751/601
25.1 Image processing in the scanner section
A. Shading correction
B. AE correction
C. Area discrimination
D. Brightness/density conversion
E. Filter /magnification and contraction
F. Density gamma (conversion)
G. Skew adjustment
H. Compression
I. Storage of image data
25.1.1 Shading correction

This is a measure to obtain an even distribution of light of the CCD. The following corrections are 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 (L1) is stored as the maximum output value of the pixel.
B. Black correction
The output voltage of each pixel of the CCD sensor when the exposure lamp (L1) is turned off is stored as the
minimum output value of the pixel.
C. Shading correction
Based on the difference between the white data and black data for each pixel stored in the white correction and
the black correction, the result of calculation that the image data read from the original falls on what step in this
range is output in the 10 bits accuracy.
94
Theory of Operation Ver.2.0 Mar. 2010 25. IMAGE PROCESSING
25.1.2 AE processing
The AE control selects automatically a density suitable for the original density and the copy is made properly.
bizhub 751/601
A. Sampling area
(1) While in the platen mode
While in the normal copy
[2]
[2]
[1] 57aat2c077na
[1] 30 mm [2] 10 mm
While in the auto erase outside original mode

Entire original area detected by the original area discrimination scan (pre-scan)
(2) While in the DF mode
[3]
[3]
[2] [1]
57aat2c078na
[1] 2 mm [3] 10 mm
[2] 2 mm
B. Execution timing
While in the platen print: At the time of 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.
95
25. IMAGE PROCESSING Theory of Operation Ver.2.0 Mar. 2010
25.1.3 Area discrimination

To make a copy of the original under the appropriate condition (to make an appropriate filter processing), check
bizhub 751/601
the read section to see if it is a character or a dot picture, and use the results in the image processing section at
the later stage.
25.1.4 Brightness/density conversion

The signal obtained after the shading correction is a signal corresponding to the light reflected from the original,
and this is normally called a brightness signal. In this brightness/density conversion section, the brightness sig-
nal of 1024 stages is converted into the density of 225 stages.
25.1.5 Filter/magnification and contraction

A. Filter processing
An appropriate filter processing is made according to the type of the original and the magnification selected.
Character: Make the shading of the original conspicuous.
Dot section: Suppress moire.
Picture: Increase the reproducibility of gradation.
B. Magnification and contraction

For this machine, the magnification and contraction in the sub scan direction is made by the scan speed of the
exposure unit (in the platen mode) or the conveyance speed of DF (in the DF mode), and the magnification and
contraction in the main scan direction is made by processing images electrically.
25.1.6 Density gamma (conversion)

To the data obtained after the filter/magnification and contraction processing, select a density curve correspond-
ing to the density selected on the operation panel. An appropriate density curve is provided for each of the char-
acter/picture/character and the picture/thin character modes.
25.1.7 Skew adjustment

Detect an uneven original skew amount for each DF original with the DF original conveyance sensor (PS306) and
the original skew sensor (PS307), and adjust the skew amount detected with the sensors while shifting the
image data in the image processing.
25.1.8 Compression
To store more image data, data is stored temporarily in the image memory after the images have been com-
pressed.
The memory of 1GB is equipped.
25.1.9 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 optional hard disc.
96
Theory of Operation Ver.2.0 Mar. 2010 25. IMAGE PROCESSING
25.2 Image processing in the write section
bizhub 751/601
A. Elongation/rotation
B. 1dotPWM
C. Frequency conversion
25.2.1 Elongation/rotation
When outputting images from the memory, elongate the compressed data to restore them to their original state.
Rotate the image in the direction of 90 degrees or 180 degrees as required.
25.2.2 1dotPWM
While in the normal mode, the laser writing is made in 1bitED (2-value error diffusion).
25.2.3 Frequency conversion

Write in the memory once the data obtained after the PWM conversion, and read it in accordance with the write
clock signal of the printer.
97
26. OTHERS Theory of Operation Ver.2.0 Mar. 2010
26. OTHERS
bizhub 751/601
26.1 Fan control

26.1.1 Composition
[12] [13] [14] [15] [16]
[11] [17]
[1]
[2]
[10]
[3]
[4]
[5]
[9]
[8] [7] [6] 57aat2e012nb
[1] CPU cooling fan (FM22) [10] Suction fan /Fr (FM6)
[2] Developing suction fan (FM4) [11] Cleaner cooling fan (FM5)
[3] Developing cooling fan (FM12) [12] Polygon cooling fan (FM2)
[4] Ozone fan (FM21) [13] Scanner cooling fan (FM9)
[5] Power supply cooling fan /2 (FM15) [14] Paper exit fan (FM8)
[6] Power supply cooling fan /1 (FM16) [15] Cooling fan /1 (FM1)
[7] Exhaust fan /Rr (FM19) [16] HDD cooling fan (FM24): optional
[8] Transfer/separation suction fan (FM3) [17] Overall control board cooling fan (FM23)
[9] ADU cooling fan (FM10)
98
Theory of Operation Ver.2.0 Mar. 2010 26. OTHERS
26.1.2 Operation
A. Cooling fan /1 (FM1) control
bizhub 751/601
(1) Purpose
To exhaust around the drum and the fusing section.
(2) ON timing
While in the warm-up, turns ON (rotates at a low speed) in accord with the drum motor (M2).
While in the idle, turns ON at all times.
While in the print, rotates at a high speed in accord with M2, and rotates at a low speed a specified period
of time after completion of the print.
(3) OFF timing

While in the warm-up, turns OFF in accord with M2.
After completion of the warm-up, does not turn OFF until the power switch (SW2) is turned OFF.
B. Polygon cooling fan (FM2) control

(1) Purpose
To cool down around the polygon motor (M15) and the write section.
(2) ON timing
Turns ON (rotates at a low speed) in accord with the polygon motor (M15).
While in the warm-up and during idling, turns ON (rotates at a low speed) at all times.
While in the print, rotates at a high speed in accord with the fusing motor (M4) and rotates at a low speed
when the drum motor (M2) turns OFF.
(3) OFF timing

After completion of the warm-up, does not turn OFF until the power switch (SW2) is turned OFF.
C. Transfer/separation suction fan (FM3) control

(1) Purpose
To exhaust around the transfer/separation corona unit and the conveyance section.
(2) ON timing
While in the warm-up and the print, turns ON in accord with the drum motor (M2).
(3) OFF timing

While in the idle, turns OFF at all times.
While in the warm-up and the print, turns OFF in accord with the turning-OFF of M2.
D. Developing suction fan (FM4) control

(1) Purpose
To collect toner scattered from the developing unit into the developing suction filter.
(2) ON timing
While in the warm-up and the print, turns ON in accord with the drum motor (M2).
(3) OFF timing

While in the idle, turns OFF at all times.
While in the warm-up, in the print and after completion of print, turns OFF in accord with the turning-OFF of
M2.
99
E. Cleaner cooling fan (FM5) control

(1) Purpose
bizhub 751/601
To cool down around the cleaning section.
(2) ON timing
Turns ON a specified period of time after the power switch (SW2) turns ON.
(3) OFF timing

Not to turn OFF until the power switch (SW2) is turned OFF.
F. Suction fan /Fr (FM6) control

(1) Purpose
To cool down around the paper exit section and the fusing section with suction.
(2) ON timing
Turns ON in accord with the drum motor (M2) only when the 1st sheet of paper is fed.
While in the print, turns ON if it is in the single sided print mode when the fusing exit sensor (PS30) turns ON for
detection.
(3) OFF timing

Turns OFF a specified period of time after the paper exit sensor (PS37) turns OFF.
G. Exhaust fan /Rr (FM19) control

(1) Purpose
To cool down around the paper exit section and the fusing section with exhaust.
(2) ON timing
While in the print, turns ON if it is in the double sided print mode with the temperature inside the machine in
excess of a fixed temperature when the fusing exit sensor (PS30) turns ON for detection.
(3) OFF timing

H. Paper exit fan (FM8) control

(1) Purpose
To cool down around the paper exit section with exhaust.
(2) ON timing
While in the print, turns on in accord with the drum motor (M2).
(3) OFF timing

I. Scanner cooling fan (FM9) control

(1) Purpose
To cool down around the exposure lamp (L1) and the scanner.
(2) ON timing
Turns ON in accord with the turn ON of the exposure lamp (L1).
100
(3) OFF timing

Turns OFF in accord with the turn OFF of the exposure lamp (L1).
bizhub 751/601
J. ADU cooling fan (FM10) control
(1) Purpose
To cool down around the ADU reverse motor (M9) and the ADU reverse section.
(2) ON timing
Turns ON in accord with the turn ON of the ADU reverse motor (M9).
(3) OFF timing

Turns OFF in accord with the turn OFF of the ADU reverse motor (M9).
K. Developing cooling fan (FM12) control

(1) Purpose
To cool down around the developing unit with suction.
(2) ON timing
While in the print, turns ON when it is in the double sided print mode or mixed with the single sided print and
double sided print.
(3) OFF timing

Turns OFF in accord with the turn OFF of the drum motor (M2).
L. Power supply cooling fan /2 (FM15) control

(1) Purpose
To cool down the DC power source /1 (DCPS1) with exhaust.
(2) ON timing
While in the warm-up and in the print, rotates at a high speed.
While in the idle and in the low power mode, rotates at a low speed.
(3) OFF timing

Turns OFF in accord with the turning-OFF of SW2.
While in the sleep mode, turns OFF.
M. Power supply cooling fan /1 (FM16) control

(1) Purpose
To cool down the DC power supply /1 (DCPS1) with suction.
(2) ON timing
While in the warm-up and in the print, rotates at a high speed.
While in the idle and in the low power mode, rotates at a low speed.
(3) OFF timing

Turns OFF in accord with the turning-OFF of SW2.
While in the sleep mode, turns OFF.
101
N. Ozone fan (FM21) control

(1) Purpose
bizhub 751/601
To collect the ozone that is accumulated in the machine to the ozone filter /Lw with exhausting.
(2) ON timing
Turns ON in synchronized with the developing suction fan (FM4).
(3) OFF timing

Turns OFF in synchronized with FM4.
O. CPU cooling fan (FM22) control

(1) Purpose
To cool down the CPU of the overall control board (OACB) with suction.
(2) ON timing
While in the copy/print/scan, rotates at a high speed.
While in the idle, and while in the low power mode and the normal sleep mode, changes over between the
high speed rotation and the low speed rotation according to the temperature detected by the CPU.
(3) OFF timing

While rotating at a low speed, turns OFF when the temperature detected by the CPU gets below the prescribed
temperature.
P. Overall control board cooling fan (FM23)

(1) Purpose
To cool the overall control board with suction.
(2) ON timing
It rotates in low speed during copying/printing/scanning, idling, and in the low power mode.
(3) OFF timing

Turns OFF in the sleep mode.
Q. HDD cooling fan (FM24) control

(1) Purpose
To cool down the HD-510 with suction.
(2) ON timing
Turns ON while in the idle and the print.
(3) OFF timing

Turns OFF while in the low power mode and the sleep mode.
102
26.2 Counter control
bizhub 751/601
26.2.1 Composition
1000 OACB
Vendor2
PWB1 PRCB 36
213 35 218
Vendor1
LCDB CNT1 CNT2 PS37
57aat2c080nc
26.2.2 Operation
A. Paper exit counter
Item Specifications/mechanism
Total counter (CNT1) Displays the cumulative number of prints in all print modes.
Mechanical counter driven by the electronic signal.
Counts up for each paper exit signal.
Electronic counter Displays the cumulative number of prints on the operation panel.
Data collection *1
Counts up for each paper exit signal.
Key counter (CNT2) Counter that disables the copy operation when the specified number of
optional copies is made. (Can be removed.)
Mechanical counter driven by the electronic signal.
*1: The following data are collected.
Service total
By modes
Trouble (SC)
Fixed parts
PM
Reuse
Fax communications errors
ADF passage count
JAM
Optional parts
Warning
Coverage block data
Time series jam
Time series (SC)
High coverage data
Block jam occurrence
Block trouble (SC) occurrence
103
B. Copy vendor (Vendor 1)

The following shows the specifications of the connecting connector.
bizhub 751/601
Connector Pin No. Signal name Description Output timing Type of signal
36 1 Paper feed Output from the start L output while in Open collector output
motor (M1) key being turned ON the copy opera-
signal up to the completion tion
of paper exit
2 Paper feed Output each time L output each
signal paper is supplied time paper is sup-
plied from each
tray
3 Paper size Signal output by When the paper
signal (0) paper sizes *1 size is changed
4 Paper size
signal (1)
5 Paper size
signal (2)
6 Paper size
signal (3)
7 Double sided Signal output while in While in the selec-
copy selection the double sided tion of the double
signal copy sided copy
8 CPF signal (0) Signal output by CPF While in the selec-
9 CPF signal (1) modes tion of the CPF
mode
10 PGND 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
F4 H L L H
104
C. Copy vendor (Vendor 2)

The following shows the specifications of the connecting connector.
bizhub 751/601
Connector Pin No. Signal name Description
1000 1 Vendor 5V
2 Main body 5V
3 Rxd Signel line from MFP to vending device
4 Txd Signal line from vending device to MFP
5 GND GND for signal
6 I/O port Not used
7 I/O port Not used
8 NC Not used
105
26.3 Parts that operate when the power switch is turned ON

bizhub 751/601
26.3.1 Parts that operate when the power cord is plugged into the power outlet.
A. Composition
RL2
SW3
SW1
CBR1
NF Coil/2 DCPS1
CBR2
EU/Taiwan only
LU
HTR101
HTR2
HTR1
T1
57aat2e013nb
B. Operation
When the dehumidification heater switch (SW3) is turned ON, when the power cord is plugged into the power
outlet, the dehumidification heaters /1 (HTR1) and /2 (HTR2), and the dehumidification heater (HTR101) of LU
are turned ON.
The AC line is provided with the circuit breakers /1 (CBR1) and /2 (CBR2) which cut off the AC line by them-
selves immediately when an excessive current flows due to a short circuit while plugging the power cord into the
power outlet. And, noises that enter through the power line are reduced by the noise filter (NF).
106
26.3.2 Parts that operate when the main power switch (SW1) is turned ON
A. Composition
bizhub 751/601
Coil/1 EU only
CBR1 SW1
NF Coil/2 DCPS1
CBR2 5VDC
12VDC
EU/Taiwan only
PRCB
SW2
DCPS2 OACB PWB1 PWB4
5VDC
HD-510
57aat2e014nb
B. Operation
Turning ON the main power switch (SW1) supplies the AC power source to the DC power sources /1 (DCPS1)
and /2 (DCPS2). In this manner, DCPS2 generates 5 VDC to supply it to the overall control board (OACB) and
the printer control board (PRCB). OACB supplies this DC power source to the VR board (PWB4) through the
operation board /1 (PWB1) and put the power switch (SW2) in the standby for input. At the same time, it turns
on the power source lamp. And also, when the network setting: set, inputting the AC power source allows
DCPS1 to generate 5 VDC and 12 VDC to supply it to the OACB and HD-510 (optional).
DCPS that generates 5 VDC is provide with a power save mechanism so that it consumes less power while in
the stand-by.
107
26.3.3 Parts that operate when the power switch (SW2) is turned ON
A. Composition
bizhub 751/601
RL1
L2
DCPS1 L3
CBR1 SW1
5VDC
12VDC L4
24VDC
NF Coil/2
CBR2 RL1
SW2
EU/Taiwan Only
PRCB OACB PWB1 PWB4
57aat2e015nb
B. Operation
When the power switch (SW2) is turned ON with the main power switch (SW1) ON, the DC power source /1
(DCPS1) supplies the 24V DC power source system for the drive of various types of load in addition to the
power source systems that have been supplied so far. And also, it also supplies the AC power source to the fus-
ing heater lamp /1 (L2), /2 (L3), and /3 (L4) when the main relay (RL1) turns on. In this manner, each of the
boards are supplied with the power source to start the initial operation of the main body.
108
26.4 Authentication unit
bizhub 751/601
26.4.1 Authentication unit (Biometric type) (AU-101)
A finger vein pattern is used for personal identification.
Vein patterns are inside the body and cannot be visually recognized. This makes vein patterns extremely dif-
ficult to forge or falsify. The vein pattern authentication system can provide high security.
With ultra-red LED radiation, a finger vein pattern is captured by camera and its image is created. The vein
pattern image is registered and a person can be identified if the person's vein pattern matches the regis-
tered one at the time of user authentication.
Ultra-red LED
Finger
Vein image
Camera
Authentication unit (AU-101) Vein

A00JT2C256AA
26.4.2 Authentication unit (IC card type: AU-201)

A non-contact IC card, such as an employee ID card, is used for personal identification.
The system supports the communications protocol in compliance with Type A, Type B, and Felica (Type C)
of ISO14443.
Only Felica and Type A cards can be used for bizhub 751/601 machines.
Simply placing the IC card on the authentication unit will let the unit read the data from the card.
Abcde Fgdhi
ABCDE_Co.
Non-contact IC card
Authentication unit (AU-201)

A00HT2C302AA
109
bizhub 751/601
Blank page
110
DF-614
2008.11
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

Theory of Operation Ver.1.0 Nov. 2008 CONTENTS
CONTENTS
DF-614
DF-614
OUTLINE
2. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Single sided original mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Double sided original mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2.1 Rear scan 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2.2 Rear scan 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2.3 Front scan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Mixed original mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3.1 AMS not used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3.2 AMS used (single sided/double sided) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Z-folding original mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3. COMPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4. PAPER FEED SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1.1 Paper feed drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1.2 Original stopper drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2.1 Size detection control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2.2 Pick-up mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2.3 Separation mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2.4 Original empty detection control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2.5 Registration control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5. CONVEYANCE SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1.1 Conveyance drive 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1.2 Conveyance drive 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1.3 Conveyance roller pressure/release drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2.2 Skew adjustment control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2.3 Cooling fan control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6. REVERSE SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1.1 Reverse drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1.2 Reverse gate drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2.1 Reverse control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2.2 Mixed original mode control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.2.3 Z-fold original mode control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7. ORIGINAL EXIT SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
i
CONTENTS Theory of Operation Ver.1.0 Nov. 2008
7.1.1 Exit gate drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

7.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.2.1 Paper exit mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DF-614
7.2.2 Stamp control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ii
Theory of Operation Ver.1.0 Nov. 2008 1. PRODUCT SPECIFICATIONS
OUTLINE
DF-614
A. Type
Name Reverse automatic document feeder

Type Sheet-through type automatic document feeder
B. Functions
Original size Inch : 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 71/4 x 101/2, 71/4 x 101/2S,
51/2 x 81/2, 51/2 x 81/2S, A3, B4, A4, B5, B5S, B6S, Tab paper
Metric : A3, B4, A4, A4S, B5, B5S, A5, A5S, 11 x 17, 81/2 x 11,
Foolscap, 8K, 16K, 16KS, Tab paper
Maximum original size: 297 x 431.8 mm
Minimum original size: 100 x 139.7 mm
Original stacking capacity 100 sheets, max. (80g/m2 or 20 lbs)
Original read speed (A4 Single sided copy mode : 75 sheets/min.
size) Double sided copy mode : 42 sheets/min.
Original feed layout Set with the front side up, at center as standard
Original image read position Dedicated slit glass section
Resolution 600 dpi
1
1. PRODUCT SPECIFICATIONS Theory of Operation Ver.1.0 Nov. 2008
C. Original
Type of paper High-quality paper of 50 to 200 g/m2

DF-614
Amount of curling Up to 10 mm with 5 originals overlapped one another
[1]
a
15jat1c001na
a Amount of curling: up to 10 mm
[1] Original
Originals other than those With the following originals, no severe problems are found such as frequent
that paper feed and jams and major damage to the originals, although it is not possible to obtain a
throughput can be guaran- numeric value indicating reliability that can be specified in product guarantee
teed terms:
Recycled paper, straw paper, heat sensitive paper, originals fed in the
mixing of perforated original mode, high-quality paper of 35 to 50 g/m2,
irregular-sized originals (such as CF originals), coated paper, originals
with a rough surface (such as letterhead), folded originals (Z-folded or
folded in two)
Originals not allowed to be The following originals are not allowed to be used:
fed OHP paper, blueprint master, label paper, offset master, bonded original,
high-quality paper of less than 35 g/m2 or more than 201 g/m2
2
Combination of mixed origi- For Metric

nals Reference original (original with a maximum width)
A3 A4 B4 B5 A4S A5 B5S A5S B6S
DF-614
Other A3 U {
origi- A4 { U
nals B4 ~ ~ U {
B5 ~ ~ { U
A4S ~ ~ ~ ~ U {
A5 ~ ~ ~ ~ { U
B5S X X ~ ~ ~ ~ U
A5S X X X X X X X U
B6S X X X X X X X ~ U
U: Same size {: Same group ~: Different group X: Mixing not allowed
: Cannot be set
For Inch
Reference original (original with a maximum width)

11 x 17 81/2 x 11 81/2 x 14 81/2 x 11S 51/2 x 81/2 51/2 x 81/2S
Other 11 x 17 U {
origi- 81/2 x 11 { U
nals 81/2 x 14 ~ ~ U { {
81/2 x 11S ~ ~ { U {
51/2 x 81/2 ~ ~ { { U
51/2 x 81/2S X X X X X U
U: Same size {: Same group ~: Different group X: Mixing not allowed
: Cannot be set
D. Maintenance
Maintenance Same as the main body.
E. Machine data
Power source 24V/5.1V DC (supplied from the main body)

Maximum power consumption 53W or less
Dimensions 625 (W) mm x 576 (D) mm x 154 (H) mm
Weight Approx. 12.9 kg
Humidity 10 to 80% RH (with no condensation)
NOTE
3
2. PAPER PATH Theory of Operation Ver.1.0 Nov. 2008
2. PAPER PATH
2.1 Single sided original mode
DF-614
[5]
[4] [3] [2] [1] 15jat1c002na
[1] Exit roller [4] Conveyance roller /1

[2] Conveyance roller /2 [5] Registration roller
[3] Slit glass
4
Theory of Operation Ver.1.0 Nov. 2008 2. PAPER PATH
2.2 Double sided original mode

2.2.1 Rear scan 1
DF-614
[4]
[3]
[2] [1] 15jat1c003na
[1] Reverse exit roller [3] Reverse gate

[2] Reverse roller [4] Registration roller
2.2.2 Rear scan 2
[7]
[6]
[5] [4] [3] [2] [1] 15jat1c004na
[1] Reverse exit roller [5] Conveyance roller /1

[2] Exit gate [6] Reverse gate
[3] Conveyance roller /2 [7] Reverse roller
[4] Slit glass
5
2.2.3 Front scan
[8] [9]
DF-614
[7]
[6]
[5] [4] [3] [2] [1] 15jat1c005na

[2] Exit gate [7] Registration roller
[4] Slit glass [9] Succeeding original
[5] Conveyance roller /1
6
2.3 Mixed original mode

2.3.1 AMS not used
DF-614
Single sided original mode: same as the normal single sided original mode
Double sided mode: same as the normal double sided original mode
2.3.2 AMS used (single sided/double sided)

A. Original size detection scan (both)
[4]
[3]
[2] [1] 15jat1c006na

[2] Reverse roller [4] Registration roller
B. Front and rear reversal scan (single sided)/rear scan (double sided)
[7]
[6]
[5] [4] [3] [2] [1] 15jat1c007na
[1] Reverse exit roller [5] Conveyance roller /1

[2] Exit gate [6] Reverse gate
[4] Slit glass
7
C. Front scan (both)
[8] [9]
DF-614
[7]
[6]
[5] [4] [3] [2] [1] 15jat1c008na

[2] Exit gate [7] Registration roller
[4] Slit glass [9] Succeeding original
[5] Conveyance roller /1
8
2.4 Z-folding original mode

Only the 1st page is scanned in the same conveyance path with the one when AMS is used in the mixed original
DF-614
mode and the succeeding pages are scanned in the normal conveyance path in the single or double sided orig-
inal mode.
9
DF-614
Blank page
10
Theory of Operation Ver.1.0 Nov. 2008 3. COMPOSITION
DF-614
3. COMPOSITION
Conveyance section Paper feed section
Slit glass (read position) Reverse section Paper exit section 15jat2c001na
11
4. PAPER FEED SECTION Theory of Operation Ver.1.0 Nov. 2008
4. PAPER FEED SECTION

4.1 Drive
DF-614
[1]
[2]
[3]
[4]
[5]
FRONT 15jat2c002na
[1] Original separation motor (M3) [4] Separation roller

[2] Original feed roller [5] Up/down plate
[3] Pick-up roller
12
Theory of Operation Ver.1.0 Nov. 2008 4. PAPER FEED SECTION
4.1.2 Original stopper drive
[2]
DF-614
FRONT [1] 15jat2c003na
[1] Reverse gate solenoid (SD1) [2] Original stopper
13
4.2 Operation
4.2.1 Size detection control
DF-614
A. Plain original mode

(1) Size detection in the main scan direction
The dimension of the original in the main scan direction is detected according to the position of the guide plate
installed on the original size VR (VR301).
(2) Size detection in the sub scan direction

The dimension of the original in the sub scan direction is detected according to the ON/OFF combination of the
original size sensors /Rt (PS309) and /Lt (PS310).
B. Mixed original mode/Z-fold original mode

(1) Size detection in the main scan direction
The dimension of the original in the main scan direction is detected according to the position of the guide plate
installed on the original size VR (VR301).
(2) Size detection in the sub scan direction

The dimension of the original in the sub scan direction (the dimension in the conveyance direction) is detected
according to the ON time period of the original registration sensor /1 (PS304) [2] when the original is fed by the
registration roller [1].
In the mixed original mode, the size detection in the sub scan direction is performed for every original. However,
in the z-folding original mode, the detection is performed only for the 1st original. The paper path for the 2nd and
succeeding originals are different in the single sided original mode and the double sided original mode.
[2]
[1]
15jat2c004na
[1] Registration roller [2] Original registration sensor /1 (PS304)
14
4.2.2 Pick-up mechanism

The original separation motor (M3) sends up the up/down plate [1] to push up the original to the pick-up roller
[2]. The pick-up (original feed) operation is conducted since the pick-up roller is rotated in the forward direction
DF-614
by the M3.
[2]
[1]
15jat2c005na
[1] Up/down plate [2] Pick-up roller
4.2.3 Separation mechanism

Of the originals that have been fed by the pick-up roller, only one sheet of original is conveyed to the registration
roller [4] side by the original feed roller [1] driven by the original separation motor (M3). Only the top sheet of the
original will be fed even if plural sheets are fed because of the torque limiter in the separation roller [2].
The original is stopped being fed after a specified period of time since the original registration sensor /1 (PS304)
[3] turns ON. The original is pressed against the registration roller and forms a loop [5] along with the shape of
the guide to straighten it up.
[4] [5] [1]
[3] [2] 15jat2c006na
[1] Original feed roller [4] Registration roller

[2] Separation roller [5] Loop
[3] Original registration sensor /1 (PS304)
4.2.4 Original empty detection control

The detection of the presence of original in the original tray section while in the scan stop is made by the original
empty sensor (PS301). The original empty detection while in the scan is made by the original set sensor (PS302)
to stop the original feed from the trays 1 to 4 and the LU after PS302 detects the trailing edge of the last original.
15
4.2.5 Registration control

A. Registration timing in the single sided original mode
After a specified period of time since the start signal [1] on the main body is transmitted, the original separation
DF-614
motor (M3) turns ON [2] and rotates at a high speed to send up the up/down plate and rotate the original feed
roller in the forward direction. The original is picked up (fed) and conveyed to the registration roller.
After a specified period of time since the original registration sensor /1 (PS304) turns ON by detecting the lead-
ing edge of the original, M3 is switched to rotate at a low speed and continue to convey the original. The original
comes into contact with the registration roller and then a loop is formed when PS304 turns ON [3] to adjust an
original skew.
The 2nd and succeeding originals are picked up after a specified period of time since the original registration
sensor /3 (PS312) turns OFF [4] by detecting the trailing edge of the previous original. Then it conducts the same
loop formation operation as that in the 1st original.
[1] [2] [3] [4] [5]
Original registration sensor /3 (PS312)
Main body exposure unit reading position
470 mm/s
F
Original separa- 200 mm/s
tion motor (M3)
200 mm/s
R
470 mm/s
15jat2c007na
[1] Start signal from the main body [4] Feeding of the 2nd sheet of original
[2] Feeding of the 1st sheet of original [5] Loop formation of the 2nd sheet of paper
[3] Loop formation of the 1st sheet of paper
16
B. Registration timing in the double sided/mixed/z-folding original modes

The pick-up operation for the 1st sheet of original and the loop formation operation are same as those in the sin-
gle sided original mode.
DF-614
The pick up (paper feed) of the 2nd and succeeding originals is started when the original feed motor (M1) com-
pletes the conveyance of the preceding original from the reversal section [4] after the back-side scanning. Then
it conducts the same loop formation operation as that in the 1st sheet of original.
[1] [2] [3] [4] [5]
470 mm/s
F
Original separa- 200 mm/s
tion motor (M3)
200 mm/s
R
470 mm/s
640 mm/s
F 400 mm/s
370 mm/s
Original feed motor
(M1) 370 mm/s
R 400 mm/s
640 mm/s
15jat2c008na
[1] Start signal from the main body [4] Feeding of the 2nd sheet of original
[2] Feeding of the 1st sheet of original [5] Loop formation of the 2nd sheet of paper
[3] Loop formation of the 1st sheet of paper
17
5. CONVEYANCE SECTION Theory of Operation Ver.1.0 Nov. 2008
5. CONVEYANCE SECTION
5.1 Drive
DF-614
5.1.1 Conveyance drive 1
[1]
[2]
FRONT 15jat2c009na
[1] Original feed motor (M1) [2] Registration roller
5.1.2 Conveyance drive 2
[4]
[1]
[3]
[2]
FRONT 15jat2c010na
[1] Paper exit roller [3] Conveyance roller /2

[2] Conveyance roller /1 [4] Original conveyance motor (M2)
18
Theory of Operation Ver.1.0 Nov. 2008 5. CONVEYANCE SECTION
5.1.3 Conveyance roller pressure/release drive
DF-614
[2] [1]
FRONT 15jat2c011na
[1] Conveyance roller pressure/release motor [2] Conveyance roller /1 driven roller
(M4)
19
5.2 Operation
DF-614
In this section, we discuss about the single sided original mode. Refer to "6. REVERSE SECTION" for the double
sided/ mixed/z-folding original modes. (Refer to P.23)
A. Original re-feed
The original feed motor (M1) rotates in the reverse direction at a high speed and the registration roller [1] driven
by M1 feeds the original again when the exposure unit on the main body moves to the read position. The reverse
gate solenoid (SD1) that opens the reverse gate [3] when the start key is turned ON turns OFF and closes the
reverse gate when the original registration sensor /1 (PS304) detects the leading edge of the original. Then the
re-fed original is conveyed to the conveyance roller /1 [4].
[1] [2]
[4] [3] 15jat2c012na
[1] Registration roller [3] Reverse gate

[2] Original registration sensor /1 (PS304) [4] Conveyance roller /1
20
B. Original scan
The conveyance rollers /1 [8] and /2 [5] and the original exit roller [3] are driven by the original conveyance motor
(M2). The original feed motor (M1) switches its rotation from a high speed to low when the original registration
DF-614
sensor /2 (PS305) [10] detects the leading edge of the original that has passed the reverse gate [11]. Then the
registration roller [12] conveys the original at the same speed with the conveyance rollers /1 and /2 and the orig-
inal exit roller.
The original is read when it passes over the slit glass after the original conveyance sensor (PS306) [7] turns ON.
The pressure of the driven roller [9] of the conveyance roller /1 is released only when the trailing edge of the orig-
inal passes to prevent the read failure due to the shock at the conveyance.
The read original is exited to the original exit section [4] via beneath of the original exit gate [4]. At the time, the
succeeding original [1] is picked up (fed), if any.
[12] [1]
[11]
[2]
[10]
[9]
[8]
[7] [6] [5] [4] [3] 15jat2c013na
[1] Succeeding original [7] Original conveyance sensor (PS306)

[2] Paper exit section [8] Conveyance roller /1
[3] Paper exit roller [9] Driven roller
[4] Paper exit gate [10] Original registration sensor /2 (PS305)
[5] Conveyance roller /2 [11] Reverse gate
[6] Slit glass [12] Registration roller
21
C. Scan timing of the single sided original
[1] [2] [3] [4] [5] [6] [7]

DF-614
Original feed 370 mm/s

motor (M1) F
640 mm/s
Original conveyance motor (M2) 370 mm/s
Original conveyance sensor (PS306)
Original exit sensor (PS303)
VALID
Reverse gate solenoid (SD1)
Conveyance roller pressure/release motor (M4)
15jat2c014na
[1] Start signal from the main body [5] Original exit of the 1st sheet of original
[2] Re-feeding of the 1st sheet of original [6] Scanning of the 2nd sheet of original
[3] Scanning of the 1st sheet of original [7] Original exit of the 2nd sheet of original
[4] Re-feeding of the 2nd sheet of original
5.2.2 Skew adjustment control

The original conveyance sensor (PS306) and the original skew sensor (PS307) are provided to make adjust-
ments when the original is conveyed with its leading edge skewed. PS306 and PS307 are provided on the front
and rear faces of the section between the conveyance roller /1 and the slit glass to detect the amount of skew
based on the time difference when the leading edge of the original turns ON these sensors. The amount of skew
detected is adjusted by means of image processing.
The skew adjustment control is effective for all document sizes and adjusts the skew up to 0.25%.
5.2.3 Cooling fan control

To prevent the original feed motor (M1), the original conveyance motor (M2), and the original separation motor
(M3) from getting too hot at the operation, the motors are cooled by the cooling fan (FM1). The cooling fan turns
ON when the original is started to be fed and turns OFF when M2 turns OFF.
22
Theory of Operation Ver.1.0 Nov. 2008 6. REVERSE SECTION
6. REVERSE SECTION
6.1 Drive
DF-614
6.1.1 Reverse drive
[1]
[2]
[4]
[1] Original feed motor (M1) [3] Pressure roller release solenoid (SD3)
[2] Reverse exit roller [4] Reverse roller
6.1.2 Reverse gate drive
[2]
[1] Reverse gate solenoid (SD1) [2] Reverse gate
23
6. REVERSE SECTION Theory of Operation Ver.1.0 Nov. 2008
6.2 Operation
6.2.1 Reverse control
DF-614
In this section, we discuss about the double sided original mode. In the double sided original mode, the read
order of the original is 2 1 4 3 and the front face is read first and then the back face is read. In the
mixed/z-folding original modes, the reverse control is performed in the same manner as in the double sided orig-
inal mode. Refer to "5. CONVEYANCE SECTION" for the single sided mode. (Refer to P.18)
A. Original re-feed
The original feed motor (M1) rotates in the reverse direction at a high speed and the registration roller [1] driven
by M1 re-feeds the original when the exposure unit on the main body moves to the read position. The reverse
gate solenoid (SD1) turns ON and opens the reverse gate [4] when the start key is turned ON. Then the re-fed
original is conveyed to the reverse roller [3] and the reverse exit roller [2].
[1] [2]
[4]
[3] 15jat2c017na
[1] Registration roller [3] Reverse roller

24
B. Reversing the original from the front face to back

The registration roller [1], the reverse roller [4], and the reverse exit roller [3] are driven by the original feed motor
(M1). M1 conveys the original by rotating in the forward direction at a high speed when conveying the original to
DF-614
the reverse roller. It switches to rotate in the reverse direction at a middle speed after a specified period of time
since the original registration sensor /1 (PS304) [2] detects the trailing edge of the original and turns OFF. At the
time, the trailing edge of the original is at the position just passed the reverse gate [6]. The document is returned
to the reverse gate since the rotating direction of M1 is reversed. Although the reverse gate is still open, the orig-
inal is conveyed to the conveyance roller /1 [5] due to its shape. Then the surface of the original is reversed.
[1] [2]
[6]
[5] [4] [3] 15jat2c018na
[1] Registration roller [4] Reverse roller

[2] Original registration sensor /1 (PS304) [5] Conveyance roller /1
25
C. Original back face scan

The original feed motor switches its rotational speed from a middle speed to low in the reverse direction after a
specified period of time since the original registration sensor /2 (PS305) [8] detects the leading edge of the orig-
DF-614
inal that passes the reverse gate [9] and turns ON. At the time, the original conveyance motor (M2) also turns
ON and starts rotating at a low speed. The back face of the original is scanned by the conveyance rollers /1 [6]
and /2 [3].
The original is read when it passes over the slit glass [4] after the original conveyance sensor (PS306) [5] turns
ON. The pressure of the driven roller [7] of the conveyance roller /1 is released only when the trailing edge of the
original passes to prevent the read failure due to the shock at the conveyance.
The read original is conveyed to the original exit gate [2]. However, it is conveyed to the reverse exit roller since
the original exit gate solenoid (SD2) turns ON and the original exit gate is closed. At the time, the leading edge
and trailing edge of the original cross each other since the pressure roller release solenoid (SD3) turns ON and
the pressure of the reverse exit roller is released for a specified period of time. The succeeding original [1] is
picked up (fed), if any.
[1]
[9]
[8]
[7]
[6]
[5] [4] [3] [2] 15jat2c019na
[1] Succeeding original [6] Conveyance roller /1

[2] Paper exit gate [7] Driven roller
[3] Conveyance roller /2 [8] Original registration sensor /2 (PS305)
[4] Slit glass [9] Reverse gate
[5] Original conveyance sensor (PS306)
26
D. Reversing the original from the back face to front/original front face scan
The original is conveyed to the reverse exit roller [1] even though the gate opens during scanning the back face
of the original since the leading edge of the original has passed the original exit gate [2] at the time. Once the
DF-614
scan is completed, the original feed motor (M1) rotates in the forward direction at a high speed and the original
conveyance motor (M2) switches its rotation from a low speed to high. The scanned original is conveyed to the
reverse exit roller at a high speed.
The pressure roller release solenoid (SD3) turns OFF when the trailing edge of the original goes through the orig-
inal exit gate. The original is conveyed in the reverse direction because the pressure of the reverse exit roller gets
back and M1 switches its rotation to a middle speed in the reverse direction. At the time, the original is conveyed
to the reverse roller [3] side since the original exit gate is at its normal position. Then the surface of the original is
reversed. The succeeding operation is same as that when scanning the back face of the original.
[3] [2] [1] 15jat2c020na
[1] Reverse exit roller [3] Reverse roller

[2] Paper exit gate
E. Original exit
Once the front face of the original is scanned, the original is conveyed to the original exit section [1] via the origi-
nal exit roller [2] since the original exit gate [3] is open. At the time, the succeeding original [5] is conveyed to the
reverse roller [4] if any.
[4] [5] [1]
[3] [2] 15jat2c021na
[1] Paper exit section [4] Reverse roller

[2] Paper exit roller [5] Succeeding original
[3] Paper exit gate
27
F. Scan timing of the double sided original
[1] [2] [3] [4] [5] [6] [7] [8] [9]

DF-614
Original registration
sensor /3 (PS312)
sensor /1 (PS304)
Main body exposure
unit reading position
640
mm/s
F 400
mm/s
370
Original feed mm/s
motor
(M1) 370
mm/s
R 400
mm/s
640
mm/s
Original 640
conveyance mm/s
motor F
(M2) 370
mm/s
sensor /2 (PS305)
Original conveyance
sensor (PS306)
Original exit sensor

(PS303)
VALID
Reverse gate
solenoid (SD1)
Original exit gate
solenoid (SD2)
Pressure roller release

solenoid (SD3)
Conveyance roller
pressure/release motor (M4)
15jat2c022na
[1] Start signal from the main body [6] Original exit of the 1st sheet of original
[2] Re-feeding of the 1st sheet of original [7] Back face scanning of the 2nd sheet of original
[3] Back face scanning of the 1st sheet of original [8] Front face scanning of the 2nd sheet of original
[4] Re-feeding of the 2nd sheet of original [9] Original exit of the 2nd sheet of original
[5] Front face scanning of the 1st sheet of original
6.2.2 Mixed original mode control

The mixed original sizes copy mode is applicable to both the same size originals and the different size originals.
Since the size detection in the direction of the original feed is made according to the ON time of the original reg-
istration sensor /1 (PS304), the size detection operation is made prior to the scan operation for each original.
6.2.3 Z-fold original mode control

In the Z-folding mode, the same detection operation as that in the mixed original sizes copy mode is made on
the 1st sheet of original to determine the original size. For the 2nd and succeeding originals, the normal original
conveyance is conducted depending on the single sided original mode and the double sided original mode.
28
Theory of Operation Ver.1.0 Nov. 2008 7. ORIGINAL EXIT SECTION
7. ORIGINAL EXIT SECTION

7.1 Drive
DF-614
7.1.1 Exit gate drive
[2]
[1] Exit gate solenoid (SD2) [2] Paper exit gate
7.2 Operation
7.2.1 Paper exit mechanism
In the double sided original mode, it switches the paper path to eject the original or to convey to the reversal
section to read again by sending up or down the original exit gate. After scanning the front face of the original in
the double sided original mode, the original exit gate solenoid (SD2) turns ON and the original exit gate moves
down to convey the original to the reversal section. After scanning the front face of the document, SD2 turns
OFF and the original exit gate moves up to convey the original to the original exit section.
29
7. ORIGINAL EXIT SECTION Theory of Operation Ver.1.0 Nov. 2008
7.2.2 Stamp control

A. Fax stamp operation
In the FAX mode, the stamp is placed onto the front face of each original in both single and double sided original
DF-614
modes to show the original has been scanned. The stamp is driven by the stamp solenoid (SD4) and placed
when passing through the original exit roller. At the time, the original conveyance motor (M2) turns OFF and the
original is stopped temporarily.
B. Stamp position
[5]
[4]
[1]
[2]
[3] 15jat2c024na
[1] 12 mm 5 mm [4] Sub scan direction

[2] Stamp position [5] Front face
[3] 10 mm 2 mm
30
LU-405/406
2008.11
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
LU-405/406
LU-405/406
OUTLINE
2. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. COMPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. PAPER FEED SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2.1 Paper feed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2.2 Paper empty detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2.3 Remaining paper detection control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5. UP/DOWN SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2.1 Up/down control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2.2 Dehumidification heater control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2.3 Interlock control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
i
LU-405/406
Blank page
ii
OUTLINE
LU-405/406
A. Type
Type Side mount type large capacity paper feed tray
B. Functions
Maximum tray capacity LU-405 4,000 sheets (for paper of 80 g/m2 or 20 lbs)
LU-406 4,000 sheets (for paper of 80 g/m2 or 20 lbs)
C. Type of paper
Paper size LU-405 Inch: 81/2 x 11, A4, wide paper,

custom size (up to 223 mm x 314 mm)
Metric: A4, B5, 81/2 x 11, 16K, wide paper,
LU-406 Inch: 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, A3, B4, A4,
A4S, Foolscap, wide paper,
Metric: A3, B4, A4, A4S, Foolscap, 11 x 17, 81/2 x 14,
81/2 x 11, 81/2 x 11S, 8K, 16K, wide paper,
D. Maintenance
E. Machine data
Power source 24V/5V DC, 27.3V AC (supplied from the main body)
Maximum power consump- LU-405 82W or less
tion LU-406 100W or less
Weight LU-405 Approx. 30 kg
LU-406 Approx. 42 kg
Dimensions LU-405 W 430 mm x D 639 mm x H 690 mm
LU-406 W 670 mm x D 639 mm x H 695 mm
NOTE
1
2. PAPER PATH
LU-405/406
15jst1c001na
2
LU-405/406
3. COMPOSITION
Paper feed section
Up/down section
15jst2c001na
3

LU-405/406
4.1 Drive
A. Paper feed drive
[1]
[10]
[9]
[2]
[8] [5]
[6]
[3]
[7] [4] 15jst2c002na
[1] Paper feed motor (M101) [6] Separation roller

[2] Feed clutch (CL101) [7] To the front side
[3] Pick-up roller [8] Torque limiter
[4] Paper feed roller [9] Pre-registration roller
[5] One-way mechanism [10] Pre-registration clutch (CL102)
4
B. Pick-up drive
LU-405/406
[4]
[3]
[1]
[2] 15jst2c003na
[1] Pick-up roller [3] Pick-up solenoid (SD100)

[2] To the front side [4] Paper feed roller
5
4.2 Operation
LU-405/406

A. Pick-up control
Paper is picked up when the pick-up solenoid (SD100) is turned OFF. When SD100 is turned OFF [2], the pick-
up roller goes down to press the paper by its own weight.
The pick-up roller pressing the paper is rotated through the transmission of the rotational driving force of the
paper feed motor (M101) when the feed clutch (CL101) turns ON [3], and then picks up the paper to convey it to
the paper feed roller. Since the paper feed roller rotates together with the pick-up roller, the paper is conveyed to
the pre-registration roller. When the pre-registration sensor (PS107) provided short of the pre-registration roller
turns ON [4], the SD100 also turns ON to evacuate the pick-up roller, and then it turns OFF the CL101 after a
specified period of time to stop the rotation of the paper feed roller and the pick-up roller.
When the 1st sheet of paper turns OFF [5] after passing through PS107, SD100 also turns OFF to let the pick-
up roller go down and pick up [6] the 2nd sheet of paper.
Feed clutch (CL101)

Pick-up solenoid (SD100)
Pre-registration sensor (PS107)
LU exit sensor (PS106)
[1] [2][3] [4] [5] [6] 15jst2c004na
[1] Start key ON [4] Evacuation of the pick-up roller

[2] Paper pressing by the pick-up rollers own weight [5] Dropping of the pick-up roller
[3] Transmission of the driving force to the pick- [6] Pick-up of the 2nd sheet of paper
up roller and the paper feed roller
6
The separation of paper is made by the separation roller [5].
LU-405/406
The separation roller [5] is driven in the opposite direction [10] of the paper conveyance direction [9] through the
torque limiter [8] to be pressed against the feed roller [1] by means of the pressure [6] of the spring [7] as well as
the operating pressure generated by the torque of the torque limiter. This operating pressure of the feed roller/
separation roller/torque limiter becomes a limit torque to prevent the double feed of paper.
When there is no paper found between the separation roller and the feed roller, or when only one sheet of paper
is being conveyed, the operating pressure is in excess of the limit torque and the separation roller is driven by
the feed roller for rotation [4].
When two or more sheets of paper are conveyed between the separation roller and the feed roller, the limit
torque is bigger than the frictional force between the sheets of paper. As a result, the separation roller rotates in
the reverse direction [10] to push back in the tray direction [3] the paper [2] below that is in contact with the sep-
aration roller to separate it.
[10] [1]
[9]
[2]
[3]
[4]
[8]
[7] [6] [5] 15jst2c005na
[1] Feed roller [6] Pressure

[2] 2nd sheet of paper [7] Spring
[3] To the tray [8] Torque limiter
[4] Driven for rotation [9] Direction of conveyance
[5] Separation roller [10] Rotation in the direction of separation
7
C. Pre-registration control
The pre-registration roller is driven by the paper feed motor (M101) through the pre-registration clutch (CL102).
LU-405/406
The turning ON or OFF of CL102 turns on or off the transmission of the driving force to start or stop the rotation.
The paper conveyed by the feed roller is pressed against the pre-registration roller, that has been stopped since
CL102 turned OFF, and forms a loop [2] to correct a paper skew. After a specified period of time since it forms
the loop, CL102 turns ON [3] and the pre-registration rotates to convey the paper to the main body with its skew
corrected. At this time, the feed clutch (CL101) turns ON [4] for a short period of time to rotate the feed roller to
assist the conveyance until the pre-registration roller nips the paper securely.
Feed clutch (CL101)
Pick-up solenoid (SD100)
Pre-registration clutch (CL102)
Pre-registration sensor (PS107)

LU exit sensor (PS106)
[1] [2] [3] [4] [2] [3] [4] 15jst2c006na
[1] Start key ON [3] Paper conveyance to the main body

[2] Skew corrected by forming a loop [4] Paper conveyance assist
8

The paper empty detection is made in the combination of the upper limit sensor (PS109) [6] and the paper
LU-405/406
empty sensor (PS108) [1] that turn ON and OFF.
When there remains paper in the tray, the paper lift plate [4] goes up and the paper pushes up the actuator [2] to
turn ON PS108 [1]. When it goes further up, the actuator [5] is pushed up to turn ON PS109 [6].
When there remains no paper, the actuator [2] gets in the hole [3] of the paper lift plate [4] and it cannot be
pushed up, and as a result, the actuator [5] only is pushed up to allow PS109 [6] to turn ON. If only PS109 turns
ON, it is determined that the paper is empty and the main body displays the message on its operation panel.
While in the paper feed operation, PS108 turns OFF from ON with PS109 ON to detect a paper empty condi-
tion.
[1]
[6] [2]
[3]
[5]
[4] 15jst2c007na
[1] Paper empty sensor (PS108) [4] Paper lift plate

[2] Actuator of PS108 [5] Actuator of PS109
[3] Hole [6] Upper limit sensor (PS109)
9

The remaining paper detection is made by the rotating position of the remaining paper detection gear [6] inter-
LU-405/406
locked with the shaft [5] of paper lift motor (M100) that drives the paper lift plate.
The remaining paper detection gear is integrated with the actuator [7]. The position of this actuator is detected
by the four sensors of the remaining paper sensor /1 (PS102) [1], the remaining paper sensor /2 (PS103) [2], the
remaining paper sensor /3 (PS104) [3], and the remaining paper sensor /4 (PS105) [4].
The calculation of the remaining paper is made in the combination of the four sensors that turn ON and OFF.
LU-405
[7] [1]
[6]
[2]
[5] [3]
[4] 15jst2c008na
[1] Remaining paper sensor /1 (PS102) [5] Shaft of the paper lift motor (M100)
[2] Remaining paper sensor /2 (PS103) [6] Remaining paper detection gear
[3] Remaining paper sensor /3 (PS104) [7] Actuator
[4] Remaining paper sensor /4 (PS105)
10
LU-406
[7] [1] [2] [3]
LU-405/406
[4]
[5]
[6] 15jwt2c001na
[1] Remaining paper sensor /1 (PS102) [5] Shaft of the paper lift motor (M100)
[2] Remaining paper sensor /2 (PS103) [6] Remaining paper detection gear
[3] Remaining paper sensor /3 (PS104) [7] Actuator
[4] Remaining paper sensor /4 (PS105)
It is possible to know the remaining paper in 8 steps by the four sensors that turn ON and OFF. However, the
remaining paper is displayed in 5 steps on the main body operation panel. The remaining paper amount is
shown on the main body operation panel by the number of crossbars or their flashing in the tray mark.
Remaining paper sensors 1/, /2, /3 and /4, and the remaining paper
Number of sheets PS102 PS103 PS104 PS105 Display of remaining paper amount on the
loaded operation panel
0 to 700 OFF OFF OFF OFF 1 crossbar flashing
701 to 1200 ON OFF OFF OFF 1 crossbar lit up
1201 to 1700 ON ON OFF OFF 2 crossbars lit up
1701 to 2200 ON ON ON OFF 2 crossbars lit up
2201 to 2700 ON ON ON ON 3 crossbars lit up
2701 to 3200 OFF ON ON ON 3 crossbars lit up
3201 to 3700 OFF OFF ON ON 4 crossbars lit up
3701 or more OFF OFF OFF ON 4 crossbars lit up
NOTE
The number of sheets loadable shown in the table above is rough estimates based on paper
weighing 80 g/m2. The number of sheets loadable varies depending on the thickness of paper.
11
5. UP/DOWN SECTION Theory of Operation Ver.1.0 Nov. 2008
5. UP/DOWN SECTION
LU-405/406
5.1 Drive
A. LU-405
[12]
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[11]
[8]
[9]
[10] 15jst2c009na
[1] Remaining paper detection gear [7] Lift wire /Fr4

[2] Paper lift motor (M100) [8] Lift wire /Fr3
[3] Lift wire /Rr1 [9] Lift wire /Fr2
[5] Lift wire /Rr3 [11] To the front side
[6] Lift wire /Rr4 [12] Paper lift plate
12
Theory of Operation Ver.1.0 Nov. 2008 5. UP/DOWN SECTION
B. LU-406
LU-405/406
[12]
[2]
[1]
[3]
[4]
[6] [5]
[7]
[11]
[8]
[9]
[10] 15jwt2c002na
[1] Paper lift motor (M100) [7] Lift wire /Fr4

[2] Remaining paper detection gear [8] Lift wire /Fr3
[5] Lift wire /Rr3 [11] To the front side
[6] Lift wire /Rr4 [12] Paper lift plate
13
5.2 Operation
LU-405/406

The paper lift plate is brought up or down by driving the paper lift motor (M100) to wind up the lift wire around
the pulley or wind it off from the pulley.
The paper lift plate is tied up with four lift wires each at front and rear. The lift wires /Fr3, /Fr4, /Rr3 and /Rr4 are
tied in the direction in which the paper lift plate is brought up, and the lift wires /Fr1, /Fr2, /Rr1 and /Rr2 tied in
the direction in which it is brought down.
When the paper lift plate is brought up, the lift wires /Fr3, /Fr4, /Rr3 and /Rr4 are wound up around the pulley,
and each two lift wires /Fr1, /Fr2, /Rr1, /Rr2 at front and rear are wound off from the pulley.
When it is brought down, the lift wires that were wound up while it was brought up are wound off and the lift wire
that were wound off while it was brought up are wound up to bring down the paper lift plate.
A. Up operation
When the upper door open/close sensor (PS100) turns ON [1] with the upper door closed, the paper lift motor
(M100) also turns on (in normal rotation) to bring up [2] the paper lift plate, and M100 turns OFF when the upper
limit sensor (PS109) turns ON [3].
While in the print operation, when PS109 turns OFF [4] from ON due to the insufficient height of paper caused
by paper being fed, M100 turns ON again (in normal rotation) to bring up the paper lift plate until PS109 turns
ON [5], and then M100 turns OFF.
This up operation of the paper lift plate is repeated for each sheet of paper that is fed.
[6][7]
Paper lift motor Forward

(M100)
Reverse
Upper door open/close sensor (PS100)
Upper limit sensor (PS109)
[1] [2] [3] [4] [5] [4] [5] 15jst2c010na
[1] Upper door closed [5] Completion of lifting to the upper limit position
[2] Lifting of the paper lift plate [6] Feeding of the 1st sheet of paper
[3] Stopping at the upper limit position of the [7] Feeding of the 2nd sheet of paper
paper lift plate
[4] Insufficient height of paper caused by paper
being feed
14
Theory of Operation Ver.1.0 Nov. 2008 5. UP/DOWN SECTION
B. Down operation
When the upper door open/close sensor (PS100) turns OFF [1] with the upper door open, the paper lift motor
LU-405/406
(M100) turns ON (in reverse rotation) and then turns OFF a specified period of time after the paper lift plate starts
to go down to stop [2] the paper lift plate at the position where it goes about 120 mm down.
When the tray down switch (SW100) is pressed [3] with PS100 turned OFF, M100 turns ON (in reverse rotation)
to bring down [4] the paper lift plate by another 120 mm and then stops. Each time SW100 is pressed, the plate
goes about 120 mm down. However, when the lower limit sensor (PS101) turns ON to detect the lower limit of
the paper lift plate, M100 stops [5]. Even when SW100 is pressed [6] with PS101 turned ON, the paper lift plate
does not go down.
Forward
Paper lift motor
(M100)
Reverse
Upper door open/close sensor (PS100)
Tray down switch (SW100)
Lower limit sensor (PS101)
[1] [2] [3] [4] [3] [3] [5] [6] 15jst2c011na
[1] Upper door closed [4] 120 mm down

[2] Stop of the paper lift plate [5] Stop at the lower limit position.
[3] Start of the down operation when the tray [6] Disregard of SW100 being turned ON when
down switch (SW100) turns ON the lower limit sensor (PS101) turns ON
5.2.2 Dehumidification heater control

The dehumidification heater (HTR101) is equipped in the inside of the LU to protect paper against humidity.
HTR101 is provided with 27.3 VAC from the main body, the turning ON/OFF of which is made by the dehumidi-
fication heater switch (SW3) of the main body.
5.2.3 Interlock control

The front door interlock switch (MS101) and the front door open/close sensor (PS110), and the upper door
interlock switch (MS102) and the upper door open/close sensor (PS100) are provided in the inside of the LU.
The power source of the paper feed motor (M101) is supplied through MS101 and MS102. When the front door
or upper door is opened, MS101 or MS102 turns OFF to shut off the power supply to the paper feed motor
(M101).
When PS110 or PS100 turns OFF while in the paper feed operation, the LU drive board (LUDB) turns OFF a
drive signal to M101 to stop the paper feed operation.
15
LU-405/406
Blank page
16
SF-602
2008.11
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
SF-602
SF-602
OUTLINE
2. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. COMPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. CONVEYANCE SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2.1 Conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2.2 Paper stack alignment mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2.3 Conveyance cover open/close detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. TRAY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.1.1 Shift drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.1.2 Tray up down drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2.1 Shift control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2.2 Tray up down control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
i
SF-602
Blank page
ii
OUTLINE
SF-602
A. Type
Type Paper exit tray with shift function
B. Functions
Mode Straight mode Discharged into the shift tray with no processing.
Shift mode Shifted 30 mm and discharged into the shift tray.
Tray capacity A4, A4S, B5, B5S, 81/2 x 11, 81/2 x 11S :1250 sheets
(paper weight: 80 g/m2 or A3, B4, A5, 11 x 17, 81/2 x 14 : 500 sheets.
20 lbs) A5S, B6S, A6S, 51/2 x 81/2, 51/2 x 81/2S :100 sheets
C. Type of paper
Type of paper Same as the main body.

Paper size Straight mode A3, B4, A4, A4S, B5, B5S, A5, A5S, B6S, A6S, Foolscap
11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2, 51/2 x 81/2S
8K, 16K, 16KS
Custom size: 105mm x 139mm to 305mm x 458mm
Shift mode A3, B4, A4, A4S, B5, B5S, A5, A5S, Foolscap
11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2, 51/2 x 81/2S
8K, 16K, 16KS
Amount of paper curl
[1]
a
15jpt1c003na
a Amount of curl: 10 mm or less

[1]: 5 sheets of paper immediately after printing
D. Maintenance
1
E. Machine data
Power source DC24V (supplied from the main body)

SF-602
Maximum power consumption 48W or less

Dimensions When the main tray is drawn out W 490 mm x D 600 mm x H 480 mm
When the main tray is put in W 400 mm x D 600 mm x H 480 mm
NOTE
2
2. PAPER PATH
SF-602
15jpt1c002na
3
SF-602
Blank page
4
SF-602
3. COMPOSITION
Conveyance
section
Tray section
15jpt2c001na
5
4.1 Drive
SF-602
[5]
[1]
[4]
[2]
[3] 15jpt2c002na
[1] Conveyance roller [4] Reverse roller

[2] Conveyance motor (M701) [5] Paper exit roller
[3] Belt
6
4.2 Operation
SF-602
The conveyance of paper is made by the conveyance motor (M701) and the detection of paper is made by the
conveyance sensor (PS701).
A. Single sided print mode

A start signal from the main body rotates the conveyance motor (M701) at low speed [1] and a paper exit ON
signal from the main body changes the rotation to a high speed [2]. And a specified period of time after a paper
exit signal from the main body turns OFF, the rotation changes to a low speed [3]. M701 turns OFF [4] a speci-
fied period of time after the conveyance sensor (PS701) detects the trailing edge of the last paper.
Main body paper exit signal
Conveyance sensor (PS701)

High speed
Conveyance
motor (M701) Low speed
[4]
[1] [2] [3] 15jpt2c003na
[1] Start signal from the main body [3] Changeover to a low speed rotation
[2] Changeover to a high speed rotation [4] M701 turns OFF after PS701 detects the
trailing edge of the paper
B. Double sided print mode

A start signal from the main body allows the conveyance motor (M701) to rotate at low speed, a main body
paper exit ON signal changes the rotation to a middle speed, and turning OFF the main body paper exit signal
changes the rotation to a high speed. And then the rotation changes to a low speed after a specified period of
time.
M701 turns off a specified period of time after the conveyance sensor (PS701) detects the trailing edge of the
last paper.
7
4.2.2 Paper stack alignment mechanism

The alignment of exited paper in the sub-scanning direction is made by the reverse roller [4] made of sponge.
The gear drive from the paper exit roller [1] rotates the reverse roller in the direction opposite [5] to the paper exit
SF-602
to send back paper for the paper stack alignment.

In order to absorb vertical movement caused by the up down operation of the shift tray [3], the paper exit roller
[1] can oscillate up and down [2] with its shaft as a pivot.
[4] [5]
[1]
[3]
[2]
15jpt2c004na
[1] Paper exit roller [4] Reverse roller

[2] Oscillating operation [5] Rotation of the reverse roller
[3] Shift tray (metal frame section)
4.2.3 Conveyance cover open/close detection control

A start signal from the main body starts the conveyance drive control. However, when the conveyance cover
switch (SW701) is turned OFF, an error signal is transmitted to the main body with no print made.
8
Theory of Operation Ver.1.0 Nov. 2008 5. TRAY SECTION
5. TRAY SECTION
5.1 Drive
SF-602
5.1.1 Shift drive
[1]
[2]
[10]
[11]
[3]
[4]
[9] [7]
[6] [5]
[8]
15jpt2c005na
[1] Home position /2 (rear side) [7] Shift home sensor (PS702)
[2] Crank shaft [8] Shift plate
[3] Worm wheel [9] Shift table
[4] Belt [10] Shift tray
[5] Shift motor (M703) [11] Home position /1 (front side)
[6] Worm gear
9
5. TRAY SECTION Theory of Operation Ver.1.0 Nov. 2008
5.1.2 Tray up down drive
[7] [1]
SF-602
[2]
[3]
[4]
[5]
[6]
15jpt2c006na
[1] Tray up down motor (M702) [5] Tray lower limit sensor (PS704)
[2] Tray upper limit sensor (PS703) [6] Up down pulley /Lw
[3] Tray upper limit switch (SW702) [7] Shift tray
[4] Up down belt
10
5.2 Operation
5.2.1 Shift control
SF-602
While in the sort/group mode, the shift tray is moved to a position 30 mm shifted in the main scanning direction
to stack paper ejected from the main body for the sort/group operation.
A. Shift mechanism
The shift motor (M703) [4] drives the crank shaft [9] installed to the worm wheel [2] through the belt [5] and the
worm gear [6] to drive the shift plate [13] 30 mm in the main scanning direction [11]. The shift tray is driven
through the claw [14] of the shift tray [12] that is engaged with the groove [15] of the shift plate.
The worm wheel [2] is integrated with the actuator [3]. The shift home sensor (PS702) [8] detects 2 positions [1]
and [10] of the shift tray in the main scan direction.
[11]
[15]
[10] [1]
[9] [2]
[12]
[14] [3]
[8]
[4]
[7]
[6] [5]
[13] 15jpt2c007na
[1] Home position /2 (rear side) of the shift tray [9] Crank shaft
[2] Worm wheel [10] Home position /1 (front side) of the shift tray
[3] Actuator [11] 30 mm (shift amount)
[4] Shift motor (M703) [12] Shift tray
[5] Belt [13] Shift plate
[6] Worm gear [14] Claw of the shift tray
[7] To the front side [15] Groove of the shift plate
[8] Shift home sensor (PS702)
11
In addition to the shift operation by the shift motor (M703), the shift tray performs the tray up down operation. To
make it possible for a smooth shift operation to be obtained without interfering with the tray up down operation,
the weight of the ejected paper and the tray is taken on by the shift table [1] that moves freely in the main scan-
SF-602
ning direction. The shift tray is provided with the horizontal rollers [2].
[1]
[2]
15jpt2c008na
[1] Shift table [2] Horizontal roller
B. Shift control
The shift of paper is made by the shift motor (M703), and while in the sort/group mode, it is driven.
(1) Sort/group mode

A shift request signal [1] from the main body turns ON the shift motor (M703) [2] after a specified period of time
to start the shift operation, and a signal from the shift home sensor (PS702) [3] turns OFF the M703.
Even while the last paper is being ejected, the shift tray is shifted [4] to stand by for the next print.
Main body shift request signal
Shift motor (M703)
Shift home sensor (PS702)
[1] [2][3] [4] 15jpt2c009na
[1] Shift request signal from the main body [3] Completion of shift
[2] Start of the shift operation [4] Shift for printing
12
(2) Non sort mode

While in the non sort mode, the shift motor (M703) does not drive.
Paper ejected from the main body is exited into the shift tray as being left at the position to which it was shifted
SF-602
after completion of the preceding print operation.
5.2.2 Tray up down control

The up down operation of the tray is made by the tray up down motor (M702) that rotates in the normal or
reverse direction.
A. Control
A start signal [1] from the main body turns ON the tray up down motor (M702) to bring down the tray. A specified
period of time after that, M702 rotates in the reverse direction to bring up the tray and it stops when the tray
upper limit sensor (PS703) turns ON [2].
The drive of M702 while in the paper exit causes the same operation as mentioned above when the conveyance
sensor (PS701) detects the trailing edge of paper at the time of the ejection of odd number of sheets of paper
[3]. And the uneven paper exit is prevented by keeping a fixed distance between the upper surface of the paper
exited into the shift tray and the paper exit opening.
Tray up down UP
motor (M702)
DOWN
Tray upper limit sensor (PS703)
[1] [2] [3] 15jpt2c010na
[1] Start signal from the main body [3] Ejection of the odd number of sheets of paper
[2] Tray up down operation
B. Paper full control

When the tray lower limit sensor (PS704) turns ON, the tray up down motor (M702) stops with a paper full signal
is transmitted to the main body.
13
C. Up abnormality detection
The actuator of the tray upper limit switch (SW702) [2] is integrated structurally with the actuator of the tray
upper limit sensor (PS703) [3]. When the shift tray [1] goes up abnormally beyond PS703, SW702 turns ON to
SF-602
stop the tray up down motor (M702).
[1]
[2]
[3] 15jpt2c011na
[1] Shift tray [3] Tray upper limit sensor (PS703)

[2] Tray upper limit switch (SW702)
14
FS-524/525/610
2008.11
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
FS-524/525/610
FS-524/525/610
OUTLINE
2. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Non-sort/sort/group mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Sub tray mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Stapling mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Folding/saddle stitching mode (FS-610) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Tri-folding mode (FS-610) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3. COMPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4. TRANSFER SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2.1 Punch registration control (available only when PK is installed) . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2.2 FS transfer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2.3 Gate drive control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2.4 Bypass gate control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2.5 Shift control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2.6 Paper exit roller control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2.7 Paper exit opening solenoid control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2.8 Paper exit opening control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.9 Sub tray paper exit control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5. MAIN TRAY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2.1 Tray lift control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6. STACKER SECTION (FS-524/525) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.2.1 Alignment control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.2.2 Stopper control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2.3 Stacker entrance transfer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.2.4 Stacker paper exit control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7. STACKER SECTION (FS-610) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.2.1 Alignment /Up control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.2.2 Alignment /Lw control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.2.3 Stopper control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.2.4 Stacker entrance transfer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.2.5 Stacker paper exit control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8. STAPLER (FS-524/525) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
i
8.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.2.1 Stapler movement control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
FS-524/525/610
8.2.2 Stapler control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

9. STAPLER (FS-610) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9.2.1 Stapler movement control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9.2.2 Stapler control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
10. FOLDING/SADDLE STITCHING/TRI-FOLDING (FS-610). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10.2.1 Folding knife control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10.2.2 Folding transfer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10.2.3 Tri-folding gate control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
ii
OUTLINE
FS-524/525/610
A. Type
Name Finisher
Type Flat-stapling device (FS-524/525)
Saddle stitch device (FS-610)
Stapling method Incline clinch method
Shifting method Exit paper shifting method
B. Functions
(1) Functions
Non-sort mode Exited to the main tray with no processing made.

Sort/group mode Exited to the main tray after being shifted for every copy.
Sub tray mode Exited to the sub tray with no processing made.
Stapling mode Exited to the main tray after being stapled.
At corner Parallel or skew depending on the paper size (FS-524/525)
Front parallel/back 45 inclined (FS-610)
At 2 places Symmetry at the center with 162 mm pitches (FS-524/525)
Symmetry at the center with 128 to 160 mm pitches (FS-610)
Folding mode Exited to the booklet tray with the paper folded into two at its center (FS-610 only).
Saddle stitching mode Exited to the booklet tray with the paper folded into two after being stitched and
folded at the center of the paper (FS-610 only).
Tri-folding mode Exited to the booklet tray after being overlapped up to 3 sheets and being tri-
folded (FS-610 only).
(2) Stapling
Max. flat-stapling capacity FS-524 50 sheets of 60 to 90 g/m2 paper

FS-525 100 sheets of 60 to 80 g/m2 paper
90 sheets of 80 g/m2 paper + 4 sheets of 200 g/m2 paper
50 sheets of 81 to 105 g/m2 (However, guarantee is not given to
some paper according to the paper type)
FS-610 50 sheets of 60 to 80 g/m2 paper
48 sheets of 80 g/m2 paper + 2 sheets of 200 g/m2 paper
Max. saddle stitching FS-610 20 sheets of 60 to 80 g/m2 paper
capacity 19 sheets of 80 g/m2 paper + 1 sheet of 200 g/m2 paper
1
(3) Folding (FS-610)

FS-524/525/610
Folding 3 sheets of 60 to 90 g/m2 paper

Tri-folding 3 sheets of 60 to 80 g/m2 paper
1 sheet of 81 to 90 g/m2 paper
(4) Max. paper capacity
Main tray FS-524/ Non-sort mode, 3000 sheets: A4, A4S, B5, B5S, 81/2 x 11, 81/2 x 11S,
(Weighing 80g/m2) 525 sort/group mode 16K, 16KS
1500 sheets: A3, B4, 11 x 17, 81/2 x 14, Foolscap, 8K,
Custom size (Max. 320 x 450 mm)
500 sheets: A5, A5S, B6, 51/2 x 81/2, 51/2 x 81/2S
Stapling mode Max. 1000 sheets
No. of sheets Size in the sub scan direction is The others
per stapling 150 to 417mm
2 to 9 100 copies 50 copies
51 to 60 20 copies (FS-525 only)
61 to 100 10 copies (FS-525 only)
FS-610 Non-sort mode, 2500 sheets: A4, A4S, B5, B5S, 81/2 x 11, 81/2 x 11S,
sort/group mode 16K, 16KS
1500 sheets: A3, B4,11 x 17, 81/2 x 14, Foolscap, 8K,
Custom size (Max. 314 x 460 mm)
500 sheets: A5, A5S, B6, 51/2 x 81/2, 51/2 x 81/2S
Stapling mode 1000 sheets
No. of sheets Size in the sub scan direction is The others
per stapling 418mm or longer
Booklet tray Saddle stitching mode Size in the sub scan direction is less than 299mm : 15 copies in 5
(Weighing 80g/m2) sheets of saddle stitching
(FS-610 only) The others: 20 copies in 5 sheets of saddle stitching
Folding mode Size in the sub scan direction is less than 299mm : 25 copies in 3
sheets of folding
The others : 33 copies in 3 sheets of folding
Tri-folding mode 50 copies in 1 sheet of folding
Sub tray 200 sheets: A3, B4, A4, A4S, B5, B5S, A5, A5S, B6S, A6S, 12 x 18, 11 x 17, 81/2 x 14,
(Weighing 80g/m2) 81/2 x 11, 81/2 x 11S, 51/2 x 81/2, 51/2 x 81/2S, Foolscap, 8K, 16K, 16KS,
Custom size: Max. 331 x 488 mm, Min. 100 x 139 mm
2
C. Type of paper
(1) Non-sort mode, sort/group mode, sub tray mode
FS-524/525/610
Paper size A3, B4, A4, A4S, B5, B5S, A5, A5S*1, B6S*2, A6S*2, 11 x 17, 81/2 x 14,
81/2 x 11, 81/2 x 11S, 51/2 x 81/2, 51/2 x 81/2S*1, Foolscap, 8K, 16K, 16KS
Applicable paper Plain paper, special paper (same as the main body)
Paper weight 50 to 200 g/m2
*1 Non-sort mode only

*2 Sub tray mode only
(2) Staple mode
Paper size A3, B4, A4, A4S, B5, B5S, A5

12 x 18*1, 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2,
Foolscap, 8K, 16K, 16KS
Applicable paper Plain paper, special paper
Paper weight 60 to 90 g/m2 (FS-524)
60 to 80 g/m2 (FS-525/610)
*1 FS-610 only
(3) Saddle stitching/folding mode (FS-610)
Paper size A3, B4, A4S

12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11S
8K
Paper weight 60 to 80 g/m2 (saddle stitching mode)
60 to 90 g/m2 (folding mode)
(4) Tri-folding mode (FS-610)
Paper size A4S, 81/2 x11S

16KS
Paper weight 60 to 90 g/m2
3
D. Maintenance
FS-524/525/610
E. Machine data
Power source 24V/5VDC (supplied from the main body)

Maximum power consump- 80VA
tion
Dimensions When the main tray is pulled out: 790.5 (W) x 656 (D) x 990 (H) mm
When the main tray is set in: 674.5 (W) x 656 (D) x 990 (H) mm
Weight Approx. 60 kg (approx. 65 kg for FS-610)
4
2. PAPER PATH
FS-524/525/610
2.1 Non-sort/sort/group mode
[6]
[5]
[1]
[2]
[4]
[3]
FS-610 only
15jkt1c002nb
[1] Paper path from PI (PI-504 installed) [4] Main tray

[2] Paper path from the main body [5] Paper exit unit
[3] Gate [6] Shift unit (sort/group mode only)
5
2.2 Sub tray mode

FS-524/525/610
[1]
[4]
[2]
[3]
FS-610 only
15jkt1c003nb
[1] Paper path from PI (PI-504 installed) [3] Gate

[2] Paper path from the main body [4] Sub tray
6
2.3 Stapling mode
FS-524/525/610
[8]
[1]
[7] [2]
[3]
[4]
[5]
[6]
FS-610 only
15jkt1c004nb
[1] Paper path from PI (PI-504 installed) [5] Flat-stapling stopper

[2] Paper path from the main body [6] Stapler*
[3] Gate [7] Main tray
[4] Clincher* [8] Paper exit unit
* The illustrations for the clincher and stapler are for FS-610.
7
2.4 Folding/saddle stitching mode (FS-610)

FS-524/525/610
[1]
[2]
[3]
[4]
[8]
[5]
[6]
[7]
15jmt1c001na
[1] Paper path from PI (PI-504 installed) [5] Folding knife

[2] Paper path from the main body [6] Saddle stitching stopper
[3] Gate [7] Booklet tray
[4] Clincher [8] Stapler
8
2.5 Tri-folding mode (FS-610)
FS-524/525/610
[1]
[2]
[3]
[4]
[7]
[5]
[6]
15jmt1c002na
[1] Paper path from PI (PI-504 installed) [5] Saddle stitching stopper
[2] Paper path from the main body [6] Booklet tray
[3] Gate [7] Tri-folding stopper
[4] Folding knife
9
FS-524/525/610
Blank page
10
FS-524/525/610
3. COMPOSITION
Between FS-524/525 and FS-610, the transfer section and main tray section are in common but the stacker
section and stapler are different.
Transfer section
Stacker section (FS-524/525)
Main tray section
Stapler
(FS-610)
Stapler (FS-524/525)
Folding/saddle stitching/tri-folding (FS-610) Stacker section (FS-610)
15jkt2c001na
11
4. TRANSFER SECTION Theory of Operation Ver.1.0 Nov. 2008
4. TRANSFER SECTION
FS-524/525/610
4.1 Drive
[17] [18] [19] [20] [21] [22] [23] [1]
[2]
[16]
[3]
[4]
[15] [5]
[6]
[14]
[13]
[7]
[12]
[8]
[11] [10] [9]
[24] 15vlt2c001na
[1] FNS transfer motor (M1) [13] Gate

[2] PI transfer roller [14] Shift roller
[3] Entrance roller [15] Main tray exit roller
[4] Registration shutter [16] Paper exit opening solenoid (SD4)
[5] Registration shutter motor (M303) [17] Paper exit roller motor (M7)
[6] Transfer roller /A [18] Sub tray paper exit motor (M21)
[7] Transfer roller /B [19] Sub tray paper exit roller
[8] Bypass gate [20] Paper exit motor (M8)
[9] Intermediate transfer roller [21] Shift roller motor (M2)
[10] Bypass gate solenoid (SD5) [22] Sub tray transfer roller
[11] Paper exit belt [23] Gate motor (M12)
[12] Paper exit arm [24] Paper assist arm
12
Theory of Operation Ver.1.0 Nov. 2008 4. TRANSFER SECTION
4.2 Operation
FS-524/525/610
4.2.1 Punch registration control (available only when PK is installed)
The registration shutter motor (M303) [6] rotates to rotate the registration shutter drive assembly [5] after a spec-
ified period of time since the paper exit sensor (PS37) on the main body detects the leading edge of the paper.
Then, the motor stops rotating when the registration shutter home sensor (PS307) [4] turns OFF. It rotates the
registration shutter [7] the specified angle and moves it to the right of the entrance roller [2]. Paper is contacted
with the registration shutter and forms the loop [3] to correct the paper misalignment. After a specified period of
time, M303 rotates in the reverse direction until PS307 turns ON and it restarts the paper transfer.
This operation is not performed when the wide paper (220 mm or more in the transfer direction) is used or in the
no punching mode.
The loop is formed at the PI side when the punching operation is performed on the paper transferred from PI.
For more detailed information, refer To PI-504 service manual.
[8]
[1] [2]
[3]
[2]
[4]
[7]
[6] [5] 15jkt2c003na
[1] Main body [5] Registration shutter drive assembly

[2] Entrance roller [6] Registration shutter motor (M303)
[3] Loop [7] Registration shutter
[4] Registration shutter home sensor (PS307) [8] PK (option)
4.2.2 FS transfer control

The FS transfer is conducted by the 24V DC motor controlled by the FNS control board (FNSCB).
A. Door switch control

The FS transfer drive control is started when transmitting the start signal from the main body. However, en error
message is transmitted to the main body PRCB and the control is not started if the door switch (MS1) turns OFF.
B. FS transfer control
The FNS transfer motor (M1) rotates in high speed when pressing the start key. In the mode the paper is exited
from the main body in slow speed, M1 rotates in slow speed when the main body paper exit sensor (PS37) turns
ON. Then it rotates in high speed after a specified period of time since the FNS entrance sensor (PS4) turns ON.
When exiting to the main tray, M1 rotates in middle speed to in sync with the FS paper exit line speed after a
specified period of time since PS4 detects the trailing edge of the paper. Then after a specified period of time,
M1 returns to rotate in high speed and waits for the subsequent paper.
13
4.2.3 Gate drive control

The gate switches among the paper transfer path to the main tray, the one to the sub tray, and the one to the
FS-524/525/610
stacker.
A. Gate operation
The gate motor (M12) drives the gate cam [2], and then 2 cams /UP [3] and /Lw [4] of the gate cum drive the 2
gates /UP [5] and /Lw [6] respectively. The gate home sensor (PS16) [7] detects the home position.
[1]
[7]
[2]
[3]
[4]
[5]
[6]
15jkt2c004na
[1] Gate motor (M12) [5] Gate /Up

[2] Gate cam [6] Gate /Lw
[3] Cam /Up [7] Gate home sensor (PS16)
[4] Cam /Lw
B. Gate control
The FNS control board (FNSCB) controls the gate.
The gate turns ON when transmitting the FS operation signal from the main body, and then it stops either at the
sub tray (home position) [1], stacker [2], or main tray [3]. It does not move when exiting to the sub tray because
the sub tray is the home position.
When completing the printing, the gate home sensor (PS16) detects the home position and stops the gate.
[1] [2] [3] 15jkt2c005na
[1] Sub tray (home position) [3] Main tray

[2] Stacker
14
4.2.4 Bypass gate control

The bypass gate is located in the paper path to the stacker section. The bypass gate is the gate to transfer the
FS-524/525/610
subsequent paper during the stapling operation for eliminating the time loss and increasing the productivity.
A. Bypass gate operation

The bypass gate solenoid (SD5) [2] drives the bypass gate [1].
For the small size paper (A4, B5, and 81/2 x 11), it operates only for the 1st page of the 2nd and following copies
to transfer the paper to the bypass route [3]. The 2nd page of the 2nd and following copies is transferred to the
regular route [4] and overlapped under the 1st page, and then the transferred to the stacker section.
[3]
[3]
[1] [4]
[2]
15jkt2c006na
[1] Bypass gate [3] Bypass route

[2] Bypass gate solenoid (SD5) [4] Regular route
15
B. Bypass gate control

The bypass gate only operates for the small size paper (A4, B5, and 81/2 x 11) in the stapling mode. The FNS
FS-524/525/610
control board (FNSCB) controls the bypass gate solenoid (SD5).

When stapling 2 sheets of paper for 3 copies, SD5 operates as follows.
(1) For the 1st copy

When the paper for the 1st copy is transferred, the bypass gate solenoid (SD5) does not operate.
(2) For the 2nd copy

The bypass gate solenoid (SD5) turns ON and draws the 1st paper of the 2nd copy to the bypass after a speci-
fied period of time since the staple operation for the 1st copy is started [4]. SD5 turns OFF after a specified
period of time since the FNS entrance sensor (PS4) detects the trailing edge of the paper [6].
(3) For the 3rd and following copies

The bypass gate (SD5) turns ON and draws the 1st paper of the 3rd copy to the bypass after a specified period
of time since the FNS entrance sensor (PS4) detects the trailing edge of the last paper of the 2nd copy [7]. SD5
turns OFF after a specified period of time since PS4 detects the trailing edge of the paper [8].
[1] [2] [3]
FNS entrance sensor (PS4)
FNS transfer motor (M1)
Bypass gate solenoid (SD5)
Stapler movement motor (M11)
[4] [5][6] [7] [8] 15jkt2c007na
[1] The 1st copy [5] Drawing the 1st paper of the 2nd copy to
[2] The 2nd copy the bypass
[3] The 3rd copy [6] Trailing edge of the 1st paper of the 2nd copy
[4] Stapling operation for the 1st copy started [7] Trailing edge of the last paper of the 2nd copy
[8] Trailing edge of the 1st paper of the 3rd copy
16
4.2.5 Shift control

The FNS transfer motor (M1) drives the shift roller. The shift roller moves itself backward to shift the paper while
FS-524/525/610
transferring the paper to the main tray.
A. Shift operation
During conveying the paper to the main tray [1], the crank mechanism [3] shifts the shift movable section [5]
including the shift roller [4] approximately 30 mm backward [6] to shift and exit the paper when shift roller motor
(M2) [2] rotates.
The shift roller home sensor (PS18) [7] detects the shift position.
[7] [2]
[4]
[5]
[1] [3]
[3]
[2]
[5] [4]
[6]
[7] 15jkt2c008na
[1] To the main tray [5] Shift movable section

[2] Shift roller motor (M2) [6] Rear
[3] Crank mechanism [7] Shift roller home sensor (PS18)
[4] Shift roller
17
B. Shift control
In the sort/group mode, the shift roller motor (M2) turns ON [2] and shifts the shift movable section after a spec-
FS-524/525/610
ified period of time since the FNS entrance sensor (PS4) detects the trailing edge of the paper [1]. The FNS
transfer motor (M1) drives the shift roller. It shifts the paper while transferring it.
M2 stops when the shift roller completes the shift operation and the shift roller home sensor (PS18) turns ON [3].
Then, M2 turns ON [4] again after a specified period of time since it stops. It stops when PS18 turns OFF [5].
This operation replaces the shift movable section to its original position, and then it stands by for the subsequent
paper to be shifted.
These operations are repeated for every paper to offset it.
[1]
930 mm/s
FNS transfer motor
(M1) 400 mm/s
Shift roller motor (M2)
Shift roller home sensor (PS18)
[2] [3] [4] [5] 15jkt2c009na
[1] Trailing edge of the paper detected [4] Moving to the home position started
[2] Shift started [5] Moving to the home position completed
[3] Shift completed
18
4.2.6 Paper exit roller control

The paper exit roller motor (M7) controlled by the FNS control board (FNSCB) drives the main tray paper exit
FS-524/525/610
roller and the paper exit belt.
A. Non-sort/sort/group mode
The paper exit roller motor (M7) rotates in high speed when the FNS entrance sensor (PS4) detects the leading
edge of the paper [1]. M7 rotate in low speed [2] and exits the paper after a specified period of time since PS4
detects the trailing edge of the paper.
To transfer the subsequent paper, M7 rotate in high speed again after a specified period of time since the main
tray paper exit sensor (PS6) detects the trailing edge of the paper [3].
M7 stops after a specified period of time since PS6 detects the last paper.
Paper exit roller 400 mm/s

motor (M7)
253 mm/s
Main tray paper exit sensor (PS6)
[1] [2] [3] 15jkt2c010na
[1] Leading edge of the paper detected [3] Preparing to transfer the subsequent paper
[2] Paper exit started
B. Stapling mode (when the paper length is B5S or longer in the paper feed direction)
Transmitting the FNS signal [1] from the main body, the paper exit roller motor (M7) rotates to drive the paper exit
belt in the stacker section. M7 stops and the paper exit arm moves to the home position for the stapling mode
when the paper exit belt home sensor (PS9) turns ON [3].
The paper exit opening is open if the paper length is longer than B5S in the paper feed direction. The paper exit
motor (M8) closes the paper exit opening when the stapling operation is completed. M7 rotates to drive the
paper exit arm when the paper exit home sensor (PS12) detects the opening is closed [6]. The paper exit arm
lifts up the paper to the paper exit roller, and then the paper exit roller exits the paper to the main tray.
M7 stops when PS9 turns ON [7].
Paper exit roller motor (M7)
Paper exit belt home sensor (PS9)
Paper exit motor (M8)
Paper exit home sensor (PS12)
[1] [2] [3] [4] [5] [6] [7] 15jkt2c030na
[1] FNS signal turned ON [5] Closing the paper exit opening
[2] Opening the paper exit opening [6] Paper exit opening closed
[3] Paper exit arm home position [7] Paper exit arm home position
[4] Stapling operation completed
19
4.2.7 Paper exit opening solenoid control

The paper exit roller is usually releasing the nip except when exiting the paper because its rotation is slower than
FS-524/525/610
the transfer roller. However, the nip movable section moves to nip the paper when the paper reaches to the
paper exit opening.
A. Paper exit opening solenoid operation

When the paper reaches to the paper exit opening, the paper exit opening solenoid (SD4) [1] moves the nip
movable section [2] to nip the paper by pressurizing the nip roller [4] to the main tray paper exit roller [3] and exit
the paper to the main tray direction [5].
The main tray paper exit sensor (PS6) [6] detects the paper exit.
[1] [1]
[5]
[4]
[4]
[2]
[6]
[2] [3] 15jkt2c011na
[1] Paper exit opening solenoid (SD4) [4] Nip roller

[2] Nip movable section [5] To the main tray
[3] Main tray exit roller [6] Main tray paper exit sensor (PS6)
B. Timing to turn ON the paper exit opening solenoid

(1) Non-sort/sort/group mode
The paper exit opening solenoid (SD4) turns ON after a specified period of time since the FNS entrance sensor
(PS4) detects the trailing edge of the paper.
(2) Stapling mode

The paper exit opening solenoid (SD4) turns ON to nip the paper after a specified period of time since the sta-
pling operation is completed.
C. Timing to turn OFF the paper exit opening solenoid

In all modes, the paper exit opening solenoid (SD4) turns OFF after a specified period of time since the main tray
paper exit sensor (PS6) detects the paper.
20
4.2.8 Paper exit opening control

In the stapling mode (when the paper length is B5S or longer in the paper feed direction) and the folding/saddle
FS-524/525/610
stitching/tri-folding mode, the paper exit opening is opened from the beginning of the printing operation to the
end of the stapling operation because the paper protrudes.
A. Paper exit opening/closing operation

The paper exit opening unit [3] opens/closes by the crank mechanism [2] when the paper exit motor (M8) [1]
rotates. The paper exit home sensor (PS12) [4] detects the opening/closing of the paper exit opening. (On FS-
525, PS12 and the paper exit home sensor /2(PS100) [5] detect it.)
[3] [2] [3]
[2]
[1]
[1]
[4]
[4] [5] 15vlt2c002na
[1] Paper exit motor (M8) [4] Paper exit home sensor (PS12)
[2] Crank mechanism [5] Paper exit home sensor /2 (PS100)
[3] Paper exit unit (FS-525 only)
21
B. Paper exit opening/closing control (FS-524/610)

(1) Stapling mode (when the paper length is B5S or longer in the paper feed direction)
FS-524/525/610
Transmitting the FNS signal [1] from the main body, the paper exit motor (M8) rotates [2] to open the paper exit
opening.
When the stapling operation completes, M8 turns ON [3] again to close the paper exit opening. It stops when
the paper exit home sensor (PS12) detects the paper exit opening is closed.
These operations are repeated for every stapled bundle.
[5]
Stapler motor /Fr (M14)

Clincher motor /Fr (M15)
Stapler motor /Rr (M9)
Clincher motor /Rr (M10)
Paper exit opening solenoid (SD4)
[1] [2] [3] [4] 15jkt2c013na
[1] FNS start signal turned ON [4] Paper exit opening closed
[2] Opening the paper exit opening [5] Paper nipped by the paper exit opening
[3] Closing the paper exit opening solenoid (SD4)
(2) Folding/saddle stitching/tri-folding mode (FS-610 only)

Transmitting the start signal [1] from the main body, the paper exit motor (M8) rotates [2] to open the paper exit
opening.
M8 turns ON [3] again to close the paper exit opening after a specified period of time since the folding paper exit
sensor (PS25) or the folding full sensor (PS29) detects the trailing edge of the last page. It stops when the paper
exit home sensor (PS12) detects the paper exit opening is closed [4].
Folding paper exit sensor (PS25)
[1] [2] [3] [4] 15jkt2c014na
[1] FNS start signal turned ON [3] Closing the paper exit opening
[2] Opening the paper exit opening [4] Paper exit opening closed
22
C. Paper exit opening/closing control (FS-525)

(1) Stapling mode (when 51 or more sheets of paper are stapled with the size in the sub scan direc-
FS-524/525/610
tion shorter than B5S)
When the stacker entrance sensor (PS5) detects [1] the leading edge of the 51st sheet of paper while in the
paper stack, the paper exit motor (M8) turns ON to open the paper exit opening. As a result, when the paper exit
home sensor (PS12) turns OFF [2], M8 turns off.
When the alignment (close) of the last paper to be stapled is completed [7], the stapling operation starts. At the
same time, M8 also turns ON to close the paper exit opening. As a result, when the paper exit home sensor/2
(PS100) turns ON, M8 turns off.
After the paper exited, the paper exit opening returns to the home position, which is maintained until the stack-
ing operation of the 50th sheet of paper for the next stapling is completed.
Stacker entrance sensor /Fr (PS5)
Close
Alignment motor /Up
(M5) Open

Paper exit home sensor /2 (PS100)
[1] [2] [3] [4] [5] [6] [7] [8] 15vlt2c003na
[1] Start of the paper stack of the 51st sheet of [5] Completion of the paper stack of the 52nd
paper/Start of opening operation of the sheet of paper
paper exit opening
[2] Paper exit opening being opened [6] Start of the paper stack of the last paper to
be stapled
[3] Completion of the paper stack of the 51st [7] Completion of the alignment (close) of the
sheet of paper last paper/Start of the closing operation of
the paper exit opening
[4] Start of the paper stack of the 52nd sheet of [8] PS100 OFF
paper
23
(2) Stapling mode (when the size in the sub scan direction is B5S or longer)
The FS operation signal [1] from the main body allows the paper exit motor (M8) to rotate [2] to open the paper
FS-524/525/610
exit opening.
Upon completion of the stapling operation, M8 turns ON [3] again to start the closing operation of the paper exit
opening, and it turns off when the paper exit home sensor (PS12) detects [4] the close position.
This operation is repeated for each bundle of paper to be stapled.
[5]
Paper exit opening solenoid (SD4)
[1] [2] [3] [4] 15vlt2c004na
[1] FS operation start signal turned ON [4] Paper exit opening being closed
[2] Start of the opening operation of the paper [5] Paper nip by means of the paper exit open-
exit opening ing solenoid (SD4)
[3] Start of the closing operation of the paper
exit opening
24
4.2.9 Sub tray paper exit control

The sub tray paper exit motor (M21) controlled by the FNS control board (FNSCB) drives the sub tray paper exit
FS-524/525/610
roller.
A. Sub tray paper exit motor (M21) control

The sub tray paper exit motor (M21) rotates in high speed when the sub tray paper exit sensor (PS1) detects the
leading edge of the paper.
M21 rotates in low speed after a specified period of time since the FNS entrance sensor (PS4) detects the trail-
ing edge of the paper. M21 stops after a specified period of time since PS1 detects the trailing edge of the
paper.
B. Sub tray full detection

When the exited paper on the sub tray reached to a specified thickness, the sub tray full sensor (PS19) turns ON
and the sub tray full information is sent to the main body. Then, the main body displays the message on its dis-
play panel.
25
5. MAIN TRAY SECTION Theory of Operation Ver.1.0 Nov. 2008
5. MAIN TRAY SECTION

FS-524/525/610
5.1 Drive
[5] [1]
[2]
[4]
[3]
15jkt2c015na
[1] Lift pulley /Up [4] Lift pulley /Lw

[2] Lift wire [5] Main tray
[3] Main tray lift motor (M3)
26
Theory of Operation Ver.1.0 Nov. 2008 5. MAIN TRAY SECTION
5.2 Operation
FS-524/525/610
5.2.1 Tray lift control
A. Tray lift operation
The worm gear installed in the shaft of the main tray lift motor (M3) [6] winds up the lift wire.
It lifts up or down the main tray [9] depending on the winding direction. Rotating the lift pulley /Lw clockwise and
counterclockwise in view of front, the main tray is lifted up and down respectively.
[1]
[9]
[2]
[3]
[8]
[4]
[5]
[7] [6]
15jkt2c016na
[1] Stapler paper exit upper limit sensor (PS7) [6] Main tray lift motor (M3)
[2] Main tray upper limit sensor (PS2) [7] Lift pulley /Lw
[3] Counter reset sensor (PS15) [8] Lift pulley /Up
[4] Main tray lower limit sensor (PS3) [9] Main tray
[5] Timing belt
B. Paper detection
The main tray upper limit sensor (PS2) [2] and the stapler paper exit upper limit sensor (PS7) [1] keep the speci-
fied distance between the upper surface of the paper exited to the main tray (the upper surface of the main tray
if there is no exited paper) and the paper exit opening to eliminate the misalignment of the exited paper.
During the consecutive printing operation, FS counts the number of exited paper and stops the printing when it
reaches the maximum capacity.
If the exited paper is ejected during the printing operation, the tray moves up and the counter reset sensor
(PS15) [3] turns ON and resets the counter. It makes possible to exit paper with no limitation.
The main tray lower limit sensor (PS3) [4] detects the lower limit of the tray. During the intermittent printing oper-
ation, PS3 controls the capacity of the paper exit because the counter does not integrate the total number of
exited paper.
27
5. MAIN TRAY SECTION Theory of Operation Ver.1.0 Nov. 2008
C. Tray lift control

The main tray lift motor (M3) lifts up and down the main tray by rotating in the forward and reverse direction
FS-524/525/610
respectively. The FNS control board (FNSCB) controls M3.
(1) Non-sort/sort/group mode

Transmitting the FNS signal from the main body, the tray lift motor (M3) lifts up the tray until the main tray upper
limit sensor (PS2) turns ON.
M3 lifts down the tray when the paper passes the main tray paper exit sensor (PS6). M3 lifts up the tray again
after a specified period of time since the PS2 turns OFF, and then stops when PS2 turns ON.
These operations are repeated for every paper.
[2]
Main tray upper limit sensor (PS2)
UP
Tray lift motor (M3)
DOWN
[1] 15jkt2c017na
[1] FNS start signal turned ON [2] Paper exited to the main tray
(2) Stapling mode

Transmitting the FNS signal from the main body, the tray lift motor (M3) lifts up the tray until the stapler paper exit
upper limit sensor (PS2) turns ON.
The tray lift motor (M3) lifts down the main tray after a specified period of time since the paper exit roller motor
(M7) turns ON. After a specified period of time, M3 rotates in the reverse direction to lift up the main tray, and
then stops when the stapler paper exit upper limit sensor (PS7) turns OFF.
[2]
400 mm/s
Paper exit roller
motor (M7) 253 mm/s
Reverse
Stapler paper exit upper limit sensor (PS7)
Tray lift motor (M3) UP
DOWN
[1] [3] [4] 15jkt2c018na
[1] FNS start signal turned ON [3] Main tray lifted down
[2] Paper bundle exited to the main tray [4] Main tray lifted up
28
Theory of Operation Ver.1.0 Nov. 2008 6. STACKER SECTION (FS-524/525)
6. STACKER SECTION (FS-524/525)
FS-524/525/610
6.1 Drive
[12]
[1]
[2]
[11] [3]
[2] [4]
[13]
[4] [5]
[10] [14] [9] [6]

[6]
[8]
[7]
15vlt2c005na
[1] Coupling (from M7) [8] Paper exit belt

[2] Alignment motor /Up (M5) [9] Swing belt /Lw
[3] Paper assist motor (M51) [10] Swing belt /Up
[4] Stacker entrance motor (M13) [11] Paper exit arm
[5] Paper assist solenoid (SD51) [12] Alignment plate /Up
[6] Stacker entrance roller [13] Paper assist arm (FS-525 only)
[7] Paper assist roller [14] Paper guide (FS-525 only)
29
6. STACKER SECTION (FS-524/525) Theory of Operation Ver.1.0 Nov. 2008
6.2 Operation
FS-524/525/610
6.2.1 Alignment control

The alignment motor /Up (M5) rotates in the forward/reverse direction to open/close the alignment plate /Up to
perform the alignment of the paper transferred to the stacker in the main scan direction.
[3]
[2]
[1]
FRONT
15jkt2c031na
[1] Alignment motor (M5) [3] Alignment plate /Up

[2] Alignment home sensor (PS8)
A. Alignment operation
The alignment motor /Up (M5) rotates to open/close the alignment plate /Up via the alignment belt /Up.
The alignment home sensor /Up (PS8) detects the home position of the alignment plate /Up.
B. Alignment control
Transmitting the FNS signal from the main body, the alignment motor /Up (M5) rotates to close the alignment
plate, and then it stops the alignment plate at the standby position that is a little wider than the paper width.
M5 performs the alignment operation by rotating in the forward and reverse direction to move the alignment
plate back and forth after a specified period of time since the stacker entrance sensor (PS5) detects the trailing
edge of the paper. The alignment operation is performed for every paper.
Stacker entrance sensor (PS5)
Alignment home sensor /Up (PS8)
Alignment motor / CLOSE

Up (M5)
OPEN
[1] [2] [3]

15jkt2c020na
[1] FNS start signal turned ON [3] Alignment operation

[2] Standing by for the paper at the paper size
30
6.2.2 Stopper control

The secured 5 stoppers determine the position where the paper transferred to the stacker stops. When stapling
FS-524/525/610
at the corner, the 3 stoppers excluding the 2 outside stoppers secured to the stapler unit determine the position
because the stapler moves to the front and rear sides.
15jkt2c021na
31
6.2.3 Stacker entrance transfer control

The stacker entrance motor (M13) drives the stacker entrance roller, swing belt /Up, and the swing belt /Lw to
FS-524/525/610
transfer the paper to the stacker, align the trailing edge of the paper, and adjust the staple wait timing.
A. Stacker entrance operation

The downsizing of the device is achieved by adopting the stack method whose incline angle is approximately
70. The corrugation roller is adopted for the stacker entrance roller [5] to assist the paper exit to the stacker.
After the paper falls to the stacker, the swing belts /Up [7], /Lw [6] and the paper guide (FS-525 only) align the
paper with its trailing edge.
To assist in aligning the curled paper with the trailing edge according to the number of sheets stacked and the
paper size, the paper assist solenoid (SD51) [3] pressurizes the paper while the paper assist motor (M51) [1]
drives the paper assist roller [2].
[1]
[2]
[3]
[4]
[7] [5]
[6]
[8]
15vlt2c006na
[1] Paper assist motor (M51) [5] Stacker entrance roller

[2] Paper assist roller [6] Swing belt /Lw
[3] Paper assist solenoid (SD51) [7] Swing belt /Up
[4] Stacker entrance sensor (PS5) [8] Paper guide (FS-525 only)
32
B. Stacker entrance transfer control

(1) Stapling mode (the paper size is not A4, B5, or 81/2 x 11, without the bypassing operation)
FS-524/525/610
Transmitting the FNS signal from the main body [1], the stacker entrance motor (M13) turns ON and rotates in
high speed.
M13 rotates in low speed to transfer the paper in low speed [3] when the stacker entrance sensor (PS5) detects
the trailing edge of the paper. When the paper assist roller is driven, the paper assist motor (M51) and the paper
assist solenoid (SD51) operate to assist the stacking operation. M13 rotates in high speed and stands by for the
subsequent paper after a specified period of time since it rotates in low speed.
After the last paper of the copy passes, M13 stops when the stapling operation is started.
M13 turns ON and rotates in high speed to stand by for the subsequent paper when the paper exit motor (M8)
completes the closing operation.
[2] [6]
Stacker entrance High speed

Paper assist motor (M51)
Paper assist solenoid (SD51)
Stapler motors (M9 and M14)
[5]
[1] [3] [4] 15jkt2c023nb
[1] FNS start signal turned ON [4] Stapling operation

[2] Paper transferred to the stacker in low [5] Closing the paper exit opening
speed [6] Standing by for the paper of the subsequent
[3] Paper assist roller in operation copy
33
(2) Stapling mode (the paper size is A4, B5, or 8 /2 x 11, with the bypassing operation)
1
The 1st copy is transferred by the same operation for the paper whose size is other than A4, B5, or 81/2 x 11.
FS-524/525/610
When transferring the 1st and 2nd paper of the 2nd and following copies, the stacker entrance motor (M13)
stops after a specified period of time since the stacker entrance sensor (PS5) detects the trailing edge of the last
paper of the 1st copy [3]. To prevent the paper of the 2nd copy is transferred to the stacker before the stapling
operation for the 1st copy is completed, the 1st paper for the 2nd copy stands by in the bypass path.
The stacker entrance motor (M13) turns ON and rotates in high speed after a specified period of time since the
FNS entrance sensor (PS4) detects the trailing edge of the 2nd paper. Then the 1st and 2nd paper are over-
lapped and transferred to the stacker.
[3] [4] [5]

High speed
Stacker entrance
[1] [2] [6] 15jkt2c024na
[1] FNS start signal turned ON [4] 1st paper of the 2nd copy
[2] Paper transferred to the stacker in low speed [5] 2nd paper of the 2nd copy
[3] Trailing edge of the last paper of the 1st [6] 1st and 2nd paper of the 2nd copy trans-
copy detected ferred simultaneously
When transferring the 3rd and following paper of the 2nd and following copies, the paper is transferred to the
stacker by the same operation for the paper of the 1st copy.
34
6.2.4 Stacker paper exit control

The paper exit roller motor (M7) controlled by the FNS control board (FNSCB) drives the paper exit belt of the
FS-524/525/610
stacker via the coupling gear.
A. Paper exit belt operation

The paper exit arm [2] mounted on the paper exit belt [1] exits the paper to the main tray in the stapling mode.
The paper exit roller motor (M7) [4] drives the paper exit belt [1] via the coupling pin [3].
The paper exit belt home sensor (PS9) [5] detects the home position of the paper exit arm.
Only with FS-525, if six or more sheets of A4S or larger paper are stacked in staple mode, M7 rotates reversely
to feed the paper exit belt in reverse direction. By this operation, the paper assist arm [6] (equipped in FS-525
only) slips under stacked sheets of paper and warps the paper for paper curl prevention.
[4]
[3]
[2]
[5]
[1]
[6]
15vlt2c007na
[1] Paper exit belt [4] Paper exit roller motor (M7)
[2] Paper exit arm [5] Paper exit belt home sensor (PS9)
[3] Coupling pin [6] Paper assist arm (FS-525 only)
35
B. Paper exit arm control

(1) Stapling mode (when the paper length is shorter than B5S in the paper feed direction)
FS-524/525/610
Completing the stapling operation, the paper exit roller motor (M7) rotates to drive the paper exit belt in the
stacker section. The paper exit arm lifts up the paper to the paper exit roller, and then the paper exit roller exits
the paper to the main tray. M7 stops when the paper exit belt home sensor (PS9) turns ON.
Completing the stapling operation, the paper exit motor (M8) rotates. When the paper exit home sensor (PS12)
detects the paper exit opening is closed, the paper exit roller motor (M7) rotates to drive the paper exit arm in
the stacker section. The paper exit arm lifts up the paper to the paper exit roller, and then the paper exit roller
exits the paper to the main tray.
M7 stops when the paper exit belt home sensor (PS9) turns ON.
36
Theory of Operation Ver.1.0 Nov. 2008 7. STACKER SECTION (FS-610)
7. STACKER SECTION (FS-610)
FS-524/525/610
7.1 Drive
[11] [12] [13] [14] [15]
[1]
[2]
[3]
[4]
[10] [5]
[6]
[7]
[9] [8] 15jmt2c001na
[1] Coupling (from M7) [9] Alignment plate /Lw

[2] Alignment motor /Up (M5) [10] Flat-stapling stopper release solenoid /Fr (SD8),
[3] Stacker entrance motor (M13) Flat-stapling stopper release solenoid /Rr (SD7)
[4] Stacker entrance roller [11] Paper assist roller
[5] Flat-stapling stopper /Fr, Flat-stapling stopper /Rr [12] Paper assist solenoid (SD51)
[6] Alignment motor /Lw (M16) [13] Paper exit arm
[7] Saddle stitching stopper [14] Paper assist motor (M51)
[8] Saddle stitching stopper motor (M18) [15] Alignment plate /Up
37
7. STACKER SECTION (FS-610) Theory of Operation Ver.1.0 Nov. 2008
7.2 Operation
FS-524/525/610
7.2.1 Alignment /Up control

In the stapling/saddle stitching/tri-folding mode, the alignment motor /Up (M5) rotates in the forward/reverse
direction to open/close the alignment plate /Up to perform the alignment of the paper transferred to the stacker
in the main scan direction.
[3]
[2]
[1]
FRONT
15jmt2c023na
[1] Alignment motor (M5) [3] Alignment plate /Up

[2] Alignment home sensor (PS8)
A. Alignment /Up operation

The alignment motor /Up (M5) rotates to open/close the alignment plate via the alignment belt.
The alignment home sensor /Up (PS8) detects the home position of the alignment plate.
B. Alignment /Up control

Transmitting the FNS signal from the main body, the alignment motor /Up (M5) rotates to close the alignment
plate /Up [1], and then it stops the alignment plate at the standby position that is a little wider than the paper
width [2].
plate /Up back and forth after a specified period of time since the stacker entrance sensor (PS5) detects the
trailing edge of the paper. The alignment operation is performed for every paper [3].
Alignment home sensor /Up (PS8)
Alignment motor CLOSE

/Up (M5)
OPEN
[1] [2] [3] 15jmt2c002na
[1] Closing the alignment plate /Up (FNS signal) [3] Alignment operation for every paper
[2] Standby position of the alignment plate /Up
38
7.2.2 Alignment /Lw control

In the saddle stitching/folding/tri-folding mode, the alignment plate /Up and the alignment plate /Lw move back
FS-524/525/610
and forth to align the paper in the main scan direction.
The alignment motor /Lw (M16) performs the alignment operation by rotating in the forward and reverse direc-
tion to move the alignment plate back and forth.
[1]
[2]
[3]
FRONT
15jmf5c024na
[1] Alignment plate home sensor /Lw (PS24) [3] Alignment plate /Lw
[2] Alignment motor /Lw (M16)
A. Alignment /Lw operation

The alignment motor /LW (M16) rotates to open/close the alignment plate via the alignment belt.
The alignment home sensor /Lw (PS24) detects the home position of the alignment plate.
B. Alignment /Lw control

In the saddle stitching/folding/tri-folding mode, transmitting the FNS signal from the main body, the alignment
motor /Lw (M16) rotates to close the alignment plate /Lw [1], and then it stops the alignment plate at the
standby position that is a little wider than the paper width [2].
plate /Lw back and forth after a specified period of time since the stacker entrance sensor (PS5) detects the
trailing edge of the paper. The alignment operation is performed for every paper [3].
Alignment plate home sensor /Lw (PS24)
Alignment motor CLOSE

/Lw (M16)
OPEN
[1][2] [3] 15jmt2c003na
[1] Closing the alignment plate /Lw (FNS signal) [3] Alignment operation for every paper
[2] Standby position of the alignment plate /Lw
39
7.2.3 Stopper control

The stopping position in vertical direction of paper conveyed to the stacker is different among the stapling mode,
FS-524/525/610
the saddle stitching mode, and the folding mode.

2 stoppers (the saddle stitching stopper and the flat-stapling stopper) control the stopping position of paper.
A. Stopper operation
In the stapling mode, the flat-stapling stopper [1] is set on the paper path by the pushing pressure by the spring
[2]. The flat-stapling stopper [1] determines the position of the leading edge of the fallen paper.
In the saddle stitching/folding/tri-folding mode, the flat-stapling release solenoids (SD7 and SD8) turn ON and
evacuate the flat-stapling stopper from the paper path. Then, the paper falls down to the saddle stitching stop-
per [3] without contacting with the flat-stapling stopper.
The saddle stitching stopper motor (M18) [5] moves the saddle stitching stopper up and down in accordance
with the paper size. The saddle stitching stopper home sensor (PS23) [6] detects the home position.
[1]
[1]
[2]
[4]
[5]
[6]
[3]
[3] 15jmt2c004na
[1] Flat-stapling stopper [4] Flat-stapling stopper release solenoids (SD7 and SD8)
[2] Spring [5] Saddle stitching stopper motor (M18)
[3] Saddle stitching stopper [6] Saddle stitching stopper home sensor (PS23)
40
B. Stopper control
(1) Folding mode
FS-524/525/610
Transmitting the FNS signal from the main body [1], the saddle stitching stopper motor (M18) rotates [2] to move
down the saddle stitching stopper to the stopping position in accordance with the paper size.
After completing the alignment operation of the last paper [3], M18 rotates [4] to move down the saddle stitching
stopper to the folding position.
After completing the folding operation, when the folding paper exit sensor (PS25) detects the trailing edge of the
paper bundle, M18 rotates [5] to move up the saddle stitching stopper to the alignment position in accordance
with the paper size and stand by for the paper of the subsequent copy.
[3]
Alignment motor /Up (M5)
Alignment motor /Lw (M16)
Saddle stitching stopper home sensor (PS23)
Saddle stitching UP
stopper motor (M18)
DOWN
[1] [2] [4] [5] 15jmt2c005na
[1] FNS start signal turned ON [4] Moving to the folding position for the paper size
[2] Moving to the alignment position for the [5] Moving to the alignment position for the
paper size subsequent copy
[3] Last paper of the copy aligned
41
(2) Saddle stitching mode

FS-524/525/610
After completing the stapling operation [3], the alignment motors /Up (M5) and /Lw (M16) open the alignment
plate and M18 rotates [4] to move down the saddle stitching stopper to the folding position.
paper bundle, M18 rotates [5] to move up the saddle stitching stopper to the saddle stitching position in accor-
dance with the paper size and stand by for the paper of the subsequent copy.
[3]

Clincher motor /Fr (M15)
Saddle stitching stop- UP

per motor (M18)
DOWN
[1] [2] [4] [5] 15jmt2c006na
[1] FNS start signal turned ON [4] Moving to the folding position for the paper size
[2] Moving to the saddle stitching position for [5] Moving to the saddle stitching position for
the paper size the subsequent copy
[3] Stapling operation
42
(3) Tri-folding mode

FS-524/525/610
After completing the alignment operation of the last paper [3], M18 rotates [4] to move down the saddle stitching
stopper to the 1st folding position in the tri-folding.
paper bundle, M18 rotates [5] to move up the saddle stitching stopper to the alignment position in accordance
with the paper size and stand by for the paper of the subsequent copy.
[3]
Saddle stitching stop- UP

per motor (M18)
DOWN
[1] [2] [4] [5] 15jmt2c007na
[1] FNS start signal turned ON [4] Moving to the 1st folding position
[2] Moving to the alignment position for the [5] Moving to the alignment position for the
paper size subsequent copy
[3] Last paper of the copy aligned
(4) Flat-stapling mode

The saddle stitching stopper motor (M18) does not operate in the flat-stapling mode.
43
7.2.4 Stacker entrance transfer control

The stacker entrance motor (M13) drives the stacker entrance roller, swing belt to transfer the paper to the
FS-524/525/610
stacker, align the trailing edge of the paper, and adjust the staple wait timing.
A. Stacker entrance operation

The downsizing of the device is achieved by adopting the stack method whose incline angle is approximately
70. The corrugation roller is adopted for the stacker entrance roller [5] to assist the paper exit to the stacker.
After the paper falls to the stacker, the swing belt [6] align the paper with its trailing edge.
To assist in aligning the curled paper with the trailing edge according to the number of sheets stacked and the
paper size, the paper assist solenoid (SD51) [1] pressurizes the paper while the paper assist motor (M51) [3]
drives the paper assist roller [2].
[1]
[2]
[3]
[4]
[5]
[7] [6]
15jmt2c008na
[1] Paper assist solenoid (SD51) [5] Stacker entrance roller

[2] Paper assist roller [6] Swing belt
[3] Paper assist motor (M51) [7] Stacker empty sensor (PS20)
[4] Stacker entrance sensor (PS5)
44
B. Stacker entrance transfer control

(1) Stapling mode (the paper size is not A4, B5, or 81/2 x 11, without the bypassing operation)
FS-524/525/610
high speed.
M13 rotates in low speed [3] when the stacker entrance sensor (PS5) detects the trailing edge of the paper and
then the paper assist roller starts to rotate to transfer the paper to the stacker in low speed. When the paper
assist roller is driven, the paper assist motor (M51) and the paper assist solenoid (SD51) operate to assist the
stacking operation. M13 rotates in high speed and stands by for the subsequent paper after a specified period
of time since it rotates in low speed.
After the last paper of the copy passes, M13 stops when the stapling operation is started [5].
M13 turns ON [6] and rotates in high speed to stand by for the subsequent paper when the paper exit motor
(M8) completes the closing operation.
[2] [6]
High speed
Stacker entrance
Paper assist motor (M51)
Paper assist solenoid (SD51)
Stapler motors (M9 and M14)
[5]
[1] [3] [4] 15jmt2c009nb

[2] Paper transferred to the stacker in low [5] Closing the paper exit opening
speed [6] Standing by for the paper of the subsequent
[3] Paper assist roller in operation copy
45
(2) Stapling mode (the paper size is A4, B5, or 8 /2 x 11, with the bypassing operation)
1
The 1st copy is transferred by the same operation for the paper whose size is other than A4, B5, or 81/2 x 11.
FS-524/525/610
When transferring the 1st and 2nd paper of the 2nd and following copies, the stacker entrance motor (M13)
stops after a specified period of time since the stacker entrance sensor (PS5) detects the trailing edge of the last
paper of the 1st copy [3]. To prevent the paper of the 2nd copy is transferred to the stacker before the stapling
operation for the 1st copy is completed, the 1st paper for the 2nd copy stands by in the bypass path.
The stacker entrance motor (M13) turns ON and rotates in high speed after a specified period of time since the
FNS entrance sensor (PS4) detects the trailing edge of the 2nd paper [5]. Then the 1st and 2nd paper are over-
lapped and transferred to the stacker [6].
[3] [4] [5]
High speed
Stacker entrance
motor (M13)
Low speed
[1] [2] [6] 15jmt2c010na
[1] FNS start signal turned ON [4] 1st paper of the 2nd copy
[2] Paper transferred to the stacker in low speed [5] 2nd paper of the 2nd copy
[3] Trailing edge of the last paper of the 1st [6] 1st and 2nd paper of the 2nd copy trans-
copy detected ferred simultaneously
When transferring the 3rd and following paper of the 2nd and following copies, the paper is transferred to the
stacker by the same operation for the paper of the 1st copy.
46
(3) Folding/saddle stitching mode

FS-524/525/610
high speed.
M13 rotates in low speed [2] to transfer the paper in low speed when the stacker entrance sensor (PS5) detects
the trailing edge of the paper. M13 rotates in high speed and stands by for the subsequent paper after a speci-
fied period of time since it rotates in low speed.
M13 stops after completing the alignment operation [4] of the last paper of the copy [3].
M13 turns ON and rotates in high speed to stand by for the subsequent paper when the folding paper exit sen-
sor (PS25) detects the trailing edge of the paper bundle [5].
[3] [6]
Stacker entrance High speed

motor (M13)
Low speed
Alignment motors /Up (M5) and /Lw (M16)
[1] [2] [4] [5] 15jmt2c011na
[1] FNS start signal turned ON [4] Last paper of the copy aligned
[2] Paper transferred to the stacker in low speed [5] Folding paper exit operation
[3] Last paper of the copy [6] Standing by for the paper of the subsequent
copy
47

FS-524/525/610
high speed.
M13 rotates in low speed [2] to transfer the paper in low speed when the stacker entrance sensor (PS5) detects
the trailing edge of the paper. M13 rotates in high speed and stands by for the subsequent paper after a speci-
fied period of time since it rotates in low speed.
M13 stops after completing the alignment operation of the last paper of the copy [3] and the movement of the
saddle stitching stopper to the tri-folding position [4].
M13 turns ON and rotates in high speed to stand by for the subsequent paper when the folding paper exit sen-
sor (PS25) detects the trailing edge of the paper bundle [5].
[3] [6]
High speed
Stacker entrance
DOWN
Saddle stitching stop-
per motor (M18)
UP
[1] [2] [4] [5] 15jmt2c012na
[1] FNS start signal turned ON [4] Saddle stitching stopper moving to the tri-fold-
[2] Paper transferred to the stacker in low speed ing position
[3] Last paper of the copy [5] Tri-folding paper exit operation
[6] Standing by for the paper of the subsequent
copy
48
7.2.5 Stacker paper exit control

The paper exit roller motor (M7) controlled by the FNS control board (FNSCB) drives the paper exit belt of the
FS-524/525/610
stacker via the coupling gear.
A. Paper exit belt operation

The paper exit arm [2] mounted on the paper exit belt [1] exits the paper to the main tray in the stapling mode.
The paper exit roller motor (M7) [4] drives the paper exit belt via the coupling pin [3].
The paper exit belt home sensor (PS9) [5] detects the home position of the paper exit arm.
[4]
[3]
[2]
[5]
[1]
15jmt2c013na
[1] Paper exit belt [4] Paper exit roller motor (M7)
[2] Paper exit arm [5] Paper exit belt home sensor (PS9)
[3] Coupling pin
49
B. Paper exit arm control

(1) Stapling mode (when the paper length is shorter than B5S in the paper feed direction)
FS-524/525/610
Completing the stapling operation, the paper exit roller motor (M7) rotates to drive the paper exit belt in the
stacker section. The paper exit arm lifts up the paper to the paper exit roller, and then the paper exit roller exits
the paper to the main tray. M7 stops when the paper exit belt home sensor (PS9) turns ON.
Completing the stapling operation, the paper exit motor (M8) rotates. When the paper exit home sensor (PS12)
detects the paper exit opening is closed, the paper exit roller motor (M7) rotates to drive the paper exit arm in
the stacker section. The paper exit arm lifts up the paper to the paper exit roller, and then the paper exit roller
exits the paper to the main tray.
M7 stops when the paper exit belt home sensor (PS9) turns ON.
(3) Folding/saddle stitching mode

After completing the stapling operation, the saddle stitching stopper motor (M18) drives the saddle stitching
stopper to move the paper to the folding position. To prevent the paper exit arm to contact with the paper
standing by at the folding position, the paper exit arm does not rotate.

The paper exit roller motor (M7) rotates in the reverse direction to assist in transferring the paper to the tri-folding
position after completing the paper alignment operation. M7 stops when the paper exit belt home sensor (PS9)
turns ON.
50
Theory of Operation Ver.1.0 Nov. 2008 8. STAPLER (FS-524/525)
8. STAPLER (FS-524/525)
FS-524/525/610
8.1 Drive
[11] [12] [13] [14] [1] [2] [3]
[4]
[5]
[10] [9] [8] [7]
[6]
15jkt2c026na
[1] Stapler /Rr [8] Stapler movement motor (M11)

[2] Stapler rotation shaft /Rr [9] Stapler movement home sensor (PS11)
[3] Rack mounting platform [10] Stapler drive rack /Fr
[4] Stapler spring /Rr [11] Stapler spring /Fr
[5] Parallel stapling position [12] Stapler rotation shaft /Fr
[6] One-corner stapling position [13] Stapler /Fr
[7] Stapler drive rack /Rr [14] Pinion gear
51
8. STAPLER (FS-524/525) Theory of Operation Ver.1.0 Nov. 2008
8.2 Operation
FS-524/525/610
8.2.1 Stapler movement control

A. Stapler movement operation
Since the stapler /Fr [11] and the stapler /Rr [1] operate symmetrically, the explanation is given of the stapler /Rr
[1].
The stapler movement motor (M11) [9] moves the stapler. When M11 rotates as shown in [10], it drives the sta-
pler drive rack [8] backward with the stapler via the pinion gear [12].
The stapler spring [6] always applies a rotational force to [7] on the stapler. However, the stapler does not rotate
because the height of the stapler guide roller [3] is restricted to the same height as the stapler rotational shaft by
the rack mounting platform [4].
When the stapler moves backward, the guide roller is pressed into the flute [5] on the rack mounting platform
and the stapler rotates as much as the difference to the stapler rotation shaft [2] so that the stapler moves to the
one-corner stapling position.
[11] [12] [1] [2] [3] [4]

[5]
[6]
[10] [9] [8] [7]

15jkt2c029na
[1] Stapler /Rr [7] Pressed by the spring

[2] Stapler rotation shaft /Rr [8] Stapler drive rack /Rr
[3] Guide roller [9] Stapler movement motor (M11)
[4] Rack mounting platform [10] Rotational direction at the one-corner stapling
[5] Flute [11] Stapler /Fr
[6] Stapler spring /Rr [12] Pinion gear
B. Stapler movement control

(1) Size movement in 1 staple
Transmitting the FNS signal from the main body, the stapler movement motor (M11) turns ON to widen the dis-
tance between the staplers. It stops when they are positioned at the specified positions.
(2) 2 staples
The staplers do not move because the stapling operation is performed at the home position.
52
Theory of Operation Ver.1.0 Nov. 2008 8. STAPLER (FS-524/525)
8.2.2 Stapler control

The stapling operation is performed by the stapler motors /Rr (M9) and /Fr (M14).
FS-524/525/610
A. Stapling operation
In the stapling operation, the stapler motors /Rr (M9) and /Fr (M14) [3] in the staplers /Rr and /Fr drive the
clincher side [2] to press the paper [1]. Then, the staple is pushed out from the stapler side [4] and bent at the
clincher side.
[1]
[4]
[2]
[3] 15jkt2c027na
[1] Paper [3] Stapler motors /Rr (M9) and /Fr (M14)
[2] Stapler (clincher side) [4] Stapler (stapler side)
53
8. STAPLER (FS-524/525) Theory of Operation Ver.1.0 Nov. 2008
B. Staple control
(1) Stapling
FS-524/525/610
After completing the alignment operation of the alignment plate, the stapler motors /Rr (M9) and /Fr (M14) per-
form the stapling operation.
The stapling operation is completed when the stapler motor home sensors /Rr (PS30) and /Fr (PS31) in the sta-
plers /Rr and /Fr detect the home position and turn ON.
(2) Nip operation of stapler (FS-525 only)

When 60 or more sheets of paper are stapled, the staplers/Rr and /Fr perform the nip operation to prevent
paper bending. With 60 to 89 sheets, it is performed for every 5 sheets and with 90 to 100 sheets, it is per-
formed for every single sheet.
(3) Clogged staple detection

During the stapling operation, it is determined that the staple has been clogged and the stapler motors /Rr (M9)
and /Fr (M14) turn OFF if the stapler motor home sensors /Rr (PS30) and /Fr (PS31) do not turn ON after a spec-
ified period of time since they turn OFF.
(4) Cartridge detection

The cartridge set switches /Rr (SW1) and /Fr (SW3) detect the presence of a cartridge or the incorrect setting of
a cartridge.
When no cartridge is set or it is set incorrectly, the main body displays the error message on its display panel.
(5) Staple detection control

When the staples run out, the staple empty switches /Rr (SW2) and /Fr (SW4) turn ON and the main body dis-
plays the error message on its display panel.
54
Theory of Operation Ver.1.0 Nov. 2008 9. STAPLER (FS-610)
9. STAPLER (FS-610)
FS-524/525/610
9.1 Drive
[9] [10]
[2] [10] [11]

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

[6]
[4] [3]
15jmt2c014na
[1] Stapler movement motor (M11) [7] Stapler /Fr

[2] Upper side of the timing belt [8] Stapler movement home sensor (PS11)
[3] Clincher rotation motor (M4) [9] Stapler /Rr
[4] Clincher /Rr [10] Stapler rotation motor (M6)
[5] Clincher /Fr [11] Timing belt
[6] Lower side of the timing belt
55
9. STAPLER (FS-610) Theory of Operation Ver.1.0 Nov. 2008
9.2 Operation
FS-524/525/610
9.2.1 Stapler movement control

The staplers move in the horizontal direction for adjusting their distance. The stapler at the rear also rotates. The
movement is made according to the stapling mode.
A. Horizontal movement operation

The stapler movement motor (M11) [1] moves the staplers in the horizontal direction.
The stapler /Rr [8] and the clincher /Rr [3] are mounted at the top [2] of the timing belt [9] and the stapler /Fr [6]
and the clincher /Fr [4] are mounted at the bottom [5] of the timing belt.
The stapler movement home sensor (PS11) [7] detects the distance between the stapler and the clincher.
[2] [9]
[7] [8]
[6]
[5]
[1]
[2]
[3]
[4]
[5] 15jmt2c015na
[1] Stapler movement motor (M11) [6] Stapler /Fr

[2] Upper side of the timing belt [7] Stapler movement home sensor (PS11)
[3] Clincher /Rr [8] Stapler /Rr
[4] Clincher /Fr [9] Timing belt
[5] Lower side of the timing belt
56
B. Rotational movement operation

The stapler /Rr and the clincher /Rr rotate 45 for performing 1 staple/one-corner stapling at rear.
FS-524/525/610
The stapler rotation motor (M6) [10] rotates the stapler /Rr [9] and the clincher rotation motor (M4) [5] rotates the
clincher /Rr [7].
The ball rock mechanism that consists of the ball [1] and the spring [2] securely locks the stapler and the clincher
at 0 or 45.
The illustrations [3] and [4] show the mechanism locked and unlocked respectively.
[10]
[9]
[5]
[8] [1] [2]

[7]
[6]
[3] [4] 15jmt2c016na
[1] Ball [6] Clincher rotation home sensor (PS14)

[2] Spring [7] Clincher /Rr
[3] Locked [8] Stapler rotation home sensor (PS13)
[4] Unlocked [9] Stapler /Rr
[5] Clincher rotation motor (M4) [10] Stapler rotation motor (M6)
57
C. Stapler movement control

(1) Size movement in 1 staple/front and 2 staples
FS-524/525/610
Transmitting the FNS signal from the main body, the stapler movement motor (M11) turns ON to widen the dis-
tance between stapler and clincher. It stops when they are positioned at the specified positions.
M11 turns ON after a specified period of time since the main tray paper exit sensor (PS6) detects the last paper.
M11 stops when the stapler movement home sensor (PS11) turns ON.
(2) Size movement in 1 staple/one-corner stapling at rear

Transmitting the FNS signal from the main body [1], the stapler movement motor (M11) turns ON to widen the
distance between the stapler and the clincher [2]. The stapler rotation motor (M6) and the clincher rotation motor
(M4) turn ON to rotate the stapler /Rr and the clincher /Rr and move them diagonally [3] after a specified period
of time since M11 turns ON.
M4 and M6 turn ON and rotate the stapler /Rr and the clincher /Rr to the home position [5] after a specified
period of time since the trailing edge of the last paper passes the main tray paper exit sensor (PS6). The rota-
tions are stopped when the stapler rotation home sensor (PS13) and the clincher rotation home sensor (PS14)
turn ON. At the same time, M11 turns ON [6], and it stops when the stapler movement home sensor (PS11)
turns ON.
[2] [6]
Stapler movement home sensor (PS11)
Stapler movement CLOSE

motor (M11) OPEN
Stapler rotation home sensor (PS13)
Stapler rotation Forward

motor (M6)
Reverse
Clincher rotation home sensor (PS14)
Clincher rotation Forward

motor (M4)
Reverse
[4]
[1] [3] [5] 15jmt2c017na

[2] Stapler /Rr and clincher /Rr moving horizon- [5] Stapler /Rr and clincher /Rr moving to the
tally home position rotational
[3] Stapler /Rr and clincher /Rr rotating 45 [6] Stapler /Rr and clincher /Rr moving to the
home position horizontally
58
9.2.2 Stapler control

The stapling operation is performed by the stapler motors /Rr (M9) and /Fr (M14) and the clincher motors /Rr
FS-524/525/610
(M10) and /Fr (M15).
A. Stapling operation
In the stapling operation, the stapler motors /Rr (M9) and /Fr (M14) in the staplers /Rr and /Fr [6] push out the
paper press section [4] to the clinchers [2] by the cam mechanism [5] to hold the paper [1] and punch out the
staples [3]. Then, the clincher motors /Rr (M10) and /Fr (M15) in the staplers /Rr and /Fr bend the staples.
[6] [1]
[2]
[3]
[5]
[4]
[2]
[3] [6]
15jmt2c018na
[1] Paper [4] Paper press section

[2] Clincher [5] Cam mechanism
[3] Staple [6] Staplers /Rr and /Fr
59
B. Staple control
(1) Stapling
FS-524/525/610
After completing the alignment operation of the alignment plate, the stapler motors /Rr (M9) and /Fr (M14) per-
form the stapling operation. After a specified period of time, the clincher motors /Rr (M10) and /Fr (M15) bend
the staples.
The stapling operation is completed when the clincher motor home sensors /Rr (PS32) and /Fr (PS33) and the
stapler motor home sensors /Rr (PS30) and /Fr (PS31) detect the home position and turn ON.
(2) Clogged staple detection

During the stapling operation, it is determined that the staple has been clogged and the stapler motors /Rr (M9)
and /Fr (M14) and the clincher motors /Rr (M10) and /Fr (M15) rotate in the reverse direction to replace the sta-
plers and the clinchers to the home positions if the stapler motor home sensors /Rr (PS30) and /Fr (PS31) and
the clincher motor home sensors /Rr (PS32) and /Fr (PS33) do not turn ON after a specified period of time since
they turn OFF.
(3) Cartridge detection

The cartridge set switches /Rr (SW1) and /Fr (SW3) detect the presence of a cartridge or the incorrect setting of
a cartridge.
When no cartridge is set or it is set incorrectly, the main body displays the error message on its display panel.
(4) Staple detection control

When the staples run out, the staple empty switches /Rr (SW2) and /Fr (SW4) turn ON and the main body dis-
plays the error message on its display panel.
60
Theory of Operation Ver.1.0 Nov. 2008 10. FOLDING/SADDLE STITCHING/TRI-FOLDING (FS-610)
10. FOLDING/SADDLE STITCHING/TRI-FOLDING (FS-610)
FS-524/525/610
10.1 Drive
[6] [7]
[1]
[5]
[4]
[2]
[3]
15jmt2c019na
[1] Folding knife [5] Tri-folding gate solenoid (SD6)

[2] Folding knife motor (M19) [6] Tri-folding gate
[3] Folding transfer motor (M20) [7] Folding roller
[4] Tri-folding roller
61
10. FOLDING/SADDLE STITCHING/TRI-FOLDING (FS-610) Theory of Operation Ver.1.0 Nov. 2008
10.2 Operation
FS-524/525/610
10.2.1 Folding knife control

The folding knife motor drives the folding knife. The folding knife is used in the folding/saddle stitching/tri-folding
mode. In the tri-folding mode, it is used at the 1st folding.
A. Folding knife operation

The folding knife motor (M19) rotates the crank shaft a half turn via the gear and pushes the paper [2] to the nip
section with the folding knife [5].
The folding rollers [4] draw and fold the paper.
The position of the saddle stitching stopper [6] controls the folding position.
[4] [1]
[5]
[2]
[3]
[6]
15jmt2c020na
[1] Folding knife home sensor (PS22) [4] Folding roller

[2] Paper [5] Folding knife
[3] Folding passage sensor (PS26) [6] Saddle stitching stopper
B. Folding knife control

The folding knife motor (M19) turns ON and sticks out the folding knife to the paper after a specified period of
time since the folding passage sensor (PS26) [3] detects the paper and the saddle stitching stopper stops at the
folding position.
M19 stops when the folding knife reciprocates and the folding knife home sensor (PS22) [1] turns OFF.
62
Theory of Operation Ver.1.0 Nov. 2008 10. FOLDING/SADDLE STITCHING/TRI-FOLDING (FS-610)
10.2.2 Folding transfer control

The folding transfer motor (M20) drives the folding roller. Then, the folding roller drives the tri-folding roller.
FS-524/525/610
A. Folding transfer control
The folding knife motor (M19) turns ON [2] after a specified period of time since the folding passage sensor
(PS26) detects the paper and the saddle stitching stopper stops at the folding position. When M19 turns ON the
folding knife home sensor (PS22), the folding transfer motor (M20) turns ON [3] and drives the folding roller to
perform the 1st folding and the tri-folding roller to perform the 2nd folding at the tri-folding operation, and then it
exits the paper to the booklet tray.
M20 stops after a specified period of time since the folding paper exit sensor (PS25) detects the trailing edge of
the paper bundle.
[5]
Folding passage sensor (PS26)
Saddle stitching UP
stopper motor (M18) DOWN
Folding knife home sensor (PS22)
Folding knife motor (M19)
Folding transfer 80 mm/s

motor (M20)
400 mm/s
[1] [2] [3] [4] 15jmt2c021na
[1] Saddle stitching stopper moved [3] Paper fold

[2] Paper pressed to the folding roller by the [4] Paper transferred
folding knife [5] Standby position of the folding knife
B. Booklet full detection

The folding full sensor (PS29) that consists of the LED light emitting section and the light receiving section
detects the booklet tray paper full.
It determines the booklet tray is full if the exited paper shields the folding full sensor for the specified period of
time.
63
10. FOLDING/SADDLE STITCHING/TRI-FOLDING (FS-610) Theory of Operation Ver.1.0 Nov. 2008
10.2.3 Tri-folding gate control

The tri-folding gate switches between the folding/saddle stitching path and the tri-folding path. The tri-folding
FS-524/525/610
gate solenoid (SD6) drives the tri-folding gate.
A. Tri-folding 2nd folding operation

The tri-folding gate solenoid (SD6) [5] drives the tri-folding gate [6] to switch the paper path to the tri-folding path
for leading the paper exited from the folding roller [1] to the tri-folding stopper [4].
To perform the 2nd folding, the loop [2] formed when the paper contacts with the tri-folding stopper are drawn
between the folding roller and the tri-folding roller [3]. Then the paper is exited to the booklet tray [8].
The position of the tri-folding stopper determines the folding position in the 2nd folding.
[1]
[5] [9]
[6] [7]
[2]
[4]
[8]
[3] [3]
15jmt2c022na
[1] Folding roller [6] Tri-folding gate

[2] Loop [7] Paper
[3] Tri-folding roller [8] Booklet tray
[4] Tri-folding stopper [9] Folding paper exit sensor (PS25)
[5] Tri-folding gate solenoid (SD6)
B. Tri-folding gate control

After the saddle stitching stopper stops at the tri-folding position, the tri-folding gate solenoid (SD6) [5] turns ON
and drive the tri-folding gate [6] to switch the paper path to the tri-folding stopper.
SD6 turns OFF after a specified period of time since the folding paper exit sensor (PS25) [9] detects the trailing
edge of the paper bundle.
64
PI-504
2008.11
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
PI-504
PI-504
OUTLINE
2. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Auto sheet feeding (online operation). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Manual sheet feeding (offline operation). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. COMPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. PAPER FEED SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1.1 Paper feed drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1.2 Tray lift drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2.1 Tray lift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2.2 Pick-up mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2.3 Separation mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
i
PI-504
Blank page
ii
OUTLINE
PI-504
A. Type
Name Post inserter

Type Torque limiter separation type seat feeding device
B. Functions
Auto sheet feeding (online Feeds the sheet to FS automatically under the instruction from the main body.
operation)
Manual sheet feeding Feeds the sheet to FS under the instruction from the operation panel of PI.
(offline operation) You can select the following 5 post processing modes:
1 staple/back mode
2 staples (flat-stapling) mode
Punch mode (when PK-502/503/504/505 is installed on FS)
Saddle stitching mode (when installed on FS-610)
Tri-folding mode (when installed on FS-610)
Note
The tray /Lw only supports the manual sheet feeding.
The wide paper is not supported.
C. Type of paper
Paper size Tray /Up A4, A4S, B5, B5S, A5,

81/2 x 11, 81/2 x 11S, 51/2 x 81/2, 16K, 16KS, wide paper
Tray /Lw A3, B4, A4, A4S, B5, B5S, A5, Foolscap,
11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2, 8K, 16K, 16KS,
wide paper
Paper weight Plain paper 60 to 90 g/m2 of the high-quality paper and the recycle paper
Special paper 50 to 59 g/m2 of the thin paper
91 to 200 g/m2 of the thick paper
Printing paper 50 to 200 g/m2 of the double-sided art paper, mat coated paper,
high-quality paper
Capacity Tray /Up, /Lw 200 sheets (80 g/m2) or 30 mm or less in height
Sheet curling
[1]
a
15jft1c001na
a Curling: 10 mm or less
[1] 5 sheets
1
D. Maintenance

PI-504
E. Machine data
Power source 24V/5V DC (supplied from FS)

Maximum power consump- 30W
tion
Dimensions 511 (W) x 620 (D) x 220 (H) mm
Weight Approx. 10.5 kg
Temperature 10 to 30C [18 to 23C]

Humidity 10 to 80% RH [40 to 60% RH] (with no condensation)
* The value within "[" and "]" is applied when using the printing paper.
Note
2
2. PAPER PATH
2.1 Auto sheet feeding (online operation)
PI-504
[1]
[2] 15jft1c002na
[1] Paper path from the tray /Up [2] Paper path from the tray /Lw
3
2.2 Manual sheet feeding (offline operation)

PI-504
[1]
15jft1c003na
[1] Paper path from the tray /Lw
4
PI-504
3. COMPOSITION
Tray /Up section Pick-up /Up section
Separation /Up section
Conveyance
section
Tray /Lw section
Pick-up /Lw section

Separation /Lw section 15jft2c001na
5

4.1 Drive
PI-504
[1] [2] [3] [4]

[5]
[6]
[7]
[8]
[9]
[10]
[14]
[13] [11]
[12]
[18]
[17] [15]
[16]
15jft2c002na
[1] Pick-up roller /Lw [10] Paper feed roller /Lw

[2] Pick-up roller /Up [11] Conveyance roller /Lw
[3] Pick-up solenoid /Up (SD201) [12] Separation roller /Lw
[4] Paper feed roller /Up [13] Pick-up solenoid /Lw (SD202)
[5] Conveyance clutch (CL201) [14] Transfer motor (M203)
[6] Separation roller /Up [15] Pick-up solenoid /Up, /Lw (SD201, SD202)
[7] Conveyance clutch /Lw (CL202) [16] Front
[8] Conveyance roller /Up [17] Pick-up roller /Up and /Lw
[9] Registration clutch (CL203) [18] Paper feed roller /Up and /Lw
6
PI-504
[3]
[1]
[2] 15jft2c003na
[1] Front [3] Tray lift motor /Up (M201)

[2] Tray lift motor /Lw (M202)
7
4.2 Operation
4.2.1 Tray lift mechanism
PI-504
The tray lift motors /Up (M201) [2] and /Lw (M202) [7] move up and down the trays /Up and /Lw by rotating in
the forward and reverse direction to drive the lift arms /Up [10] and /Lw [4] and move up and down the lift plates
/Up [8] and /Lw [6], respectively.
At the upper limit positions, the tray upper limit sensors /Up (PS204) [1] and /Lw (PS209) [3] detect the actuators
lifted up by the lift plates.
At the lower position of the tray, the tray lower limit sensors /Up (PS205) [9] and /Lw (PS210) [5] detect the actu-
ators coupled with the lift arms /Up and /Lw.
[9] [10]
[8]
[1]
[7]
[2]
[3]
[6]
[5] [4]
15jft2c004na
[1] Tray upper limit sensor /Up (PS204) [6] Tray lift plate /Lw
[2] Tray lift motor /Up (M201) [7] Tray lift motor /Lw (M202)
[3] Tray upper limit sensor /Lw (PS209) [8] Tray lift plate /Up
[4] Lift arm /Lw [9] Tray lower limit sensor /Up (PS205)
[5] Tray lower limit sensor /Lw (PS210) [10] Lift arm /Up
8
4.2.2 Pick-up mechanism

The pick-up solenoids /Up (SD201) [2] and /Lw (SD202) turn ON to pick up the paper. The release arm [5] held
upward by the spring [1] lifts up the pick-up roller mounting plate [4] to release the pick-up roller [3]. When
PI-504
SD201 and SD202 turn ON, the release arm moves backward, and then the pick-up roller mounting plate and
the pick-up roller fall down by their own weight. The pick-up roller driven by the transfer motor (M203) presses
the paper and picks it up to transfer it to the separation section.
[4] [5]
[1]
[3] [2] 15jft2c005na
[1] Spring [4] Pick-up roller mounting plate

[2] Pick-up solenoid /Up (SD201) [5] Release arm
[3] Pick-up roller
9
4.2.3 Separation mechanism

The separation roller [4] is driven to rotate in the opposite direction from the paper transfer direction [2]. When
transferring no or 1 sheet of paper, the separation roller rotates in the paper transfer direction to transfer the
PI-504
paper to the paper transfer section because the frictional force between the paper feed roller [1] or the paper
and the separation roller [4] is stronger than the frictional force of the torque limiter [3].
When transferring 2 or more sheets of paper, the separation roller rotates in the reverse direction to prevent the
bottom sheet from being transferred because the frictional force between the sheets is stronger than the fric-
tional force of the torque limiter [3].
[7]
[6] [1]
[2]
[5]
[3]
[4]
15jft2c006na
[1] Paper feed roller [5] 2nd sheet

[2] Paper transfer direction [6] 1st sheet
[3] Torque limiter [7] Pick-up roller
[4] Separation roller
10

Transmitting the FS start signal [1], the transfer motor (M203) rotates in low speed and the pick-up solenoids /
UP (SD201) and /Lw (SD202) turn ON. At the time, the tray lift motors /Up (M201) and /Lw (M202) rotate in the
PI-504
forward direction to lift up the trays /Up and /Lw.
M201 and M202 stop when the tray upper limit sensors /Up (PS204) and /Lw (PS209) turn ON [2], and after a
specified period of time, the conveyance clutch /Up (CL201) and /Lw (CL202) turn ON and the paper is picked
up from the tray. Only 1 sheet of paper is transferred by the transfer roller because of the separation roller.
M203 rotates in high speed when the paper reaches the paper passage sensors /Up (PS201) and /Lw (PS206)
[3]. At the time, the paper is pressed against the transfer roller and forms a loop because the registration clutch
(CL203) is OFF. After a specified period of time, CL203 turns ON [4] and M203 drives the paper to FS.
M203 switches to rotate in low speed to feed the subsequent paper since the paper passed PS201/PS206 [5],
and then CL203 turns OFF after a specified period of time.
Transfer motor 253 mm/s

(M203)
670 mm/s
Conveyance clutch /Lw (CL202)
Tray lift motor /Lw (M202)
Tray upper limit sensor /Lw (PS209)
Pick-up solenoid /Lw (SD202)
Paper passage sensor /Lw (PS206)
[1] [2] [3] [4] [5] 15jft2c007na
[1] FS start signal turned ON [4] Registration clutch (CL203) turned ON

[2] Tray reached at the upper limit [5] Trailing edge of the paper passed the paper
[3] Paper reached the paper passage sensors / passage sensors /Up (PS201) and /Lw
Up (PS201) and /Lw (PS206) (PS206)
11

The paper size VRs /Up (VR201) [1] and /Lw (VR202) [3] coupled with the side guide [2] detects the paper size in
the main scan direction.
PI-504
The paper set sensors /Up (PS203) [5] and /Lw (PS208) [4] and the L size sensor /Lw (PS212) [6] detects the
paper size in the sub scan direction.
[1]
[6] [2]
[5] [4] [3]

15jft2c008na
[1] Paper size VR /Up (VR201) [4] Paper set sensor /Lw (PS208)
[2] Side guide plate [5] Paper set sensor /Up (PS203)
[3] Paper size VR /Lw (VR202) [6] L size sensor (PS212)
12
PK-502
2008.11
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE
2011/08 1.01 Correction of an error in writing

CONTENTS
PK-502
PK-502
OUTLINE
2. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. COMPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. PUNCH SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2.1 Punch control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5. PUNCH SCRAPS BOX SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2.1 Punch scraps box control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
i
PK-502
Blank page
ii
OUTLINE
PK-502
A. Type
Name Punch kit

Type FS-integrated type punching operation device
B. Functions
Punching method Stops and punches every paper

No. of holes 2 holes
Hole diameter 6.5 mm
Hole pitch 80 mm
Supported mode Punch mode
Applicable post processing Sort, group, staple
mode
C. Type of paper
Paper size A3, B4, A4, A4S, B5, B5S, A5, A5S,
11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2, 51/2 x 81/2S
Foolscap, 8K, 16K
Supported paper Recommended Same as the specified paper of the main body
general paper
Recommended Same as the specified paper of the main body
recycle paper
General paper High-quality paper 60 to 128 g/m2
(i.e. high-quality
paper)
Punch prohibited paper Label paper, tab paper, OHP paper, blue print master, holed paper, and the
other paper that may interfere with the operation of the punch unit or the punch
blade.
Paper curling
a [1]
15knt1c001na
a Curling: 10 mm or less
[1] 5 sheets of paper
1
D. Maintenance

PK-502
E. Machine data
Power source 24V/5VDC (supply from FS)

Maximum power consump- 20VA
tion
Dimensions W 68 mm x D 442 mm x H 120 mm
Weight Approx. 2 kg
NOTE
2
2. PAPER PATH
PK-502
[1]
[2]
[3]
[4]
15knt1c002na
[1] Paper path from PI [3] Paper path from the main body
[2] Punch unit [4] Punch scraps box
3
PK-502
Blank page
4
PK-502
3. COMPOSITION
Punch section
Punch scraps box

section
15knt2c001na
5
4. PUNCH SECTION Theory of Operation Ver.1.0 Nov. 2008
4. PUNCH SECTION
4.1 Drive
PK-502
[6]
[1]
[2]
[5]
[4] [3]
15knt2c002na
[1] Eccentric cam [4] Registration shutter

[2] Drive arm [5] Punch blade
[3] Registration shutter motor (M303) [6] Punch motor (M801)
6
Theory of Operation Ver.1.0 Nov. 2008 4. PUNCH SECTION
4.2 Operation
4.2.1 Punch control
PK-502
A. Registration loop control
The registration shutter motor (M303) [6] rotates to rotate the registration shutter drive assembly [5] after a spec-
ified period of time since the paper exit sensor (PS37) on the main body detects the leading edge of the paper.
Then, the motor stops rotating when the registration shutter home sensor (PS307) [4] turns OFF. It rotates the
registration shutter [7] 75 and moves it to the right of the entrance roller [2]. Paper is contacted with the regis-
tration shutter and forms the loop [3] to correct the paper misalignment.
After a specified period of time, M303 rotates in the reverse direction until PS307 turns ON and it restarts the
paper transfer.
This operation is not performed when the wide paper (216 mm or more in the transfer direction) is used or in the
no punching mode.
For more detailed information, refer to PI-504 service manual.
[8]
[1] [2]
[3]
[2]
[4]
[7]
[6] [5]
15knt2c003na

[4] Registration shutter home sensor (PS307) [8] PK
7
B. Punch control
Transmitting the start signal from the main body, the FNS conveyance motor (M1) rotates.
In the punch mode, M1 stops temporarily after a specified period of time since the FNS entrance sensor (PS4)
PK-502
detects the trailing edge of the paper.

At the same time, the punch motor (M801) [11] drives the shaft [13] to rotate a full circle. The eccentric cams [2]
and [12] rotate in sync with the shaft to move down the punch blade [1] to conduct the punch operation. M801
stops and the punch operation is completed when the punch home sensor (PS801) [3] turns ON.
M1 rotates again to convey the paper after a specified period of time since it stops temporarily.
[2]
[11]
[1]
[2]
[10]
[9]
[3]
[8] [4]
[2]
[5]
[6]
[7]
15knt2c004na
[1] Punch blade [7] Paper

[2] Eccentric cam [8] Punch blade at the upper position
[3] Punch home sensor (PS801) [9] Front side
[4] Punch blade at the lower position [10] Punch motor (M801)
[5] Drive arm [11] Shaft
[6] Punch blade
8
Theory of Operation Ver.1.0 Nov. 2008 5. PUNCH SCRAPS BOX SECTION
5. PUNCH SCRAPS BOX SECTION

5.1 Drive
PK-502
The punch scraps box section comprises no moving parts.
9
5. PUNCH SCRAPS BOX SECTION Theory of Operation Ver.1.0 Nov. 2008
5.2 Operation
5.2.1 Punch scraps box control
PK-502
A. Punch scraps box full detection

The punch scraps generated by the punch operation falls in the punch scraps box [3]. The punch scraps box full
sensor (PS802) [1] turns ON and transmits the "full punch scraps box" information to the main body when the
punch scraps box becomes full of punch scraps.
B. Punch scraps box detection

The punch scraps box set sensor (PS804) [5] detects whether the punch scraps box is set or not. PS804 turns
OFF and transmits the "no punch scraps box" information to the main body if the punch scraps box is not set.
[1]
[5]
[2]
[3]
[4]
15knt2c005na
[1] Punch scraps box full sensor (PS802) [4] Front side
[2] Punch unit [5] Punch scraps box set sensor (PS804)
[3] Punch scraps box
10
PK-503/504/505
2008.11
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE
2011/08 1.01 Correction of an error in writing

CONTENTS
PK-503/504/505
PK-503/504/505
OUTLINE
2. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. COMPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. PUNCH SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1.1 Punch shift drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1.2 Punch drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2.1 Punched hole No. switching operation (PK-505 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2.2 Punch standby position movement control
(For explanation, the part number for PK-505 is used.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2.3 Punch position correction control (For explanation, the part number for PK-505 is used.). . . . . 11
4.2.4 Punch control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5. PUNCH SCRAPS BOX SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2.1 Punch scraps box control (For explanation, the part number for PK-505 is used.) . . . . . . . . . . 16
i
PK-503/504/505
Blank page
ii
OUTLINE
PK-503/504/505
A. Type
Name Punch kit

Type FS-integrated type punching operation device
B. Functions
Punching method Stops and punches every paper

No. of holes PK-503: 2 holes
PK-504: 4 holes
PK-505: 2 holes/3 holes (inch) or 2 holes/4 holes (metric)
Hole diameter 6.5 mm
Hole pitch PK-503: 80 mm
PK-504: 21, 70, 21 mm
PK-505: 80 mm
Supported mode Punch mode
Applicable post processing Sort, group, staple
mode
C. Type of paper
Paper size PK-503: A3, B4, A4, A4S, B5, B5S, A5, A5S,
11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2, 51/2 x 81/2S
Foolscap, 8K, 16K, 16KS
PK-504: A3, B4, A4, B5, Foolscap
PK-505 (2 holes metric):
A3, B4, A4, A4S, B5, B5S, A5, Foolscap, 8K, 16K, 16KS
PK-505 (4 holes metric):
A3, B4, A4, B5, 8K, 16K
PK-505 (2 holes inch):
11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2, 51/2 x 81/2S
PK-505 (3 holes inch):
11 x 17, 81/2 x 11
Supported paper Recommended 80 g/m2
general paper
Recommended Same as the specified paper of the main body
recycle paper
General paper High-quality paper 60 to 128 g/m2
(i.e. high-quality
paper)
Punch prohibited paper Label paper, tab paper, OHP paper, blue print master, holed paper, and the
other paper that may interfere with the operation of the punch unit or the punch
blade.
1
Paper curling
a
PK-503/504/505
[1]
15knt1c001na
a Curling (10 mm or less)

[1] 5 sheets of paper
D. Maintenance
E. Machine data
Power source 24V/5VDC (supply from FS)

Maximum power 40 VA
consumption
Dimensions PK-503/PK-504: 130 (W) x 470 (D) x 115 (H) mm
PK-505: 150 (W) x 515 (D) x 135 (H) mm
Weight Approx. 3 kg
Note
2
2. PAPER PATH
PK-503/504/505
[1]
[2]
[3]
[4]
15kjt1c002na
[1] Paper path from PI [3] Paper path from the main body
[2] Punch unit [4] Punch scraps box
3
PK-503/504/505
Blank page
4
PK-503/504/505
3. COMPOSITION
Punch section
Punch scraps
box section
15kjt2e001na
5
4. PUNCH SECTION
PK-503/504/505
4.1 Drive
4.1.1 Punch shift drive
[6] [7] [1]
[5] [3] [2]
[4]
15kjt2c002na
[1] Punch unit [5] Punch shift motor (M802 for PK-503/504,
[2] Guide shaft and M302 for PK-505)
[3] Belt [6] Rack
[4] Front [7] Punch shift home sensor (PS803 for PK-
503/504, and PS303 for PK-505)
6
4.1.2 Punch drive

A. PK-503/PK-504
PK-503/504/505
[6]
[1]
[2]
[5]
[4] [3]
15kjt2c003na
[1] Eccentric cam [4] Registration shutter

[2] Drive arm [5] Punch blade
[3] Registration shutter motor (M303) [6] Punch motor (M801)
7
Revision history
Revision mark:
corresponding page.
NOTE
2011/08 2.02 Addition of precautions on executing ISW

2010/12 2.01 Revision in relation to change of description
2010/03 2.0 1 Revision due to the addition of a new optional unit (LK)
5. FIRMWARE VERSION UP Field Service Ver.2.0 Mar. 2010
5. FIRMWARE VERSION UP
bizhub 751/601
5.1 Precautions on rewriting the firmware

A. Check items
When rewriting the firmware, be sure to check the type (G00, G80) of current firmware and execute ISW with the
same type of firmware.
Since the type of firmware differs depending on the board, an error code or malfunction code is displayed by
executing ISW with wrong firmware.
NOTE
Depending on the board, there are 2 types of firmware; G00-xxxx, G80-xxxx.
When the rewrite is executed with the type that does not match the current firmware type, the
rewrite does not complete normally and an error code or malfunction code occurs.
Contact the service manager of the authorized distributor for the method to identify the board.
B. Target board
Control board that has different types
Main body: Printer control board (PRCB)
5.2 Combination of firmware and board

5.2.1 Table of combination (Main body: Printer control board (PRCB))
Types of board
Regular board Substitute board
57AA-902 A0PNH820
Types of FW G00-xxxx OK NG
After ISW completed normally, a
malfunction code (C-C104) occurs
at the reboot
G80-xxxx NG OK
After ISW completed normally, a
malfunction code (C-C104) occurs
at the reboot
A. NG screen display
C-C104
B. Recovery procedure
1. After ISW completed normally, a malfunction code (C-C104) occurs at the reboot
2. Turn OFF the sub power switch (SW2).
3. While pressing the "Utility/Counter" button, turn ON the SW2 to enter the service mode.
4. Execute ISW with a proper firmware.
NOTE
After C-C104 is displayed, the firmware version that had been installed before the ISW is not dis-
played in the service mode.
For the printers C1, C2, C3, C4 and C5, ISW cannot be executed individually.
162
B. PK-505
PK-503/504/505
[3] [1]
[1]
[12] [13] [2]
[2]
[3]
[9] [10] [11]

[8]
[7] [4]
[6] [5]
15kjt2e007na
[1] Punch motor (M301) [8] Groove of the switching cam

[2] Eccentric cam [9] Projection of the punch blade
[3] Slide link [10] Projection of the switching cam
[4] Switching cam [11] Punch blade
[5] When the punch blade is driven [12] Punch blade of the 3-hole punch
[6] When the punch blade is not driven [13] Punch blade of the 2-hole punch
[7] Switching cam shaft
8
4.2 Operation
PK-503/504/505
4.2.1 Punched hole No. switching operation (PK-505 only)
Number of punched holes of PK-505 is switched between 2 to 4 and 2 to 3 holes depending on the country.
Number of punched holes is switched by the rotating direction of the punch motor (M301) [3].
The motor M301 drives the slide link in the main scanning direction through the eccentric cam. As a result, the
projection of the switching cam is pushed in the slide link moving direction and the switching cam is rotated
around its axis.
The projection of the punch blade is fitted into the groove of the switching cam. In the 2 to 3 punched hole
mode, the groove of the switching cam of the 3-hole punching blade is shaped so that the rear side is concen-
tric with the rotating axis and the front side is curved toward the rotating axis. For this reason, when the switch-
ing cam is rotated clockwise, the punching blade is driven downward and when the cam is rotated
counterclockwise, the punching blade is not driven. The shape of the groove of the punching blade for 2 holes is
contrary to it on the right and left sides. When the switching cam is rotated counterclockwise, the punching
blade is driven.
When the number of punched holes is switched to 2 to 4 holes, the 2 punching blades at both ends are driven
only when the switching cam is rotated clockwise in the same way as in the 2 to 3 hole mode. As the 2 punching
blades at the center should be driven in both cases of 2 or 4 hole punching, shape of the groove of the switch-
ing cam is symmetrical on the right and left sides and both the front and rear sides are curved in the rotating axis
direction.
4.2.2 Punch standby position movement control (For explanation, the part number for PK-505 is
used.)
Turning ON the device, the punch shift motor (M302) rotates to move the punch unit [6] to the home position
until the punch shift home sensor (PS303) turns ON.
Selecting the punch mode, M302 rotates to move the punch unit [6] so that the paper size sensor (PS305) [1] of
the punch unit [6] is positioned 5 mm inward [2] from the side edge of the paper.
PS305 consists of 5 sensors. Each sensor detects the following paper.
Sensor Paper size
1 A5S, 51/2 x 81/2S
2 B5S, 16KS
3 A4S, A5, 81/2 x 11S, 81/2 x 14S, 51/2 x 81/2, Foolscap
4 B4, B5, 8K, 16K
5 A3, A4, 11 x 17, 81/2 x 11
* The sensors are numbered 1 to 5 from the front side
And, when the stand-by position is 5 mm for B5 and B4 paper sizes, the corner of the paper passes through
below the punch hole and the stand-by position is changed to 1.5 mm to prevent the hitching of the paper.
9
The punch unit returns to the home position at the end of the job.
PK-503/504/505
[5] [6] [1]

[2]
[3]
[4]
15kjt2c004na
[1] Paper size sensor (PS305) [4] Paper

[2] Moving distance from the paper edge [5] Punch blade
[3] Paper transfer direction [6] Punch unit
Note
In the model PK-505, the paper size sensor (PS305) is positioned on the front side and its opera-
tion is contrary to that in the above illustration on the right and left sides.
10
4.2.3 Punch position correction control (For explanation, the part number for PK-505 is used.)
For the punch unit positioned from the side edge of the paper to the inside (refer to "4.2.2 Punch standby posi-
PK-503/504/505
tion movement control (For explanation, the part number for PK-505 is used.)"), the punch position is adjusted in
the following procedure so that punching is made symmetrically to the center of paper at all times. The punch
position correction is operated by moving the punch unit back and forth while conveying the paper.
When the FNS entrance sensor (PS4) detects the leading edge of the paper, the punch unit [11] is moved to
the rear side until the paper size sensor (PS305) [2] detects the side edge of the paper. If you conduct the
punch operation on the paper conveyed from PI, it is started when the paper passage sensor /Up (PS201)
or /Lw (PS206) detects the leading edge of the paper.
Then, the punch unit [11] is moved to the front side until PS305 [2] detects the side edge of the paper (the
side edge reference position detection).
Once it detects the side edge reference position [3], the punch unit is moved further [11] so that the center
of the punch blade [1] is positioned to the center of the paper [5]. The moving distance and its direction are
depending on the paper size. It is stopped temporarily at the side edge reference position if it is moved to
the rear side.
[10] [11] [1] [2]

[3]
[9] [8]
[7]
[6]
[5] [4]
15kjt2c005na
[1] Center of the punch blade [7] Punch unit moving direction
[2] Paper size sensor (PS305) [8] Rear side
[3] Side edge reference position [9] Front side
[4] Paper [10] Punch blade
[5] Center of the paper [11] Punch unit
[6] Paper transfer direction
Note
In the model PK-505, the paper size sensor (PS305) is positioned on the front side and its opera-
tion is contrary to that in the above illustration on the right and left sides.
11
4.2.4 Punch control

A. Registration loop control (For explanation, the part number for PK-505 is used.)
PK-503/504/505
The registration shutter motor (M303) [6] rotates to rotate the registration shutter drive assembly [5] a specified
period of time after the paper exit sensor (PS37) on the main body detects the leading edge of the paper. Then,
the motor stops rotating when the registration shutter home sensor (PS307) [4] turns OFF. It rotates the registra-
tion shutter [7] 75 and moves it to the right of the entrance roller [2]. Paper is contacted with the registration
shutter and forms the loop [3] to correct the paper misalignment.
After a specified period of time, M303 rotates in the reverse direction until PS307 turns ON and it restarts the
paper transfer.
This operation is not performed when the wide paper (216mm or more in the transfer direction) is used or in the
no punching mode.
For more detailed information, refer to PI-504 service manual.
[8] [2]
[1]
[3]
[2]
[4]
[7]
[6] [5]
15kjt2e006na

[4] Registration shutter home sensor (PS307) [8] PK
12
B. Punch control (PK-503/PK-504)

Transmitting the start signal from the main body, the FNS conveyance motor (M1) rotates.
PK-503/504/505
In the punch mode, M1 stops temporarily a specified period of time after the FNS entrance sensor (PS4) detects
the trailing edge of the paper.
At the same time, the punch motor (M801) [11] drives the shaft [13] to rotate a full circle. The eccentric cams [2]
and [12] rotate in sync with the shaft to move down the punch blade [1] to conduct the punch operation. M801
stops and the punch operation is completed when the punch home sensor (PS801) [3] turns ON.
M1 rotates again to convey the paper a specified period of time after it stops temporarily.
[2]
[11]
[1]
[2]
[10]
[9]
[3]
[8] [4]
[2]
[5]
[6]
[7]
15kjt2c001na
[1] Punch blade [7] Paper

[2] Eccentric cam [8] Punch blade at the upper position
[3] Punch home sensor (PS801) [9] Front side
[4] Punch blade at the lower position [10] Punch motor (M801)
[5] Drive arm [11] Shaft
[6] Punch blade
13
C. Punch control (PK-505)

The FNS transfer motor (M1) is driven by the main body start signal.
PK-503/504/505
In the punching mode, the motor M1 stops temporarily after the FNS entrance sensor (PS4) detects the rear edge of paper.
At the same time, the punch motor (M301) [3] rotates in the direction according to the number of punched holes
and the slide link [5] moves. The switching cam rotates according to the movement of the slide link and the
punching blade [7] lowers to punch a hole.
Moving distance of the slide link [5] is controlled by detecting the eccentric cam actuator [4] with the punch
home sensor (PS301) [1]. When the actuator rotates 180 degrees, first punching is completed. In the second
punching, M301 is reversed. When the actuator reverses 180 degrees, punching is completed. Forward and
reverse rotations are repeated alternately.
The rotating speed of M301 is controlled by detecting the rotation of the punch encoder plate [6] fixed to the
axis of M301 with the punch encoder sensor (PS306) [2].
Then, M301 reverses and the punch home sensor (PS301) [1] returns to ON and the M301 stops finally.
When a specified time elapsed after M1 stops temporarily, M1 resumes rotating and paper is transferred.
[1]
[2]
[7] [6]
[3]
[4]
[5]
[1]
[8]
[1]
[9]
15kjt2e008na
[1] Punch home sensor (PS301) [7] Punching blade

[2] Punch encoder sensor (PS306) [8] Operation of 4-hole punching in the 2 to 3 hole
[3] Punch motor (M301) mode and 4-hole punching in the 2 to 4 hole mode
[4] Actuator [9] Operation of 3-hole punching in the 2 to 3 hole
[5] Slide link mode and 2-hole punching in the 2 to 4 hole mode
[6] Punch encoder plate
14
Theory of Operation Ver.1.0 Nov. 2008 5. PUNCH SCRAPS BOX SECTION
5. PUNCH SCRAPS BOX SECTION
PK-503/504/505
5.1 Drive
The punch scraps box section comprises no moving parts.
15
5. PUNCH SCRAPS BOX SECTION Theory of Operation Ver.1.0 Nov. 2008
5.2 Operation
PK-503/504/505
5.2.1 Punch scraps box control (For explanation, the part number for PK-505 is used.)
A. Punch scraps box full detection
The punch scraps generated by the punch operation falls in the punch scraps box [3]. The punch scraps box full
sensor (PS302) [1] turns ON and transmits the "no punch scraps box" information to the main body when the
punch scraps box becomes full of punch scraps.

The punch scraps box set sensor (PS304) detects whether the punch scraps box is set or not. PS304 turns
OFF and transmits the "no punch scraps box" information to the main body if the punch scraps box is not set.
[1]
[5]
[2]
[3]
[4]
15kjt2c007na
[1] Punch scraps box full sensor (PS302) [4] Front side
[2] Punch unit [5] Punch scraps box set sensor (PS304)
16
ZU-604/605
2008.11
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
ZU-604/605
ZU-604/605
OUTLINE
2. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. COMPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. CONVEYANCE SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2.1 Conveyance path switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2.2 Conveyance line speed switching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5. PUNCH SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2.1 Punch control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2.2 Punch position movement control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2.3 Punch hole switching control (ZU-605) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6. PUNCH SCRAPS CONVEYANCE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2.1 Punch scraps conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2.2 Punch scraps control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7. Z-FOLDING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.2.1 1st folding control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.2.2 2nd folding control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
i
ZU-604/605
Blank page
ii
OUTLINE
ZU-604/605
A. Type
Type Z-folding multi punching device
B. Functions
Punch Punching method Reciprocal punching method (punching each paper)

No. of holes ZU-604: Swedish 4 holes
ZU-605: Metric area 2 holes/4 holes (switched automatically)
Inch area 2 holes/3 holes (switched automatically)
Hole diameter ZU-604: 6.5 mm
ZU-605 (Metric area): 6.5 mm
ZU-605 (Inch area): 8.0 mm
Hole position
a a
c
b d b d
c
[1] [2]
a a
b b
d b d
b b
[3] [4]
15ktt1e001na
Model Type/No. of a (mm) b (mm) c (mm) d *1

type holes *1
[1] ZU-604 Swedish/ 10.5 70 21 Center of
4 holes the paper
[2] ZU-605 Inch/2 holes 9.5 70
Metric/ 10.5 80
2 holes
[3] ZU-605 3 holes 9.5 108
[4] ZU-605 4 holes 10.5 80
*1 Adjustable of 5mm
1
Z-folding Z-folding method Buckle folding method with the roller pair
Folding length
ZU-604/605
L
[1]
L
[2]
15ktt1e002na
Paper L (mm) a (mm)

size
[1] Z-folding A3 209 or less 3.5 1.5
B4 181 or less
11 x 17 215 or less
8K 194 or less
[2] Folding 81/2 x 14 241.7 or less
Folding precision
a a
[1] [2]
[3] 15ktt1e003na
a: 2 mm or less
[1] 1st folding
[2] 2nd folding
[3] Folding (81/2x 14 paper)
2
Maximum tray capacity The maximum number of sheets for the FS main tray at the
(80g/m2) Z-folding operation
ZU-604/605
Z folding continuous: Max. 30 sheets
Z-folding/stapling: See the table below
No. of sheets per staple No. of set on

No. of fold sheets No. of unfold the main tray
sheets
1 sheets 1 to 40 sheets 20 set
5 sheets 0 sheet 2 set
6 to 30 sheets Stapling not available
C. Type of paper
No punch mode Same as the main body.

Punch mode Paper size 2 holes A3, B4, A4, A4S, B5, B5S, A5, A5S, Foolscap,
8K, 16K, 16KS
11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S,
51/2 x 81/2, 51/2 x 81/2S
3 holes A3, B4, A4, 8K, 16K
11 x 17, 81/2 x 11
4 holes A3, B4, A4, 8K, 16K
11 x 17, 81/2 x 11
Swedish A3, B4, A4, B5
4 holes
Combination with the folding/saddle stitching mode is
not available.
Type of paper 50 to 90 g/m2 of the high-quality paper and the plain paper
Special paper is not guaranteed. The punching of label
paper, tab paper, OHP paper, blue print master and
binding-holed paper are not allowed.
Z-folding mode Paper size A3, B4, 8K
11 x 17, 81/2 x 14 (Folding)
For B4 paper (including the mix of the paper), the com-
bination with the stapling mode is not available.
Type of paper 50 to 90 g/m2 of the high-quality paper and the plain paper
Special paper is not supported. Label paper, tab paper,
OHP paper, blue print master, holed paper, and low
stiffness paper are not supported in Z-folding mode.
3
Paper curling
[1]
ZU-604/605
15kvt1c001na
a Amount of curl: 10 mm or less

[1] 5 sheets of paper immediately after the printing
D. Maintenance
E. Machine data
Power source 100 to 240 VAC (automatic switching)

DC5V (supplied from the main body)
Maximum power consump- 120 W or less
tion
Dimensions 169 (W) x 660 (D) x 930 (H) mm
F. Operational environment
Note
4
2. PAPER PATH
ZU-604/605
A. Straight mode/punch mode (for the small size paper)
15kvt1c002na
B. Punch mode (for the large size paper)
15kvt1c003na
5
C. Z-folding mode/punch + Z-folding mode

ZU-604/605
[1]
[3]
[2]
15kvt1c004na
[1] From the main body to the 1st folding [3] From the 2nd folding to the paper exit
[2] From the 1st folding to the 2nd folding
6
ZU-604/605
3. COMPOSITION
Z-folding section
Conveyance section
Punch section
Punch scraps con-

veyance section
15kvt2c001na
7
ZU-604/605
4.1 Drive
A. Conveyance drive
[9]
[8]
[1]
[2]
[3]
[7]
[4]
[6]
[5] 15kvt2c002na
[1] Gate /Up [6] Registration motor (M1)

[2] 1st folding roller [7] Exit roller
[3] Conveyance roller [8] 2nd folding roller
[4] Registration roller [9] Conveyance motor (M6)
[5] Gate /Lw
8
B. Gate drive
ZU-604/605
[4]
[1]
[3]
[2]
15kvt2c003na
[1] Gate /Up [3] Gate solenoid /Lw (SD1)

[2] Gate /Lw [4] Gate solenoid /Up (SD2)
9
4.2 Operation
ZU-604/605
4.2.1 Conveyance path switching

The gates /Lw and /Up switch the conveyance path. The gate solenoids /Lw (SD1) and /Up (SD2) drive the
gates /Lw and /Up respectively.
A. Gate /Lw
The gate /Lw [4] switches the paper path between the straight conveyance path [2] and the upper conveyance
path [1].
The gate /Lw is set to the straight conveyance path [2] when the gate solenoid /Lw (SD1) [3] turns OFF [6]. The
gate /Lw is set to the upper conveyance path [1] when SD1 turns ON [5].
[3]
[1]
[2]
[4]
[6] [5]
15kvt2c004na
[1] Upper conveyance path [4] Gate /Lw

[2] Straight conveyance path [5] SD1 turned ON
[3] Gate solenoid /Lw (SD1) [6] SD1 turned OFF
10
B. Gate /Up
The gate /Up [5] switches the paper path of the paper that was conveyed to the upper conveyance path by the
ZU-604/605
gate /Lw. The gate /Up is set to the paper path to the exit side [3] when the gate solenoid /Up (SD2) [4] turns
OFF [6]. The gate /Up is set to the paper path [2] to the 1st folding stopper [1] when SD2 turns ON [7].
[1]
[4]
[2]
[3]
[5]
[6] [7]
15kvt2c005na
[1] 1st folding stopper [5] Gate /Up

[2] Conveyance path to the 1st folding stopper [6] SD2 turned OFF
[3] Conveyance path to the exit side [7] SD2 turned ON
[4] Gate solenoid /Up (SD2)
C. Operation timing
(1) Z-folding mode
In the Z-folding mode for the all paper size, the gate solenoid /Lw (SD1) and the gate solenoid /Up (SD2) turn
ON when the paper edge sensor board (PESB) detects the leading edge of the paper [1], and then the gate /Lw
is set to the upper conveyance path and the gate /Up is set to the conveyance path to the 1st folding stopper.
SD1 and SD2 turn OFF [2] a specified period of time after the last paper turns OFF the exit sensor (PS9).
[1] [2]
Paper edge sensor board (PESB)
Exit sensor (PS9)
Gate solenoid /Lw (SD1)
Gate solenoid /Up (SD2)
15kvt2c006na
[1] Leading edge of the paper detected by the [2] Gate solenoid /Lw (SD1) and gate solenoid /
paper edge sensor board (PESB) Up (SD2) turned OFF
11
(2) Punch mode for the small size paper (A4, B5, A5, A5S, 16K, 8 /2 x 11, 51/2 x 81/2, 51/2 x 81/2S)
1
Gate solenoids /Lw (SD1) and /Up (SD2) always remain OFF, and never turn ON.
ZU-604/605
(3) Punch mode for the large size paper (other than the small size paper)
The gate solenoid /Lw (SD1) turns ON when the paper edge sensor board (PESB) detects the leading edge of
the paper, and then the gate /Lw is set to the upper conveyance path. The gate solenoid /Up (SD2) remains OFF
and the gate /Up remains being set to the paper path to the exit side.
SD1 turns OFF a specified period of time after the last paper turns OFF the exit sensor (PS9).
(4) Straight exit mode

Gate solenoids /Lw (SD1) and /Up (SD2) always remain OFF, and never turn ON.
The gate /Lw remains being set to the straight conveyance path.
4.2.2 Conveyance line speed switching

The conveyance motor (M6) drives the conveyance drive roller [9], the 1st folding roller [1], and the 2nd folding
roller [8], which perform the folding operation, as well as the conveyance roller [2] and the exit roller [6]. The
paper edge sensor board (PESB) [3], the passage sensor (PS1) [7], and the exit sensor (PS9) [5] detect the
paper.
[9]
[1]
[8]
[2]
[7]
[6]
[3]
[5]
[4]
15kvt2c007na
[1] 1st folding roller [6] Exit roller

[2] Conveyance roller [7] Passage sensor (PS1)
[3] Paper edge sensor board (PESB) [8] 2nd folding roller
[4] Registration roller [9] Conveyance drive roller
[5] Exit sensor (PS9)
12
A. Operation timing
(1) Z-folding
ZU-604/605
Transmitting the start signal from the main body, the conveyance motor (M6) turns ON [1] and rotates in high
speed. M6 rotates in low speed [2] and perform the 1st and 2nd folding operations [3] a specified period of time
after the paper edge sensor board (PESB) detects the leading edge of the paper.
M6 rotates in high speed [4] to perform the paper exit operation of the 1st paper [5] and to convey the 2nd
paper [8] in sync with the paper exit speed of the main body when the passage sensor (PS1) detects the leading
edge of the paper and turns ON after the 2nd folding operation.
M6 turns OFF when the exit sensor (PS9) detects the trailing edge of the last paper [6].
[7] [8] [9]

Passage sensor (PS1)
Exit sensor (PS9)
Conveyance High speed

motor (M6)
Low speed
[6]
[1] [2] [3] [4] [5] 15kvt2c008na
[1] Start signal [6] M6 turned OFF when the trailing edge of the
[2] Conveyance motor (M6) driven in low speed last paper is detected
[3] 1st and 2nd folding operations [7] 1st paper
[4] M6 driven in high speed [8] 2nd paper
[5] Paper exit operation [9] 3rd (last) paper
13
(2) Punch + Z-folding

Transmitting the start signal from the main body, the conveyance motor (M6) turns ON [1] and rotates in high
ZU-604/605
speed. M6 rotates in low speed [2] and perform the 1st folding operation a specified period of time after the
paper edge sensor board (PESB) detects the leading edge of the paper.
M6 turns OFF [3] for the punching operation a specified period of time after PESB detects the trailing edge of the
paper. After the punching operation, M6 turns ON and perform the 2nd folding operation [4]. M6 rotates in high
speed [5] to perform the paper exit operation of the 1st paper [6] and to convey the 2nd paper [9] in sync with
the paper exit speed of the main body when the passage sensor (PS1) detects the leading edge of the paper
and turns ON after the 2nd folding operation.
M6 turns OFF when the exit sensor (PS9) detects the trailing edge of the last paper [7].
[8] [9] [10]
Exit sensor (PS9)
Conveyance High speed

motor (M6)
Low speed
[7]
[1] [2] [3] [4] [5] [6] 15kvt2c009na
[1] Start signal [6] Paper exit operation

[2] Conveyance motor (M6) driven in low speed [7] M6 turned OFF when the trailing edge of the
[3] M6 stopped for the punching operation last paper is detected
[4] 2nd folding operation [8] 1st paper
[5] M6 driven in high speed [9] 2nd paper
[10] 3rd (last) paper
14

The registration control corrects paper skew in the Z-folding mode and the punch mode.
ZU-604/605
The paper exited from the main body is pressed against the stopped registration roller [3] and forms a loop [2] to
correct skew of the paper [1], and then the paper is conveyed with its leading edge nipped.
The registration motor (M1) [4] drives the registration roller.
[1]
[2]
[4] [3]
15kvt2c010na
[1] Leading edge of the paper [3] Registration roller

[2] Loop [4] Registration motor (M1)
A. Operation timing
Transmitting the start signal from the main body, the registration motor (M1) turns ON [1].
M1 stops [2] a specified period of time after the paper edge sensor board (PESB) detects the leading edge of
the paper conveyed from the main body. The paper is pressed against the registration roller and forms a loop [3]
to correct paper skew. M1 turns ON [4] and the conveyance is restarted a specified period of time after the
paper contacts with the registration roller.
M1 turns OFF a specified period of time after the paper is exited.
No registration control is conducted in the straight mode.
Registration High speed

motor (M1)
Low speed
[1] [2] [3] [4] 15kvt2c011na
[1] Start signal from the main body [3] A loop formed
[2] Registration motor (M1) stopped [4] Conveyance restarted
15
5. PUNCH SECTION
ZU-604/605
5.1 Drive
A. ZU-604
[10] [2]
[1]
[8]
[1] [2]
[7]
[6] [5]
[4]
[9]
[3] 15ktt2e001na
[1] Punch clutch (CL1) [6] Punch edges

[2] Punch motor (M4) [7] Front direction
[3] Punch shift motor (M5) [8] Eccentric cam
[4] Belt [9] Right side view
[5] Rack [10] Rear side view
16
B. ZU-605
ZU-604/605
[13] [10] [14] [11] [15] [2]
[12] [7] [1]
[10] [11] [1] [2]
[9]
[7] [6] [5]
[8] [4]
[3] 15kvt2e001na
[1] Punch clutch (CL1) [9] Front direction

[2] Punch motor (M4) [10] Cam cover
[3] Punch shift motor (M5) [11] Eccentric cam (Metric Type: 4/Inch Type: 5)
[4] Belt [12] Punch switchover cam
[5] Rack [13] Top side view
[6] Punch edges (Metric area: 4 edges/Inch [14] Cam holder
area: 5 edges) [15] Rear side view
[7] Punch switchover motor (M8)
[8] Right side view
17
5.2 Operation
ZU-604/605
The punch operation is conducted for every paper.

The controls related to the punch operation is the punch unit position movement control, the punch operation
control, and the punch hole switching control (only for ZU-605).
5.2.1 Punch control

The punch operation is conducted by transmitting the rotation of the punch motor (M4) [4] to the eccentric cam
[6] by the punch clutch (CL1) [3] and reciprocating the punch edges [8] connected to the cam holder [1] once.
M4 rotates clockwise from the view of the rear. M4 drives the eccentric cam and performs the punch operation
when CL1 turns ON. M4 keeps rotating during the punch operation.
The punch home sensor (PS6) [5] detects the home position of the punch edges.
[6]
[5]
[4]
[1]
[2]
[3]
[10] [1] [7]
[6]
[8]
[9]
15kvt2c012na
[1] Cam holder [6] Eccentric cam

[2] Front [7] Punching (lower position)
[3] Punch clutch (CL1) [8] Punch edges
[4] Punch motor (M4) [9] Paper
[5] Punch home sensor (PS6) [10] Home position (upper position)
18
A. Operation timing
The registration motor (M1) and the conveyance motor (M6) turn OFF to stop the conveyance during the punch
ZU-604/605
operation.
The punch motor (M4) turns ON [1] when the paper edge sensor board (PESB) detects the leading edge of the
paper. The punch clutch (CL1) turns ON [2] and performs the punch operation a specified period of time after
PESB detects the trailing edge of the paper, and then CL1 turns OFF after a specified period of time. M4 turns
OFF [3] a specified period of time after CL1 turns OFF.
After the punch operation, M1 and M6 turn ON to exit the paper.
Punch motor (M4)

Punch clutch (CL1)
[1] [2] [3] 15kvt2c013na
[1] Leading edge of the paper detected [3] Punch clutch (CL1) turned OFF
[2] Punch clutch (CL1) turned ON
19
5.2.2 Punch position movement control

The punch shift motor (M5) [1] moves the punch unit [3] to move the punch hole position in the main scan direc-
ZU-604/605
tion.
5 sensors of the paper edge sensor board (PESB) [8] detects the punch hole position.
The front side sensor [7] among 5 sensors detects the leading/trailing/side edge of the paper and the other 4
sensors [6] detect the side edge of the paper. The different sensor is used depending on the paper size.
The punch shift home sensor (PS5) [5] detects the home position.
The registration motor (M1) controls the punch position in the sub scan direction by its stop position.
[8]
[7] [6] [5]
[4]
[3] [2] [1] 15kvt2c014na
[1] Punch shift motor (M5) [5] Punch shift home sensor (PS5)
[2] Belt [6] Side edge sensors
[3] Punch unit [7] Leading/trailing/side edge sensor
[4] Front direction [8] Paper edge sensor board (PESB)
20
A. Standby position movement of the punch unit

In the punch mode, the punch unit [5] is set to the standby position in accordance with the paper size before the
ZU-604/605
paper [3] is conveyed.
The punch shift motor (M5) [1] moves the punch unit so that the sensor corresponding to the paper size among
5 sensors of the paper edge sensor board (PESB) [6] (in case of A4 paper, the sensor [7] is used) is positioned 5
mm [9] inward from the side edge of the paper [8].
This operation is not conducted in the no punch mode.
[5] [6] [7] [8] [9]

[4]
[1]
[3]
[2] 15kvt2c015na
[1] Punch shift motor (M5) [6] Paper edge sensor board (PESB)
[2] Paper [7] Side edge sensors
[3] Paper conveyance direction [8] Side edge of the paper
[4] Punch blade [9] 5 mm from the side edge of the paper
[5] Punch unit
21
B. Punch position correction

The punch unit [13] positioned 5 mm [1] inward from the side edge of the paper [3] conducts the punch position
ZU-604/605
correction operation by moving the punch unit back and forth while conveying the paper to correct the misalign-
ment between the conveyed paper [7] and the punch position.
Move the punch unit backward [10] until the certain side edge sensor ([2] for A4 paper) detects the side
edge of the paper [4].
Then, move the punch unit forward [11] until the side edge sensor [2] detects the side edge of the paper [5]
(the side edge reference position detection).
Move the punch unit forward further [6] so that the center of the punch edges [14] is positioned to the cen-
ter of the paper [8].
[13] [14] [1]
[12] [2]
[3]
[4]
[11]
[10]
[5]
[6]
[9]
[8] [7]
15kvt2c016na
[1] Standby position (5mm inward from the side [8] Center of the paper
edge of the paper) [9] Paper conveyance direction
[2] Side edge sensor [10] Rear side direction
[3] Side edge of the paper [11] Front side direction
[4] Side edge detection operation [12] Punch edges
[5] Side edge reference position detection [13] Punch unit
[6] Paper center position detection [14] Center of the punch edges
[7] Paper
22
5.2.3 Punch hole switching control (ZU-605)

Transmitting the start signal from the main body, the punch switchover motor (M8) [3] switches the number of
ZU-604/605
holes in the punch mode.
M8 rotates the punch switchover cam [5] clockwise and moves the eccentric cams [8] and [9] back and forth via
the cam cover [6].
When switching between the 2 holes punching and the 4 holes punching in Metric Type, 2 eccentric cams [9] in
the middle remain being held in the cam holders [7] because they are shared in both cases. When the cam
cover moves forward, the eccentric cams [8] at the outside for the 4 holes punching are held in the cam holder
so that the total of 4 eccentric cams are driven. When the cam cover move backward, 2 outside eccentric cams
are disengaged.
For the switchover between the 2 holes punching and the 3 holes punching in Inch Type, the 2 holes eccentric
cams and the 3 holes eccentric cams work exclusively. When the cam cover moves forward, the 3 holes eccen-
tric cams are held in the cam holder and the 2 holes eccentric cams are disengaged.
This operation is not conducted if the number of holes is same with the previous printing.
[8] [9] [1]

[6] [7]
[5]
[4]
[3]
[2]
[6] [8]
[7] [10]
[2]
[5]
[4]
[3] [9]
15kvt2e002na
[1] Upper side view [6] Cam cover

[2] Front side direction [7] Cam holder
[3] Punch switchover motor (M8) [8] Eccentric cam (2 holes/4 holes)
[4] Punch switchover switch (MS2) [9] Eccentric cam (4 holes)
[5] Punch switchover cam [10] Right side view
23
6. PUNCH SCRAPS CONVEYANCE SECTION Theory of Operation Ver.1.0 Nov. 2008
6. PUNCH SCRAPS CONVEYANCE SECTION

ZU-604/605
6.1 Drive
[2]
[1]
15kvt2c018na
[1] Punch scraps conveyance motor (M7) [2] Punch scraps conveyance screw gear
24
Theory of Operation Ver.1.0 Nov. 2008 6. PUNCH SCRAPS CONVEYANCE SECTION
6.2 Operation
ZU-604/605
6.2.1 Punch scraps conveyance control
The punch scraps are conveyed by the punch scraps conveyance screw [2] driven by the punch scraps convey-
ance motor (M7) [1]. They are conveyed to the punch scraps box [3] via the punch scraps collective duct [4].
M7 turns ON to rotate the punch scraps conveyance screw a specified period of time after the paper edge sen-
sor detects the trailing edge of the paper in the punch mode. The punch scraps are sent to the forward by the
rotation of the screw and collected in the punch scraps box via the punch scraps collective duct.
[1]
[4]
[3] [2]
15kvt2c019na
[1] Punch scraps conveyance motor (M7) [3] Punch scraps box
[2] Punch scraps conveyance screw [4] Punch scraps collective duct
25
6. PUNCH SCRAPS CONVEYANCE SECTION Theory of Operation Ver.1.0 Nov. 2008
6.2.2 Punch scraps control

The punch scraps box set sensor (PS7) [1] and the punch scraps full sensor (PS8) [3] monitor the punch scraps
ZU-604/605
box [2].
[3]
[2]
[1] 15kvt2c020na
[1] Punch scraps box set sensor (PS7) [3] Punch scraps full sensor (PS8)
A. Punch scraps full detection

The punch scraps full sensor (PS8) detects whether the punch scraps box is full or not. PS8 turns ON and trans-
mits the punch scraps full signal to the main body when the punch scraps box becomes full of punch scraps,
and then the main body displays the message on its operation panel.

The punch scraps box set sensor (PS7) detects whether the punch scraps box is housed or not. PS7 turns ON
and transmits the "no punch scraps box" signal to the main body when the punch scraps box is not set, and
then the main body displays the message on its operation panel.
26
Theory of Operation Ver.1.0 Nov. 2008 7. Z-FOLDING SECTION
7. Z-FOLDING SECTION
ZU-604/605
7.1 Drive
A. 1st stopper drive
[4]
[1]
[3]
[2]
15kvt2c021na
[1] Front side direction [3] 1st stopper home sensor (PS3)
[2] 1st stopper motor (M2) [4] 1st stopper
B. 2nd stopper drive
[1]
[4]
[2]
[3] 15kvt2c022na
[1] Front side direction [3] 2nd stopper home sensor (PS4)
[2] 2nd stopper motor (M3) [4] 2nd stopper
27
7. Z-FOLDING SECTION Theory of Operation Ver.1.0 Nov. 2008
7.2 Operation
ZU-604/605
7.2.1 1st folding control

The registration roller [5], the conveyance roller [4], and the 1st folding roller [3] convey the paper to the 1st fold-
ing stopper section via the gate /Up [2]. A loop [6] is formed between the 1st folding roller [3] and the convey-
ance drive roller [7] when the leading edge of the paper is pressed against the 1st folding stopper [8]. The loop
grows, and then it is caught by these rollers and the 1st folding is conducted. The paper is then conveyed to the
2nd folding stopper section.
The position of the 1st folding depends on the position of the 1st folding stopper. The 1st stopper motor (M2)
sets the position in accordance with the number of steps from the 1st stopper home sensor (PS3) [1].
In the Z-folding mode with the punch mode, the registration motor (M1) and the conveyance motor (M6) stops
to conduct the punch operation after the 1st folding operation, and then M1 and M6 turns ON to conduct the
2nd folding operation.
[8] [1]
[11]
[7]
[2]
[3]
[6]
[10]
[4]
[5] [9]
15kvt2c023na
[1] 1st stopper home sensor (PS3) [7] Conveyance drive roller
[2] Gate /Up [8] 1st folding stopper
[3] 1st folding roller [9] 1st folding
[4] Conveyance roller [10] 2nd folding direction
[5] Registration roller [11] Front side
[6] Loop
A. Operation timing
The 1st folding stopper motor (M2) turns ON [1] to drive the 1st folding stopper to the appropriate position [2] in accordance
with the paper size a specified period of time after transmitting the start signal from the main body.
Transmitting the termination signal [3] from the main body, M2 replaces the 1st folding stopper to the home position [4].
1st stopper home sensor (PS3)
1st stopper motor (M2)
Exit sensor (PS9)
[1] [2] [3] [4] 15kvt2c024na
[1] Start signal from the main body [3] Termination signal
[2] 1st folding stopper moving to the paper size [4] 1st folding stopper returning to the home position
28
Theory of Operation Ver.1.0 Nov. 2008 7. Z-FOLDING SECTION
7.2.2 2nd folding control

The paper conveyed from the 1st folding section to the 2nd folding section is stopped by the 2nd folding stop-
ZU-604/605
per [4] and forms a loop [8] between conveyance drive roller [10] and the 2nd folding roller [9]. The loop grows,
and then it is caught by these rollers and the 2nd folding is conducted.
The 2nd stopper motor (M2) turns ON to move the 2nd stopper [4] to the evacuation position [3] for the paper
conveyance when the leading edge of the paper (crease of the 1st folding) conveyed to the paper exit direction
[7] passes the passage sensor (PS1) [6].
The 2nd folding is not conducted for 81/2 x 14 paper.
[10]
[9] [12]
[13]
[8]
[7]
[6] [1]
[5]
[4]
[3] [11]
[2] 15kvt2c025na
[1] 1st folding roller [8] Loop

[2] Exit sensor (PS9) [9] 2nd folding roller
[3] Home position of the 2nd folding stopper [10] Conveyance drive roller
[4] Folding position of the 2nd folding stopper [11] Front side
[5] 2nd stopper home sensor [12] 2nd folding position
[6] Passage sensor (PS1) [13] Conveyance direction
[7] Paper exit direction
A. Operation timing
The 2nd folding stopper motor (M3) turns ON [2] to drive the 2nd folding stopper to the appropriate position [2] in accor-
dance with the paper size when the paper edge sensor board (PESB) detects the leading edge of the paper.
M3 rotates in the reverse direction to move the 2nd folding stopper to the home position [3] when the passage
sensor (PS1) detects the leading edge of the paper after the 2nd folding. It opens the paper exit path.
M3 turns ON to replace the stopper to the original position [4] for the subsequent Z-folding when the exit sensor
(PS9) detects the trailing edge of the paper.
2nd stopper home sensor (PS4)
2nd stopper motor (M3)
Exit sensor (PS9)
[1] [2] [3] [4] 15kvt2c026na
[1] Start signal from the main body [3] Moving to the home position
[2] Moving to the 2nd folding position [4] Moving to the 2nd folding position for the subsequent paper
29
7. Z-FOLDING SECTION Theory of Operation Ver.1.0 Nov. 2008
ZU-604/605
Blank page
30
2008 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.
Printed in Japan
Use of this manual should be strictly supervised to avoid
CCA0PN-M-TE2
disclosure of confidential information.

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SERVICE MANUAL Theory of Operation

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

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

Check wiring for squeezing and any other damage.

Carefully remove all toner remnants and dust from electri-

Check electrode units such as a charging corona unit for

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

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

5. Used Batteries Precautions

INDICATION OF WARNING ON THE MACHINE

For metric area:

For inch area:

MEASURES TO TAKE IN CASE OF

In addition, it is prohibited under any circumstances to copy domestic or foreign currencies,

<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