Bizhub 500 420 Service Manual Main Body Options PDF

SERVICE MANUAL
Theory of Operation
500 / 420
2006.02
Ver. 1.0
THEORY OF OPERATION TOTAL CONTENTS

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

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

Read carefully the Safety and Important Warning Items described below to understand
them before doing service work.
IMPORTANT NOTICE
Because of possible hazards to an inexperienced person servicing this product as well as
the risk of damage to the product, Konica Minolta Business Technologies, INC. (hereafter
called the KMBT) strongly recommends that all servicing be performed only by KMBTtrained 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.
:Prohibition when using the
copier.
:Direction when using the
copier.
General
precaution
Electric hazard
High
temperature
General
prohibition
Do not touch
with wet hand
Do not
disassemble
General
instruction
Unplug
Ground/Earth
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 reasoning behind this policy.
Prohibited Actions
DANGER
Using any cables or power cord not specified by KMBT.
Using any fuse or thermostat not specified by KMBT.

Safety will not be assured, leading to a risk of fire and
injury.
Disabling fuse functions or bridging fuse terminals with
wire, metal clips, solder or similar object.
Disabling relay functions (such as wedging paper between
relay contacts)
Disabling safety functions (interlocks, safety circuits, etc.)

injury.
Making any modification to the product unless instructed
by KMBT
Using parts not specified by KMBT
S-2
[2] POWER PLUG SELECTION

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

WARNING
Use power supply cord set which meets the following
criteria:
- provided with a plug having configuration intended for
the connection to wall outlet appropriate for the product's rated voltage and current, and
AC230V
- the plug has pin/terminal(s) for grounding, and

- provided with three-conductor cable having enough current capacity, and
- the cord set meets regulatory requirements for the area.
AC208V
240V
Use of inadequate cord set leads to fire or electric shock.

Attach power plug which meets the following criteria:
- having configuration intended for the connection to wall
outlet appropriate for the product's rated voltage and
current, and
- meets regulatory requirements for the area.
Use of inadequate cord set leads to the product connecting to inadequate power supply (voltage, current capacity,
grounding), and may result in fire or electric shock.
Conductors in the power cable must be connected to terminals 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
inadequate power supply (voltage, current capacity,
If proper wall outlet is not available, advice the customer
to contact qualified electrician for the installation.
Plug the power cord into the dedicated wall outlet with a
capacity greater than the maximum power consumption.
If excessive current flows in the wall outlet, fire may
result.
If two or more power cords can be plugged into the wall
outlet, the total load must not exceed the rating of the wall
outlet.
result.
Make sure the power cord is plugged in the wall outlet
securely.
Contact problems may lead to increased resistance,
overheating, and the risk of fire.
S-4
kw

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 product 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 connector on each end) specified by KMBT.
Using the damaged power cord may result in fire or electric shock.
Do not bundle or tie the power cord.
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 volatile materials that may catch fire.
A risk of fire exists.
Do not place the product in a place exposed to water such
as rain.
A risk of fire and electric shock exists.
When not Using the Product for a long time

WARNING
When the product is not used over an extended period of
time (holidays, etc.), switch it off and unplug the power
cord.
Dust collected around the power plug and outlet may
cause fire.
Ventilation
CAUTION
The product generates ozone gas during operation, but it
will not be harmful to the human body.
If a bad smell of ozone is present in the following cases,
ventilate the room.
a. When the product is used in a poorly ventilated room
b. When taking a lot of copies
c. When using multiple products at the same time
Fixing
CAUTION
Be sure to lock the caster stoppers.
In the case of an earthquake and so on, the product may
slide, leading to a injury.
S-7
Inspection before Servicing

CAUTION
Before conducting an inspection, read all relevant documentation (service manual, technical notices, etc.) and
proceed with the inspection following the prescribed procedure in safety clothes, using only the prescribed tools.
Do not make any adjustment not described in the documentation.
If the prescribed procedure or tool is not used, the product 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 electric shock exists.
S-8
Safety Checkpoints
WARNING
Check the exterior and frame for edges, burrs, and other
damages.
The user or CE may be injured.
Do not allow any metal parts such as clips, staples, and
screws to fall into the product.
They can short internal circuits and cause electric shock
or fire.
Check wiring for squeezing and any other damage.
Current can leak, leading to a risk of electric shock or
fire.
Carefully remove all toner remnants and dust from electrical 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 mounting position.
loss of eyesight.
S-9
Safety Checkpoints
WARNING
When replacing a lithium battery, replace it with a new lithium 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 installation 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, connectors, etc. that were removed for safety check and maintenance have been reinstalled in the original location. (Pay
special attention to forgotten connectors, pinched cables,
forgotten screws, etc.)
A risk of product trouble, electric shock, and fire exists.
Handling of Consumables
WARNING
Toner and developer are not harmful substances, but care
must be taken not to breathe excessive amounts or let the
substances come into contact with eyes, etc. It may be
stimulative.
If the substances get in the eye, rinse with plenty of water
immediately. When symptoms are noticeable, consult a
physician.
S-10
WARNING
Never throw the used cartridge and toner into fire.
You may be burned due to dust explosion.
Handling of Service Materials

CAUTION
Unplug the power cord from the wall outlet.
Isopropyl alcohol and acetone are highly flammable and
must be handled with care. A risk of fire exists.
Do not replace the cover or turn the product ON before

any solvent remnants on the cleaned parts have fully
evaporated.
Use only a small amount of cleaner at a time and take
care not to spill any liquid. If this happens, immediately
wipe it off.
When using any solvent, ventilate the room well.
Breathing large quantities of organic solvents can lead to
discomfort.
S-11
SAFETY INFORMATION
SAFETY INFORMATION
IMPORTANT NOTICE
The Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration 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 emitted inside this copier is completely confined within protective housings and external covers,
the laser beam cannot escape during any phase of normal user operation.
S-12
SAFETY INFORMATION
INDICATION OF WARNING ON THE MACHINE

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

AN ACCIDENT
1. If an accident has occurred, the distributor who has been notified first must immediately
take emergency measures to provide relief to affected persons and to prevent further
damage.
2. If a report of a serious accident has been received from a customer, an on-site evaluation 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 specified by every distributor.
S-15
Blank Page
S-16
Composition of the service manual

This service manual consists of the following sections and chapters:
<Theory of Operation section>
OUTLINE:
System configuration, product specifications,

unit configuration, and paper path
COMPOSITION/OPERATION: Configuration of each unit, explanation of the operating

system, and explanation of the control system
This section gives, as information for the CE to get a full understanding of the product, a
rough outline of the object and role of each function, the relationship between the electrical
system and the mechanical system, and the timing of operation of each part.
<Field service section>
OUTLINE:
System configuration, and product specifications
MAINTENANCE:
Service schedule *, maintenance steps,

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

chart, overall layout drawing
This section gives, as information required by the CE at the site (or at the customer's
premise), a rough outline of the service schedule and its details, maintenance steps, the
object and role of each adjustment, error codes and supplementary information.
The details of items with an asterisk "*" are described only in the service manual of
the main body.
C-1
Notation of the service manual

A. Product name
In this manual, each of the products is described as follows:
(1) IC board:
Standard printer
(2) bizhub 500 / 420:
Main body
(3) Microsoft Windows 95:
Windows 95
Microsoft Windows 98:
Windows 98
Microsoft Windows Me:
Windows Me
Microsoft Windows NT 4.0:
Windows NT 4.0 or Windows NT
Windows 2000
Microsoft Windows XP:
Windows XP
When the description is made in combination of the OS's mentioned above:

Windows 95/98/Me
Windows NT 4.0/2000
Windows NT/2000/XP
Windows 95/98/Me/NT/2000/XP
B. Brand name
The company names and product names mentioned in this manual are the brand name or
the registered trademark of each company.
C. Electrical parts and signals

Those listed by way of example below are not exhaustive, but only some instances among
many.
Classification Load symbol
Ex. of signal name
Description
IN
PS
Sensor
PS
Door PS1
Sensor detection signal
SIG
102 PS
24V
Solenoid
SD
DRV
SOL
24V
Clutch
CL
DRV
SOL
C-2
Power to drive the solenoid

Drive signal
Power to drive the clutch
Drive signal
Motor
Ex. of signal name
Description
24V
Power to drive the motor
CONT
Drive signal
DRV1
DRV2
D1
Drive signals of two kinds
D2
_U
_V
_W
DRV1
Drive signals (control signals) of three kinds
DRV2
DRV3
D1
D2
D3
D4
DRV A
DRV A
DRV B
DRV B
Drive signals (control signals) of four kinds

Motor, phases A and B control signals
A
Motor
/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
SS
Fan
Others
FM
Operating load start/stop signal
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
HL
Speed control signal (2 speeds)
EM, Lock, LCK, FEM
Detection signal
TH1.S, ANG
Analog signal
C-3

Ground
Serial communication
Ex. of signal name
Description
SG, S.GND, S_GND
Signal 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)
DSR, DSET
Data set ready
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 longitudinally.
<Example>
Paper size
A4
A3
C-4
Feed direction
Notation
Transverse feed
A4
Longitudinal feed
A4S
Longitudinal feed
A3
SERVICE MANUAL
Theory of Operation
500 / 420
Main body
2006.02
Ver. 1.0
Revision history
After publication of this service manual, the parts and mechanism may be subject to change for
improvement of their performance.
Therefore, the descriptions given in this service manual may not coincide with the actual machine.
When any change has been made to the descriptions in the service manual, a revised version will be
issued with a revision mark added as required.
Revision mark:
To indicate clearly a section revised, show 1 to the left of the revised section.
A number within 1 represents the number of times the revision has been made.
To indicate clearly a section revised, show 1 in the lower outside section of the 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.
2006/02
1.0
Date
Service manual Ver.
Revision mark
Issue of the first edition

Descriptions of revision
Theory of Operation Ver1.0 Feb.2006
CONTENTS
bizhub 500 / 420
CONTENTS
bizhub 500 / 420
OUTLINE
1. SYSTEM CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. PRODUCT SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. UNIT CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
COMPOSITION/OPERATION
5. OVERALL CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.1
Time chart when the power is turned ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.2
Control block diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6. SCANNER SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.1
Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.2
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.3.1
Scan/exposure lamp control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.3.2
Original size detection control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.3.3
AE control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.3.4
Image processing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7. WRITE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.1
7.2
Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.2.1
Laser beam path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.2.2
Write control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.2.3
Image stabilization control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.2.4
Image processing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8. PHOTO CONDUCTOR SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

8.1
8.2
8.3
Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.2.1
Drum drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.2.2
Drum claw drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.3.1
Image creation control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.3.2
Drum claw control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.3.3
Image stabilization control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9. CHARGING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.1
9.2
Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.2.1
Charging control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.2.2
Erase lamp (EL) control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10. TRANSFER/SEPARATION SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

10.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.2.1 Transfer guide control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.2.2 Transfer/separation control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CONTENTS
10.2.3 Transfer exposure lamp (TSL) control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
bizhub 500 / 420
11. DEVELOPING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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

17. ADU SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
17.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
17.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
17.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
17.3.1 Conveyance path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
17.3.2 Conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
18. FUSING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
18.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
18.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
18.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
18.3.1 Fusing roller drive control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
18.3.2 Web drive control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
18.3.3 Fusing temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
18.3.4 Fusing roller edge cooling control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
18.3.5 Envelope conveyance mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
18.3.6 Protection against abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
18.3.7 Jam detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
19. REVERSE/EXIT SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
19.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
19.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
19.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
19.3.1 Conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
19.3.2 Reverse control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
20. INTERFACE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
20.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
20.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
21. IMAGE STABILIZATION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
21.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
21.2 Operation flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
21.2.1 Image stabilization control flow when the power switch (SW2) is turned ON . . . . . . . . . . . . . . . 83
21.2.2 Image stabilization control flow while in the print and the idle . . . . . . . . . . . . . . . . . . . . . . . . . . 86
22. IMAGE PROCESSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
22.1 Image processing in the scanner section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
22.1.1 Shading correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
22.1.2 AE control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
22.1.3 Area discrimination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
22.1.4 Brightness/density conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
22.1.5 Filter/magnification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
22.1.6 Scanner gamma correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
22.1.7 Halftone processing (error diffusion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
22.1.8 Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
22.1.9 Storage of image data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
22.2 Image processing in the write section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
23. OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
23.1 Fan control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
23.1.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
23.1.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
23.2 Counter control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
iii
bizhub 500 / 420
16.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
CONTENTS
23.2.1 Composition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
bizhub 500 / 420
23.2.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

23.3 Parts that operate when the power switch is turned ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
23.3.1 Parts that operate when the main power switch (SW1) is turned ON . . . . . . . . . . . . . . . . . . . 103
23.3.2 Parts that operate when the power switch (SW2) is turned ON . . . . . . . . . . . . . . . . . . . . . . . . 104
iv
1. SYSTEM CONFIGURATION
bizhub 500 / 420
OUTLINE
A. System configuration
[23]
[27]
[24]
[25]
[28]
[26]
[5]
[6]
[7]
[8]
[9]
[1]
[2]
[3]
[4]
[22]
[21]
[19]
[20]
[17]
[11]
[14]
[15]
[18]
[10]
[12]
[10]
[13]
[16]
50gat1e001na
[1]
[2]
Reverse automatic document feeder
[15]
(DF-607) (standard equipment)
[16]
Dehumidifier heater *2
Relay unit (RU-502)
Main body
[17]
Finisher (FS-511)
[3]
Image controller (IC-204)
[18]
Swedish punch kit G *3
[4]
Hard disk (HD-505)
[19]
Job separator (JS-502)
[5]
Stamp unit (SP-501)
[20]
Output tray kit (OT-501)
[6]
Spare TX marker stamp 2
[21]
Output tray (OT-601)
[7]
Key counter kit 4 *1
[22]
Finisher (FS-510)
[8]
Key counter *1
[23]
Mail bin kit (MT-501)
[9]
Key counter mount kit *1
[24]
Saddle stitcher (SD-502)
[10]
Dehumidifier heater 1C
[25]
Folding unit (included in SD-502)
[11]
Paper feed cabinet (PC-402)
[26]
Punch unit (PU-501)
[12]
[27]
FAX kit (FK-502)
[13]
Desk (DK-501)
[28]
Mount kit (MK-708)
[14]
Large capacity unit (LU-201)
*1
See "6.4 Option counter" in Field Service bizhub 500 / 420 main body for details.
*2
Dehumidifier heater is set up as service part.
*3
Swedish punch kit G is for Europe only.
bizhub 500 / 420
B. Configuration for optional device connection

Note
Any combination other than those listed below is not available.
No.
Combinations for paper feeding
Combinations for finishing
DK-501/PC-202/PC-402 *1
OT-501
DK-501/PC-202/PC-402 *1
DK-501/PC-202/PC-402 *1
OT-501
JS-502
RU-502 + FS-511
DK-501/PC-202/PC-402 *1
DK-501/PC-202/PC-402 *1
FS-510 *2*3
FS-510 *2*3
SD-502
DK-501/PC-202/PC-402 *1
FS-510 *2*3
MT-501
PC-202/PC-402 *4
LU-201
PC-202/PC-402 *4
LU-201
PC-202/PC-402 *4
LU-201
OT-501
OT-501
JS-502
RU-502 + FS-511
10
PC-202/PC-402 *4
LU-201
11
PC-202/PC-402 *4
LU-201
FS-510 *2*3
FS-510 *2*3
SD-502
12
PC-202/PC-402 *4
LU-201
FS-510 *2*3
MT-501
*1
Either one of DK-501, PC-202 and PC-402 can be selected.
*2
FS-510 can be installed optionally with OT-601.
*3
FS-510 can be installed optionally with PU-501.
*4
Either one of PC-202 and PC-402 can be selected.
Remarks
2. PRODUCT SPECIFICATIONS
bizhub 500 / 420
A. Type
Type
Desktop type
Copying method
Indirect electrostatic method
Original stand
Fixed
Original alignment
Left rear standard
Photo conductor
OPC
Sensitizing method
Laser writing
Paper feed trays
*1
Two trays
500 sheet x 2, 80g/m2
Bypass feed
150 sheet x 1, 80g/m2
PC-402 *1
2,500 sheet x 1, 80g/m2
PC-202 *1
500 sheet x 1, 80g/m2
LU-201 *1
2,000 sheet x 1, 80g/m2
PC-402, PC-404, and LU-201 are optional.
bizhub 500 / 420
B. Functions
Original
Sheet, book, solid object
Max. original size
A3 or 11 x 17
Copy size
Trays 1, 2
Inch:
11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S,

A3, A4, A4S, A5S, Foolscap
Metric: A3, B4, A4, A4S, B5, A5S, 11 x 17, 81/2 x 11,
81/2 x 11S, Foolscap, 8K, 16K
Bypass feed
Inch:
11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S,

A4
Metric: A3, B4, A4, A4S, B5, B5S, A5S, B6S, 81/2 x 11,
81/2 x 11S, Foolscap, 8K, 16K, 16KS
ADU
Inch:
11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S,

Metric: A3, B4, A4, A4S, B5, B5S, A5S, 11 x 17, 81/2 x 11,
81/2 x 11S, Foolscap
Magnification
Fixed magnifica-
Inch:
tion
x 1.000, x 1.214, x 1.294, x 1.545, x 2.000

x 0.500, x 0.647, x 0.772, x 0.785
Metric: x 1.000, x 1.154, x 1.224, x 1.414, x 2.000

x 0.500, x 0.707, x 0.816, x 0.866
Special magnifi-
x 0.930
cation setting
Preset zoom set-
3 types
ting
Zoom magnifica-
x 0.25 to x 4.00 (at the step of 0.1%)
tion
Vertical magnifi-
cation
Horizontal magni-
fication
Warm-up time
60 seconds or less (bizhub 500)

First copy out time
3.2 seconds or less (bizhub 500)

Continuous copy speed
50 copies /min. (A4 / 81/2 x 11) (bizhub 500)

Continuous copy count
Up to 999 sheets
Original density selection
Auto density selection, Manual (9 steps), Manual underprint density (9 steps)
Resolution
Scan
600 x 600 dpi
Write
Inch:
1,200 (equivalent) x 600 dpi
Metric: 2,400 (equivalent) x 600 dpi

Memory
Standard 192 MB
Breakdown: 64 MB (on board) + 128 MB (DIMM)
Maximum 320 MB Breakdown: 64 MB (on board) + 256 MB (DIMM) *1

Interface section
RJ45 Ethernet, Serial port (RS232-C), Serial port (USB TypeB),

Parallel port (IEEE1284), RJ-11 *2
*1
*2
256 MB (DIMM) is available from distributors.

Specification: 144 pin SO-DIMM, PC100/PC133 MHz Compliant
1 port when MK-708 and FK-502 are optionally installed.
bizhub 500 / 420
C. Type of paper
High quality paper of 60 to 90 g/m2
Plain paper *1
All trays
Special paper *2
Bypass feed only
OHP film, label paper *3, blueprint master paper *3

High quality paper of 50 to 59 g/m2 (thin paper)
*1
All trays
High quality paper of 91 to 105 g/m2 (thick paper)
Bypass feed only
Standard specified paper

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

*2
Special paper/recommended paper

Thick paper:
Inch:
Weyerhaeuser Cougar Cover 65 lbs
Metric: Xerox colortech 200 g/m2

Thin paper:
Inch:
SOISE BOND 16 lbs
Metric: NEU 60 g/m2

Label paper:
Inch:
AVERY 5160, 5352
Metric: AVERY DSP 24

OHP film:
Inch:
3M CG3700
Metric: Folex overhead X-500, 3M CG3700

Envelope:
Inch:
Preservation Wove (24 lbs) #6-3/4, #9, #10 (4-1/8 x 9-1/2)
Metric: Briefhullen 211210 (100 g/m2) #C6

Schneider Soehne Distinction 100 (100 g/m2) #lang
Schneider Soehne (Briefumschlage) (100 g/m2) #C5
*3
Label paper is loaded and fed one sheet at a time.
D. Maintenance
Maintenance
Machine service life
Every 250,000 prints

2,250,000 prints or 5 years (whichever earlier) (bizhub 500)
E. Machine data
Power source
Inch:
AC120V 12A, 60Hz
Metric: AC220-240V 10A, 50Hz

Maximum power consump- 1,560 W or less (full option)
tion
Dimensions
Main body
677 (W) x 708 (D) x 1,150 (H) mm *1
+ DF-607
+ PC or DK
Weight
*1
Approx. 91.2 kg
Overturning prevention board is not included.
bizhub 500 / 420
F.
Operating environment
Temperature
10 to 30 C
Humidity
10 to 80%RH (with no condensation)
Note
The information herein may be subject to change for improvement without notice.
3. UNIT CONFIGURATION
bizhub 500 / 420
3. UNIT CONFIGURATION
[17]
[1]
[2]
[16]
[3]
[15]
[14]
[4]
[5]
[13]
[6]
[12]
[7]
[8]
[11]
[9]
[10]
50gat1c002na
[1]
Scanner section
[10]
PC or DK (option)
[2]
Paper reverse/exit section
[11]
Paper feed section (tray 1/2)
[3]
Fusing section
[12]
Developing section
[4]
Photo conductor section
[13]
Writing section
[5]
ADU
[14]
Charging section
[6]
Transfer/separation section
[15]
Toner supply section
[7]
Registration section
[16]
Cleaning/toner recycle section
[8]
Bypass tray section
[17]
DF
[9]
LU (option)
4. PAPER PATH
bizhub 500 / 420
4. PAPER PATH
[1]
[9]
[8]
[7]
[2]
[6]
[3]
[4]
[5]
50gat1c003na
[1]
Reverse conveyance
[6]
[2]
ADU conveyance
[7]
Tray 2 paper feed

Tray 1 paper feed
[3]
Bypass paper feed
[8]
Registration conveyance
[4]
LU paper feed
[9]
Paper exit
[5]
PC paper feed
5. OVERALL CONFIGURATION
bizhub 500 / 420
5.1
Time chart when the power is turned ON

[1] [2]
[3][4]
[5]
[6]
[7]
[8]
[9]
Item
Scanner motor
(M2)
Normal
rotation
Reverse
rotation
Exposure lamp (L1)

Fusing heater lamp /1 (L2)
Fusing motor (M11)
Drum motor (M1)
Developing motor (M3)
Polygon motor (M5)
Laser (LDB)
Paper lift motor /1 (M7)
Upper limit sensor /1 (PS6)
50gat2e001na
[1]
Fusing heater lamps /1 (L2) and /2 (L3) turn
[5]
Drum motor (M1) turns ON
ON early
[6]
Dot diameter adjustment starts
[2]
Power switch (SW2) turns ON
[7]
The fusing temperature gets to the pre-
[3]
Initial communication between the overall
scribed temperature to start the preliminary

rotation for fusing
control board (OACB) and the printer control

[4]
board (PRCB)
[8]
Dot diameter adjustment completed
Shading correction
[9]
Warming up completed
Note
Each operation varies according to the setting of the software DipSW in the service mode.
The power is turned ON with DF closed.
The power is turned ON with the lift plate of the tray down.
bizhub 500 / 420
5.2
Control block diagram

CCD
IC
HDD
FK, MK
USB
I/F
RS232C LAN Parallel

I/F
I/F
I/F
OB
OACB
SC
Write
Section
FM
CL
SD
DF
PS
PRCB
SDB
M
DCPU
HV
PS
JS
[1]
10
[2]
[3]
[4]
LU
[5]
PC
[6]
[1]
Image bus
[4]
Other buses
[2]
Clock synchronous serial bus
[5]
Individual signal line
[3]
UART bus
[6]
IDE
FS, RU
50gat2c090na
6. SCANNER SECTION
6.1
bizhub 500 / 420
6. SCANNER SECTION
Composition
CCD unit
(CCDB)
Mirror unit
Exposure unit
Shading
correction
plate
50gat2c001na
6.2
Drive
[4]
[3]
[5]
[1]
[2]
50gat2c002na
[1]
Scanner wire /Rr
[4]
Exposure unit
[2]
Scanner wire /Fr
[5]
Scanner motor (M2)
[3]
V-mirror unit
11
6. SCANNER SECTION
bizhub 500 / 420
6.3
6.3.1
Operation
Scan/exposure lamp control
A. Operation when the power is turned ON

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

Movement of the exposure unit
[3]
[6]
Exposure lamp (L1) ON
(2) Home position search while in PS30 OFF
[2]
[1]
[3]
[4]
[6]
[5]
50gat2c035na
12
[1]
[4]
[2]
[5]

Movement of the exposure unit
[3]
[6]
6. SCANNER SECTION
For the original read mode, the following two types are available: the platen mode and the DF mode. While in the
platen mode, the exposure unit scans the original for reading. And while in the DF mode, since DF conveys the
original, the exposure unit remains at the prescribed position (DF read position) to read the original.
(1) When the platen is used (when DF is opened)
The operation in the platen mode varies depending on which is selected for the print density, the AE print and
the manual print.
When the AE print is selected
[4]
[3]
[2]
[1]
[5]
[6]
[7]
[8]
50gat2c037na
[1]
[5]
AE scan range
[2]
Position at which the image read is started
[6]
[3]
[7]
[4]
Position at which the running-up of the
[8]
exposure unit is started
When the manual print is selected
[4]
[3]
[2]
[1]
[5]
[6]
[7]
50gat2c036na
[1]
[5]
[2]
Position at which the image read is started
[6]
[3]
[7]
[4]
Position at which the running-up of the

exposure unit is started
Note
When the tray 1 is selected by manual, not by APS, no shading correction is made.
13
bizhub 500 / 420
B. Operation when the start key is turned ON
6. SCANNER SECTION
bizhub 500 / 420
(2) When DF is used (when DF is closed)
[3]
[2]
[1]
[4]
[5]
[6]
50gat2c038na
14
[1]
[4]
[2]
[5]
[3]
DF read position
[6]

6.3.2
6. SCANNER SECTION
Original size detection control
bizhub 500 / 420
A. Detection method
The original size detection method varies for the DF mode and the platen mode.
(1) DF mode
See DF-607 Service Manual.
(2) Platen mode
Main scan direction
Reading is made by the CCD sensor.
Sub-scan direction
Detection is made according to the ON/OFF of the APS sensor (PS32).

Original size
*1
CCD sensor
PS32
(Detection length: mm)
(ON/OFF)
A3
297
ON
11 x 17
279.4
ON
B4
257
ON
81/2 x 14 *1
215.9
ON
81/2 x 11S
215.9
ON
A4S
210
ON
A4
297
OFF
81/2 x 11
279.4
OFF
B5
257
OFF
OFF
A5
210
B5S
182
OFF
A5
148
OFF
51/2 x 81/2
139.7
OFF
B6
128
OFF
No discrimination is made between 81/2 x 14 and 81/2 x 11S. When the size is 81/2 x 14, this is detected as
81/2 x 11S.
B. Detection timing
(1) Platen mode (while in DF closed)
When the APS timing sensor (PS31) turns on while in DF closed, the original size is detected.
(2) Platen mode (while in DF open)
When the start key is pressed, the original size is detected.
15
6. SCANNER SECTION
6.3.3
AE control
bizhub 500 / 420
When AE is selected, the density level of the original is detected to adjust it to an appropriate density automatically. The sampling range of the original density in the AE control varies for the platen mode and the DF mode.
(1) AE sampling range in the platen mode
[5]
[1]
[7]
[6]
[5]
[2]
[2]
[4]
[3]
50gat2c039na
[1]
Original
[5]
[2]
L/100 mm
[6]
10 mm
Leading edge of the original
[3]
L mm
[7]
AE sampling range
[4]
30 mm
(2) AE sampling range in the DF mode
[4]
[1]
[6]
[5]
[4]
[3]
[2]
50gat2c040na
16
[1]
Original
[4]
20 mm
[2]
2.9 mm
[5]
[3]
1.5 mm
[6]
AE sampling range

6.3.4
6. SCANNER SECTION
Image processing
bizhub 500 / 420
The following items are provided for the image processing. For details, See "22. IMAGE PROCESSING".
AOC (Auto offset control)
AGC (Auto gain control)
Shading correction
AE processing
Range discrimination
Brightness/density conversion
Filter/magnification
Density gamma (conversion)
Halftone processing (error diffusion)
Skew adjustment
Compression
Storage of image data
17
7. WRITE SECTION
bizhub 500 / 420
7. WRITE SECTION
7.1
Composition
Collimator lens unit
CY2 lens
Cleaner
Laser drive board (LDB)
Index mirror
CY1 lens
Index lens
Dust-proof glass
f lens
Polygon mirror
Index board (INDEXB)

50gat2c003na
18
Operation
7.2.1
bizhub 500 / 420
7.2
7. WRITE SECTION
Laser beam path
[10]
[9]
[8]
[1]
[7]
[6]
[2]
[5]
[3]
[4]
50gat2c041na
[1]
Dust-proof glass
[6]
Polygon mirror
[2]
CY2 lens
[7]
CY1 lens
[3]
Drum
[8]
Collimator lens
[4]
[9]
Laser diode
[5]
f lens
[10]
Index mirror
7.2.2
Write control
Image data that has been processed is converted into laser beam on the laser drive board (LDB) to be irradiated
on the drum. 1 laser diode emits 2 beams and 2 lines are written per 1 scan.
To prevent the mis-centering of a written image, an INDEX signal detected by the index board (INDEXB) is used
to decide the reference position for writing in the drum shaft direction (main scan direction) to control the starting
position of the laser irradiation onto the drum.
7.2.3
Image stabilization control
The following items are provided for the image stabilization control. For details, See "21. IMAGE STABILIZATION
CONTROL".
MPC (Maximum power control)
APC (Auto power control)
Dot diameter adjustment control
19
7. WRITE SECTION
7.2.4
Image processing
bizhub 500 / 420
The following items are provided for the image processing. For details, See "22.2 Image processing in the write
section".
20
Rotation/elongation
2 dots PWM
PWM
Frequency conversion
8. PHOTO CONDUCTOR SECTION
8.1
bizhub 500 / 420

Composition
Drum
Drum claw
PGC sensor
IDC sensor (IDCS)
50gat2c004na
21
bizhub 500 / 420
8.2
8.2.1
Drive
Drum drive
[1]
[2]
50gat2c005na
[1]
8.2.2
Drum motor (M1)
[2]
Drum drive shaft
Drum claw drive
[1]
[2]
50gat2c006na
[1]
22
Drum claw
[2]
Drum claw solenoid (SD2)
8.3.1
Operation
Image creation control
When the print start signal turns ON [1], various motors turn ON to place each unit in the operating condition. At
the same time, the erase lamp (EL) turns ON to neutralize the drum and the charging corona charges the drum.
A specified period of time after the print start signal turns ON, the developing bias turns ON [2] and then a high
voltage is impressed [3] on the guide plate. When the preparation for image creation is made, an image is created on the drum surface by laser irradiation and developing.
A specified period of time after the registration clutch (CL1) turns ON [4], a high voltage is impressed on the
transfer corona [5] and the separation corona [6] to turn ON the transfer exposure lamp (TSL) [8] and the drum
claw solenoid (SD2) [9] sequentially. The ON timing [7] of TSL varies according to the type of paper. And the ON
time period of TSL also varies according to the setting environment. An image created on the drum is transferred
onto paper and then the paper is separated from the drum.
A specified period of time after the registration sensor (PS1) detects the trailing edge of paper and turns OFF
[10], each operation turns OFF. However, some operations turn OFF a specified period of time after PS1 detects
the trailing edge of the last paper and turns OFF [11], or a specified period of time after the fusing exit sensor
(PS3) detects the trailing edge of the last paper and turns OFF [13]. For the charging corona, the developing bias
and the guide plate bias, with the OFF timing [12] by the last paper of the transfer corona used as a starting
point, each of the OFF timing is interlocked.
[1][2] [3]
[4][5] [6] [10]
[11]
Drum motor (M1)

Registration sensor (PS1)
Registration clutch (CL1)
Erase lamp (EL)
Charging corona (HV)
Developing bias (HV)
Transfer corona (HV)
Separation corona (HV)
Guide plate bias (HV)
Transfer exposure lamp (TSL)
Fusing exit sensor (PS3)
[7] [8] [9]

[1]
Print start signal ON
[2]
Developing bias high voltage impressed
[12]
[8]
[13]
50gat2c103na
Transfer exposure lamp (TSL) ON (This varies according to the setting environment.)
[3]
Guide plate bias high voltage impressed
[9]
Drum claw solenoid (SD2) ON
[4]
Registration clutch (CL1) ON
[10]
Trailing edge of the 1st paper detected
[5]
Transfer corona high voltage impressed
[11]
Trailing edge of the last paper detected
[6]
Separation corona high voltage impressed
[12]
Transfer of the last paper OFF
[7]
Varies according to the type of paper.
[13]
Trailing edge of the last paper detected
23
bizhub 500 / 420
8.3

8.3.2
Drum claw control
bizhub 500 / 420
A. Purpose
Two drum claws are employed to prevent paper from winding up around the drum (winding-up jam). The contact
and severance of the drum claws to and from the drum are made by the ON/OFF of the drum claw solenoid
(SD2).
B. Swing operation
To prevent paper from getting stained at specific points and the drum [3] from being damaged, the drum claw [2]
makes a swing operation of about 7 mm against the drum surface.
The drum claw unit [4] is provided with a projection [7]. This projection is pressed by the cam [6] provided on the
gear [5] to push out the drum claw unit backward. When the gear rotates to release the cam, the drum claw unit
is sent back to the original position by the spring [1]. This operation is repeated to swing the drum claw.
[5]
[6]
[7]
[1]
[4]
8.3.3
[3]
[2]
50gat2c042na
The following items are provided for the image stabilization control. For details, See "21. IMAGE STABILIZATION
CONTROL".
24
Drum rotation control
9. CHARGING SECTION
9.1
bizhub 500 / 420
9. CHARGING SECTION
Composition
Erase lamp (EL)
Charging wire
Charging control plate
50gat2c007na
9.2
9.2.1
Operation
Charging control
A. Charging wire
The high voltage unit (HV) pressurizes 24V DC to impress a minus () DC voltage on the charging wire for discharge.
Charging output range: 500 to 1100 A
B. Charging grid
To obtain a uniform charging wire discharge, a minus () high voltage is impressed from the high voltage unit
(HV) to the charging grid.
Charging grid voltage output range: 450 to 1090 V
9.2.2
Erase lamp (EL) control
A. Purpose
To neutralize a residual potential on the drum surface and to obtain a uniform potential on the drum surface, the
erase lamp (EL) is irradiated on the drum before charging.
B. Execution timing
The erase lamp (EL) turns ON in synch with the print start signal turning ON. And it turns OFF a specified period
of time after the fusing exit sensor (PS3) detects the trailing edge of the last paper.
25
10. TRANSFER/SEPARATION SECTION
bizhub 500 / 420

10.1 Composition
Plunging prevention plate
Transfer wire
Separation wire

50gat2c008na
26
10.2.1
Transfer guide control
A. Purpose
To prevent the transfer guide plate from getting stained, a minus () DC voltage is impressed from the high voltage unit (HV).
Voltage impressed: 500 V
B. Execution timing
The impression of a voltage onto the transfer guide plate is made ON a specified period of time after the developing bias turns ON. And it turns OFF a specified period of time after the developing bias turns OFF.
10.2.2
Transfer/separation control
A. Transfer
The high voltage unit (HV) pressurizes a 24V DC to impress a plus (+) DC voltage on the transfer wire for discharging.
Transfer DC output range: 0 to 450 A
B. Separation
For separation, an AC high voltage and a minus () DC voltage are employed. The high voltage unit (HV)
impresses a voltage onto the separation wire for discharging.
Separation AC output range: 300 to 1000 A
Separation DC output range: 0 to 200 A
10.2.3
Transfer exposure lamp (TSL) control
A. Purpose
The transfer exposure lamp (TSL) is turned ON to secure transferability and prevent a reverse charge to the
drum.
B. Execution timing
The transfer exposure lamp (TSL) turns ON a specified period of time after the registration clutch (CL1) turns ON.
And it turns OFF a specified period of time after the registration sensor (PS1) turns OFF.
27
bizhub 500 / 420
10.2 Operation
11. DEVELOPING UNIT
bizhub 500 / 420
11. DEVELOPING UNIT

11.1 Composition
Developing roller
TCR sensor (TCRS)
Developer restriction blade
Agitator screw
Agitator plate
50gat2c009na
28
11. DEVELOPING UNIT
bizhub 500 / 420
11.2 Drive
[6]
[5]
[4]
[1]
[3]
[2]
50gat2c010na
[1]
Drum
[4]
Agitator screw
[2]
Developing roller
[5]
Developing unit
[3]
[6]
Agitator plate
29
11. DEVELOPING UNIT
bizhub 500 / 420
11.3 Operation
11.3.1
Developer conveyance
Developer in the developing unit is supplied by the agitator plate [4] to the developing roller [2]. The thickness of
developer attaching to the developing roller is restricted by the developer restriction blade [5]. After completion
of transfer to the drum [1], developer remaining on the developing roller is sent back to the agitator screws [3].
The 2 agitator screws rotate in the same direction to obtain an improved conveyability when developer is
changed.
[3]
[4]
[5]
[1]
[2]
30
[1]
Drum
[4]
Agitator plate
[2]
Developing roller
[5]
[3]
Agitator screw
50gat2c043na

Developing bias
A. Purpose
To make toner get easily attached to the drum while in developing, a developing bias is impressed onto the
developing roller [1].
[2]
[3]
[4]
[1]
50gat2c044na
[1]
Developing roller
[3]
Developing bias shaft
[2]
Main pole position adjusting plate
[4]
Developing bias contact
B. Timing
To prevent unnecessary carriers from attaching to the drum, a developing bias turns ON a specified period of
time after the print start signal turns ON, and it turns OFF a specified period of time after charging turns OFF.
31
bizhub 500 / 420
11.3.2
11. DEVELOPING UNIT
11. DEVELOPING UNIT

11.3.3
Developing suction control
bizhub 500 / 420
A. Purpose
To prevent the splash of toner from the developing roller, the duct [4] is provided at 2 places of the developing
unit [1]. Toner guided into the duct is sucked in by the developing suction fan (FM6) [3] to be collected by the
suction filter /A [2].
[3]
[4]
[2]
[1]
50gat2c045na
[1]
Developing unit
[3]
Developing suction fan (FM6)
[2]
Suction filter /A
[4]
Duct
B. Developing suction fan (FM6) control

The developing suction fan (FM6) turns ON in synch with the developing motor (M3) turning ON. And it turns
OFF a specified period of time after M3 turns OFF. However, while in the TCR adjustment mode, it turns OFF in
synch with M3 turning OFF.
11.3.4
The following item is provided for the image stabilization control. For details, See "21. IMAGE STABILIZATION
CONTROL".
32
Toner density control
12. TONER SUPPLY SECTION
bizhub 500 / 420

12.1 Composition
Toner remaining sensor
(PZS)
Toner bottle motor (M10)
Toner supply motor

(M4)
Toner bottle position

sensor (PS28)
Toner bottle sensor (PS4)
Toner hopper
Toner bottle
50gat2c011na
33
bizhub 500 / 420
12.2 Drive
[5]
[4]
[1]
[2]
[3]
50gat2e003na
34
[1]
Toner agitator plate
[4]
[2]
Toner conveyance screw
[5]
Toner supply motor (M4)
[3]
Toner solenoid (SD5)
12.3.1
Toner level detection control
A. Toner level detection control

Toner remaining in the toner hopper is detected by the toner remaining sensor (PZS). When toner remaining in
the hopper is found below the prescribed amount, a toner supply signal is issued to the printer control board
(PRCB). This signal is transmitted to the operation board (OB) through the overall control board (OACB). Accordingly, OB displays a message in LCD on the LCD board (LCDB).
B. Detection timing
At all times while in printing.
12.3.2
Toner supply control to the toner hopper
A. Operation
When the toner remaining sensor (PZS) detects the reduced level of remaining toner, the toner bottle motor
(M10) turns ON and rotates the toner bottle to supply toner in the toner bottle to the toner hopper.
When PZS detects the toner level being restored to its prescribed level, M10 turns OFF to get back to the standby condition.
B. Toner bottle position detection
The toner supply section is provided with the toner bottle position sensor (PS28) to detect the rotational position
of the toner bottle whether it is at the home position.
12.3.3
Toner supply control to the developing unit
A. When the power switch (SW2) is turned ON

A specified period of time after SW2 turns ON, the TCR sensor (TCRS) detects the toner density in the developing unit. At this time, when a detected value is found below the initial density recorded in the CPU in the overall
control board (OACB), the toner supply motor (M4) and the toner solenoid (SD5) turn ON to supply toner from
the toner hopper to the developing unit.
B. While in printing
While in printing, the toner density is detected by the TCR sensor (TCRS). The ON time periods of the toner supply motor (M4) and the toner solenoid (SD5) are decided according to the output voltage of TCRS to supply
toner from the toner hopper to the developing unit.
TCRS output voltage
Toner supply time period
Less than 2.01 V
0 second
2.01 to 2.14 V
0.10 seconds
2.14 to 2.22 V
0.15 seconds
2.22 to 2.28 V
0.20 seconds
2.28 to 2.32 V
0.25 seconds
2.32 to 2.39 V
0.40 seconds
2.39 V or more
0.50 seconds
35
bizhub 500 / 420
12.3 Operation

12.3.4
Toner conveyance control
bizhub 500 / 420
A. Purpose
To convey toner in the toner bottle to the toner hopper.
B. Operation
The exit [1] of the toner bottle is normally closed. However, by setting the bottle to the toner supply section, the
accordion section is pushed and compressed to let the exit open. A bottle set to the toner supply section
rotates when the toner bottle motor (M10) turns ON. When the toner bottle rotates, toner is conveyed to the exit
of the bottle along the spiral groove engraved on the surface of the toner bottle and flows out into the toner hopper.
[1]
[2]
A
50gat2e002na
[1]
36
Exit
[2]
Rotation
13. CLEANING/TONER RECYCLE SECTION
13.1 Composition
Collection screw
Cleaning blade
Scraper
Drum
Collection paddle
Neutralizing sheet
50gat2c013na
37
bizhub 500 / 420
bizhub 500 / 420
13.2 Drive
[1]
[2]
[3]
50gat2c014na
38
[1]
Drum motor (M1)
[2]
Cleaning/recycle section drive
[3]
Developer agitation drive
13.3.1
Cleaning operation
Toner scraped by the cleaning blade [4] is neutralized by the neutralizing sheet [2], then collected by the collection paddle [1], and finally guided to the collection screw [5]. At this time, toner remaining on the collection paddle is scraped by the scraper [6].
[5]
[6]
[1]
[4]
[3]
[2]
50gat2c047na
[1]
Collection paddle
[4]
Cleaning blade
[2]
Neutralizing sheet
[5]
Collection screw
[3]
Drum
[6]
Scraper
13.3.2
Toner collection mechanism
A. Purpose
To reuse toner scraped by the cleaning blade, the toner collection mechanism is provided.
B. Execution timing
The collection paddle to be used to collect toner is driven by the drum motor (M1) and the toner collection operation is made in synch with the ON/OFF of M1.
13.3.3
Toner conveyance operation
A. Toner conveyance mechanism

Toner collected is conveyed to the hopper in the toner supply section by the collection screw of the cleaning
section.
B. Execution timing
The collection screw is driven by the drum motor (M1) and the toner conveyance operation is made in synch
with the ON/OFF of M1.
39
bizhub 500 / 420
13.3 Operation
14. PAPER FEED SECTION (Tray 1/2)
bizhub 500 / 420

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

Pick-up roller
Feed roller
Lift plate
Separation roller
Tray 2
50gat2c104na
40
14.2.1
bizhub 500 / 420
14.2 Drive
Paper feed drive
[1]
[12]
[13]
[2]
[3]
[4]
[5]
[6]
[11]
[7]
[10]
[8]
[9]
50gat2c016na
[1]
Feed motor (M9)
[8]
Feed roller /2
[2]
Feed clutch /1 (CL4)
[9]
Separation roller /2
[3]
Feed roller /1
[10]
Pick-up roller /2
[4]
Separation roller /1
[11]
Tray 2
[5]
Vertical conveyance roller
[12]
Tray 1
[6]
Vertical conveyance clutch (CL3)
[13]
Pick-up roller /1
[7]
14.2.2
Tray lift drive
[3][4]
[1]
[2]
[1]
Lift arm
[3]
[2]
Lift plate
[4]
50gat2c017na
41
bizhub 500 / 420
14.3 Operation
14.3.1
Up/down control
A. Up drive operation
The lift drive shaft [3] is rotated by the paper lift motors /1 (M7) [6] and /2 (M8) [7]. The lift drive shaft is provided
with the lift arm [1] and the lift plate [2] is pushed up when the lift drive shaft rotates. In this way, the up drive
operation of the lift plate is conducted.
B. Down drive operation
Pulling out the tray disengages the coupling [8] of the paper lift motors /1 (M7) and /2 (M8) from the lift drive
shaft. In this way, the driving force of M7 or M8 that holds the lift plate at the upper position is released and the
lift plate goes down by its own weight.
[6] [7]
[8]
[9][10]
[1]
[4] [5]
[3]
[2]
[1]
Lift arm
[6]
[2]
Lift plate
[7]
[3]
Lift drive shaft
[8]
Coupling
[4]
Tray set sensor /1 (PS8)
[9]
[5]
[10]
50gat2c051na
C. Operation timing
When the tray is set, the tray set sensors /1 (PS8) and /2 (PS14) turn ON. In this way, the paper lift motors /1
(M7) and /2 (M8) turn ON to raise the lift plate. When the lift plate goes up and the upper most paper that is
loaded turns ON the upper limit sensors /1 (PS6) and /2 (PS13), M7 and M8 turn OFF to stop the up drive operation.
When the paper feed operation causes PS6 and PS13 to turn OFF from ON while in the print operation, M7 and
M8 turn ON again to raise the lift plate. In this way, when PS6 and PS13 turn ON again, M7 and M8 turn OFF to
stop the up drive operation.
42

Paper size detection control
A. Paper size detection mechanism

(1) Size detection in the main scan direction
The side guide plate [12] is provided with the size detection actuator [7]. And interlocked with the side guide
plate, this actuator sticks out to the rear side of the tray. The size detection actuator is provided with the 2 lines
of notches, which are detected by the paper size sensors /Fr1 (PS11) [11] and /Rr1 (PS10) [10], or the paper
size sensors /Fr2 (PS17) [3] and /Rr2 (PS16) [4] equipped individually on the rear of the main body. The notches
of the size detection actuator vary for each paper size and the paper size is detected in the main scan direction
by the combination of the ON/OFF of PS10 and PS11, or PS16 and 17.
(2) Size detection in the sub scan direction
The rear guide plate [13] is provided with the size detection actuator [1], which rotates in interlock with the rear
guide plate. The size detection actuator is provided with a projection [2]. When this projection comes at the rear
side of the tray, it pushes the detection levers [9] and [6] of the paper size boards /1 (PSB/1) [8] and /2 (PSB/2)
[6] equipped on the back of the main body. 4 detection levers are equipped on each of the paper size board and
they individually turn ON and OFF the paper size detection switches /1 (SW101) to /4 (SW104) provided on each
board. On the other hand, the projections of the size detection actuator vary in their circumterence and the intervals between each of these projections, and accordingly, either one of the 4 detection levers is to be pushed
according to the position of the guide plate. In this way, the paper size in the sub scan direction is detected by
the combination of the ON/OFF of SW101 to SW104.
[12]
[13]
[8] [9]
[7]
[6][5]
[1]
[10]
[4]
[11]
[3]
[2]
[1]
Size detection actuator
[8]
Paper size board /1 (PSB/1)
[2]
Projection
[9]
Detection lever
Paper size sensor /Rr1 (PS10)
[3]
Paper size sensor /Fr2 (PS17)
[10]
[4]
[11]
[5]
Detection lever
[12]
Side guide plate
[6]
[13]
Rear guide plate
[7]
Size detection actuator
50gat2c048na
43
bizhub 500 / 420
14.3.2
bizhub 500 / 420
B. Paper size detection table

Paper size
Paper size boards /1 (PSB/1), /2 (PSB/2)

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

Paper feed control
A. Pick-up mechanism
The pick-up roller [4] is brought up and down mechanically by the lever [6] provided on the rear side of the paper
feed unit. When the tray is set, the lever is pushed by the tray to bring down the pick-up roller. In this way, the
pick-up roller comes in contact with paper to pick it up.
[6]
[1]
[5]
[3]
[4]
[2]
50gat2c098na
[1]
Feed roller
[4]
Pick-up roller
[2]
Separation roller
[5]
When the tray is not set (with the pick-up
[3]
When the tray is set (with the pick-up roller

brought down)
roller brought up)

[6]
Lever
45
bizhub 500 / 420
14.3.3
B. Pick-up control
bizhub 500 / 420
(1) Tray 1 pick-up control

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

50gat2c099na
[1]
[3]
Paper feed request signal
[2]
Pick-up of the 1st paper
[4]
Pick-up of the 2nd paper
(2) Tray 2 pick-up control

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

Vertical conveyance sensor (PS2)
50gat2c100na
46
[1]
[4]
[2]
[5]

[3]
Vertical conveyance of the 1st paper
[6]
Vertical conveyance of the 2nd paper
The separation roller [5] is pressed against the feed roller [8] by the operating pressure generated by the pressure [2] of the spring [4] and the torque of the torque limiter [3]. This operating pressure of the feed roller, separation roller and torque limiter becomes a limit torque to prevent the double feed of paper.
When there is no paper between the separation roller and the feed roller, or when only one sheet of paper is conveyed, the operating pressure of the feed roller, the paper and the spring is in excess of the limit torque, and
therefore, the separation roller rotates [6] following the rotation of the feed roller. When two or more sheets of
paper are conveyed between the separation roller and the feed roller, the limit torque is greater than the frictional
force between 2 sheets of paper, and accordingly, the separation roller stops and the lower side paper [7] in
contact with the separation roller is not conveyed.
[8]
[1]
[2]
[3]
[7]
[6]
[5]
[4]
50gat2c101na
[1]
Paper conveyance direction
[5]
Separation roller
[2]
Pressing
[6]
Driven rotation
[3]
Torque limiter
[7]
2nd sheet of paper
[4]
Spring
[8]
Feed roller
47
bizhub 500 / 420
C. Separation mechanism

14.3.4
Paper empty control
bizhub 500 / 420
The paper empty of the tray is detected by the paper empty sensors /1 (PS5) [3] and /2 (PS12) [4]. And to
prompt the supply of paper before paper in the tray runs out completely, the paper near-empty sensors /1 (PS9)
[7] and /2 (PS15) [8] are equipped. The lift drive shaft [2] that brings up the lift plate [5] is provided with the actuator [1] and PS9 and PS15 are turned ON and OFF by this actuator. When a sufficient amount of paper is loaded
on the tray, the actuator turns ON PS9 and PS15. However, when the amount of paper gets reduced and the lift
plate goes up, the actuator turns OFF PS9 and PS15. In this way, it is detected that the paper loaded in the tray
comes near to an end.
[7] [8]
[1]
[2]
[3][4]
[6]
[5]
50gat2c050na
48
[1]
Actuator
[5]
Lift plate
[2]
Lift drive shaft
[6]
Coupling
[3]
Paper empty sensor /1 (PS5)
[7]
Near-empty sensor /1 (PS9)
[4]
[8]

Paper remaining detection mechanism
The front cover [4] of the tray is provided with the paper remaining display window [3], and the paper remaining
in the tray can be checked through this window. The inside of the paper remaining display window is provided
with the display lever [2] which is interlocked with the up/down position of the lift plate [1]. The display lever is red
in color and it is indicated that the more the red portion that can be seen through the paper remaining display
window, the less paper there remains in the tray.
[1]
[4]
[3]
[2]
[1]
Lift plate
[3]
Paper remaining display window
[2]
Display lever
[4]
Front cover
50gat2c053na
49
bizhub 500 / 420
14.3.5
15. BYPASS SECTION
bizhub 500 / 420
15. BYPASS SECTION

15.1 Composition
Pick-up solenoid /BP (SD1)

Feed roller
Separation roller
Lift plate
50gat2c019na
50
15. BYPASS SECTION
15.2.1
bizhub 500 / 420
15.2 Drive
Paper feed drive
[4]
[1]
[2]
[3]
50gat2c018na
[1]
Feed clutch /BP (CL6)
[3]
Separation roller
[2]
Feed roller
[4]
Feed motor (M9)
15.2.2
Tray lift drive
[4]
[5]
[3]
[1]
[2]
50gat2c020na
[1]
Cam
[4]
[2]
Lift plate
[5]
[3]
Spring
51
15. BYPASS SECTION
bizhub 500 / 420
15.3 Operation
15.3.1
Up/down control
A. Up drive operation
The lift plate [4] is of the construction in which it is pushed up by the spring [5] provided on the lower section.
However, while in the stand-by condition, it is hold down by the cam [3] provided on the lift drive shaft [6]. And
the ON/OFF of the gear [7] of the lift drive shaft is controlled by the stopper [1] that is driven by the pick-up solenoid /BP (SD1) [2]. When the feed motor (M9) is turned ON by a print start signal, SD1 turns ON a specified
period of time after that. In this way, the stopper is released and the driving force of M9 is transmitted to the lift
drive shaft. When the cam that holds down the lift plate is released by the rotation of the lift drive shaft, the lift
plate is brought up by the force of the spring. When the lift sensor (PS23) [8] is turned ON by the rotation of the
lift drive shaft, SD1 turns OFF to stop the up drive of the lift plate. This up drive operation causes paper loaded in
the tray to come in contact with the feed roller to allow paper to be fed.
[7]
[2]
[8]
[6]
[1]
[6]
[5]
[4] [3]
50gat2c054na
[1]
Stopper
[5]
[2]
[6]
Spring
Lift drive shaft
[3]
Cam
[7]
Gear
[4]
Lift plate
[8]
Lift sensor (PS23)
B. Down drive operation

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

Paper size detection control
A. Size detection in the main scan direction

According to the position of the guide plate connected to the paper size VR/BP (VR1), the paper size is
detected in the main scan direction.
B. Size detection in the sub scan direction
The paper size is detected by the combination of the ON/OFF of the paper size sensors /BP1 (PS19), /BP2
(PS20), /BP3 (PS21) and /BP4 (PS22).
C. Paper size detection table
Paper size
A6S
Paper size sensors
Paper size VR/BP (VR1)
BP1
BP2
BP3
BP4
(PS19)
(PS20)
(PS21)
(PS22)
OFF
OFF
OFF
OFF
B6S
detection width (mm)

80 or more - less than 115
115 or more - 144 or less
A5
B5
A5S
ON
OFF
OFF
OFF
B5S

A4S
81/2 x 11
A4
Foolscap
ON
ON
OFF
OFF
81/2 x 14
ON
ON
ON
OFF
B4
11 x 17
A3

ON
ON
ON
ON

53
bizhub 500 / 420
15.3.2
15. BYPASS SECTION
15. BYPASS SECTION

15.3.3
Paper feed control
bizhub 500 / 420
A. Pick-up control
When the feed motor (M9) is turned ON by the print start signal [1], the pick-up solenoid /BP (SD1) and the vertical conveyance clutch (CL3) also turn ON a specified period of time after that. When SD1 turns ON, the lift
plate goes up [2] and paper comes into contact with the feed roller. After that, the feed clutch /BP (CL6) turns
ON. Through these operations, the driving force of M9 is transmitted to the feed roller and the vertical conveyance roller to conduct the pick-up [3] and the vertical conveyance [4] of the 1st sheet of paper. When paper is
conveyed and the vertical conveyance sensor (PS2) turns ON, CL6 turns OFF to complete the pick-up operation. However, since CL3 keeps turning ON, paper is conveyed to the registration section by the vertical conveyance roller. In this way, when the registration sensor (PS1) turns ON, CL3 turns OFF a specified period of time
after that. The pick-up [6] and the vertical conveyance [8] of the 2nd and succeeding sheets of paper are conducted using the paper feed request signal [5] as a starting point. When the last paper turns ON PS2, SD1 turns
ON to bring down [7] the lift plate.
[1]
[3]
[4]
[5]
[6]
[8]
Feed motor (M9)

[2]
54
[7]
50gat2c102na
[1]
[5]
[2]
Lift plate goes up
[6]

[3]
[7]
Lift plate goes down
[4]
Vertical conveyance of the 1st paper
[8]
Vertical conveyance of the 2nd paper
15. BYPASS SECTION
The separation roller [7] is pressed against the feed roller [1] by the operating pressure generated by the pressure [4] of the spring [5] and the torque of the torque limiter [6]. This operating pressure of the feed roller, separation roller and torque limiter becomes a limit torque to prevent the double feed of paper.
When there is no paper between the separation roller and the feed roller, or when only one sheet of paper is conveyed, the operating pressure of the feed roller, the paper and the spring is in excess of the limit torque, and
therefore, the separation roller rotates [3] following the rotation of the feed roller.
When two or more sheets of paper are conveyed between the separation roller and the feed roller, the limit
torque is greater than the frictional force between 2 sheets of paper, and accordingly, the separation roller stops
and the lower side paper [2] in contact with the separation roller is not conveyed.
[1]
[8]
[7]
[6]
[5]
[4]
[3]
[2]
50gat2c106na
[1]
Feed roller
[5]
[2]
2nd sheet of paper
[6]
Torque limiter
[3]
Driven rotation
[7]
Separation roller
[4]
Pressing
[8]
15.3.4
Spring
Paper empty control
The paper empty of the tray is detected by the paper empty sensor /BP (PS18).
55
bizhub 500 / 420
B. Separation mechanism
16. REGISTRATION SECTION
bizhub 500 / 420

16.1 Composition
Registration roller
Loop roller
50gat2c021na
56
bizhub 500 / 420
16.2 Drive
[1]
[6]
[2]
[3]
[5]
[4]
50gat2c022na
[1]
Registration roller
[4]
Loop roller
[2]
Feed motor (M9)
[5]
Tray 1
[3]
Loop clutch (CL2)
[6]
57
bizhub 500 / 420
16.3 Operation
16.3.1
Loop control
A. Registration path
Paper fed from the tray 1 [10], the tray 2 [8], the by-pass tray [6], PC/LU [7] and ADU [4] hits against the registration roller [2] through the loop roller [12]. And until the loop roller turns OFF, a loop is formed [3] and a paper
skew is corrected.
The loop roller is driven by the feed motor (M9) and the loop of paper is controlled by the registration sensor
(PS1) [13] equipped just before the registration roller.
[1]
[13]
[2]
[12]
[3]
[11]
[4]
[10]
[5]
[9]
[6]
[7]
[8]
50gat2c055na
58
[1]
Drum
[8]
[2]
Registration roller
[9]
Tray 2 paper conveyance

Paper feed unit /2
[3]
Loop
[10]
Tray 1 paper conveyance
[4]
ADU paper conveyance
[11]
Paper feed unit /1
[5]
Vertical conveyance section
[12]
Loop roller
[6]
By-pass tray paper conveyance
[13]
[7]
PC/LU paper conveyance
The feed motor (M9) and the loop clutch (CL2) are turned ON by the print start signal [1]. In this way, the driving
force of M9 is transmitted to the loop roller and paper conveyed from each of the paper feed sections is conveyed to the registration roller. When the registration sensor (PS1) detects the leading edge of paper and turns
ON [3], CL2 turns OFF a specified period of time after that. At this time, since paper is being conveyed for a
specified period of time after being hit against the registration roller, a loop [4] is formed and a paper skew is corrected.
The print signal [5] turns ON the registration clutch (CL1) to transmit the driving force of M9 to the registration
roller. At this time, CL2 also turns ON to drive the loop roller for a loop assist [7].
When PS1 detects the trailing edge of paper and turns OFF [8], CL1 also turns OFF a specified period of time
after that to complete the registration operation. However, CL2 keeps tuning ON to conduct a loop formation [9]
of the next paper. After that, the same operations are repeated.
When PS1 detects the trailing edge of the last paper and turns OFF [11], M9, CL1 and CL2 also turn OFF a
specified period of time after that to complete a series of registration operations.
[1]
[2] [3] [5]
[7] [8]
[10]
[11]
Feed motor (M9)

Loop clutch (CL2)
[4]
[6]
[9]
[1]
Print start signal
[2]
Conveyance of the 1st paper
[3]
Detection of the leading edge of 1st paper
[9]
[4]
Loop formation of the 1st paper
[10]
Print signal for the 2nd paper
[5]
Print signal for the 1st paper
[11]
Detection of the trailing edge of the last
[6]
1st paper registration roller ON
[7]
Loop assist of the 1st paper, and convey-
[8]
50gat2c056na
Detection of the trailing edge of the 1st

paper
Loop formation of the 2nd paper
paper
ance of 2nd of paper
59
bizhub 500 / 420
B. Registration operation
17. ADU SECTION
bizhub 500 / 420
17. ADU SECTION

17.1 Composition
Conveyance roller /1
50gat2c023na
60
17. ADU SECTION
bizhub 500 / 420
17.2 Drive
[1] [2]
[3] [4]
[6]
[5]
50gat2c024na
[1]
ADU conveyance clutch /Up (CL7)
[4]
[2]
[5]
[3]
ADU conveyance clutch /Lw (CL8)
[6]
Feed motor (M9)
61
17. ADU SECTION
bizhub 500 / 420
17.3 Operation
17.3.1
Conveyance path
Paper the one side of which has been printed is conveyed to ADU by the reverse roller [12]. The paper conveyed
to ADU is also conveyed to the loop roller [6], the registration roller [7] and the drum [8] by the conveyance rollers
/1 [2], /2 [3] and /3 [5] and the other side is printed. Paper both sides of which has been printed passes through
the fusing roller [9] and fusing exit roller [10] to be exited from the main body paper exit roller [11].
The conveyance rollers /1, /2 and /3 are driven by the feed motor (M9), but the ON/OFF of the conveyance roller
/1 is controlled by the ADU conveyance clutch /Up (CL7) and that of the conveyance rollers /2 and /3 controlled
by the ADU conveyance clutch /Lw (CL8). This control is used to prevent the interference of each sheet of paper
that circulates through the conveyance path when two or more sheets of paper are printed. And, to detect the
position of paper that is circulating, the ADU conveyance sensor /1 (PS24) [1] and /2 (PS25) [4] are equipped.
[12]
[1]
[11]
[2]
[10]
[9]
[3]
[8]
[7]
[4]
[6]
[5]
50gat2c057na
62
[1]
ADU conveyance sensor /1 (PS24)
[7]
[2]
[8]
Registration roller
Drum
[3]
[9]
Fusing roller
[4]
[10]
Fusing exit roller
[5]
[11]
Main body paper exit roller
[6]
Loop roller
[12]
Reverse roller

Conveyance control
When printing two or more sheets of paper in the double sided print mode, the conveyance control in ADU varies according to the length of paper in the sub scan direction. The following 3 control methods are provided for
the conveyance control.
Conveyance control
Length of applicable paper in the sub scan direction
1 sheet self-contained double sided print
B4 (364 mm) to Ledger (431.8 mm)
2 sheets self-contained double sided print
Letter (215.9 mm) to B4 (364 mm)
3 sheets self-contained double sided print
B5 (182 mm) to Letter (215.9 mm)
A. 1 sheet self-contained double sided print operation

Note
A figure in the illustration (shown in the square) represents the page number.
1. With the 1st sheet of paper fed, the image of the

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

reverse/exit section, and then conveyed to ADU
after being turned over.
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63
bizhub 500 / 420
17.3.2
17. ADU SECTION
17. ADU SECTION
bizhub 500 / 420
3. The 1st sheet of paper in ADU is conveyed without interruption.
50gat2c060na
4. The 1st sheet of paper is fed again and the image

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

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

repeated.
50gat2c062na
64
17. ADU SECTION
Note
1. With the 1st sheet of paper fed, the image of the

50gat2c063na

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

of paper is fed.
50gat2c064na
3. The image of the 4th page (the back side of the

2nd sheet of paper when the original is double
sided) is printed on the 2nd sheet of paper. At this
time, the 1st sheet of paper is conveyed into ADU.
50gat2c065na
65
bizhub 500 / 420
B. 2 sheets self-contained double sided print operation
17. ADU SECTION
bizhub 500 / 420

4
1
At this time, the 3rd sheet of paper is fed and the

2nd sheet of paper is turned over at the paper
reverse/exit section to be conveyed into ADU.
50gat2c066na
5. While the 1st sheet of paper is being exited, the

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

being turned over at the paper reverse/exit section. At this time, the 2nd sheet of paper that has
been standing by is fed again.
2
1
4
50gat2c068na
7. The image of the 3rd page (the front side of the

2nd sheet of paper when the original is double
sided) is printed on the 2nd sheet of paper. At this
time, the 3rd sheet of paper has been conveyed
2
1
into ADU and the 4th sheet of paper is fed at the
same time.
50gat2c069na
66
17. ADU SECTION
image of the 8th page (the back side of the 4th

is printed on the 4th sheet of paper. At this time,
the 3rd sheet of paper is standing by on this side
3
2
of the conveyance roller /3.
1
6
50gat2c070na
9. The 4th sheet of paper is turned over at the paper

reverse/exit section to be conveyed to ADU. At
this time, the 3rd sheet of paper that has been

standing by is fed again.
3
2
repeated.
1
6
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67
bizhub 500 / 420
8. While the 2nd sheet of paper is being exited, the
17. ADU SECTION
bizhub 500 / 420
C. 3 sheets self-contained double sided print operation

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

50gat2c072na

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

of paper is fed and the image of the 4th page (the
back side of the 2nd sheet of paper when the
original is double sided) is printed.
50gat2c073na
3. The 1st sheet of paper is standing by at the conveyance roller /3. The 2nd sheet of paper is turned
over at the paper reverse/exit section to be conveyed to ADU. At this time, the 3rd sheet of paper
is fed and the image of the 6th page (the back
side of the 3rd sheet of paper when the original is
double sided) is printed.
50gat2c074na
68
17. ADU SECTION
reverse/exit section and the 2nd sheet of paper is
conveyed in ADU without interruption. However,

the 1st sheet of paper remains standing by at the
conveyance roller /3.
50gat2c075na


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


since the 2nd sheet of paper is standing by at the
conveyance roller /3, the 3rd sheet of paper stops
when the interval between this sheet and the 2nd

sheet of paper comes to the prescribed distance.
50gat2c077na
7. The 4th sheet of paper is conveyed to the paper

reverse/exit section. At this time, the conveyance
of the 2nd and the 3rd sheets of paper resumes in
ADU.
2
1
4
50gat2c078na
69
bizhub 500 / 420
4. The 3rd sheet of paper is conveyed to the paper
17. ADU SECTION
bizhub 500 / 420
8. The 2nd sheet of paper is fed again and the image

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

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


4
3
2
1
since the 3rd sheet of paper is standing by at the

conveyance roller /3, the 4th sheet of paper stops
10
when the interval between this sheet and the 3rd

sheet of paper comes to the prescribed distance.

50gat2c080na
70
repeated.
18. FUSING SECTION
bizhub 500 / 420
18. FUSING SECTION

18.1 Composition
Fusing web
Fusing heater
lamp /1 (L2)
Fusing roller
Paper exit roller
Fusing pressure roller
Decurler roller
Fusing claw
50gat2c025na
18.2 Drive
[1]
[2]
50gat2c026na
[1]
Fusing unit drive
[2]
Fusing motor (M11)
71
18. FUSING SECTION
bizhub 500 / 420
18.3 Operation
18.3.1
Fusing roller drive control
A. Speed switchover control

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

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

While in the warm-up, the preliminary rotation is conducted for the fusing roller and the fusing pressure roller.
The time of preliminary rotation varies according to the detected temperature of the drum temperature sensor
and the thermistors /1 (TH1) and /2 (TH2). And the starting temperature of the preliminary rotation varies for
bizhub 500 and 420.
C. Rotation control while in the print
The fusing motor (M11) that drives the fusing roller and the fusing pressure roller is turned ON by the print start
signal. And it turns OFF a specified period of time after the fusing exit sensor (PS3) detects the trailing edge of
the last paper.
While in the print with paper stopping at the registration section, the fusing roller and the fusing pressure roller
run idle. In this way, the fusing temperature gets near to the set temperature for each type of paper selected in
the paper setting of the setup menu.
18.3.2
Web drive control
The fusing web is driven by the web solenoid (SD4).

The number of ON times is controlled by SD4 according to the web count of the fixed part counter so that the
web shift amount per print becomes constant.
72

Fusing temperature control
The fusing roller is heated by the fusing heater lamps /1 (L2) and /2 (L3). The fusing pressure roller is heated by
the thermal conduction from the fusing roller.
The surface temperature of the fusing roller is detected by the thermistors /1 (TH1) [2] and /2 (TH2) [1]. TH1 and
TH2 monitor the surface temperature of the fusing roller at specified intervals to control the ON/OFF of L2 and
L3 through the AC drive circuit in the DC power supply (DCPS) so that a prescribed temperature can be
obtained.
[1]
[2]
50gat2c081na
[1]
Thermistor /2 (TH2)
[2]
Thermistor /1 (TH1)
A. Warm-up
Warm-up is conducted when the main power switch (SW1), the power switch (SW2) and the interlock switch
(MS) turn ON, and also when the system returns from the low power mode or the sleep mode.
While in the warm-up, the fusing heater lamps /1 (L2) and /2 (L3) turn ON. And it turns OFF at the prescribed
temperature. The temperature at which the warm-up completes varies for bizhub 500 and 420.
B. While in the print
The set temperature of the fusing roller varies according to the type of paper and the paper size. The ON/OFF of
the fusing heater lamps /1 (L2) and /2 (L3) are controlled so that the prescribed temperature is obtained.
When plain paper or thick paper is selected, to prevent the set temperature from going down due to the passage of paper, the set temperature is raised up to the prescribed temperature for a specified period of time from
the start of printing for each print.
When the fusing roller and the fusing pressure roller are stopped due to the completion or interruption of the
print, each roller is kept running for a specified period of time after L2 and L3 turn OFF to avoid an overshoot.
C. While in the stand-by
While in the stand-by condition, the temperature of the fusing roller is controlled in 3 steps according to the
elapsed time after the completion of warm-up or printing, whether DF is opened or closed, and whether each
key is pushed down or not.
While in the stand-by, the ON/OFF of the fusing heater lamps /1 (L2) and /2 (L3) are controlled so that the fusing
roller gets to the prescribed temperature.
Through these control operations, an overshoot is avoided and fusibility immediately after the release from the
stand-by condition is secured.
73
bizhub 500 / 420
18.3.3
18. FUSING SECTION
18. FUSING SECTION
D. Low power mode and sleep mode
bizhub 500 / 420
When each key is not pressed within a specified period of time after the completion of the last print, the system
changes into the low power mode or the sleep mode. The starting time for operation can be set individually for
the low power mode and the sleep mode. When the same starting time for operation is set for both modes, the
sleep mode takes precedence over the low power mode.
When the system changes into the low power mode, the ON/OFF of the fusing heater lamps /1 (L2) and /2 (L3)
is controlled so that the fusing roller gets to the prescribed temperature. The controlled temperature at this time
becomes lower than other controlled temperatures. And when the system changes into the sleep mode, the
power supply to L2 and L3 is shut off to put the system in the stand-by condition.
18.3.4
Fusing roller edge cooling control
A. Purpose
When printing continuously the sheets of paper the size of which is short in the main scan direction, the temperature gets high at both edges of the fusing roller and the fusing pressure roller where no paper passages is
made. So, to prevent the temperature from getting high, the edges of each roller are cooled down by the fusing
cooling fans /Fr (FM2) and /Rr (FM8). This control operation is also conducted to avoid a fusing overshoot when
the main body makes an emergency stop due to the occurrence of a jam.
B. Fusing cooling fan control
The fusing cooling fans /Fr (FM2) and /Rr (FM8) vary depending on whether the size of paper in the main scan
direction is large or small. And their operations also vary when a jam occurs.
(1) Small size
Small size paper refers to the one the size of which is 200 mm or less in the main scan direction.
ON timing
When the fusing exit sensor (PS3) detects the leading edge of paper exited and turns ON.
OFF timing
When the fusing motor (M11) turns OFF.
(2) Large size

Large size paper refers to the one the size of which is 201 mm or more in the main scan direction.
ON timing
When the detected temperature of the thermistor /2 (TH2) is over the prescribed temperature.
OFF timing
When the detected temperature of TH2 goes down below the prescribed temperature.
(3) When a jam occurs.
ON timing
A jam is detected inside the main body.
OFF timing
A specified period of time after the fusing cooling fans /Fr (FM2) and /Rr (FM8) turn ON.
Note
When the power switch (SW2) turns OFF due to the occurrence of a jam, or when the interlock
switch (MS) is turned OFF by opening ADU, the power supply to each fan is shut off and, even if it
is within a specified period of time, the fan turns OFF. However, when SW2 and MS are turned ON
within a specified period of time, FM2 and FM8 turn ON again.
74
18. FUSING SECTION
The air inside the machine is sucked in by the fusing cooling fans /Fr (FM2) [6] and /Rr (FM8) [1] to be blown
against the edges of the fusing roller [3] through the ducts [2] and [5]. In this way, the edges of the fusing roller
are cooled down and the surface temperature of the edges of the fusing pressure roller [4] that is in contact also
goes down.
[1]
[2]
[6]
[3]
[4]
[5]
50gat2c082na
[1]
Fusing cooling fan /Rr (FM8)
[4]
[2]
Duct
[5]
Duct
[3]
Fusing roller
[6]
Fusing cooling fan /Fr (FM2)
18.3.5
Envelope conveyance mechanism
When printing envelopes, to prevent the occurrence of paper crease due to the thickness of paper, it is possible
to switch the nip pressure of the fusing roller and the fusing pressure roller. The nip pressure is manually
switched by the envelope lever [1].
[1]
50gat2c083na
[1]
Envelope lever
75
bizhub 500 / 420
C. Fusing cooling path
18. FUSING SECTION

18.3.6
Protection against abnormality
bizhub 500 / 420
When the thermistors /1 (TH1) and /2 (TH2) detects a stipulated temperature (233C) 5 times at the prescribed
intervals, this is deemed to be a high temperature abnormality and the fusing heater lamps /1 (L2) and /2 (L3) are
turned OFF. The thermostat (TS) also monitors an abnormal temperature rise and, when the detected temperature gets to 220 10C, the AC power lines to L2 and L3 are shut off.
For each condition in the warm-up, print, stand-by and the low power modes, the detected temperatures of
TH1 and TH2 and the number of times when L2 and L3 turned ON are calculated. And it is considered that a
low temperature abnormality occurs when certain conditions are met. When a low temperature abnormality
occurs, the power supply to L2 and L3 is cut off.
When these fusing temperature abnormalities occur, the system is placed in the SC latch condition with a message shown in the touch panel. After repairing with the cause of abnormality identified, it is necessary to release
the SC latch by the software DipSW3-1 for restoration.
RL1
DCPS
TS
CBR
NF
RL2
AC
drive
section
L2
L3
PRCB
TH1
Control
section
RL
drive
section
RL1
RL2
TH2
50gat2c084na
18.3.7
Jam detection control
Only while in the print, when the detected temperatures of the thermistors /1 (TH1) and /2 (TH2) go down in a
moment more than the prescribed temperature, this is considered as a wind-up jam and the operation of the
main body is stopped with a message shown in the touch panel.
76
19. REVERSE/EXIT SECTION
bizhub 500 / 420

19.1 Composition
Reverse roller
Exhaust fan /Rr (FM9)
Reverse gate
Reverse gate
Reverse solenoid (SD3)
Exhaust fan /Fr (FM3)
Reverse roller
50gat2c027na
19.2 Drive
[4]
[1]
[3]
[2]
50gat2c028na
[1]
Reverse motor (M6)
[3]
Reverse gate
[2]
[4]
Reverse roller
77
bizhub 500 / 420
19.3 Operation
19.3.1
Conveyance control
A. Reverse gate
The reverse gate is driven by the ON/OFF of the reverse solenoid (SD3). Paper conveyed from the fusing section
is switched by the reverse gate between the paper exit section and the reverse section.
B. Conveyance path
(1) Paper exit path
The reverse solenoid (SD3) is normally turned OFF and the reverse gate [1] is held in the position in which it
blocks the conveyance path to the reverse roller [4]. In this manner, paper conveyed from the fusing exit roller
(decurler roller) [2] is guided to the main body paper exit roller [3] along the internal form of the reverse gate to be
exited.
[4]
[1]
[3]
[2]
50gat2c085na
78
[1]
Reverse gate
[3]
[2]
Fusing exit roller (decurler roller)
[4]
Reverse roller
While in the double sided print, the reverse solenoid (SD3) turns ON when the print on the back side is completed, and the reverse gate [1] is switched in the direction in which the conveyance path to the reverse roller [4]
is opened. In this way, paper conveyed from the fusing exit roller (decurler roller) [2] is guided to the reverse roller
along the external form of the reverse gate.
[4]
[1]
[3]
[2]
50gat2c086na
[1]
Reverse gate
[3]
[2]
Fusing exit roller (decurler roller)
[4]
Reverse roller
79
bizhub 500 / 420
(2) Reverse path

19.3.2
Reverse control
bizhub 500 / 420
A. Switch-back mechanism
While in the double sided print, paper that passes through the reverse gate [3] is conveyed to the outside of the
main body by the reverse roller [5] and then sent back again to the inside of the main body. At this time, the
paper is guided to the conveyance roller /1 [1] side, not to the reverse gate side from the metal frame form of the
conveyance path. In this way, the paper is turned over to be conveyed to the registration section again through
ADU.
The ON/OFF timing of the reverse solenoid (SD3) that drives the reverse gate is controlled by the fusing exit sensor (PS3) [2]. And the switchover between the normal rotation and the reverse rotation of the reverse motor (M6)
that drives the reverse roller is controlled by the reverse sensor (PS27) [4].
[5]
[4]
[1]
[3]
[2]
50gat2c087na
80
[1]
[4]
Reverse sensor (PS27)
[2]
[5]
Reverse roller
[3]
Reverse gate
While in the double sided print, when the fusing exit sensor (PS3) detects the leading edge of paper of which the
printing of the back side has been completed and turns ON [1], the reverse solenoid (SD3) turns ON to switch
the reverse gate a specified period of time after the registration clutch (CL1) turns ON for back side printing. In
this manner, the paper is conveyed to the reverse section. A specified period of time after the reverse sensor
(PS27) detects the leading edge of paper and turns ON [2], the reverse motor (M6) rotates in the normal direction [3] and the reverse roller conveys the paper to the outside of the main body. And then, a specified period of
time after PS3 detects the trailing edge of the paper and turns OFF [4], SD3 turns OFF [5] to bring the reverse
gate back to its original position. And when PS27 detects the trailing edge of the paper and turns OFF [6], the
rotation of M6 is switched [7] from the normal rotation to the reverse rotation and the reverse roller sends the
paper back to the inside of the main body to convey it to ADU. In this manner, the paper is turned over.
[1]
Reverse motor (M6)
[3]
[5]
[7]
Normal
rotation
Reverse
rotation

[2]
[4]
[6]
50gat2c088na
[1]
Switchover of the reverse gate
[5]
Return to the reverse gate
[2]
Detection of the leading edge of paper
[6]
Detection of the trailing edge of paper
[3]
Normal rotation of the reverse roller ON
[7]
[4]
Detection of the trailing edge of paper
Switchover of the reverse roller from the

normal rotation to the reverse rotation
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B. Reverse control
20. INTERFACE SECTION
bizhub 500 / 420
20. INTERFACE SECTION

20.1 Composition
Serial port (RS-232C)
Parallel port (based on IEEE1284)
USB port (USB TypeB)

RJ45 Ethernet connector
50gat2c089na
20.2 Specifications
Item
Serial port (RS-232C)
82
Specifications
For CS Remote Care
Parallel port (based on IEEE1284)
For ISW of the copier/printer
USB port (USB TypeB)
For ISW of the copier/printer
RJ45 Ethernet connector
(Spare)
21. IMAGE STABILIZATION CONTROL
21.1 Outline
This machine employs various image stabilization controls to realize the top quality print image at all times. The
operation of the image stabilization control varies between while in the power switch (SW2) ON and while in the
print.
21.2 Operation flow

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

(1) Purpose
To meet the warm-up specifications, the fusing heater lamps /1 (L2) and /2 (L3) are turned ON early enough so
that the surface temperature of the fusing roller goes up to the prescribed temperature in its early stage.
(2) Execution timing
When the power switch (SW2) is turned ON, without waiting for the initialization of the overall control, the fusing
heater lamp is turned ON by the signal on the printer control board (PRCB). However, since turning ON the fusing heater lamps /1 (L2) and /2 (L3) at the same time causes an excessive inrush current, turn ON L3 first, and
then turn ON L2 a little after that. After turning ON L2 and L3, conduct the ON/OFF control at specified intervals
to maintain the prescribed temperature of the fusing roller that is stipulated in each operation mode.
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B. Drum rotation
bizhub 500 / 420
(1) Purpose
Prevent the drum charge leak such as an image flow at high humidity
When left in the low/normal humidity condition, prevent the uneven density due to the difference in sensitivity between the section facing the cleaner and the developing of the drum and other sections.

It turns ON a specified period of time after the power switch (SW2) turns ON, and turns OFF when the dot diameter adjustment is completed. However, when the 30 seconds extension of the early morning drum rotation is
selected in the software DipSW setting, it turns OFF 30 seconds after the completion of the dot diameter adjustment.
Note
For bizhub 420, since the early morning dot diameter adjustment is not selected by default, no
drum rotation is made.
(1) Purpose
Stabilize the image over a long period of time by preventing the change of the laser 1 dot diameter due to the
write system being stained or the change of developability.
(2) Method
Create a dot pattern patch of a fixed density on the drum. The laser PWM at this time is maximum.
Read this dot pattern patch with the IDC sensor (IDCS) and calculate the difference between the sensor
output and the specified value.
Determine the correction amount of the laser power based on a value calculated to make corrections of the
laser power.
Repeat several times the control operations described above.

When left for more than 8 hours, executed a specified period of time after the power switch (SW2) is turned ON.
However, this can be changed with the software DipSW setting.
Note
For bizhub 420, since the early morning dot diameter adjustment is not selected by default, no
execution is made.
D. Fusing preliminary rotation
(1) Purpose
Make uniform the surface temperature of the fusing roller and the fusing pressure roller.
When the detected temperature of the thermistors /1 (TH1) and /2 (TH2) gets to the stipulated temperature.
Note
The stipulated temperature at which the fusing preliminary rotation is made varies for bizhub 500
and 420.
84
(1) Purpose
To detect the environmental temperature and humidity to maintain the image quality, feedback is made to various controls.
(2) Method
A temperature sensor and a humidity sensor are equipped inside the machine.
When the power switch (SW2) is turned ON, and only when it has been left unused for more than 8 hours after
the SW2 was turned OFF last time and the fusing temperature is considered below the stipulated temperature,
an environmental decision is made based on a value measured by the sensor.
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E. Environmental decision control

21.2.2
Image stabilization control flow while in the print and the idle
bizhub 500 / 420
The following shows the image stabilization control flow while in the print and the idle.

Every 20 prints
Start of print
A. Toner density control

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

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

(1) Purpose
Because of developer and photosensitive material being deteriorated due to durability, it becomes difficult to
secure the stable amount of toner on the photosensitive material. For that reason, calculate the correction
amount based on the machine inside temperature and the time period during which the photosensitive material
is driven and make corrections of the output values of the charging grid and the developing bias to secure the
stable amount of toner.
(2) Method
Detect the machine inside humidity with the humidity sensor (HUMS) when turning ON the power switch (SW2)
8 hours or more after turning it OFF.
Calculate the correction amount based on the machine inside humidity detected and the time period during
which the photosensitive material is driven.
Make corrections of the output value of the charging grid and the developing bias based on the correction
amount calculated.
When the time period during which SW2 is turned ON after OFF is less than 8 hours, use the value of the
machine inside humidity detected last time.
For each job print.
86
(1) Purpose
While in the continuous print, reduce the variance in image density for each print.
(2) Method
Create a dot pattern patch between images of which more than 20 prints have been run off. The laser PWM
at this time is maximum.
Read this dot pattern patch with the IDC sensor (IDCS) and calculate the difference between the sensor
output and the specified value.
Determine the correction amount of the laser power based on a value calculated to make corrections of the
laser power.
Repeat several times the control operations described above.
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C. Dot diameter adjustment
22. IMAGE PROCESSING
bizhub 500 / 420

22.1 Image processing in the scanner section
A. Shading correction
B. AE control
C. Area discrimination
D. Brightness/density conversion
E. Filter/magnification
F. Density gamma (conversion)
G. Half tone processing (error diffusion)
H. Compression
I. Storage of image data (option)
88

Shading correction
This is the measure to obtain an even distribution from light of the CCD sensor. 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 is stored as the maximum output of the pixel.
b.
Black correction
The output voltage of each pixel of the CCD sensor when the exposure lamp is turned off is stored as the minimum output of the pixel.
Conduct calculation to find out what step in this range falls on the image data read from the original based on
the difference between the black and white data for each pixel stored in the steps a. and b. above, and output
the results of the calculation in the 10 bits accuracy.
Voltage at which the read is made
[1]
White
+1.4
0V
Width in which the read is made
Black
After shading correction
[2]
White
255
0
Width in which the read is made
Black
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[1]
AD conversion input
[2]
Shading correction output
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bizhub 500 / 420
22.1.1

22.1.2
AE control
bizhub 500 / 420
Through the AE control, a density suitable for the original density is automatically selected and the copy is made
properly.
A. Sampling area
(1) While in the platen mode
[5]
[1]
[7]
[6]
[5]
[2]
[2]
[4]
[3]
50gat2c092na
[1]
Original
[5]
[2]
L/100 mm
[6]
10 mm
[3]
L mm
[7]
AE sampling range
[4]
30 mm
(2) While in the DF mode
[4]
[1]
[6]
[5]
[4]
[3]
[2]
50gat2c093na
[1]
Original
[4]
20 mm
[2]
2.9 mm
[5]
[3]
1.5 mm
[6]
AE sampling range
B. Execution timing
90
While in the platen print: At the pre-scan before the actual scan when the print or the read starts.
While in the DF print
: At the same time as when the original is read.

Area discrimination
To make a copy of the original under the correct condition (to make a correct filter processing), check the read
section to see if it is a character or a dot picture, and use the results at the image processing unit at the later
stage.
22.1.4
Brightness/density conversion
The signal obtained after the shading correction is a signal corresponding to the light reflected from the original,
and this is generally called a brightness signal. In this brightness/density conversion section, the brightness signal is converted in density as shown in the graph below.
Density
255
Brightness
1024
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bizhub 500 / 420
22.1.3

22.1.5
Filter/magnification
bizhub 500 / 420
A. Filter processing
An appropriate filter processing is made according to the type of an original and the magnification selected.
(1) Character
: Make the shading of an original conspicuous.
(2) Dot section
: Suppress moire.
(3) Picture
: Increase the reproducibility of gradation.
B. Magnification processing
For this machine, the sub scan direction magnification is made by the scan speed of the exposure unit (platen
mode) or by the conveyance speed of the DF (DF mode), and the main scan direction magnification is made by
processing images electrically.
(1) Main scan magnification processing while in enlargement
As shown in the drawing below, if the data of each pixel obtained when the original is read by the CCD are D1 to
D5, the positions of the data read when enlarged are E1 to E5. However, when the write is made only with the
data thus read, the following problems occur.
a. There occurs a clearance between data, and this results in a distorted image.
b. The data position does not fall in exactly with the write position.
As shown with dotted lines in the drawing below, when there is no read data that corresponds exactly to the
write position, a density is decided for the write as shown below and appropriate processing is made.
[1]
D1
[2]
E1
[3]
W1
D2
D3
E2
W2
W3
D4
D5
E3
W4
E4
W5
W6
E5
W7
W8
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92
[1]
Position at which the original is read
[2]
Data position while in enlargement
[3]
Write position
As shown in drawing below, if the data of each pixel obtained when the original is read by the CCD are D1 to
D5, the positions of the data read when reduced are R1 to R5. They are overlapping each other and do not correspond to the write position. Therefore, a density is decided for the write as shown below and an appropriate
processing is made.
[1]
D1
[2]
R1
[3]
W1
D2
R2
W2
D3
R3
D4
R4
W3
D5
R5
W4
W5
50gat2c096na
[1]
Position at which the original is read
[2]
Data position while in reduction
[3]
Write position
(3) Density adjustment

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

22.1.6
Scanner gamma correction
bizhub 500 / 420
To the data obtained after the filter/magnification processing, select a density curve corresponding to the density button selected on the operation panel. An appropriate density curve is provided for each of the character/
picture/character and the picture/thin character modes.
22.1.7
Halftone processing (error diffusion)
To make effective use of the installed memory and obtain an excellent copy image, error diffusion processing is
employed, which is one of the pseudo-intermediate processing methods.
22.1.8
Compression
To store more image data, data is stored temporarily in the image memory after the images has been compressed.
22.1.9
Storage of image data
The image/setting of the originals read by the scanner or the images sent from the IC can be stored as a file in
the hard disk in the main body. (option)
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bizhub 500 / 420
22.2 Image processing in the write section

A. Rotation/elongation
B. PWM
C. Frequency conversion
A. Rotation/elongation
Rotate the image in the direction of 90 degrees and 180 degrees as necessary.
When outputting images from the memory, expand the compressed data to restore them to their original state.
B. PWM
The period of time the laser is turned ON is changed by changing the pulse width.
C. Frequency conversion
Write in the memory once the data after the PWM conversion and read it in accord with the write clock signal of
the printer.
95
23. OTHERS
bizhub 500 / 420
23. OTHERS
23.1 Fan control
23.1.1
Composition
[8]
[9]
[10]
[7]
[6]
[1]
[5]
[2]
[4]
[3]
50gat2c029na
96
[1]
[6]
[2]
[7]
[3]
Conveyance suction fan (FM5)
[8]
Power supply cooling fan (FM1)
[4]
Drum cooling fan (FM4)
[9]
Overall control board cooling fan (FM10)
[5]
[10]
Developing cooling fan (FM7)

23.1.2
23. OTHERS
Operation
bizhub 500 / 420
A. Power supply cooling fan (FM1) control

(1) Purpose
Cool down the DC power supply (DCPS) and the high voltage unit (HV2) with suction air.
(2) ON timing
It turns ON a specified period of time after the drum motor (M1) turns ON.
While in the auto toner supply mode and the TCR adjustment mode, it turns ON in synch with the turn-ON
of M1.
While in the low power mode and the stand-by condition, it turns ON in synch with the turn-ON of the drum
cooling fan (FM4).
(3) OFF timing
While in the initial charging mode, the auto toner supply mode and the TCR adjustment mode, it turns OFF
in synch with the turn-OFF of the drum motor (M1).
In cases other than the above, it turns OFF a specified period of time after M1 turns OFF.
While in the low power mode and the stand-by condition, it turns OFF in synch with the turn-OFF of FM4.
B. Fusing cooling fan /Fr (FM2) and /Rr (FM8) control

(1) Purpose
While in the continuous print of small size paper (paper width: 200 mm or less), cool down both edges of
the fusing roller to suppress a temperature rise on the section of the fusing roller through which no paper
passes.
Suppress a temperature rise when printing large size paper (paper width: 201 mm or more).
Suppress a fusing overshoot caused by an emergency stop when a jam occurs.
(2) ON timing
While in the print of small size paper, they turn ON when the fusing exit sensor detects the first job paper .
While in the print of large size paper, they turn ON when the thermistor /2 (TH2) goes over the prescribed
temperature.
They turn ON when the print operation is stopped by a jam.
(3) OFF timing
While in the print of small size paper, they turn OFF in synch with the turn-OFF of the fusing motor (M11).
While in the print of large size paper, they turn OFF when TH2 detects a temperature lower than the prescribed temperature.
They turn OFF a specified period of time after it turns ON by a jam.
C. Exhaust fan /Fr (FM3) and /Rr (FM9) control

(1) Purpose
With exhaust air, cool down paper conveyed and remove heat around the reverse section in the machine.
(2) ON timing
They turn ON in synch with the turn-ON of the drum motor (M1).
(3) OFF timing
While in the initial charging mode and the TCR adjustment mode, they turn OFF in synch with the turn-OFF
of M1.
In cases other than the above, they turn OFF a specified period of time after the turn-OFF of M1.
97
23. OTHERS
D. Drum cooling fan (FM4) control
bizhub 500 / 420
(1) Purpose
Cool around the drum and the toner bottle with suction air.
(2) ON timing
After completion of the print, it turns ON a specified period of time after the drum motor (M1) turns OFF.
It turns ON when the machine inside temperature goes over the prescribed temperature.
(3) OFF timing
It turns OFF a specified period of time after it turns ON after completion of the print.
While it turns ON after completion of the print, it turns OFF the moment M1 turns ON.
It turns OFF when the machine inside temperature goes down below the prescribed temperature.
E. Conveyance suction fan (FM5) control

(1) Purpose
Exhaust by sucking air around the conveyance path between the drum and the fusing unit, and stabilize the
conveyability of paper and remove exhaust heat and ozone at the same time.
(2) ON timing
It turns ON in synch with the turn-ON of the drum motor (M1).
While in the low power mode and the stand-by condition, it turns ON in synch with the turn-ON of the drum
cooling fan (FM4).
(3) OFF timing
While in the initial charging and the TCR adjustment mode, it turns OFF in synch with the turn-OFF of M1.
In cases other than the above, it turns OFF a specified period of time after M1 turns OFF.
While in the low power mode and the stand-by condition, it turns OFF in synch with the turn-OFF of FM4.
F.
Developing suction fan (FM6) control
(1) Purpose
Suck air from the underside of the developing unit to prevent the splash of toner and exhaust air.
(2) ON timing
It turns ON in synch with the turn-ON of the developing motor (M3).
(3) OFF timing
98
It turns OFF a specified period of time after M3 turns OFF.
While in the TCR adjustment mode, it turns OFF in synch with the turn-OFF of M3.
23. OTHERS
G. Developing cooling fan (FM7)
bizhub 500 / 420
(1) Purpose
Take in fresh air to cool down the developing motor (M3).
(2) ON timing
After completion of the print, it turns ON a specified period of time after M3 turns OFF.
While in the auto toner supply mode, it turns ON in synch with the turn-ON of M3.
It turns ON when the machine inside temperature goes over the prescribed temperature.
(3) OFF timing
After completion of the print, it turns OFF a specified period of time after it turns ON.
While in the auto toner supply mode, it turns OFF in synch with the turn-OFF of M3.
It turns OFF when the machine temperature goes down below the prescribed temperature.
H. Overall control board cooling fan (FM10) control

(1) Purpose
Cool down the overall control board (OACB) with suction air.
(2) ON timing
It turns ON when the power switch (SW2) turns ON.
(3) OFF timing
It turns OFF when SW2 turns OFF.
99
23. OTHERS
bizhub 500 / 420
23.2 Counter control

23.2.1
Composition
CN35
CN36
OACB
PRCB CN30
OB
SDB CN64
36
CN939
CN936
TCT
KCT
LCDB
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[1]
100
Coin vendor /2

Operation
A. Paper exit counter

Item
Specifications/mechanism
Total counter (TCT)
Display accumulated number of prints in all print modes.
Electronic counter
Display accumulated number of prints on the touch
Counts up by a paper exit signal.

panel.
Data collection *1
Counts up by a paper exit signal.
Key counter (KCT), optional
Counting the designated number of prints allows no further copy operation (can be removed).
*1
For data collected, See "10.6 Counter" in Field service bizhub 500/420 Main body. (See P.178)
[2]
[1]
CN936 (KCT connecting connector)
[1]
[2]
50gat2c031na
Total counter (TCT)
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bizhub 500 / 420
23.2.2
23. OTHERS
23. OTHERS
bizhub 500 / 420
B. Coin vendor/2 (Parallel)

The following shows the specifications of the connecting connector.
Connector Pin No.
36
Signal name
M1 signal
Description
Output timing
Type of signal
Output from the start
L output while in the
Open collec-
key being turned ON
print operation
tor output
up to the completion of
paper exit
2
Paper feed signal
Output each time
L output each time
paper is supplied
paper is supplied from

each tray
Paper size signal (0)
Signal output by paper
When the paper size is
sizes *1
changed
Double sided print
Signal output while in
While in the selection
selection signal
the double sided print
of the double sided
CPF signal (0)
Signal output by CPF
While in the selection
CPF signal (1)
modes
of the CPF mode
10
P.GND
Ground
print
*1
Output signals by paper sizes

Size
102
Paper size signal

(3)
(2)
(1)
A3
(0)
L
B4
A4
A4S
B5
B5S
Special
11 x 17
81/2 x 14
81/2 x 11
81/2 x 11S
51/2 x 81/2 / A5
8 x 13, 81/8 x 131/4, 81/4 x 13, 81/2 x 13
23. OTHERS
23.3.1
bizhub 500 / 420
23.3 Parts that operate when the power switch is turned ON

Parts that operate when the main power switch (SW1) is turned ON
A. Composition
SW2
PSWB
SW1
OB
DCPS
5VDC
CBR
NF
DCPS
section
IC
12VDC
OACB
FK
HD
SC
24VDC
PC
LU
PRCB
50gat2c032na
B. Operation
Turning ON the main power switch (SW1) supplies an AC power source to DC power supply (DCPS).
In this way, each power source of 12V DC and 5V DC is supplied to the overall control board (OACB).
OACB supplies 5V DC to the operation board (OB) to be placed in the condition of standing by for the turn-ON
of the power switch (SW2).
When equipped optionally with the FAX kit (FK-502) and the hard disk (HD-505), each power source of 12V DC
and 5V DC is supplied through OACB.
103
23. OTHERS
Parts that operate when the power switch (SW2) is turned ON
A. Composition
SW2
PSWB
OB
SW1
CBR
RL1
OACB
NF
RL2
bizhub 500 / 420
23.3.2
DCPS
section
24VDC
L2, L3
AC drive
section
DCPS
50gat2c033na
B. Operation
Turning ON the power switch (SW2) transmits an ON signal of SW2 to the overall control board (OACB) through
the operation board (OB). In this way, OACB sends out a control signal to the DC power supply (DCPS) and
DCPS supplies each power source of 12V DC and 5V DC to all boards and optional devices, including the
printer control board (PRCB).
After that, OACB sends out to DCPS a control signal that generates a 24V DC power source, which is supplied
to all drive boards and optional devices. And when the main relay (RL1) and the sub relay (RL2) turn ON, an AC
power source is supplied to the fusing heater lamps /1 (L2) and /2 (L3) to start the initial operation of this
machine.
104
SERVICE MANUAL
Theory of Operation
DF-607
2006.02
Ver. 1.0
Revision history
Revision mark:
NOTE
2006/02
1.0
Date
Service manual Ver.
Revision mark

Theory of Operation Ver. 1.0 Feb. 2006
DF-607
CONTENTS
DF-607
1.
PRODUCT SPECIFICATIONS ................................................................................1
2.
PAPER PATH ...........................................................................................................4
2.1
In 1-sided mode ....................................................................................................4
2.2
In 2-sided mode ....................................................................................................4
OUTLINE
OUTLINE
3.
COMPOSITION .......................................................................................................5
4.
DRIVE......................................................................................................................6
5.
OPERATION............................................................................................................7
5.1
Document pick-up mechanism..............................................................................7
5.1.1
Pick-up operation ..........................................................................................7
5.2
Document feed/conveyance mechanism ..............................................................8
5.3
Raised/lowered position detecting mechanism...................................................12
5.3.1
DF 15 open/close detection mechanism....................................................12
5.3.2
DF open/close detection mechanism ..........................................................12
OUTLINE
DF-607
Blank Page
ii
OUTLINE
PRODUCT SPECIFICATIONS
DF-607
1.
A. Type
Reverse Automatic Document Feeder
Paper Feed
Paper Feed from top of stack
Type
Turnover
Switch back system
Paper Exit
Straight exit system
Installation
Screw cramp to the main unit
Document Alignment
Center
Document Loading
Left image side up
OUTLINE
Name
B. Functions
Modes
1-Sided Mode / 2-Sided Mode
C. Paper type
Standard Mode
Plain Paper
Type of Document
Mixed Original Detection

Mode
Plain Paper
FAX Mode
Plain Paper
1-Sided Mode
35 to 128 g/m2 (9.25 to 34 lbs)
2-Sided Mode
50 to 128 g/m2 (13.25 to 34 lbs)
1-Sided / 2-Sided Mode
50 to 128 g/m2 (13.25 to 34 lbs)
1-Sided Mode
35 to 128 g/m2 (9.25 to 34 lbs)
2-Sided Mode
50 to 128 g/m2 (13.25 to 34 lbs)
Inch area
A3, A4S, A4, B4, B5S, B5
Detectable Document
11 x 17, 81/2 x 14, 81/2 x 11S, 81/2 x 11, 81/2 x 51/2S, 81/2 x 51/2
Size*1
Metric area
A3, A4S, A4, A5S, A5, B4, B5S, B5, B6S
11 x 17, 81/2 x 11S, 81/2 x 11
Capacity
80 sheets (80 g/m2) or load height of 11 mm or less.
*1: For the Combined Original Detection Mode, Refer to the Mixed Original Detection Enabled
Size Combination Table.
DF-607
D. Paper feed prohibited originals

If fed, trouble occurrence will be highly possible.
Type of Original
Possible Trouble
Original that is stapled or clipped.
Feed failure, damage to the original, or drive failure

due to clip clogging
Book original
Original weighing less than 35g/m2 or 128g/m2

Feed failure
or more
OUTLINE
Torn original
Feed failure, damaged sheet
Highly curled original (15 mm or more)
Original misfeed due to dog-ear or skew
OHP transparencies
Feed failure
Label Sheet
Feed failure
Offset master
Feed failure
Sheets clipped or notched
Damaged sheet
Sheets patched
Patched part folded or torn sheet
E. Paper feed not guaranteed originals

If fed, paper feed will be possible to some extent but trouble occurrence will be possible.
Type of Original
Sheets lightly curled
(Curled amount: 10 - 15 mm)
Possible Trouble
Dog-eared, exit failure
Heat Sensitive Paper
Edge folded, exit failure, conveyance failure
Coated Paper (Ink Jet Paper)
Take-up failure, conveyance failure
Translucent paper
Paper immediately after paper exit from the

main unit
Paper with many punched holes (e.g., loose

Multi-page feed due to flashes from holes
leaf) limited to vertical feeding
Sheets with 2 to 4 holes
Conveyance failure
Sheets two-folded or Z-folded

(amount of non-flatness: 15 mm or less)
Take-up failure, conveyance failure, image deformation
Sheets folded
Image deformation, multi-page feed, take-up failure
DF-607
F. Mixed original feed chart

For Metric
Other
originals
A4
B4S
B5
A4S
A5
B5S
A5
A3
A4
B4S
B5
A4S
A5
B5S
A5S
OUTLINE
Reference original (original with a maximum width)

A3
U: Same size {: Same group ~: Different group X: Mix prohibited : No need to set
For Inch
11 x 17
Other
originals
81/2 x 11
81/2 x 14
81/2 x 11S
51/2 x 81/2
51/2 x 81/2 S
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
G. Maintenance
Maintenance
Same as the main body.
H. Machine data
Power Requirements
24V DC 10% (supplied from the main body)
Max. Power
Consumption
48 W or less
Dimensions
582 (W) x 558 (D) x 145 mm (H)
Weight
Approx. 10 kg
I.
Temperature
10 to 30C
Humidity
10 to 80% RH (with no condensation)
NOTE
These specifications are subject to change without notice.
2. PAPER PATH
2.
OUTLINE
DF-607
2.1
PAPER PATH
In 1-sided mode
[3]
[2]
[1]
[1] Exit
16eat1c001na
[3] Feed (Scanning the 1st side)
[2] Conveyance and turnover
2.2
In 2-sided mode
[3]
[2]
[1]
16eat1c002na
[1] Exit
[2] Conveyance and switchback
[3] Feed (Scanning the 1st side)

Conveyance and turnover (Scanning the 2nd
side)
Conveyance
3. COMPOSITION
COMPOSITION
DF-607
3.
Conveyance section
Switchback section
Document exit section
Document feed section
16eat2c001na
4. DRIVE
DRIVE
DF-607
4.
[1]
[2]
16eat2c002na
[1] Original Feed Motor (M1)
[2] Original Conveyance Motor (M2)
5.1
OPERATION
Document pick-up mechanism
The Document Pick-Up Section consists of the Pick-Up Rollers, Feed Roller and Separation
Roller, and this section is driven by the Original Feed Motor (M1).
5.1.1
DF-607
5.
5. OPERATION
Pick-up operation
When the Start key is pressed, the Original Feed Motor (M1) [3] starts rotating backward,
causing the Pick-Up Roller [4] to lower and start rotating at the same time. At the same time,
the Feed Roller [2] starts rotating.
The Pick-Up Rollers are in the raised position when in the standby state and in the lowered
position during feeding.
[3]
[4]
[2]
[1]
[1] Separation Roller
[2] Feed Roller
[4] Pick-Up Roller
16eat2c003na
5. OPERATION
5.2
Document feed/conveyance mechanism
DF-607
When the original reaches the Registration Sensor, the Original Feed Motor (M1) [5] starts
rotating forward and, at the same time that the Pickup Roller goes up, drive is then supplied
to the Registration Roller [3].
When the Original Conveyance Motor (M2) [4] starts rotating forward, the two Conveyance
Rollers [2] and the Exit/Turnover Roller [1] feed the document toward the exit direction.
Parts
Backward
rotation
M1
Forward
rotation
M2
Direction of
Rotation
Details
The Pickup Rollers lower and start rotating and the Feed
Roller rotates.
The Registration Roller rotates.
Backward
rotation
The Conveyance Roller and Exit/Turnover Roller rotate in

the direction to turn over the original.
Forward
rotation
The Conveyance Roller and Exit/Turnover Roller rotate in

the direction to feed the original out.
[5]
[1]
[4]
[3]
[2]
16eat2c004na
[1] Exit/Turnover Roller
[4] Original Conveyance Motor (M2)
[2] Conveyance Roller
[3] Registration Roller
5. OPERATION
A. Operation flow in the 1-sided mode

DF-607
[4]
[1]
[2]
16eat2c005na
[1] Exit
[3] Scanning the 1st side
[2] Original Exit Sensor (PS10)
[4] Original Detection Sensor (PS8)
1. When the Start key is pressed, the Original Feed Motor (M1) starts rotating backward,
causing the Pick-Up Roller to lower and start a paper take-up sequence.
2. A specified period of time after the leading edge of the original turns ON PS8 [4], the
scanning of the 1st side of the original starts.
3. The original is conveyed for a given period of time after the trailing edge of the last
page of the document has deactivated the PS10 [2]. It is then fed into [1] the Exit Tray
and the Original Conveyance Motor (M2) is deenergized.
[3]
DF-607
5. OPERATION
B. Operation flow in the 2-sided mode

1. When the Start key is pressed, the Original Feed Motor (M1) starts turning backward,
causing the Pick-Up Roller to lower and start feeding the 1st page of the document.
A specified period of time after the leading edge of the original turns ON the Original
Detection Sensor (PS8) [4], the scanning of the 1st side of the original starts.
The Original Conveyance Motor (M2) is deenergized to stop [1] the original after the
lapse of a given period of time after the trailing edge of the 1st page has deactivated
the Original Exit Sensor (PS10) [2].
[4]
[1]
[3]
[2]
16eat2c006na
[1] Stop
[3] Scanning the 1st side
[2] Original Exit Sensor (PS10)
[4] Original Detection Sensor (PS8)
2. M2 is turned backward to turn over [3] the original. After the Registration Roller, M2 is
turned forward to allow the Scanner to scan the backside of the 1st page.
3. After the conveyance sequence for turnover has been started, the Pressure Roller
Release Solenoid (SD1) is energized so that the Exit/Turnover Roller is retracted.
[3]
[1]
[2]
[1] Stop
[2] Scanning the 2nd side
10
16eat2c007na
[3] Turnover
5. OPERATION
DF-607
4. To ensure that pages of the document are in the proper order, the page is turned over
[3] again before being ejected [1] into the Exit Tray.
[3]
[1]
[2]
[1] Exit
16eat2c008na
[3] Turnover
[2] Scanning the 2nd side
11
5. OPERATION
DF-607
5.3
5.3.1
Raised/lowered position detecting mechanism

DF 15 open/close detection mechanism
When DF is closed down to about 15 or less, the Original Cover Angle Detection Lever of
the main body is pressed down to turn ON the APS Timing Sensor (PS31).
5.3.2
DF open/close detection mechanism
A magnet is provided so that the open/close of DF can be detected on the main body side.
When DF is closed, the DF Open/Close Switch (SW3) of the main body is turned ON by the
magnet.
[1]
16eat2c009na
[1] DF Open/Close Switch (SW3)
12
SERVICE MANUAL
Theory of Operation
PC-202
(
500 / 420)
2006.02
Ver. 1.0
Revision history
Revision mark:
NOTE
2006/02
1.0
Date
Service manual Ver.
Revision mark

PC-202
CONTENTS
PC-202
1.
2.
PAPER PATH ...........................................................................................................2

OUTLINE
OUTLINE
3.
COMPOSITION .......................................................................................................3
4.
DRIVE......................................................................................................................4
5.
OPERATIONS .........................................................................................................5
Paper Feed Section ..............................................................................................5
5.1.1
Paper feed mechanism..................................................................................5
5.1.2
Paper lifting motion........................................................................................6
5.2
5.1
Tray Section ..........................................................................................................7
5.2.1
Paper size detection ......................................................................................7
5.2.2
Paper level indicator mechanism...................................................................8
OUTLINE
PC-202
Blank Page
ii
OUTLINE
PC-202
1.
Name
2 way Paper Take-Up Cabinet
Type
Front loading type 2 way paper take-up device
Installation
Desk type
Document Alignment
Center
OUTLINE
A. Type
B. Paper type
56 to 90 g/m2
Paper Type
Plain paper
Paper Size
Metric: A3, B4, A4, A4S, B5, A5S, 11 17, 81/2 11, 81/2 11S, Foolscap
Inch: 11 17, 81/2 14, 81/2 11, 81/2 11S, 51/2 81/2S, A3, A4, A4S, Foolscap
Tray 3
550 sheets (80 g/m2)
Tray 4
Capacity
C. Maintenance
Maintenance
D. Machine specifications
Power Requirements
24V DC 10 %, 5V DC 5 % (supplied from the main body)
Power Consumption
15 W or less
Dimensions
570 mm (W) 548 mm (D) 263 mm (H)
Weight
Approx. 26.0 kg
E. Operating environment
Temperature
Humidity
NOTE
2. PAPER PATH
PAPER PATH
PC-202
2.
[4]
[1]
OUTLINE
[2]
[3]
4061t1c001na
[1] Convey to the main body
[3] Tray 4 paper feed
[2] Vertical conveyance through PC
[4] Tray 3 paper feed
3. COMPOSITION
PC-202
COMPOSITION
Tray 3
Paper Feed
Section
Tray 4
3.
4061t2c001na
4. DRIVE
DRIVE
PC-202
4.
[4]
[1]
[3]
[2]
4061t2c002na
[1] Vertical Conveyance Motor /3 (M120)
[3] Vertical Conveyance Motor /4 (M121)
[2] Paper Feed Motor /4 (M123)
[4] Paper Feed Motor /3 (M122)
5.1
OPERATIONS
Paper Feed Section
5.1.1
PC-202
5.
5. OPERATIONS
Paper feed mechanism
The Paper Feed Motor (M122, M123) drives the Pick-up Roller [8] and Feed Roller [6] to
take up and feed a sheet of paper into the main body.
Then, the Vertical Conveyance Motor /3, /4 (M120, M121) transports the paper through the
vertical conveyance section.
The Pick-up Roller takes up sheet of paper and the Feed Roller and Separation Roller [5]
ensure that only one sheet of paper is separated and fed into the main body.
When the Tray is slid in, the lever [7] is pushed to lower the Pick-up Roller.
The Upper Limit Sensor /3, /4 (PS114, PS123) [9] then detects the upper limit position when
the paper lifting plate is raised.
The Paper Empty Sensor /3, /4 (PS115, PS124) [1] detects when paper in the Tray runs out.
[8]
[9]
[7]
[6]
[5]
[2]
[4]
[3]
[1]
4061t2c003na
[1] Paper Empty Sensor /3, /4 (PS115, PS124)
[6] Feed Roller
[2] Actuator
[7] Lever
[3] Pick-up Roller Feed Position
[8] Pick-up Roller
[4] Pick-up Roller Home Position
[9] Upper Limit Sensor /3, /4 (PS114, PS123)
5. OPERATIONS
5.1.2
Paper lifting motion
PC-202
When the Tray is slid into the main body and the Tray Set Sensor /3, /4 (PS112, PS121) is
activated, the Paper Lift Motor /3, /4 (M124, M125) starts rotating to raise the Lifting Plate
[3].
The paper stack of the Tray pushes up the Pick-up Roller [1]. When the upper limit position
is detected by the Upper Limit Sensor /3, /4 (PS114, PS123) [4], it stops raising the lifting
plate.
As paper is consumed during the print cycle and the Pick-up Roller is lowered, M124, M125
is energized until PS114, PS123 is blocked again.
A. When the Tray is slid in
1. The lifting plate [3] goes up and the top surface of the paper stack pushes up the roller
[1].
2. The lifting motion stops as soon as the Upper Limit Sensor /3, /4 (PS114, PS123)
detects the upper limit position.
[1]
[4]
[3]
[2]
4061t2c004na
[1] Pick-up Roller
[3] Lifting Plate
[2] Lift-up Arm
B. During a print cycle

1. As the paper is consumed, the Upper Limit Sensor /3, /4 (PS114, PS123) [1] is
unblocked.
2. The lifting plate goes up.
[1]
4061t2c005na
5.2.1
Tray Section
Paper size detection
Moving the Sub Scan Direction Restriction Plate of the Tray rotates the Circular Plate [1]
provided on the bottom of the Tray.
The length of paper in the sub scan direction is detected by the Paper Size Detection Switch
[8] provided on the Paper Size Detect Boards /3 and /4 (PSDB3, PSDB49) [7] that is driven
by the Lever interlocked with the Circular Plate.
The detection of the length of paper in the main scan direction is made by detecting a notch
on the Lever of the Main Scan Direction Restriction Plate by the Paper Size Sensors /Rr3,
/Fr3 (PS118, PS119) [2] or /Rr4, /Fr4 (PS127, PS128) [3].
The paper size is determined by the combination of the 4 Paper Size Detection Switches
and the 2 Paper Size Sensors.
The setting of the Tray is detected by the Tray Set Sensors /3, /4 (PS112, PS121) [6].
PC-202
5.2
5. OPERATIONS
[9]
[7]
[5]
[8]
[1]
[6]
[4]
[3]
[2]
4061t2c006na
[1] Circular Plate
[6] Tray Set Sensor /3, /4 (PS112, PS121)
[2] Paper Size Sensor /Rr3, /Rr4 (PS118,

PS127)
[7] Paper Size Detect Board /3, /4 (PSDB3,

PSDB4)
[3] Paper Size Sensor /Fr3, /Fr4 (PS119, PS128)
[8] Paper Size Detection Switch
[4] Paper Lift Motor /3, /4 (M124, M125)
[9] Sub scan direction size detection
[5] Main scan direction size detection
5. OPERATIONS
5.2.2
Paper level indicator mechanism
PC-202
All Trays are universal paper size tray.

There is a window in the front cover of the Tray that serves as the Paper Level Indicator [3]
showing the amount of paper that is still available for use.
A red lever [1] is attached to the bottom plate [5] of the Tray and as the lifting plate [4] raises,
the red lever becomes visible in the window.
The more the red lever is visible, the lesser the amount of paper will be available for use.
[5]
[4]
[3]
[1]
[2]
4061t2c007na
[1] Lever
[4] Lifting Plate
[2] Operated by the Lifting Plate
[5] Tray Bottom Plate
[3] Paper Level Indicator
SERVICE MANUAL
Theory of Operation
PC-402
(
500 / 420)
2006.02
Ver. 1.0
Revision history
Revision mark:
NOTE
2006/02
1.0
Date
Service manual Ver.
Revision mark

PC-402
CONTENTS
PC-402
1.
PRODUCT SPECIFICATION...................................................................................1
2.
PAPER PATH ...........................................................................................................2

OUTLINE
OUTLINE
3.
COMPOSITION .......................................................................................................3
4.
DRIVE......................................................................................................................4
5.
OPERATIONS .........................................................................................................5
Paper Feed Section ..............................................................................................5
5.1.1
5.2
5.1
Paper feed mechanism..................................................................................5
Tray Section ..........................................................................................................6
5.2.1
Up/down mechanism.....................................................................................6
5.2.2
Shift Gate drive mechanism ..........................................................................7
5.2.3
Shifter drive mechanism................................................................................8
5.2.4
Paper empty detection ..................................................................................9
OUTLINE
PC-402
Blank Page
ii
1. PRODUCT SPECIFICATION
OUTLINE
PRODUCT SPECIFICATION
PC-402
1.
Name
2500 sheets paper feed cabinet
Type
Front loading type LCC
Installation
Desk type
Document Alignment
Center
OUTLINE
A. Type
B. Paper type
Paper Type
Plain paper
Paper Size
Metric: A4
Inch: 81/2 11
Capacity
2500 sheets (80 g/m2)
56 to 90 g/m2
C. Maintenance
Maintenance
Power Requirements
Power Consumption
45 W or less
Dimensions
570 mm (W) 548 mm (D) 263 mm (H)
Weight
Approx. 26.0 kg
Temperature
Humidity
NOTE
2. PAPER PATH
PAPER PATH
PC-402
2.
OUTLINE
[1]
[2]
[5]
[4]
[3]
4061t1c201na
[1] Convey to the main body
[4] From the Sub Tray to Main Tray
[2] Tray paper feed
[5] Sub Tray
[3] Main Tray
3. COMPOSITION
PC-402
COMPOSITION
Tray Section
Sub Tray
Paper Feed Section
3.
Main Tray
4061t2c201na
4. DRIVE
DRIVE
PC-402
4.
[7]
[8]
[9]
[10]
[1]
[2]
[6]
[3]
[5]
[4]
4061t2c202na
[1] Paper Lift Motor (M5)
[6] Shift Gate Drive Section
[2] Paper Lift Drive Section
[7] Tray Lock Solenoid (SD1)
[3] Shifter Drive Section
[8] Paper Feed Motor (M1)
[4] Shift Motor (M4)
[9] Vertical Conveyance Motor (M2)
[5] Shift Gate Motor (M3)
[10] Vertical Conveyance Drive Section
OPERATIONS
5.1
Paper Feed Section
5.1.1
PC-402
5.
5. OPERATIONS
Paper feed mechanism
The Paper Feed Motor (M1) drives the Pick-up Roller [8] and Feed Roller [6] to take up and
feed a sheet of paper into the main body.
Then, the Vertical Conveyance Motor (M2) transports the paper through the vertical conveyance section.
The Pick-up Roller takes up sheet of paper and the Feed and Separation Rollers [5] ensure
that only one sheet of paper is separated and fed into the main body.
When the Tray is slid in, the lever [7] is pushed to lower the Pick-up Roller.
The Upper Limit Sensor (PS4) [9] then detects the upper limit position when the paper lifting
plate is raised.
The Paper Empty Sensor (PS3) [1] detects when paper in the Main Tray runs out.
[8]
[9]
[7]
[6]
[5]
[2]
[1]
[4]
[3]
4061t2c203na
[1] Paper Empty Sensor (PS3)
[6] Feed Roller
[2] Actuator
[7] Lever
[3] Pick-up Roller Feed Position
[8] Pick-up Roller
[4] Pick-up Roller Home Position
[9] Upper limit Sensor (PS4)
5. OPERATIONS
5.2
PC-402
5.2.1
Tray Section
Up/down mechanism
The Main Tray [3] is suspended by the cables [1] at the front and rear.
As the Paper Lift Motor (M5) [5] turns forward or backward, the cables are wound to raise or
lower the Main Tray.
The Lower Limit Sensor (PS13) [2] detects the Main Tray at its lower limit position.
[1]
[2]
[5]
[3]
[4]
4061t2c204na
[1] Cables
[4] Sub Tray
[2] Lower Limit Sensor (PS13)
[5] Paper Lift Motor (M5)
[3] Main Tray

Shift Gate drive mechanism
If the Main Tray runs out of paper, while the Sub Tray is loaded with paper, the paper stack
on the Sub Tray is moved to the Main Tray [2].
At this time, the Shift Gate Motor (M3) [4] is energized to retract the front and rear Shift
Gates [1].
PC-402
5.2.2
5. OPERATIONS
[1]
[4]
[3]
[1]
[1] Shift Gate move to outside
[3] Shifter
[2] Shifter move
[4] Shift Gate Motor (M3)
[2]
4061t2c205na
5. OPERATIONS
5.2.3
Shifter drive mechanism
PC-402
After completion of the evacuation of the Shift Gate, starts the movement of the Shifter [2].
The movement of paper from the Sub Tray to the Main Tray is made by the Shifter that is
driven by the Shift Motor (M4) [1].
The stopping of the movement of the Shifter to the Main Tray side is made by the Shift Position Sensor (PS11) [4].
The movement to the home position starts when the Tray Release Key is pressed.
The stopping of the movement of the Shifter to the home position is made by the Shift Home
Sensor (PS12) [3].
[3]
[2]
[2]
[4]
[1]
[1]
[1] Shift Motor (M4)
[3] Shift Home Sensor (PS12)
[2] Shifter
[4] Shift Position Sensor (PS11)
4061t2c206na

5.2.4
5. OPERATIONS
Paper empty detection
[1]
[3]
[2]
[1] Main Tray
[3] Sub Tray Empty Sensor (PS9)
[2] Main Tray Empty Board (MEB)
[4] Sub Tray
[4]
PC-402
Paper empty detection of Main Tray is performed by Main Tray Empty Board (MEB) [2].
Paper empty detection of Sub Tray is performed by Sub Tray Empty Sensor (PS9) [3].
4061t2c207na
PC-402
5. OPERATIONS
Blank Page
10
SERVICE MANUAL
Theory of Operation
LU-201
2006.02
Ver. 1.0
Revision history
After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance.
Revision mark:
To indicate clearly a section revised, show 1 in the lower outside section of the corresponding
page.
NOTE
2006/02
1.0
Date
Service manual Ver.
Revision mark

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

D. Maintenance
Maintenance
Same as the main body
E. Machine data
Power source
24/5V DC (supplied from the main body)
Power consumption
30 W or less (internal heater is not used)
Dimensions
424 (W) x 515 (D) x 295 (H) mm
Weight
Approx. 16 kg
F.
Temperature
Humidity
Note
2. PAPER PATH
LU-201
2. PAPER PATH
[3]
[4]
[5]
[1]
[2]
16aat1c001na
[1]
Lift plate
[4]
Feed roller
[2]
Separation roller
[5]
Pick-up roller
[3]
Conveyance roller
3. COMPOSITION
LU-201
3. COMPOSITION
Paper feed section
Tray section
16aat2c001na
4. PAPER FEED SECTION

LU-201
4.1
4.1.1
Drive
Paper feed drive
A. Front side drive
[3]
[4]
[1]
[2]
16aat2c002na
[1]
Pick-up solenoid (SD151)
[3]
Feed roller
[2]
Conveyance roller
[4]
Pick-up roller
B. Rear side drive
[3]
[2]
[1]
16aat2c007na
[1]
Feed motor (M150)
[2]
Conveyance roller
[3]
Feed clutch (CL151)
4.2.1
Operation
Paper feed control
LU-201
4.2
A. Pick-up mechanism
(1) Drive transmission
The driving force of the feed motor (M150) is transmitted to the paper feed gear /3 [4] through various gears. The
paper feed gear /3 is connected with the pick-up solenoid (SD151) [1] through the claw [2]. When SD151 is
turned OFF, the coupling between the paper feed gear /3 and the paper feed coupling gear /B [3] provided on
the front stage is disengaged and the paper feed gear /3 does not rotate. When SD151 turns ON, the claw is
released to engage the paper feed gear /3 to the paper feed coupling gear /B. In this way, the paper feed gear /
3 rotates and the driving force is transmitted to the paper feed roller unit [6] through the paper feed gear [5] to
pick up paper.
[3]
[4]
[2]
[5]
[6]
[1]
16aat2c003na
[1]
[4]
Paper feed gear /3
[2]
Claw
[5]
Paper feed gear
[3]
Paper feed coupling gear /B
[6]
Paper feed roller unit
(2) Paper feed roller unit up/down mechanism

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

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

4.2.2
Remaining paper detection control
LU rotates in interlock with the up/down operation of the lift plate. The actuator is provided with the remaining
paper sensors /1 (PS154) [3] and /2 (PS151) [2] and the remaining paper is detected by the combination of the
ON/OFF of these sensors. And the no paper detection in the tray is made by the paper empty sensor (PS153)
[5].
Remaining paper quantity
PS151
Full quantity
OFF
PS154
ON
Medium quantity
ON
ON
Small quantity
ON
OFF
[5]
[4]
[3]
[1]
[2]
16aat2c005na
[1]
Actuator
[4]
Direction of rotation when the tray goes up
[2]
Remaining paper sensor /2 (PS151)
[5]
Paper empty sensor (PS153)
[3]
LU-201
As paper in the tray gets reduced, the lift plate goes up gradually. The actuator [1] provided on the rear side of
5. TRAY SECTION
5. TRAY SECTION
LU-201
5.1
5.1.1
Drive
Tray lift drive
[8]
[1]
[2]
[7]
[3]
[4]
[6]
[5]
16aat2c006na
[1]
Actuator
[5]
Lift plate
[2]
Wire
[6]
Wire
[3]
Coupling
[7]
Spring
[4]
Parallel pin
[8]
Paper lift motor (M151)
5.2.1
Operation
Tray lift control
When the upper door is closed, a parallel pin for the up drive of the lift plate is pushed out to be coupled to the
coupling of the paper lift motor (M151). Closing the upper door also turn ON the upper door interlock switch
(MS151) to supply a 24V DC to the load of the drive system. In this way, M151 turns ON to bring up the lift plate.
When the lift plate goes up and the upper limit sensor (PS152) detects the upper surface of paper, M151 turns
OFF to stop the up drive of the lift plate. When PS152 turns OFF by the paper feed operation, M151 turns ON
again to keep on bringing up the lift plate until PS152 turns ON.
When the upper door is opened, the wire is pulled to release the coupling for the up drive of the lift plate. In this
way, the lift plate goes down up to the position in which a balance is kept between the weight of paper and the
spring tension.
[4]
[1]
[3]
[2]
16aat2c008na
[1]
Feed roller
[3]
Pick-up roller
[2]
Lift plate
[4]
Upper limit sensor (PS152)
LU-201
5.2
5. TRAY SECTION
LU-201
5. TRAY SECTION
Blank page
10
SERVICE MANUAL
Theory of Operation
FS-510/PU-501/
OT-601
2006.02
Ver. 1.0
Revision history
Revision mark:
NOTE
2006/02
1.0
Date
Service manual Ver.
Revision mark

FS-510/PU-501/OT-601
CONTENTS
FS-510/PU-501/OT-601
OUTLINE
1.1
FS-510 ..................................................................................................................1
1.2
PU-501..................................................................................................................3
1.3
OT-601 ..................................................................................................................4
PAPER PATH ...........................................................................................................5
2.1
Exiting Paper to the Tray /1 ...................................................................................5
2.2
Exiting Paper to the Tray /2 ...................................................................................6
2.3
Exiting Paper to OT...............................................................................................7

2.
OUTLINE
1.
3.
COMPOSITION .......................................................................................................9
4.
DRIVE....................................................................................................................10
4.1
4.2
5.
FS-510 ................................................................................................................10
PU-501................................................................................................................11
OPERATIONS .......................................................................................................12
5.1
Conveyance Section ...........................................................................................12
5.1.1
Entrance/Conveyance section .....................................................................13
5.1.2
Intermediate Conveyance Section...............................................................14
5.1.3
Exit Conveyance Section.............................................................................15
5.2
Up/down Section.................................................................................................16
5.2.1
Up/down mechanism...................................................................................16
5.2.2
Tray Up/Down operation ..............................................................................17
5.2.3
Tray Upper Limit Position Detection Mechanism .........................................18
5.2.4
Shutter Open/Close Mechanism .................................................................21
5.3
Stacker section....................................................................................................22
5.3.1
Paper aligning mechanism (sub scan direction)..........................................22
5.3.2
Paper aligning mechanism (main scan direction)........................................23
5.3.3
Exit mechanism ...........................................................................................25
5.4
Stapling ...............................................................................................................27
5.4.1
Stapling mechanism ....................................................................................27
5.4.2
Stapling Unit moving mechanism ................................................................28
5.4.3
Stapling Position..........................................................................................28
5.4.4
Staple empty detection................................................................................29
FS-510/PU-501/OT-601

6.
PU-501.................................................................................................................. 30
6.1
Composition ....................................................................................................... 30
6.2
Operation............................................................................................................ 30
6.2.1
Registration mechanism ............................................................................. 30
6.2.2
Punch mechanism ...................................................................................... 31
6.2.3
Punch status detection ............................................................................... 31
6.2.4
Punch Scraps Box full detection mechanism.............................................. 32
OUTLINE
7.
OT-601 .................................................................................................................. 33
7.1
Composition ....................................................................................................... 33
7.2
Operation............................................................................................................ 33
7.2.1
ii
Overview..................................................................................................... 33
1.
FS-510/PU-501/OT-601
OUTLINE
1.1
FS-510
A. Type
Multi tray finisher built into the main body
Installation
Installed in the main body
Document Alignment
Center
Consumables
Staples (5,000 staples/cartridge)
OUTLINE
Name
B. Functions
Modes
Non sort, sort, group, sort staple, and punch (when PU-501 is mounted)
C. Paper type
(1) Non sort
Type
Size
Weight
Max. Capacity
Tray /1
Plain paper
Metric:
A3, B4, A4, A4S, B5,
B5S, A5, A5S, B6S
11 x 17, 81/2 x 11,
Translucent paper
Envelope
Label
Tray /2
B4, 81/2 x 14
or greater
500
sheets
91 to 210 g/m2
Thick paper
OHP transparencies
50 to 90 g/m2
200 sheets
A4S, 81/2 x 11S 1000
or less
sheets
Inch:
11 x 17, 81/2 x 14,
81/2 x 11, 81/2 x 11S,
51/2 x 81/2S
A3, A4, A4S, A5S,
Foolscap
Letterhead
20 sheets
(2) Sort/Group
Type
Size
Weight
Metric:
A3, B4, A4, A4S, B5,
B5S, A5
11 x 17, 81/2 x 11,
Plain paper
Inch:
11 x 17, 81/2 x 14,
81/2 x 11, 81/2 x 11S,
51/2 x 81/2S
A3, A4, A4S, A5S,
Foolscap
Max. Capacity
Tray /1
200 sheets
A4S, 81/2 x 11S 1000

or less
sheets
50 to 90 g/m2
Tray /2
B4, 81/2 x 14
or greater
500
sheets
FS-510/PU-501/OT-601
(3) Sort Staple

Type
Size
Weight
Inch:
11 x 17, 81/2 x 14,
81/2 x 11, 81/2 x 11S,
51/2 x 81/2S
A3, A4, A4S, A5S,
Foolscap
OUTLINE
200 sheets
A4S, 81/2 x 11S 1000

or less
sheets
50 to 90 g/m2
Plain paper
Max. Capacity
Tray /1
Metric:
A3, B4, A4, A4S, B5,
B5S, A5, A5S, B6S
11 x 17, 81/2 x 14,
81/2 x 11, 81/2 x 11S,
Foolscap
Tray /2
B4, 81/2 x 14
or greater
500
sheets
D. Stapling
Staple Filling Mode
Dedicated Staple Cartridge (5000 staples)
Staple Detection
Available (Nearly Empty: 20 remaining staples)

Front: Diagonal 45 1 point *1 A3, B4, A4, B5
Rear: Diagonal 45 1 point *1 11 x 17, 81/2 x 11
Stapling Position
Front: Parallel 1 point

Rear: Parallel 1 point
Side: Parallel 2 point
A4S, B5S, A5
81/2 x 14, 81/2 x 11S, 51/2 x 81/2S
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 81/2S
*1: Diagonal 30 for B5 and B4

E. Maintenance
Maintenance
F. Machine specifications
Power Requirements
Power Consumption
66 W or less
Dimensions
319 (W) x 558 (D) x 573 mm (H)
Weight
Approx. 21.4 kg
G. Operating environment
Temperature
Humidity
1.2
FS-510/PU-501/OT-601
PU-501
A. Type
Type
Installation
FS built-in type punching operation device

Screwed to the FS
Paper Size
Inch:
2 holes: 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S
3 holes: 11 x 17, 81/2 x 11
A3, A4
Paper Type
Plain Paper (60 to 130 g/m2), Recycled Paper (60 to 130 g/m2)
Punch Hole
Metric: 4 holes, Swedish 4 holes ( 6.5 mm)

Inch: 2 and 3 holes (can be switched) ( 8 mm)
Number of Stored
Punch Wastes
Metric (4 holes): For 1,500 sheets of paper (80 g/m2)

Inch (2, 3 holes): For 1,000 sheets of paper (20 lbs)
Document Alignment
Center
OUTLINE
Metric:
A3, B4, A4, A4S, B5, B5S
11 x 17, 81/2 x 11, 81/2 x 11S, Foolscap
B. Maintenance
Maintenance
C. Machine specifications
Power Requirements
24/5V DC (Supplied from FS)
Dimensions
114 (W) x 461 (D) x 136 mm (H)
Weight
Approx. 1.9 kg
D. Operating environment
Temperature
Humidity
FS-510/PU-501/OT-601
1.3
OT-601
A. Type
Type
Additional Tray to FS
Installation
Screwed to the FS
Mode
Non sort, sort, group, and sort staple
Number of Bins
1 bin
Document Alignment
Center
OUTLINE
B. Paper Type
Mode
Size
Metric:
A3, B4, A4, A4S, B5,
B5S, A5, A5S, B6S
11 x 17, 81/2 x 11,
Non sort
Inch:
11 x 17, 81/2 x 14,
81/2 x 11, 81/2 x 11S,
51/2 x 81/2S
A3, A4, A4S, A5S,
Foolscap
Sort / group
Metric:
A3, B4, A4, A4S, B5,
B5S, A5
11 x 17, 81/2 x 11,
Sort staple
Inch:
11 x 17, 81/2 x 14,
81/2 x 11, 81/2 x 11S,
51/2 x 81/2S
A3, A4, A4S, A5S,
Foolscap
Type
Plain Paper, Recycled Paper
(56 to 90 g/m2,15 to 24 lb)
Capacity
200 sheets
OHP transparencies
Thick paper
(91 to 210 g/m2)
Special
Envelope
20 sheets
Label paper
Letterhead
Translucent paper
200 sheets
Plain Paper, Recycled paper
(56 to 90 g/m2)
200 sheets or 20 copies
C. Maintenance
Maintenance
Dimensions
282 (W) x 368 (D) x 57 mm (H)
Weight
Approx. 0.7 kg
Temperature
Humidity
NOTE
2.
2.1
2. PAPER PATH
FS-510/PU-501/OT-601
PAPER PATH
Exiting Paper to the Tray /1
[2]
[1]
OUTLINE
[3]
4349t1c001na
[1] From the main body
[3] Exiting paper to the Tray /1
[2] Convey to the Tray /1
FS-510/PU-501/OT-601
2. PAPER PATH
OUTLINE
2.2
Exiting Paper to the Tray /2
[2]
[1]
[3]
4349t1c002na

[2] Convey to the Tray /2
[3] Exiting paper to the Tray /2
2.3
2. PAPER PATH
FS-510/PU-501/OT-601
Exiting Paper to OT
[2]
[1]
OUTLINE
[3]
4349t1c003na
[3] Exiting paper to OT
[2] Convey to OT
OUTLINE
FS-510/PU-501/OT-601
2. PAPER PATH
Blank Page
3. COMPOSITION
COMPOSITION
Up/down Section
PU
Conveyance Section
OT
3.
FS-510/PU-501/OT-601
Staple Section
4349t2c001na
4.
4.1
DRIVE
FS-510
[5]
[6]
[4]
[7]
FS-510/PU-501/OT-601
4. DRIVE
[1]
[3]
[2]
4349t2c002na
[1] Stapler Drive Section
[5] Paper Exit Opening Drive Section
[2] Exit Drive Section
[6] Conveyance/Alignment Drive Section
[3] Up/down Drive Section
[7] Entrance Drive Section
[4] Shutter Drive Section
10
PU-501
4.2
4. DRIVE
FS-510/PU-501/OT-601
[1]
4512t2c001na
[1] Punch Drive Section
11
FS-510/PU-501/OT-601
5. OPERATIONS
5.
5.1
OPERATIONS
Conveyance Section
The Conveyance Section is divided into the entrance conveyance section [3], intermediate
conveyance section [1], and the exit conveyance section [2]. It controls to convey the paper
fed from the main body, stop the paper at the punching and folding positions, and drive the
paper for feeding into the exit section.
[3]
[1]
[2]
4349t2c003na
[1] Intermediate Conveyance Section

[2] Exit Conveyance Section
12
[3] Entrance Conveyance Section
5.1.1
5. OPERATIONS
Entrance/Conveyance section
A paper [5] fed from the main body is conveyed to the intermediate conveyance section.
The Entrance Motor (M3) [3] provides the drive for conveying a paper.
When the M3 is energized, the Entrance Roller [1] and Registration Roller [2] are driven to
rotate.
The Entrance Sensor (PS4) [4] detects a paper in the conveyance section.
FS-510/PU-501/OT-601
[4]
[5]
[1]
[2]
4349t2c004na
[1] Entrance Roller
[4] Entrance sensor (PS4)
[5] Paper
[3] Entrance motor (M3)
13
[3]
FS-510/PU-501/OT-601
5. OPERATIONS
5.1.2
Intermediate Conveyance Section
A paper conveyed from the entrance conveyance section is brought to a stop at the punching and folding position.
A paper is also conveyed to the exit conveyance section.
Drive for the intermediate conveyance section is provided by the Conveyance Motor (M2)
[3]. Drive of the Intermediate Conveyance Roller /1 [4] and Intermediate Conveyance Roller
/2 [2] is controlled.
The Conveyance Sensor (PS5) [1] detects paper in the intermediate conveyance section.
[4]
[1]
[3]
[2]
4349t2c005na
14
[1] Conveyance Sensor (PS5)
[3] Conveyance Motor (M2)
[2] Intermediate Conveyance Roller /2
5.1.3
5. OPERATIONS
FS-510/PU-501/OT-601

Exit Conveyance Section
The paper is exited onto each of the trays.

The Exit Motor (M1) [1] provides drive for the Exit Roller [3], Stacker Paddle [5], and Exit
Paddle [2].
[4]
[3]
[1]
[2]
4349t2c006na
[1] Exit motor (M1)
[4] Exit roller release motor (M6)
[2] Exit Paddle
[5] Stacker Paddle
[3] Exit Roller
15
[5]
FS-510/PU-501/OT-601
5. OPERATIONS
5.2
5.2.1
Up/down Section
Up/down mechanism
The Up/down mechanism is operated to select a specific tray, thereby feeding the paper exit
onto a specific tray.
[1]
4349t2c007na
[1] Tray Lift Motor (M11)
16
5.2.2
5. OPERATIONS
Tray Up/Down operation
The Tray is moved up or down by the Tray Lift Motor (M11) that turns forward or backward
to drive the front and rear belts.
The Lower Limit Sensor (PS14) [1] detects the Tray at its lower limit position.
The Tray Overrun Switch (SW3) [2] is provided for protection when the trays overruns normal position.
FS-510/PU-501/OT-601
[2]
[1]
4349t2c008na
[2] Tray Overrun Switch (SW3)
17
FS-510/PU-501/OT-601
5. OPERATIONS
5.2.3
Tray Upper Limit Position Detection Mechanism
Each of the Tray moves up or down according to the amount of paper fed onto it.
When the Upper Limit Sensor (PS15) [1] turns ON for each exit of paper, bring down once
the Lift Tray until PS15 turns OFF so that the upper surface of paper on the Tray is kept at
the same level at all times while in the paper exit.
Bring up again the Tray until PS15 turns ON.
[1]
4349t2c009na
[1] Upper Limit Sensor (PS15)
18
5. OPERATIONS
A. Tray Position Detection

Tray position detection is controlled according to the number of times the Tray Position Sensor (PS3) [1] is activated after the Lower Limit Sensor (PS14) [2] has been activated.
(1) Tray position detection operation
1. During the initial operation sequence, the Tray is subjected to a descent motion until
the Lower Limit Sensor (PS14) is activated.
[1]
[2]
FS-510/PU-501/OT-601
4349t2c010na
[1] Tray Position Sensor (PS3)
19
FS-510/PU-501/OT-601
5. OPERATIONS
2. After PS14 has been activated, the Up/Down Section is subjected to an ascent motion.
3. When PS3 [1] is activated a first time after the ascent motion of the Up/Down Section
has been started, it is determined that the Up/Down Section is now located at the
paper exit opening for the Tray /1.
[1]
4349t2c011na
[1] Tray Position Sensor (PS3)
4. When PS3 is activated a second time after the ascent motion of the Up/Down Section
has been started, it is determined that the Up/Down Section is now located at the
paper exit opening for the Tray /2.
5. Drive is stopped when PS3 is activated with Upper Limit Sensor (PS15) of the target
tray in the activated position.
* If OT is installed, OT is at the exit port when the position sensor is activated twice and the
Tray /2 is at the exit port when the position sensor is activated three times.
B. Paper Full Detection
When the Tray Position Sensor (PS3) changes from the activated to deactivated state with
the Upper Limit Sensor (PS15) in the activated state, a paper full condition is detected and
the corresponding message will appear on the operation panel.
20
5.2.4
5. OPERATIONS
Shutter Open/Close Mechanism
The paper exit section is provided with the Shutter [3] and this Shutter is normally in the up
condition (the condition in which the Paper Exit Opening is opened). However, when the Tray
goes up and down, the Paper Exit Opening is closed to prevent an accident such as hands
getting caught in the Paper Exit Opening.
The Shutter is opened or closed by the Shutter Motor (M12) [2] that turns a gear train for
raising or lowering the Shutter.
The Shutter Home Sensor (PS16) [4] detects the position of the gear, thereby determining
the position of the Shutter.
When the Shutter does not close while in the Tray up/down operation, the Shutter Switch
(SW2) [1] turns OFF to shut off a 24V DC and stop the up/down of the Tray at once.
FS-510/PU-501/OT-601
[4]
[1]
[3]
[2]
4349t2c012na
[1] Shutter Switch (SW2)
[3] Shutter
[2] Shutter Motor (M12)
[4] Shutter Home Sensor (PS16)
21
FS-510/PU-501/OT-601
5. OPERATIONS
5.3
5.3.1
Stacker section
Paper aligning mechanism (sub scan direction)
Sheets of paper are aligned properly and stapled together inside the stacker section before
being fed out onto the corresponding tray.
In the Sort, Group, Staple, or Half Fold/Fold & Staple mode, each copy set is stored in the
Stacker with the Upper Exit Roller separated from the Lower Exit Roller.
The Stacker Sensor (PS8) detects paper in the Stacker.
The Stacker Paddle and Aligning Belt are driven when the Exit Motor (M1) is rotated in
reverse.
A. Operation
1. The paper fed out from the main body is held downward by the Drop Lever [7] and
dropped down into the Stacker by the Intermediate Conveyance Roller /2 [4].
2. The paper dropped into the Stacker is pressed against the Paper Stopper [5] by the
Paddle [3] and Aligning Belt [1] so that it is aligned properly in the sub scan direction.
[7]
[3]
[3]
[7]
[1]
[5]
[4]
[6]
[1]
[3]
[2]
4349t2c013na
[1] Aligning Belt
[6] Stacker sensor (PS8)
[3] Stacker Paddle
[7] Drop Lever
22
[5] Paper Stopper
[2] Exit Motor (M1)
5.3.2
5. OPERATIONS
Paper aligning mechanism (main scan direction)
Aligning Plates are moved and the Paddle is rotated so as to align the paper at the stapling
position.
The paper in the Stacker is aligned in the main scan direction by two Alignment Motors and
aligning plates.
A. Aligning plates
The aligning plates [6] are moved to the front or rear in accordance with the paper size.
The Alignment Sensor /Rr (PS6) [4], /Fr (PS7) [1] detects the position of each aligning plate.
FS-510/PU-501/OT-601
[6]
[5]
[7]
[4]
[3]
[2]
[1]
4349t2c014na
[1] Alignment sensor /Fr (PS7)
[5] Paper Aligning Portion
[2] Alignment motor /Fr (M5)
[6] Aligning Plate
[3] Alignment motor /Rr (M4)
[7] Paper Stoppers
[4] Alignment sensor /Rr (PS6)
23
FS-510/PU-501/OT-601
5. OPERATIONS
B. Paper aligning sequence

In normal print and staple mode, the paper is fed into the tray at its center position.
If no stapling is involved in the Sort or Group Print mode, the aligning plate shifts 15 mm to
the front or rear from the center. This stacks papers in a saw tooth manner, each being offset by about 30 mm with respect to the others.
This shifting motion is not performed when papers are fed into the MT or the SD.
[5]
[1]
[2]
[4]
[3]
4349t2c015na
[1] 30mm
[4] Normal/Staple
[2] Center
[5] Aligning Plate
[3] Shift (Sort/Group)
24
5.3.3
5. OPERATIONS
Exit mechanism
[4]
[3]
The paper exit roller section is provided with the Paper Holding Paddle [3] to hold the paper
exited onto the Tray while in the sort mode so that the paper does not have an uneven edge.
The subsequent copy set is fed out with the copy sets previously resident on the tray being
held down by the paper holding paddle.
The Exit Paddle Home Sensor (PS11) [1], Spring Clutch [4], and Exit Paddle Solenoid (SD2)
[2] control the retracted position and paper holding position of the paper holding paddle.
[1]
[2]
4349t2c016na
[1] Exit Paddle Home Sensor (PS11)
[3] Paper Holding Paddle
[2] Exit Paddle Solenoid (SD2)
[4] Spring Clutch
FS-510/PU-501/OT-601
25
FS-510/PU-501/OT-601
5. OPERATIONS
A. Exit Roller up/down mechanism

While in the sort mode and the staple mode, the Exit Roller /Up is pressed to the Exit Roller
/Lw after the paper is stacked in the Stacker.
The press/release of the Exit Roller /Up is driven by the Exit Roller Release Motor (M6) [3].
The Exit Roller Home Sensor (PS12) [4] detects the position of the Exit Roller /Up, whether
it is in the released or pressed position.
[4]
[2]
[1]
[3]
4349t2c017na
26
[1] Unblocked (Released)
[3] Exit Roller Release Motor (M6)
[2] Blocked (Pressed)
[4] Exit Roller Home Sensor (PS12)
5.4
5.4.1
5. OPERATIONS
Stapling
Stapling mechanism
Stapling is performed by the Stapling Unit.

When the Stapling Motor [1] is rotated, the Clinch Arm [3] lowers. The Stapler [2] thereafter
goes up to drive a staple in the paper.
Five different types of stapling are available: parallel front one point, parallel rear one point,
slant front one point, slant rear one point and parallel two points.
FS-510/PU-501/OT-601
[3]
[1]
[2]
4349t2c018na
[1] Stapling Motor
[3] Clinch Arm
[2] Stapler
27
FS-510/PU-501/OT-601
5. OPERATIONS
5.4.2
Stapling Unit moving mechanism
The Stapling Unit is moved by the Stapler Movement Motor (M7) [3].
M7 drives the belt so that the Stapling Unit is moved to the corresponding stapling position.
The stapling stop position is controlled by the period of time during which the M7 is kept
energized, as counted from the time when the Stapler Home Sensor (PS10) [4] has been
activated.
[1]
[5]
[4]
[3]
[2]
4349t2c019na
[1] Home
[4] Stapler Home Sensor (PS10)
[2] Staple change position
[5] Stapling Unit
[3] Stapler Movement Motor (M7)
5.4.3
Stapling Position
A single stapling unit is moved to perform 2-point stapling.
[3]
[2]
[1]
4349t2c020na
[1] Parallel two points

[2] Slant one point
28
[3] Parallel one point
5.4.4
5. OPERATIONS
Staple empty detection
Staple Empty Sensor [2] detect whether or not there are staples still left.
When the number of staples left in the staple cartridge becomes about 20, a staple sheet
empty condition results, causing a corresponding empty message to appear on the operation panel.
When the empty condition is detected, the corresponding empty indication is given on the
operation panel. At the same time, the Stapling Unit moves to the front.
When a new staple cartridge is loaded, the stapling motor is energized until the Stapler
Ready Sensor [1] detects a staple, which results in the staple to be fed up to the stapling
position.
[1]
[2]
4349t2c021na
[1] Stapler Ready Sensor
FS-510/PU-501/OT-601
[2] Staple Empty Sensor
29
FS-510/PU-501/OT-601
6. PU-501
6.
6.1
PU-501
Composition
4512t2c002na
6.2
6.2.1
Operation
Registration mechanism
For punch and holding operations, a loop is formed in the paper at the Registration Roller [2]
to correct skew of the paper.
The Entrance Sensor (PS4) [1] detects the leading edge of the paper and the Registration
Roller forms a loop in the paper.
The Registration Clutch (CL1) is then energized after a given period of time after the PS4 is
activated by the leading edge of the paper, this causes the Registration Roller to start turning.
[2]
[1]
4512t2c003na
[1] Entrance Sensor (PS4)
30
6.2.2
6. PU-501
Punch mechanism
After a given period of time after the Entrance Sensor (PS4) [3] has detected the trailing
edge of the paper, the Conveyance Motor (M2) of FS is deenergized and a punch hole operation is made at the trailing edge portion in each sheet of paper.
Punch holes are made when the slide cam [1] makes a reciprocating motion, as driven by
the drive cam which is rotated by the Punch Motor (M1) [2] provided in the punch unit.
FS-510/PU-501/OT-601
[1]
[2]
[3]
4512t2c004na
[1] Slide Cam
[2] Punch Motor (M1)
[4] Puncher
6.2.3
Punch status detection
The punch status is detected by using the Punch Position Sensor /1 (PS2) [1], /2 (PS3) [2],
Punch Home Sensor, and the Encoder Sensor (PS4) [3].
[1] [2]
[3]
4512t2c005na
[1] Punch Position Sensor /1 (PS2)
[3] Encoder Sensor (PS4)
[2] Punch Position Sensor /2 (PS3)
31
[4]
FS-510/PU-501/OT-601
6. PU-501
6.2.4

Punch Scraps Box full detection mechanism
Punch scraps produced as a result of punching operation is stored in the Punch Scraps
Box.
The Punch Scraps Box is provided with the Punch Scraps Full Sensor (PS1) [1]. When a
punch waste is detected, the corresponding message is displayed on the operation panel.
PS1 is a reflector type sensor that detects height of the punch scraps.
PS1 also detects whether a Punch Scraps Box is loaded.
[1]
4512t2c006na
[1] Punch Scraps Full Sensor (PS1)
32
7.1
OT-601
Composition
4625t2c001na
7.2
7.2.1
Operation
Overview
Mounting the optional OT provides a total of three trays.

The OT is attached at different positions depending on whether options SD or MT is
mounted or not.
The capacity of each tray is different depending on the position of the OT is attached.
When the short-circuit connector shipped with OT is mounted, the machine determines that
OT has been mounted.
[5]
[6]
[4]
[7]
[3]
[8]
[2]
[1]
4625t2c002na
[1] When MT/SD is installed
[5] 200 sheets
[2] FS only
[6] 200 sheets
[3] 500 sheets
[7] 200 sheets
[4] 200 sheets
[8] 200 sheets
33
7.
7. OT-601
FS-510/PU-501/OT-601
FS-510/PU-501/OT-601
7. OT-601
Blank Page
34
SERVICE MANUAL
Theory of Operation
FS-511/RU-502
2006.02
Ver. 1.0
Revision history
Revision mark:
page.
NOTE
2006/02
1.0
Date
Service manual Ver.
Revision mark

CONTENTS
FS-511/RU-502
CONTENTS
FS-511/RU-502
OUTLINE
1.1
FS-511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2
RU-502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. COMPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1
FS-511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2
RU-502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1
RU conveyance section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1.1
5.2
5.2.1
5.3
5.4
5.5
Conveyance mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FS conveyance section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Entrance conveyance mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2.2
Gate mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2.3
Sub tray conveyance mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2.4
Main tray/handling tray conveyance mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2.5
Roller separation mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2.6
Conveyance operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Main tray section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.3.1
Main tray up/down mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.3.2
Main tray shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Punch section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.4.1
Punch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.4.2
Punch hole switchover mechanism (for inch area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Staple section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.5.1
Alignment mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.5.2
Stapler movement mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.5.3
Stapling mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.5.4
Staple sheet empty control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
FS-511/RU-502
CONTENTS
Blank page
ii
FS-511/RU-502
OUTLINE
1.1
FS-511
A. Type
Type
Multi staple finisher
Installation
Floor-mounted type
Document alignment
Center
Consumables
Staples
B. Functions
Mode
Normal
Non-sort, sort, group, sort-staple
Punch
Non-sort-punch, sort-punch, group-punch,

sort-staple-punch
C. Type of paper
Maximum load capacity: (80 g/m2) when loaded with paper of the same size.
(1) Straight
Type of paper
Size of paper
Weight
Max. capacity
Exit tray
60 to 90 g/m2
250 sheets
Sub tray
91 to 130 g/m2
20 sheets
Max. number of
sheets stapled
Plain paper
A3, B4, A4, A4S, B5,
Recycled paper B5S, A5S, and B6S

51/2 x 81/2S, 81/2 x 11,
Thick paper
Thin paper
OHP
81/2 x 11S, 81/2 x 14,
11 x 17
50 to 59 g/m2
transparencies
Label
Envelope
Label sheet
Letterhead
FS-511/RU-502
(2) Non-sort, sort, group

Type of paper
Size of paper
Weight
Max. capacity
Exit tray
Max. number of
50 to 130 g/m2
3000 sheets
Main tray
Max. number of
sheets stapled
Plain paper
A3, B4, A4, A4S, B5,
Recycled paper B5S

81/2 x 11, 81/2 x 11S,
Thick paper
Thin paper
(A4S or smaller)
1500 sheets
(B4 or larger)
81/2 x 14, 11 x 17
(3) Sort-staple, group-staple

Type of paper
Size of paper
Weight
Max. capacity
Exit tray
60 to 90 g/m2
3000 sheets
Main tray
50 sheets
Max. number of
sheets stapled
Plain paper
A3, B4, A4, A4S, B5,
Recycled paper B5S

81/2 x 11, 81/2 x 11S,
(A4S or smaller)
1500 sheets
(B4 or larger)
81/2 x 14, 11 x 17
(4) Punch
a.
Metric/Swedish
Type of paper
Size of paper
Weight
Max. capacity
Exit tray
60 to 90 g/m2
Main tray
sheets stapled
Plain paper
A3, B4, A4, A4S, B5,
Recycled paper B5S

b.
Sub tray
Inch 2 holes
Type of paper
Size of paper
Weight
Max. capacity
Exit tray
60 to 90 g/m2
Main tray
Max. number of
sheets stapled
Plain paper
81/2 x 11S, 81/2 x 14
c.
Sub tray
Recycled paper
Inch 3 holes
Type of paper
Size of paper
Weight
Max. capacity
Exit tray
60 to 90 g/m2
Main tray
Max. number of
sheets stapled
Plain paper
Recycled paper
81/2 x 11S, 11 x 17
Sub tray
Staple filling method
Dedicated staple cartridge (5000 staples)
Staple detection
Available (near empty: 20 remaining staples)
Staple position *1
Rear: Diagonal 45 1 point
Metric: A3, B4, A4, B5
Front: Diagonal 45 1 point
Inch: 81/2 x 11, 11 x 17
Metric: B4, B5
Inch:
Metric: A4S, B5S
Inch: 81/2 x 11S, 81/2 x 14
Side: 2 points
FS-511/RU-502
D. Stapling
A4, A4S, A3, B5, B5S, B4, 81/2 x 11, 81/2 x 11S,
81/2 x 14, 11 x 17
Manual staple
*1
None
In case of the 1-staple mode, conduct a parallel and a skew adjustment according to the length in the
main scan direction.
Parallel: main scan direction 182 to 216 mm
Diagonal: main scan direction 216 to 297 mm
E. Punch
No. of holes
Inch:
2 holes, 3 holes
Metric: 4 holes
Punch scraps full detection
F.
None
Maintenance
Maintenance
G. Machine data
Power source
24V DC 10 % (supplied from the main body)
Power consumption
64 W or less
Dimensions
538 (W) x 637 (D) x 978 (H) mm
Weight
39.2 kg
H. Operating environment
Temperature
10 to 30 C
Humidity
10 to 80 % RH (with no condensation)
Note
FS-511/RU-502
1.2
RU-502
A. Type
Type
Roller method relay conveyance unit
B. Functions
Conveyance
Paper conveyance from the main body to FS
C. Type of paper
Paper size
Paper type
Amount of curling
b = 10 mm or less
(5 sheets)
16fat1c001na
D. Maintenance
Maintenance
E. Machine data
Power source
5.1V DC 5 % (supplied from FS)
Dimensions
474.5 (W) x 469.5 (D) x 254.4 (H) mm
Weight
Approx. 4.5 kg
F.
Temperature
10 to 30 C
Humidity
Note
2. PAPER PATH
FS-511/RU-502
2. PAPER PATH
A. Non-sort mode (sub tray paper exit)
[4]
[5]
[6]
[3]
[7]
[1]
[2]
4521t1c004na
[1]
Paper exit roller (main body)
[5]
FS-511
[2]
Bypass gate
[6]
Punch
[3]
Main gate
[7]
RU-502
[4]
Sub tray
Note: Even when mixed with the punch mode, the paper path is the same.
B. Non-sort/sort/group mode
[3]
[4]
[5]
[6]
[7]
[1]
[2]
4521t1c005na
[1]
[5]
Main gate
[2]
Bypass gate
[6]
Punch
[3]
Main tray
[7]
RU-502
[4]
FS-511
Note: Even when mixed with the punch mode, the paper path is the same.
2. PAPER PATH
FS-511/RU-502
C. Staple mode
[6]
[7]
[8]
[5]
[1]
[2]
Bypass gate
[3]
[4]
[9]
[10]
[3]
[11]
[1]
[2]
[7]
4521t1c006na
Paper path for other than the 1st paper of

the 2nd and succeeding copies.
Paper path for the 1st paper of the 2nd and
[8]
FS-511
succeeding copies
[9]
Main gate
[4]
Stapler
[10]
Punch
[5]
Handling tray
[11]
RU-502
[6]
Main tray
Note: Even when the A, B or C mode mentioned above is mixed with the punch mode, the paper path is the
same.
3. COMPOSITION
FS-511/RU-502
3. COMPOSITION
Sub tray
Conveyance
section
Punch section
RU-502
Main tray section
Staple section
4521t2c001na
4. DRIVE
FS-511/RU-502
4. DRIVE
4.1
FS-511
[12] [13]
[11]
[14]
[10]
[9]
[8]
[1]
[7]
[2]
[6]
[5]
[3]
[4]
4521t2e001na
[1]
Paddle motor /Lw (M9)
[8]
[2]
Hole punch selector motor (M14) (for inch
[9]
Paddle motor /Up (M15)
area)
[10]
Paper exit roller release motor (M13)
[3]
Tray lift motor (M7)
[11]
Conveyance motor /Lw (M2)
[4]
Shift motor (M8)
[12]
Conveyance motor /Up (M4)
[5]
Stapler moving motor (M6)
[13]
Entrance conveyance motor (M1)
[6]
Alignment motor (M5)
[14]
Punch motor (M11)
[7]
Intermediate conveyance roller release

motor (M12)
Paper exit motor (M3)
RU-502
[3]
[4]
FS-511/RU-502
4.2
4. DRIVE
[5]
[2]
[1]
16fat2c001na
[1]
Main body - fusing motor (M11)
[4]
Conveyance roller
[2]
Entrance conveyance roller (FS-511)
[5]
Coupling gear
[3]
Belt
5. OPERATION
FS-511/RU-502
5. OPERATION
5.1
RU conveyance section
5.1.1
Conveyance mechanism
The driving force from the fusing motor (M11) is transmitted through the coupling gear [2] to rotate the conveyance roller [5].
Paper conveyed from the paper exit roller [1] on the main body side is conveyed by the conveyance roller to
A jam is detected by the path sensor (PS2) [4].
the entrance roller [3] on the FS side.
[4]
[5]
[1]
[3]
[2]
16fat2c003na
10
[1]
[4]
Path sensor (PS2)
[2]
Coupling gear
[5]
Conveyance roller
[3]
Entrance roller (FS-511)
FS conveyance section
The conveyance section is made up of the entrance conveyance mechanism [6] that conducts the conveyance drive, the main route conveyance mechanism [2], the sub tray conveyance mechanism [5], the handling/paper exit conveyance mechanism [3], the gate mechanism [1] that switches the paper path and the
roller separation mechanism [4] that conducts the pressure/release of the roller.
[4]
[5]
[6]
[3]
[2]
[1]
4521t2c004na
[1]
Gate mechanism
[4]
Roller separation mechanism
[2]
Main route conveyance mechanism
[5]
Sub tray conveyance mechanism
[3]
Main tray/handling tray conveyance mecha-
[6]
Entrance conveyance mechanism
nism
11
FS-511/RU-502
5.2
5. OPERATION
5. OPERATION
5.2.1
FS-511/RU-502
Entrance conveyance mechanism
The driving force of the entrance conveyance motor (M1) [4] rotates the entrance roller [1] to convey [3]
paper [2] into FS.
[4]
[1]
[3]
[2]
4521t2c005na
[1]
Entrance roller
[3]
[2]
Paper
[4]
A. Control
(1) Sub tray paper exit
When the FS start signal turns ON, the entrance conveyance motor (M1) turns ON. And it turns OFF a
specified period of time after the sub tray exit sensor (PS1) detects the trailing edge of the last paper.
(2) Sort/staple
When the FS start signal turns ON, M1 turns ON. And it turns OFF a specified period of time after the intermediate conveyance sensor (PS3) detects the trailing edge of the last paper.
12
Gate mechanism
On the conveyance path, the following 2 types of gates are provided: the bypass gate [6] and the main gate
[3].
The bypass gate is driven by the bypass gate solenoid (SD1) [5].
The main gate is driven by the main gate solenoid (SD2) [2].
[6]
[1]
[5]
[4]
[3]
[2]
4521t2c006na
[1]
Paper
[2]
Main gate solenoid (SD2)
[4]
Paper conveyance direction when the

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

[5]
Bypass gate solenoid (SD1)
[6]
Bypass gate
13
FS-511/RU-502
5.2.2
5. OPERATION
5. OPERATION
A. Operation
FS-511/RU-502
The paper conveyance path of the bypass gate [1] is switched over in the bypass route direction [2] when
the bypass gate solenoid (SD1) turns OFF and switched over in the main gate direction [10] when it turns
ON.
The paper conveyance path of the main gate [9] is switched over in the main route direction [4] when the
main gate solenoid (SD2) turns OFF and switched over in the sub tray route direction [8] when SD2 turns
ON.
The paper conveyance to the bypass route is used when conveying each of the 1st sheets of paper of the
2nd and succeeding copies in the staple mode to increase the handling capacity of paper even while in the
stapling operation.
Conveyance path
SD1
SD2
Sub tray
ON
ON
Main tray
ON
OFF
Bypass route
OFF
[5]
[6]
[4]
[7]
[8]
[3]
[9]
[10]
[2]
[1]
4521t2c007na
[1]
Bypass gate
[6]
Main route conveyance sensor (PS4)
[2]
Bypass route
[7]
Sub tray exit sensor (PS1)
[3]
Bypass route conveyance sensor (PS2)
[8]
Sub tray route
[4]
Main route
[9]
Main gate
[5]
Intermediate conveyance sensor (PS3)
[10]
Main gate direction conveyance path
B. Control
(1) Sub tray paper exit
A specified period of time after the fusing exit sensor (PS3) of the main body turns ON and detects the leading edge of paper, the bypass gate solenoid (SD1) turns ON and the main gate solenoid (SD2) also turns
ON to switch over the conveyance path to the sub tray route.
A specified period of time after the sub tray exit sensor (PS1) turns ON with the trailing edge of paper
detected, SD1 and SD2 turn OFF.
14

Sub tray conveyance mechanism
The paper conveyance to the sub tray is made while in the non-sort mode.
The conveyance motor /Up (M4) [5] drives the conveyance roller /Up [1] and the sub tray paper exit roller [2]
to convey [3] paper [4] to the sub tray.
[5]
[1]
[4]
[3]
[2]
4521t2c008na
[1]
Conveyance roller /Up
[4]
Paper
[2]
Sub tray paper exit roller
[5]
[3]
A. Control
(1) Sub tray paper exit (with no punch)/staple mode (with no punch)
A specified period of time after the FS start signal turns ON, the conveyance motor /Up (M4) turns ON. And
it turns OFF a specified period of time after the sub tray exit sensor (PS1) turns OFF with the trailing edge of
paper detected.
(2) Sub tray paper exit (punch mode)
When the FS start signal turns ON, M4 turns ON. However it stops while in the punch operation. M4 turns
ON again after completion of the punch and it turns OFF a specified period of time after PS1 turns OFF.
15
FS-511/RU-502
5.2.3
5. OPERATION
5. OPERATION
5.2.4
FS-511/RU-502
Main tray/handling tray conveyance mechanism
The conveyance motor /Lw (M2) [7] drives the conveyance roller /Lw [1] and the intermediate conveyance
roller [9] to convey paper in the main tray direction [4]. When rotating M2 in the reverse direction, paper is
switched back [10].
The switch back is made for the 1st paper of each of the 2nd and succeeding copies when printing continuously 2 or more copies in the staple mode to convey the 1st and the 2nd sheets of paper overlapped each
other.
The paper exit motor (M3) [6] drives the paper exit roller [2] to convey paper in the main tray direction. When
rotating M3 in the reverse direction, paper is conveyed [3] to the handling tray [8].
The paper conveyance to the handling tray is made while in the staple mode.
[7]
[8]
[9]
[10]
[6]
[1]
[5]
[4]
[3]
[2]
4521t2c009na
16
[1]
Conveyance roller /Lw
[6]
[2]
Paper exit roller
[7]

[3]
Conveyance to the handling tray
[8]
Handling tray
[4]
Main tray paper exit direction
[9]
Intermediate conveyance roller
[5]
Paper
[10]
Switch back direction
5. OPERATION
1. When the FS start signal turns ON, the conveyance motor /Lw (M2) rotates in the normal direction. And
when the bypass route conveyance sensor (PS2) [3] detects the trailing edge of the 1st paper [1] of the 2nd
copy that has been conveyed to the bypass route, M2 turns OFF.
2. A specified period of time after M2 turns OFF, M2 rotates in the reverse direction to switch back the conveyance [2]. And a specified period of time after that, M2 stops to stand by for the 2nd paper.
3. A specified period of time after the main route conveyance sensor (PS4) [7] detects the leading edge of the
2nd paper [8] that has been conveyed through the main route by the conveyance motor /Up (M4), M2
rotates again in the normal direction to convey the 1st and the 2nd sheets of paper overlapped each other.
4. A specified period of time after the intermediate conveyance sensor (PS3) [6] detects the trailing edge of the
last paper, M2 turns OFF.
[5]
[6]
[7]
[8]
[1]
[4]
[3]
[2]
4521t2c010na
[1]
1st paper of the 2nd copy
[5]
Paper of the 1st copy
[2]
Switch back
[6]
[3]
[7]
[4]
Handling tray
[8]
2nd paper of the 2nd copy
17
FS-511/RU-502
A. Switch back control
5. OPERATION
B. Handling tray conveyance operation
FS-511/RU-502
(1) Sort mode
When the FS start signal turns ON, the paper exit motor (M3) rotates in the normal direction to convey
paper to the main tray. M3 turns OFF a specified period of time after the intermediate conveyance sensor
(PS3) detects the trailing edge of the last paper.
(2) Staple mode
1. When the FS start signal turns ON, M3 rotates in the normal direction. It stops a specified period of time after
PS3 [1] detects the trailing edge of paper.
2. A specified period of time after the stop, M3 rotates in the reverse direction to convey [1] paper to the handling tray [2].
3. After completion of the stapling operation, M3 rotates in the normal direction to exit [6] the stapled paper [5]
to the main tray. At this time, the 1st [4] and the 2nd [7] sheets of paper of the next copy are also conveyed
to the main tray simultaneously.
4. A specified period of time after PS3 detects the trailing edge of the 1st and the 2nd sheets of paper of the
next copy, M3 stops and rotates again in the reverse direction to convey paper to the handling tray.
[3]
[2]
18
[6]
[1]
[7]
[5]
[4]
[1]
Paper stack
[5]
Paper that has been stapled
[2]
Handling tray
[6]
Paper exit to main tray
[3]
[7]
2nd paper of the next copy
[4]
1st paper of the next copy
4521t2c011na
Roller separation mechanism
The intermediate conveyance roller and the paper exit roller are provided with a separation mechanism that
releases the pressure from the roller.
The intermediate conveyance roller release motor (M12) [1] drives the cam [5] to pressure/release the intermediate conveyance roller [2]. The home position is detected by the roller release home sensor (PS12) [4].
The paper exit roller release motor (M13) [8] drives the crank [7] to pressure/release the paper exit roller [3].
The home position is detected by the paper exit roller home sensor (PS13) [6].
[8]
[7]
[1]
[6]
[2]
[5]
[4]
[3]
4521t2c012na
[1]
[5]
motor (M12)
[6]
Cam
Paper exit roller home sensor (PS13)
[2]
[7]
Crank
[3]
Paper exit roller
[8]
[4]
Roller release home sensor (PS12)
19
FS-511/RU-502
5.2.5
5. OPERATION
5. OPERATION
A. Intermediate conveyance roller separation control
FS-511/RU-502
1. When printing continuously a large size paper (217 mm or larger) in the staple mode, the leading edge of the
2nd paper [4] gets to the intermediate conveyance roller [2] while in the switch back [1] of the 1st paper of
the 2nd and succeeding copies. To prevent this, release the pressure of the intermediate conveyance roller
and separate [3] the roller to get the 2 sheets of paper overlapped each other.
2. When the 2nd paper stops, the intermediate conveyance roller is pressured to convey the 2 sheets of paper
overlapped each other to the handling tray.
[2]
[3]
[4]
[1]
4521t2c013na
20
[1]
[3]
Separation
[2]
[4]
5. OPERATION
1. To stack [1] paper in the handling tray [2] while in the staple mode, FS start signal turns ON, and the paper
exit roller release motor (M13) turns ON. After the pressure of the paper exit roller [3] is released and the
paper exit roller is separated [4], M13 turns OFF.
2. After completion of the stapling operation, M13 turns ON again when the fusing exit sensor (PS3) of the main
body detects the trailing edge of the 2nd paper of the next copy. M13 pressures [7] the paper exit roller to
nip the paper [5], then M13 stops and the paper exits.
[3]
[4]
[2]
[6]
[1]
[7]
[5]
[1]
Conveyance to the handling tray
[5]
Paper
[2]
Handling tray
[6]
Paper exit
[3]
Paper exit roller
[7]
Pressure
[4]
Release the pressure of the paper exit roller
4521t2c014na
21
FS-511/RU-502
B. Paper exit roller separation control
5. OPERATION
5.2.6
Conveyance operation
FS-511/RU-502
A. Continuous copy in the staple mode (in case of A4S, 3 originals, and 2 copies)
1. The 1st paper [2], the 2nd paper [3] and the 3rd paper [4] of the 1st copy are conveyed to the handling tray
[1].
2. While in the conveyance of the last paper [7] of the 1st copy, the 1st paper of the 2nd copy is conveyed [6]
to the bypass route.
[2]
[3]
[4]
[5]
[7]
[6]
[1]
4521t2c015na
[1]
Handling tray
[5]
[2]
1st paper of the 1st copy
[6]
[3]
2nd paper of the 1st copy
[7]
3rd paper of the 1st copy
[4]
3rd paper of the 1st copy
3. The 1st paper [1] of the 2nd copy thus conveyed to the bypass route is switched back by the conveyance
roller /Lw [2] and the storage roller [3], and then it stops.
4. The 1st paper [4] of the 2nd copy is overlapped with the 2nd paper [5] of the 2nd copy to be conveyed.
[5]
[3]
[2]
22
[1]
[4]
[1]
[4]
[2]
Conveyance roller /Lw
[5]
[3]
Storage roller
4521t2c016na
5. OPERATION
sured to exit the paper of the 1st copy. At this time, the moment the paper of the 1st copy is exited, the 1st
and the 2nd sheets of paper [3] of the 2nd copy are also conveyed in the main tray direction.
6. After completion of the exit of the paper [6] of the 1st copy, the pressure of the paper exit roller is released [7]
and the paper exit roller [5] rotates in the reverse direction to convey the 1st and the 2nd sheets of paper [4]
of the 2nd copy to the handling tray.
[2]
[3]
[6]
[1]
[1]
[2]
Pressure the paper exit roller
[3]
[7]
[5]
[4]
[4]
4521t2c017na
1st and the 2nd sheets of paper of the 2nd

copy
1st and the 2nd sheets of paper of the 2nd
[5]
Paper exit roller
copy
[6]
[7]
Separation of the paper exit roller
23
FS-511/RU-502
5. After completion of the stapling operation of the paper [1] of the 1st copy, the paper exit roller [2] is pres-
5. OPERATION
FS-511/RU-502
5.3
Main tray section
5.3.1
Main tray up/down mechanism
The up/down of the main tray is made by the normal/reverse rotation of the tray lift motor (M7) [2].
[4]
[5]
[1]
[3]
[2]
4521t2c018na
[1]
Main tray upper limit LED (LED19)
[4]
Main tray upper limit sensor (PS19)
[2]
[5]
Main tray reset sensor (PS8)
[3]
Main tray
A. Control
(1) While in the print operation
While in the paper exit, when the main tray upper limit sensor (PS19) turns ON, the tray lift motor (M7)
rotates in the reverse direction to bring down the main tray. And M7 turns OFF when PS19 turns OFF. This
operation is repeated and stopped when the tray gets to the bottom according to the amount of paper
exited.
(2) Paper removal control
When paper loaded on the main tray is removed with the main tray reset sensor (PS8) OFF, M7 rotates in
the normal direction to bring up the main tray, and when PS8 turns ON, M7 turns OFF.
(3) Paper full detection
For the main tray, when the main tray full sensor (PS7) turns ON, this is detected as the tray being full of
paper and M7 turns OFF.
When the main tray goes up and the current of M7 is in excess of a prescribed value, this is detected as the
tray being full of paper and M7 turns OFF.
24
Main tray shift mechanism
While in the sort/group mode, the shift motor (M8) [4] is driven to shift the main tray [5] 30 mm in the main
scan direction through the shift plate [3].
The home position is detected by the shift home sensor (PS10) [2].
[1]
[5]
[4]
[2]
[3]
4521t2c019na
[1]
Shift encoder sensor (PS11)
[4]
Shift motor (M8)
[2]
Shift home sensor (PS10)
[5]
Main tray
[3]
Shift plate
A. Control
(1) Sort mode
A specified period of time after the intermediate conveyance sensor (PS3) detects the trailing edge of the
last paper of the copy, the shift motor (M8) turns ON to start the shift operation, and when the shift home
sensor (PS10) detects the shift position, M8 turn OFF.
(2) Staple mode
A specified period of time after the paper exit roller release motor (M13) turns ON to start the pressure operation, M8 turns ON to start the shift operation, and when PS10 detects the shift position, M8 turns OFF.
25
FS-511/RU-502
5.3.2
5. OPERATION
5. OPERATION
FS-511/RU-502
5.4
Punch section
5.4.1
Punch mechanism
For the punch, a hole is punched on the rear side of paper for each paper.
The driving force from the punch motor (M11) [5] is transmitted to the eccentric cam [6] by the punch clutch
(CL1) [4]. And when the eccentric cam makes a full turn, the cam holder [3] makes a round trip to punch a
hole.
The position of the reciprocating operation of the punch is detected by the punch encoder sensor (PS15).
[6]
[1]
[5]
[4]
[3]
[2]
4521t2c020na
[1]
Entrance roller
[4]
Punch clutch (CL1)
[2]
Punch blade
[5]
Punch motor (M11)
[3]
Cam holder
[6]
Eccentric cam
A. Operation
1. A specified period of time after the path sensor (PS2) of the RU detects the trailing edge of paper, the conveyance motor /Up (M4) or conveyance motor /Lw (M2) turns OFF to stop at the prescribed punch position.
2. The punch clutch (CL1) turns ON to punch a hole.

3. M4 or M2 turns ON to convey paper.
26
Punch hole switchover mechanism (for inch area)
The hole punch selector motor (M14) [5] and the hole punch position switch (SW4) [4] are employed to
move the lock holder [2] as necessary to select the hole positions (2 or 3 holes [1][6]).
[1]
[2]
[3]
S4
[4]
[5]
[6]
[7]
S4
4521t2e002na
[1]
2 holes
[5]
Hole punch selector motor (M14)
[2]
Lock holder
[6]
3 holes
[3]
Punch bars in locked position
[7]
Punch bars in locked position
[4]
Hole punch position switch (SW4)
27
FS-511/RU-502
5.4.2
5. OPERATION
5. OPERATION
FS-511/RU-502
5.5
Staple section
5.5.1
Alignment mechanism
While in the staple mode, paper is conveyed to the handling tray for alignment operation.
The alignment in the main scan direction is made by the movement of the alignment plate, and the alignment in the sub scan direction is made by the rotation of the paddle.
A. Alignment plate
The movement of the alignment plates /Fr [5] and /Rr [1] is made by the normal/reverse drive of the alignment motor (M5) [2].
The alignment plates /Fr and /Rr move with the position at the center of paper as a reference and the home
position is detected by the alignment home sensor (PS9) [4].
The distance of movement of the alignment plate is variable according to the paper size.
The alignment operation is made each time paper is conveyed to the handling tray.
[5]
[6]
[4]
[3]
[2]
[1]
Alignment plate /Rr
[4]
Alignment home sensor (PS9)
[2]
[5]
Alignment plate /Fr
[3]
Handling tray
[6]
Paper exit roller
[1]
4521t2c021na
(1) Control
1. When the intermediate conveyance sensor (PS3) detects the leading edge of the 1st paper of the job, M5
rotates in the normal direction to conduct a size movement.
2. A specified period of time after PS3 detects the trailing edge of paper, M5 rotates in the normal direction to
conduct the paper alignment. And it rotates in the reverse direction to return to the size standby position.
28
5. OPERATION
The paddle /Up [3] and /Lw [6] hit paper against the stopper to conduct the alignment in the sub scan
direction.
The drive of the paddle /Up is made by the paddle motor /Up (M15) [5] and the paddle solenoid (SD3) [4].
The drive of the paddle /Lw is made by the paddle motor /Lw (M9) [1].
[4]
[5]
[6]
[1]
[3]
[2]
4521t2c022na
[1]
[4]
Paddle solenoid (SD3)
[2]
Paper exit roller
[5]
[3]
Paddle /Up
[6]
Paddle /Lw
(1) Control
1. When the FS start signal turns ON, M15 and M9 also turn ON.
2. A specified period of time after the intermediate conveyance sensor (PS3) detects the leading edge of paper,
SD3 turns ON while a specified period of time.
3. A specified period of time after PS3 detects the trailing edge of the last paper of the copy, M15 and M9 turn
OFF.
4. In case of the last copy, the moment the paper exit motor (M3) turns OFF, M15 and M9 turn OFF.
29
FS-511/RU-502
B. Paddle
5. OPERATION
FS-511/RU-502
5.5.2
Stapler movement mechanism
The movement/rotation of the staplers /Fr [4] and /Rr [1] are made by the stapler moving motor (M6) [3].
The home position is detected by the stapler home sensor (PS14) [2] and the position is decided according
The 1 stapling at the front corner is made by the stapler /Fr, the 1 stapling at the rear corner made by the
to the drive amount of M6.

stapler /Rr, and the 2 stapling operations are made by the staplers /Fr and /Rr.
[4]
[3]
[2]
[1]
[1]
Stapler /Rr
[3]
[2]
PS14
[4]
Stapler /Fr
4521t2c023na
A. Control
When the FS start signal turns ON, the stapler moving motor (M6) turns ON, and it stops at the stapling
position.
After completion of the job, the moment the paper exit motor (M3) turns OFF, it returns to the home position.
30

Stapling mechanism
The stapling operation is made by the stapler.
When the stapler motors /Rr (M16) and /Fr (M17) [1] are driven, the clinch arm [3] goes down to drive the
staple blade [2] and hit in a staple.
[3]
[1]
[2]
4521t2c024na
[1]
Stapler motors /Rr, /Fr (M16, M17)
[2]
Staple blade
[3]
Clinch arm
A. Control
A specified period of time after the intermediate conveyance sensor (PS3) detects the trailing edge of the
last paper of the copy, the stapler motors /Rr (M16) and /Fr (M17) turn ON. After completion of the stapling
operation, the motors stop.
31
FS-511/RU-502
5.5.3
5. OPERATION
5. OPERATION
5.5.4
Staple sheet empty control
FS-511/RU-502
A. Detection mechanism
The detection of the staple sheet [6] is made by the staple empty sensors /Rr (PS20) and /Fr (PS23) [4].
The detection of the staple ready is made by the staple ready sensors /Rr (PS21) and /Fr (PS24) [2].
[5]
[6]
[4]
[3]
[2]
[1]
[1]
No staple condition
[4]
[2]
Stapler ready sensors /Rr, /Fr (PS21, PS24)
[5]
Stapler cartridge
[3]
Staple set condition
[6]
Staples
4521t2c025na
Staple empty sensors /Rr, /Fr (PS20, PS23)
B. Empty detection control
When the remaining staples get reduced to about 20, the staple empty sensors /Rr (PS20) and /Fr (PS23)
turn ON with a message displayed on the main body LCD.
In the middle of the stapling operation, when an empty condition is detected, the empty display is shown
after completion of a series of operations.
C. Staple ready detection control
After replacing (installing) a staple cartridge, the stapler motors /Rr (M16) and /Fr (17) drive until the stapler
ready sensors /Rr (PS21) and /Fr (PS24) turn ON, and then send staples to the stapling position.
32
SERVICE MANUAL
Theory of Operation
SD-502
(
500 / 420)
2006.02
Ver. 1.0
Revision history
Revision mark:
NOTE
2006/02
1.0
Date
Service manual Ver.
Revision mark

SD-502
CONTENTS
SD-502
1.
2.
PAPER PATH ...........................................................................................................2

OUTLINE
OUTLINE
3.
COMPOSITION .......................................................................................................3
4.
DRIVE......................................................................................................................4
4.1
Half-fold section ....................................................................................................4
4.2
Saddle Stitching Section .......................................................................................4
5.
OPERATIONS .........................................................................................................5
5.1
Paper Conveyance mechanism ............................................................................5
5.2
Conveyance roller pressure/release .....................................................................6
5.2.1
Pressure/release mechanism........................................................................6
5.2.2
Operation.......................................................................................................7
5.3
Stapling mechanism..............................................................................................8
5.4
Staple guide ..........................................................................................................9
5.4.1
Staple guide mechanism ...............................................................................9
5.4.2
Operation timing ............................................................................................9
5.5
Half-folding mechanism ......................................................................................10
5.5.1
5.6
Paper guide.........................................................................................................12
5.6.1
5.7
Operation.....................................................................................................11
Paper guide mechanism..............................................................................12
Tray paper detection............................................................................................13
OUTLINE
SD-502
Blank Page
ii
OUTLINE
SD-502
1.
A. Type
FS built-in saddle-stitching device
Installation
Screwed to the FS
Document Alignment
Center
Stapling Function
Center parallel two points

No. of sheets to be stapled together: 2 to 15
Consumables
Staples (2000 staples/cartridge)
OUTLINE
Type
B. Paper type
Type
Plain Paper
Size
Metric: A3, B4, A4S, B5S

Inch: 11 x 17, 81/2 11S
Capacity
56 to 90 g/m2
C. Maintenance
Maintenance
Power Requirements
24/5V DC (supplied from FS)
Power Consumption
9.5 W or less
Dimensions
445 (W) x 203 (D) x 478 mm (H)
Weight
Approx. 9.3 kg
Temperature
Humidity
NOTE
2. PAPER PATH
PAPER PATH
OUTLINE
SD-502
2.
4511t1c001na
3. COMPOSITION
SD-502
COMPOSITION
Saddle-Stitching Section
Half-Fold Section
3.
4511t2c001na
4. DRIVE
4.
SD-502
4.1
DRIVE
Half-fold section
[3]
[2]
[1]
[1] Folding Roller
4511t2c013na
[3] Half-folding Blade
[2] Folding Motor (M10)
4.2
Saddle Stitching Section
[3]
[1]
[2]
4511t2c003na
[1] Conveyance Roller /Up

[3] Exit Open/Close Motor (M9)
5.1
OPERATIONS
Paper Conveyance mechanism
Paper is conveyed by the Exit Rollers of FS and Conveyance Roller /Up [5], /Lw [2].
The Conveyance Motor (M8) [3] provides the drive for the Conveyance Roller /Lw [2].
If a center stapling operation is made with a bundle papers stored in the Stacker, a bundle
papers is conveyed to the center stapling position, through a pulse control of the Exit Roller
of FS.
A bundle papers is thereafter fed out by the Conveyance Roller /Up and /Lw.
SD-502
5.
5. OPERATIONS
[5]
[1]
[4]
[2]
[3]
4511t2c004na
[1] Exit Rollers of FS
[2] Conveyance Roller /Lw
5. OPERATIONS
5.2
SD-502
5.2.1
Conveyance roller pressure/release

Pressure/release mechanism
The Conveyance Roller /Up [1] is moved away from, or pressed up against, the Conveyance
Roller /Lw [2], when the paper is fed out as a bundle of papers.
The Saddle Exit Home Sensor (PS18) [3] is used to control the pressure/release position of
the Conveyance Roller /Up.
[1]
[3]
[2]
4511t2c005na

[2] Conveyance Roller /Lw
[3] Saddle Exit Home Sensor (PS18)

Operation
1. The Conveyance Roller /Up [5] is moved up or down by the cams which are driven by
the Exit Open/Close Motor (M9) [6].
2. When a bundle papers moves past the Conveyance Roller /Up and /Lw, the motor is
energized to press the Conveyance Roller /Up up against the Conveyance Roller /Lw,
thereby feeding a bundle papers out into the tray.
SD-502
5.2.2
5. OPERATIONS
[6]
[1]
[1]
[5]
[4]
[3]
[2]
4511t2c006na
[1] Cam
[4] Cams are rotated.
[2] Cams are rotated. + The Conveyance Roller

/Up is moved downward (pressing).

[3] The Conveyance Roller /Up is moved upward

(retraction).
5. OPERATIONS
5.3
Stapling mechanism
SD-502
The Staple units [2] position are fixed.

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

[2] Staple Unit
[3] Clincher Unit
Staple guide
The Staple Guide is used to guide the leading edge of the first sheet of paper when the first
sheet of paper is stored, thereby preventing the leading edge from contacting the Stapling
Unit and jamming.
5.4.1
SD-502
5.4
5. OPERATIONS
Staple guide mechanism
The Staple Guide Motor (M14) [3] turns the cams at the front and rear, thereby moving the
Staple Guide up or down.
The Staple Guide Home Sensor (PS26) [2] detects the position of the Staple Guide.
[3]
[2]
[1]
4511t2c008na
[1] Cam
[3] Staple Guide Motor (M14)
[2] Staple Guide Home Sensor (PS26)
5.4.2
Operation timing
1. Raising the Staple Guide

(power ON, Sleep cancelled, error reset, paper removed from tray)
2. Lowering the Staple Guide
(When the conveyance of a bundle papers to the center stapling position is completed)
3. Raising the Staple Guide
(When the trailing edge of a bundle papers deactivates the Exit Sensor (PS20))
5. OPERATIONS
SD-502
5.5
Half-folding mechanism
The Entrance Sensor (PS4) [2] of FS detects the trailing edge of the paper.
The paper feed amount is determined for each paper size as counted from the timing when
the trailing edge is detected. Half-folding is effected as follows. Specifically, the paper
undergoes a switchback operation and is conveyed to the half-folding position as the motor
is turned backward.
The Half-Folding Blade [3] is lowered and the center of the paper is pinched between the
Folding Rollers and this creates a crease in the paper.
After the half-folding, the paper is conveyed by the Conveyance Roller [7] and then the Registration Roller [1] as they are driven in that order.
[7]
[1]
[3]
[6]
[2]
[5]
[3]
[4]
4511t2c009na
[6] Conveyance Sensor (PS5)
[3] Half-Folding Blade
[4] Folding Roller Home Sensor (PS22)
10
[5] Folding Motor (M10)

Operation
When the Folding Motor (M10) is energized for one cycle of operation, the Conveyance
Guides /Lw [2] are retracted to the right and left and the Half-folding Blade [3] makes one
up-and-down reciprocating motion. In synchronism with the sequence of these operations,
the Folding Roller [1] turns one complete turn to pull the paper downward at its center.
At the same time that the Conveyance Guides /Lw returns to their original position, the Halffolding Blade goes up.
[1]
[3]
[2]
4511t2c010na
[1] Folding Roller
SD-502
5.5.1
5. OPERATIONS
[3] Half-folding Blade
[2] Conveyance Guides /Lw
11
5. OPERATIONS
SD-502
5.6
Paper guide
When a bundle papers is fed onto the tray, the Paper Guide supports the leading edge of the
paper of a large size so as to prevent it from pushing the trailing edge of the paper that has
previously been fed out.
The Paper Guide is driven only when paper with a length of 257 mm or more will be stored.
The Paper Guide advances when the Entrance Sensor (PS4) of FS is OFF and retracts
when the trailing edge of the paper passes the Exit Sensor (PS20).
5.6.1
Paper guide mechanism
The Paper Guide Motor (M13) [3] drives the Paper Guide [2].
The Paper Guide Home Sensor (PS23) [1] is used to control the home position of the Paper
Guide.
[3]
[2]
[2]
[1]
4511t2c011na
[1] Paper Guide Home Sensor (PS23)

[2] Paper Guide
12
[3] Paper Guide Motor (M13)
Tray paper detection
When paper is fed onto the tray, it pushes the actuator, which causes the Tray Empty Sensor (PS21) [1] to detect the paper.
SD-502
5.7
5. OPERATIONS
4511t2c012na
[1] Tray Empty Sensor (PS21)
13
[1]
SD-502
5. OPERATIONS
Blank Page
14
SERVICE MANUAL
Theory of Operation
MT-501
(
500 / 420)
2006.02
Ver. 1.0
Revision history
Revision mark:
NOTE
2006/02
1.0
Date
Service manual Ver.
Revision mark

MT-501
CONTENTS
MT-501
1.
2.
PAPER PATH ...........................................................................................................2

OUTLINE
OUTLINE
3.
COMPOSITION .......................................................................................................3
4.
DRIVE......................................................................................................................4
5.
OPERATIONS .........................................................................................................5
5.1
Paper conveyance mechanism .............................................................................5
5.2
Paper path selection mechanism ..........................................................................6
5.3
Paper detection .....................................................................................................7
OUTLINE
MT-501
Blank Page
ii
OUTLINE
MT-501
1.
A. Type
4 bins Mailbin (available only for printing from PC)
Installation
Screwed to the FS
Number of Bins
4 bins
Number of Sheets
Stored per Bin
Storable Paper
Plain Paper (56 to 90 g/m2)
Storable Paper Size
Metric: A4, B5, 81/2 x 11

Inch: 81/2 x 11, 51/2 x 81/2S
OUTLINE
Type
B. Maintenance
Maintenance
Power Requirements
24V DC (supplied from FS)
Dimensions
624 (W) x 503 (D) x 390 mm (H)
Weight
Approx. 8 kg
Temperature
Humidity
NOTE
2. PAPER PATH
PAPER PATH
OUTLINE
MT-501
2.
4510t1c001na
3. COMPOSITION
MT-501
COMPOSITION
3.
4510t2c001na
4. DRIVE
DRIVE
MT-501
4.
[3]
[1]
[2]
4510t2c003na

[2] Exit Roller
5.1
OPERATIONS
Paper conveyance mechanism
When the Mailbin is selected as the exit source, paper is fed off from the Finisher (FS-510)
and toward the Mailbin.
Drive for the Conveyance Rollers [2] of the Mailbin is transmitted from the Conveyance
Motor (M1) [1] by way of a belt.
As each of the Conveyance Rollers is driven, paper fed off from the Finisher is conveyed into
the Mailbin.
MT-501
5.
5. OPERATIONS
[1]
[2]
4510t2c004na
5. OPERATIONS
5.2
Paper path selection mechanism
MT-501
The Gate Solenoid /1, /2, /3 (SD1, SD2, SD3) [1] are energized or deenergized to direct
paper fed from the Finisher into a specific tray.
There are SD1, SD2, SD3 provided that will be energized or deenergized to operate the corresponding Gate [2], thereby selecting a specific paper path into a specific tray.
[1]
[2]
4510t2c005na
[1] Gate Solenoid /1, /2, /3 (SD1, SD2, SD3)
[2] Gate
Paper detection
The Paper Detection Sensor /1, /2, /3, /4 (PS1, PS2, PS3, PS4) [2] detects any sheet of
paper that is fed into the tray, causing the DF LED to light up green steadily to inform the
user that a sheet of paper has been fed into the tray.
As the paper stacks up and eventually deactivates the Paper Full Sensor /1, /2, /3, /4 (PS5,
PS6, PS7, PS8) [1], at which time a paper full condition is detected.
MT-501
5.3
5. OPERATIONS
[1]
[2]
4510t2c006na
[1] Paper Full Sensor /1, /2, /3, /4 (PS5, PS6,

PS7, PS8)
[2] Paper Detection Sensor /1, /2, /3, /4 (PS1,

PS2, PS3, PS4)
MT-501
5. OPERATIONS
Blank Page
SERVICE MANUAL
Theory of Operation
JS-502
(
500 / 420)
2006.02
Ver. 1.0
Revision history
Revision mark:
NOTE
2006/02
1.0
Date
Service manual Ver.
Revision mark

JS-502
CONTENTS
JS-502
1.
2.
PAPER PATH ...........................................................................................................2

OUTLINE
OUTLINE
3.
COMPOSITION .......................................................................................................3
4.
OPERATIONS .........................................................................................................4
Job Tray Conveyance/Exit.....................................................................................4
4.1
OUTLINE
JS-502
Blank Page
ii
OUTLINE
JS-502
1.
Name
Job Separator
Type
Expansion tray
Installation
Document Alignment
Center
OUTLINE
A. Type
B. Paper type
Exit Tray
Size
Inch:
Tray 1
(Main
Body
Tray)
11 x 17, 81/2 x 14,

81/2 x 11, 81/2 x 11S,
51/2 x 81/2S
A3, A4, A4S, A5S,
8 x 13
Metric: A3, B4, A4, A4S, B5,
B5S, A5S
11 x 17, 81/2 x 11,
81/2 x 11S, 8 x 13
11 x 17, 81/2 x 14,

81/2 x 11, 81/2 x 11S,
Tray 2
51/2 x 81/2S
(Job Tray)
B5S, A5S
Type
Plain Paper (56 to 90
g/m2)
Capacity
250 sheets
OHP transparencies
Thick paper (91 to 210g/m2)
Envelope
Special
Label
20 sheets
Letterhead
Inch:
100 sheets
C. Maintenance
Maintenance
None
Power Requirements
Power Consumption
0.2 W or less
Dimensions
450 (W) x 443 (D) x 75 mm (H)
Weight
Approx. 1.7 kg
Temperature
Humidity
NOTE
2. PAPER PATH
PAPER PATH
OUTLINE
JS-502
2.
[1]
4347t1c001na
[1] Conveyance from the main body
3. COMPOSITION
JS-502
COMPOSITION
Job Separator section
Switchback Unit section
3.
4347t2c001na
4. OPERATIONS
4.
JS-502
4.1
OPERATIONS
Job Tray Conveyance/Exit
The Switchback Unit functions to convey paper through, and feed it out from, the Job Tray.
The paper sensor section of the Job Tray is mounted to the Switchback Unit, thereby detecting paper.
When paper stacks up on the Tray [3], the actuator [2] is pushed up by the paper, indicating
that there is paper at the exit port.
[1]
[3]
[2]
4347t2c002na
[1] Paper Full Sensor (PS1)

[2] Actuator
[3] Tray
2006 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.

Use of this manual should be strictly supervised to avoid
disclosure of confidential information.
Printed in Japan
NN50GAPE1-0900
SERVICE MANUAL
Field Service
500 / 420
2006.02
Ver. 1.0
FIELD SERVICE TOTAL CONTENTS

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

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

Read carefully the Safety and Important Warning Items described below to understand
them before doing service work.
IMPORTANT NOTICE
Because of possible hazards to an inexperienced person servicing this product as well as
the risk of damage to the product, Konica Minolta Business Technologies, INC. (hereafter
called the KMBT) strongly recommends that all servicing be performed only by KMBTtrained 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.
:Prohibition when using the
copier.
:Direction when using the
copier.
General
precaution
Electric hazard
High
temperature
General
prohibition
Do not touch
with wet hand
Do not
disassemble
General
instruction
Unplug
Ground/Earth
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 reasoning behind this policy.
Prohibited Actions
DANGER
Using any cables or power cord not specified by KMBT.
Using any fuse or thermostat not specified by KMBT.

injury.
Disabling fuse functions or bridging fuse terminals with
wire, metal clips, solder or similar object.
Disabling relay functions (such as wedging paper between
relay contacts)
Disabling safety functions (interlocks, safety circuits, etc.)

injury.
Making any modification to the product unless instructed
by KMBT
Using parts not specified by KMBT
S-2
[2] POWER PLUG SELECTION

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

WARNING
Use power supply cord set which meets the following
criteria:
- provided with a plug having configuration intended for
the connection to wall outlet appropriate for the product's rated voltage and current, and
AC230V

- provided with three-conductor cable having enough current capacity, and
- the cord set meets regulatory requirements for the area.
AC208V
240V
Use of inadequate cord set leads to fire or electric shock.

Attach power plug which meets the following criteria:
- having configuration intended for the connection to wall
outlet appropriate for the product's rated voltage and
current, and
- meets regulatory requirements for the area.
Use of inadequate cord set leads to the product connecting to inadequate power supply (voltage, current capacity,
Conductors in the power cable must be connected to terminals of the plug according to the following order:
Black or Brown:
L (line)
White or Light Blue:
N (neutral)
Green/Yellow:
PE (earth)
Wrong connection may cancel safeguards within the

product, and results in fire or electric shock.
S-3
[3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE

Konica Minolta brand products are extensively tested before shipping, to ensure that all
applicable safety standards are met, in order to protect the customer and CE from the risk
of injury. However, in daily use, any electrical equipment may be subject to parts wear and
eventual failure. In order to maintain safety and reliability, the CE must perform regular
safety checks.
1.
Power Supply

WARNING
Check that mains voltage is as specified.
Connection to wrong voltage supply may result in fire or
electric shock.
?V
Connect power plug directly into wall outlet having same

configuration as the plug.
Use of an adapter leads to the product connecting to
inadequate power supply (voltage, current capacity,
If proper wall outlet is not available, advice the customer
to contact qualified electrician for the installation.
Plug the power cord into the dedicated wall outlet with a
capacity greater than the maximum power consumption.
result.
If two or more power cords can be plugged into the wall
outlet, the total load must not exceed the rating of the wall
outlet.
result.
Make sure the power cord is plugged in the wall outlet
securely.
Contact problems may lead to increased resistance,
overheating, and the risk of fire.
S-4
kw

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 product securely, a contact problem may lead to increased
resistance, overheating, and risk of fire.
Check whether the power cord is not stepped on or
pinched by a table and so on.
Check whether the power cord is damaged. Check

whether the sheath is damaged.
If the power plug, cord, or sheath is damaged, replace
with a new power cord or cord set (with plug and connector on each end) specified by KMBT.
Using the damaged power cord may result in fire or electric shock.
Do not bundle or tie the power cord.
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 volatile materials that may catch fire.
Do not place the product in a place exposed to water such
as rain.
A risk of fire and electric shock exists.
When not Using the Product for a long time

WARNING
When the product is not used over an extended period of
time (holidays, etc.), switch it off and unplug the power
cord.
Dust collected around the power plug and outlet may
cause fire.
Ventilation
CAUTION
The product generates ozone gas during operation, but it
will not be harmful to the human body.
If a bad smell of ozone is present in the following cases,
ventilate the room.
a. When the product is used in a poorly ventilated room
b. When taking a lot of copies
c. When using multiple products at the same time
Fixing
CAUTION
Be sure to lock the caster stoppers.
In the case of an earthquake and so on, the product may
slide, leading to a injury.
S-7
Inspection before Servicing

CAUTION
Before conducting an inspection, read all relevant documentation (service manual, technical notices, etc.) and
proceed with the inspection following the prescribed procedure in safety clothes, using only the prescribed tools.
Do not make any adjustment not described in the documentation.
If the prescribed procedure or tool is not used, the product 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 electric shock exists.
S-8
Safety Checkpoints
WARNING
Check the exterior and frame for edges, burrs, and other
damages.
The user or CE may be injured.
Do not allow any metal parts such as clips, staples, and
screws to fall into the product.
They can short internal circuits and cause electric shock
or fire.
Check wiring for squeezing and any other damage.
fire.
Carefully remove all toner remnants and dust from electrical parts and electrode units such as a charging corona
unit.
Current can leak, leading to a risk of product trouble or
fire.
Check high-voltage cables and sheaths for any damage.
fire.
Check electrode units such as a charging corona unit for

deterioration and sign of leakage.
Current can leak, leading to a risk of trouble or fire.
Before disassembling or adjusting the write unit (P/H unit)
incorporating a laser, make sure that the power cord has
been disconnected.
loss of eyesight.
Do not remove the cover of the write unit. Do not supply
power with the write unit shifted from the specified mounting position.
loss of eyesight.
S-9
Safety Checkpoints
WARNING
When replacing a lithium battery, replace it with a new lithium 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 installation 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, connectors, etc. that were removed for safety check and maintenance have been reinstalled in the original location. (Pay
special attention to forgotten connectors, pinched cables,
forgotten screws, etc.)
A risk of product trouble, electric shock, and fire exists.
WARNING
Toner and developer are not harmful substances, but care
must be taken not to breathe excessive amounts or let the
substances come into contact with eyes, etc. It may be
stimulative.
If the substances get in the eye, rinse with plenty of water
immediately. When symptoms are noticeable, consult a
physician.
S-10
WARNING
Never throw the used cartridge and toner into fire.
You may be burned due to dust explosion.
Handling of Service Materials

CAUTION
Unplug the power cord from the wall outlet.
Isopropyl alcohol and acetone are highly flammable and
must be handled with care. A risk of fire exists.
Do not replace the cover or turn the product ON before

any solvent remnants on the cleaned parts have fully
evaporated.
Use only a small amount of cleaner at a time and take
care not to spill any liquid. If this happens, immediately
wipe it off.
When using any solvent, ventilate the room well.
Breathing large quantities of organic solvents can lead to
discomfort.
S-11
SAFETY INFORMATION
SAFETY INFORMATION
IMPORTANT NOTICE
The Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration 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 emitted inside this copier is completely confined within protective housings and external covers,
the laser beam cannot escape during any phase of normal user operation.
S-12
SAFETY INFORMATION
INDICATION OF WARNING ON THE MACHINE

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

AN ACCIDENT
1. If an accident has occurred, the distributor who has been notified first must immediately
take emergency measures to provide relief to affected persons and to prevent further
damage.
2. If a report of a serious accident has been received from a customer, an on-site evaluation 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 specified by every distributor.
S-15
Blank Page
S-16
Composition of the service manual

This service manual consists of the following sections and chapters:
<Theory of Operation section>
OUTLINE:
System configuration, product specifications,

unit configuration, and paper path
COMPOSITION/OPERATION: Configuration of each unit, explanation of the operating

system, and explanation of the control system
This section gives, as information for the CE to get a full understanding of the product, a
rough outline of the object and role of each function, the relationship between the electrical
system and the mechanical system, and the timing of operation of each part.
<Field service section>
OUTLINE:
System configuration, and product specifications
MAINTENANCE:
Service schedule *, maintenance steps,

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

chart, overall layout drawing
This section gives, as information required by the CE at the site (or at the customer's
premise), a rough outline of the service schedule and its details, maintenance steps, the
object and role of each adjustment, error codes and supplementary information.
The details of items with an asterisk "*" are described only in the service manual of
the main body.
C-1
Notation of the service manual

A. Product name
In this manual, each of the products is described as follows:
(1) IC board:
Standard printer
(2) bizhub 500 / 420:
Main body
(3) Microsoft Windows 95:
Windows 95
Windows 98
Microsoft Windows Me:
Windows Me
Microsoft Windows NT 4.0:
Windows NT 4.0 or Windows NT
Windows 2000
Microsoft Windows XP:
Windows XP
When the description is made in combination of the OS's mentioned above:

Windows 95/98/Me
Windows NT 4.0/2000
Windows NT/2000/XP
Windows 95/98/Me/NT/2000/XP
B. Brand name
The company names and product names mentioned in this manual are the brand name or
the registered trademark of each company.
C. Electrical parts and signals

Those listed by way of example below are not exhaustive, but only some instances among
many.
Ex. of signal name
Description
IN
PS
Sensor
PS
Door PS1
Sensor detection signal
SIG
102 PS
24V
Solenoid
SD
DRV
SOL
24V
Clutch
CL
DRV
SOL
C-2
Power to drive the solenoid

Drive signal
Power to drive the clutch
Drive signal
Motor
Ex. of signal name
Description
24V
Power to drive the motor
CONT
Drive signal
DRV1
DRV2
D1
Drive signals of two kinds
D2
_U
_V
_W
DRV1
Drive signals (control signals) of three kinds
DRV2
DRV3
D1
D2
D3
D4
DRV A
DRV A
DRV B
DRV B
Drive signals (control signals) of four kinds

Motor, phases A and B control signals
A
Motor
/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
SS
Fan
Others
FM
Operating load start/stop signal
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
HL
Speed control signal (2 speeds)
EM, Lock, LCK, FEM
Detection signal
TH1.S, ANG
Analog signal
C-3

Ground
Serial communication
Ex. of signal name
Description
SG, S.GND, S_GND
Signal 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)
DSR, DSET
Data set ready
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 longitudinally.
<Example>
Paper size
A4
A3
C-4
Feed direction
Notation
Transverse feed
A4
Longitudinal feed
A4S
Longitudinal feed
A3
SERVICE MANUAL
Field Service
500 / 420
Main body
2006.02
Ver. 1.0
Revision history
Revision mark:
NOTE
2006/02
1.0
Date
Service manual Ver.
Revision mark

Field Service Ver1.0 Feb.2006
CONTENTS
bizhub 500 / 420
CONTENTS
bizhub 500 / 420
OUTLINE
1. SYSTEM CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MAINTENANCE
3. PERIODIC CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1
3.2
3.3
Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1.1
Main body (bizhub 500) / DF / PC / LU / FS / MT / SD / RU . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1.2
Main body (bizhub 420) / DF / PC / LU / FS / MT / SD / RU . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2.1
Main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2.2
DF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2.3
PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.4
LU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2.5
FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2.6
MT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2.7
SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2.8
RU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replacement parts list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.3.1
3.4
3.4.1
3.5
3.8
Replacing the filter cover assy and the suction filter /A assy . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5.3
Replacing the paper exit suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Maintenance procedure of the write section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Replacing the write unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Maintenance procedure of the photosensitive material section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.7.1
Replacing the drum unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.7.2
Replacing the drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Maintenance procedure of the transfer/separation corona section. . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.8.1
3.9
Replacing the ozone filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5.2
3.6.1
3.7
Life value of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Maintenance procedure of the external section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.5.1
3.6
Periodically replacement parts list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Life value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Replacing the transfer/separation corona unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Maintenance procedure of the developing section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.9.1
Replacing the developing unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.9.2
Replacing developer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.10 Maintenance procedure of the toner supply section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3.10.1 Replacing the filter mounting plate assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.10.2 Replacing the suction cover /2 assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.11 Cleaning/toner recycle section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.11.1 Replacing the cleaning blade assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.12 Maintenance procedure of the paper feed section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.12.1 Replacing the feed roller/pick-up roller (tray 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.12.2 Replacing the separation roller assy (tray 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
CONTENTS
3.12.3 Replacing the feed roller/pick-up roller (tray 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
bizhub 500 / 420
3.12.4 Replacing the separation roller assy (tray 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

3.13 Maintenance procedure of the bypass tray section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.13.1 Removing/reinstalling the bypass unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.13.2 Replacing the separation roller assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.13.3 Replacing the feed roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.14 Maintenance procedure of the registration section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.14.1 Cleaning the paper dust removing brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.14.2 Replacing the loop roller, the loop bearing, the registration roller /Rt,
and the registration bearings /Rt and /Lt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.15 Maintenance procedure of the fusing section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.15.1 Removing/reinstalling the fusing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.15.2 Replacing the fusing claw assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.15.3 Replacing the fusing web . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.15.4 Replacing the fusing driven roller assy /A and /B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.15.5 Removing/reinstalling the fusing heater lamps /1 (L2) and /2 (L3) . . . . . . . . . . . . . . . . . . . . . . . 84
3.15.6 Replacing the fusing roller, the fusing pressure roller, the heat insulating sleeve /A,
the fusing bearings /Up and /Lw and the fusing input gear assy . . . . . . . . . . . . . . . . . . . . . . . . 86
3.15.7 Replacing the fusing sensor assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.15.8 Replacing the fuse holder assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4. SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.1
Service material list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.2
Jig list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.3
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5. FIRMWARE VERSION UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.1
5.2
ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.1.1
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.1.2
Firmware data flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.1.3
Settings on the main body side while in ISW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
ISWTrns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.2.1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.2.2
Installation of the ISWTrns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.2.3
Usage of the ISWTrns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.2.4
Error list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6. OTHERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.1
6.2
6.3
ii
Items not allowed to be disassembled and adjusted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

6.1.1
Scanner section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.1.2
Write section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.1.3
Developing unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
6.1.4
Drum unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
List of parts to be disassembled and reassembled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Disassembling/assembling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.3.1
Removing/reinstalling the rear cover /1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.3.2
6.3.3
6.3.4
Removing/reinstalling the right cover /Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
6.3.5
Removing/reinstalling the right cover /Lw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
6.3.6
Removing/reinstalling the left cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
6.3.7
Removing/reinstalling the front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.3.8
Removing/reinstalling the original glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.3.9
Removing/reinstalling the upper covers /Fr and /Lt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
CONTENTS
6.3.11 Removing/reinstalling the front cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

6.3.12 Removing/reinstalling the operation panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
6.3.13 Removing/reinstalling the CCD unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
6.3.14 Replacing the exposure lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.3.15 Removing/reinstalling the exposure unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
6.3.16 Stretching the scanner wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
6.3.17 Removing/reinstalling the toner supply unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.3.18 Removing/reinstalling the trays 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6.4
Option counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

6.4.1
Configuration of the key counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
6.4.2
Installation procedure of the key counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
ADJUSTMENT/SETTING
7. HOW TO USE THE ADJUSTMENT/SETTING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.1
Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
8. UTILITY MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

8.1
List of utility mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
9. LIST OF ADJUSTMENT ITEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

10. SERVICE MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
10.1 List of service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
10.2 Setting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
10.2.1 Start and exit of the service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
10.3 Machine Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
10.3.1 Print Positioning: Leading Edge (Printer Area). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
10.3.2 Print Positioning: Side Edge (Printer Area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
10.3.3 Paper Feed Direction Adj. (Printer Area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
10.3.4 Printer Resist Loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
10.3.5 Bypass Tray Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
10.3.6 Image Position: Leading Edge (Scan Area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
10.3.7 Image Position: Side Edge (Scan Area). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
10.3.8 Cross Direction Adjustment (Scan Area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
10.3.9 Feed Direction Adjustment (Scan Area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
10.3.10 Lead Edge Erase Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
10.3.11 Non-Image Area Erase Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
10.4 Imaging Process Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.1 Charging Main Manual Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.2 Transfer Manual Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.3 Separation (AC) Manual Adj.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.4 Separation (DC) Manual Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.5 Grid Charging Manual Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.6 Bias Voltage Manual Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.7 TCR Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.8 Toner Auto Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.4.9 Toner Density Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
10.4.10 Laser Diameter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
10.4.11 LD1 Offset Adj. / LD2 Offset Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
10.4.12 LD1 Bias Adj. / LD2 Bias Adj.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
10.5 System 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
10.5.1 Marketing Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
iii
bizhub 500 / 420
6.3.10 Removing/reinstalling the upper cover /Rr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
CONTENTS
10.5.2 Tel/Fax Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
bizhub 500 / 420
10.5.3 Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

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

10.12.4 ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
10.12.5 Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
10.12.6 Trouble Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
10.13 List Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
10.13.1 List output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
10.14 Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
10.14.1 Test pattern list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
10.14.2 Test pattern output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
10.14.3 Running Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
10.15 Fax setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
10.16 Enhanced Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
10.16.1 List of the security setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
10.16.2 Start and termination of the security mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
10.16.3 CE Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
10.16.4 Administrator Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
10.16.5 Administrator Feature Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
10.16.6 CE Authentication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
10.17 Billing Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
10.17.1 List of the billing setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
10.17.2 Start and termination of the billing setting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
10.17.3 Counter Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
10.17.4 Management Function Choice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
11. MECHANICAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
11.1 Mis-centering adjustment of the trays 1 and 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
11.2 Mis-centering adjustment of the bypass tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
TROUBLESHOOTING
12. JAM CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
12.1 Jam code list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
13. MALFUNCTION CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
13.1 Malfunction code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
APPENDIX
14. PARTS LAYOUT DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
14.1 Main body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
14.1.1 Switch/sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
14.1.2 Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
14.1.3 Boards and others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
14.2 DF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
14.3 PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
14.3.1 PC-202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
14.3.2 PC-402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
14.4 LU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
14.5 FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
14.5.1 FS-510. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
14.5.2 FS-511. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
14.6 PU-501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
14.7 SD-502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
bizhub 500 / 420
10.12.2 Paper Size Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
CONTENTS
14.8 MT-501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
bizhub 500 / 420
14.9 RU-502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

14.10 JS-502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
15. CONNECTOR LAYOUT DRAWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
15.1 Main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
15.1.1 Connector in the board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
15.2 DF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
15.3 PC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
15.4 LU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
15.5 FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
15.6 SD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
15.7 MT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
16. TIMING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
16.1 Main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
16.2 DF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
16.3 LU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
16.4 FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
16.4.1 FS-510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
16.4.2 FS-511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
17. OVERALL WIRING DIAGRAM
17.1 Main body 1/4
17.2 Main body 2/4
17.3 Main body 3/4
17.4 Main body 4/4
17.5 DF
17.6 PC
17.6.1 PC-202
17.6.2 PC-402
17.7 LU
17.8 FS
17.8.1 FS-510/PU-501
17.8.2 FS-511
17.9 SD
17.10 MT
vi
bizhub 500 / 420
OUTLINE
A. System configuration
[23]
[27]
[24]
[25]
[28]
[26]
[5]
[6]
[7]
[8]
[9]
[1]
[2]
[3]
[4]
[22]
[21]
[20]
[11]
[19]
[14]
[17]
[15]
[18]
[10]
[12]
[10]
[13]
[16]
50gat1e001na
[1]
[2]
Reverse automatic document feeder
[15]
(DF-607) (standard equipment)
[16]
Dehumidifier heater *2
Relay unit (RU-502)
Main body
[17]
Finisher (FS-511)
[3]
Image controller (IC-204)
[18]
Swedish punch kit G *3
[4]
Hard disk (HD-505)
[19]
Job separator (JS-502)
[5]
Stamp unit (SP-501)
[20]
Output tray kit (OT-501)
[6]
Spare TX marker stamp 2
[21]
Output tray (OT-601)
[7]
Key counter kit 4 *1
[22]
Finisher (FS-510)
[8]
Key counter *1
[23]
Mail bin kit (MT-501)
[9]
Key counter mount kit *1
[24]
Saddle stitcher (SD-502)
[10]
Dehumidifier heater 1C
[25]
Folding unit (included in SD-502)
[11]
[26]
Punch unit (PU-501)
[12]
[27]
FAX kit (FK-502)
[13]
Desk (DK-501)
[28]
Mount kit (MK-708)
[14]
Large capacity unit (LU-201)
*1
See "6.4 Option counter" in Field Service bizhub 500 / 420 main body for details.
*2
Dehumidifier heater is set up as service part.
*3
Swedish punch kit G is for Europe only.
bizhub 500 / 420
B. Configuration for optional device connection

Note
Any combination other than those listed below is not available.
No.
Combinations for paper feeding
Combinations for finishing
DK-501/PC-202/PC-402 *1
OT-501
DK-501/PC-202/PC-402 *1
DK-501/PC-202/PC-402 *1
OT-501
JS-502
RU-502 + FS-511
DK-501/PC-202/PC-402 *1
DK-501/PC-202/PC-402 *1
FS-510 *2*3
FS-510 *2*3
SD-502
DK-501/PC-202/PC-402 *1
FS-510 *2*3
MT-501
PC-202/PC-402 *4
LU-201
PC-202/PC-402 *4
LU-201
PC-202/PC-402 *4
LU-201
OT-501
OT-501
JS-502
RU-502 + FS-511
10
PC-202/PC-402 *4
LU-201
11
PC-202/PC-402 *4
LU-201
FS-510 *2*3
FS-510 *2*3
SD-502
12
PC-202/PC-402 *4
LU-201
FS-510 *2*3
MT-501
*1
Either one of DK-501, PC-202 and PC-402 can be selected.
*2
FS-510 can be installed optionally with OT-601.
*3
FS-510 can be installed optionally with PU-501.
*4
Either one of PC-202 and PC-402 can be selected.
Remarks
bizhub 500 / 420
A. Type
Type
Desktop type
Copying method
Indirect electrostatic method
Original stand
Fixed
Original alignment
Left rear standard
Photo conductor
OPC
Sensitizing method
Laser writing
Paper feed trays
*1
Two trays
500 sheet x 2, 80g/m2
Bypass feed
150 sheet x 1, 80g/m2
PC-402 *1
2,500 sheet x 1, 80g/m2
PC-202 *1
500 sheet x 1, 80g/m2
LU-201 *1
2,000 sheet x 1, 80g/m2
PC-402, PC-404, and LU-201 are optional.
bizhub 500 / 420
B. Functions
Original
Sheet, book, solid object
Max. original size
A3 or 11 x 17
Copy size
Trays 1, 2
Inch:
11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S,

Metric: A3, B4, A4, A4S, B5, A5S, 11 x 17, 81/2 x 11,
81/2 x 11S, Foolscap, 8K, 16K
Bypass feed
Inch:
11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S,

A4
Metric: A3, B4, A4, A4S, B5, B5S, A5S, B6S, 81/2 x 11,
81/2 x 11S, Foolscap, 8K, 16K, 16KS
ADU
Inch:
11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S,

Metric: A3, B4, A4, A4S, B5, B5S, A5S, 11 x 17, 81/2 x 11,
Magnification
Fixed magnifica-
Inch:
tion
x 1.000, x 1.214, x 1.294, x 1.545, x 2.000

x 0.500, x 0.647, x 0.772, x 0.785
Metric: x 1.000, x 1.154, x 1.224, x 1.414, x 2.000

x 0.500, x 0.707, x 0.816, x 0.866
Special magnifi-
x 0.930
cation setting
Preset zoom set-
3 types
ting
Zoom magnifica-
tion
Vertical magnifi-
cation
Horizontal magni-
fication
Warm-up time

First copy out time

Continuous copy speed

Continuous copy count
Up to 999 sheets
Original density selection
Auto density selection, Manual (9 steps), Manual underprint density (9 steps)
Resolution
Scan
600 x 600 dpi
Write
Inch:
1,200 (equivalent) x 600 dpi
Metric: 2,400 (equivalent) x 600 dpi

Memory
Standard 192 MB
Breakdown: 64 MB (on board) + 128 MB (DIMM)
Maximum 320 MB Breakdown: 64 MB (on board) + 256 MB (DIMM) *1

Interface section
RJ45 Ethernet, Serial port (RS232-C), Serial port (USB TypeB),

Parallel port (IEEE1284), RJ-11 *2
*1
*2
256 MB (DIMM) is available from distributors.

Specification: 144 pin SO-DIMM, PC100/PC133 MHz Compliant
1 port when MK-708 and FK-502 are optionally installed.
bizhub 500 / 420
C. Type of paper
High quality paper of 60 to 90 g/m2
Plain paper *1
All trays
Special paper *2
Bypass feed only
OHP film, label paper *3, blueprint master paper *3

High quality paper of 50 to 59 g/m2 (thin paper)
*1
All trays
Bypass feed only
Standard specified paper

Plain paper:
Inch:
Metric: Konica Minolta Original (80 g/m2), Konica Minolta Profi (80 g/m2)
Recycle paper:
Inch:
Weyerhaeuser Recycled Laser Copy (20 lbs)

*2
Special paper/recommended paper

Thick paper:
Inch:
Weyerhaeuser Cougar Cover 65 lbs
Metric: Xerox colortech 200 g/m2

Thin paper:
Inch:
SOISE BOND 16 lbs
Metric: NEU 60 g/m2

Label paper:
Inch:
AVERY 5160, 5352
Metric: AVERY DSP 24

OHP film:
Inch:
3M CG3700
Metric: Folex overhead X-500, 3M CG3700

Envelope:
Inch:
Preservation Wove (24 lbs) #6-3/4, #9, #10 (4-1/8 x 9-1/2)
Metric: Briefhullen 211210 (100 g/m2) #C6

Schneider Soehne Distinction 100 (100 g/m2) #lang
Schneider Soehne (Briefumschlage) (100 g/m2) #C5
*3
Label paper is loaded and fed one sheet at a time.
D. Maintenance
Maintenance

E. Machine data
Power source
Inch:
AC120V 12A, 60Hz
Metric: AC220-240V 10A, 50Hz

Maximum power consump- 1,560 W or less (full option)
tion
Dimensions
Main body
677 (W) x 708 (D) x 1,150 (H) mm *1
+ DF-607
+ PC or DK
Weight
*1
Approx. 91.2 kg
Overturning prevention board is not included.
bizhub 500 / 420
F.
Temperature
10 to 30 C
Humidity
10 to 80%RH (with no condensation)
Note
3. PERIODIC CHECK
bizhub 500 / 420
MAINTENANCE
3. PERIODIC CHECK
3.1
Schedule
3.1.1
Main body (bizhub 500) / DF / PC / LU / FS / MT / SD / RU
Guarantee period: 5 years or 2,250,000 prints

Service item
x 10,000 prints
Main body (bizhub 500)
0
Maintenance 1
No. of
executions
25
50
75
100
125
150
175
200
8 times
4 times

Maintenance 2

Maintenance 3
2 times

Maintenance 4
1 times
DF
Every 1,250,000 prints

Maintenance 1
8 times
4 times
8 times

Maintenance 2
PC

Maintenance 1

Maintenance 2
2 times
LU

Maintenance 1
8 times
4 times

Maintenance 2
FS
Maintenance 1
MT
Maintenance 1
SD
Maintenance 1
RU
Maintenance 1
8 times
8 times
8 times
8 times

3. PERIODIC CHECK
bizhub 500 / 420
3.1.2
Main body (bizhub 420) / DF / PC / LU / FS / MT / SD / RU
Guarantee period: 5 years or 1,800,000 prints

Service item
x 10,000 prints
Main body (bizhub 420)
0
Maintenance 1
No. of
25
50
75
100
125
150
175
executions
7 times

Maintenance 2
3 times
2 times

Maintenance 3

Maintenance 4
1 times
DF
Every 1,250,000 prints

Maintenance 1
7 times

Maintenance 2
3 times
PC

Maintenance 1
7 times

Maintenance 2
2 times
LU

Maintenance 1
7 times

Maintenance 2
3 times
FS
Maintenance 1
MT
Maintenance 1
SD
Maintenance 1
RU
Maintenance 1
7 times
7 times
7 times
7 times
Every 250,000prints
Maintenance item
Note
For the replacement procedure of periodically replaced parts, see "3.5 Maintenance procedure of
the external section" to "3.15 Maintenance procedure of the fusing section".
The alcohol described in this section represents the isopropyl alchol.
3.2.1
Main body
A. Maintenance 1 (Every 250,000 prints)

No.
Unit
Description
Quantity
classification
1
Preparations
Photo con-
Drum
ductor sec-
DR510
tion
Materials
Tools used
Image check
Exterior
2
Implementation classification
Cleaning Check Lubrication Replacement
z
Alcohol/cleaning pad
Drum count reset

(Service mode)
Cleaning blade assy
Setting powder
50GA-209
Charge unit
Transfer/sep-
Transfer/separation
aration sec-
unit
Cotton swab (wire),

Cotton swab (wire)
tion
4
Developing
Developer
section
DV511
TCR adjustment
(Service mode)
5
Main body
Filter mounting plate

assy
50GA-336
Ozon filter
50GA1031
Suction filter /A assy
40LA-318
Filter cover assy
50GA-314
Suction cover /2 assy
50GA-311
Scanner
Original glass (includ-
section
ing slit glass)
Paper feed
Mirror 1 to mirror 3
Pick-up roller, feed
section
roller (Tray 1, 2)
Separation roller assy

(Tray 1, 2)
bizhub 500 / 420
3.2
3. PERIODIC CHECK
3. PERIODIC CHECK
bizhub 500 / 420
No.
Unit
Description
Quantity
classification
8
Bypass tray
Feed roller
Materials
Tools used
section
Separation roller
9
Fusing
Fusing roller
section
50GE5303
z
1
(bizhub 500)
50GA5303
(bizhub 420)
50GA5304
Fusing web
50GA-540
Fusing counter
reset
Heat insulating sleeve /A
26NA5372
Fusing bearing /Up
26NA5371
Fusing bearing /Lw
50GA5359
Fusing driven roller /A
assy
40400326
Fusing driven roller /B
assy
40400328
10 Paper reverse
section
11 Registration
section
12 Final check
Fusing sensor
Fusing claw
Thermostat
Paper exit suction filter
50GA4406
Paper dust removing
Blower brush
Registration roller /Rt
Registration roller /Lt
Loop roller
Reflective sensor
brush
Paper through, Image
Blower brush
z
check
PM count reset
Exterior cleaning
10
z
z
3. PERIODIC CHECK
No.
Unit
Description
Quantity
classification
1
Transfer/sep-
Transfer/separation
aration sec-
unit
tion
50GA-260
Fusing
Fusing sensor assy
section
50GA-544
Fuse holder assy
Materials
Tools used
bizhub 500 / 420
B. Maintenance 2 (Every 500,000 prints)
26NA-535
Fusing claw assy
50GA-533
Fusing input gear assy
50GA-546
C. Maintenance 3 (Every 750,000 prints)

No.
Unit
Description
Quantity
classification
1
Photo con-
Drum unit
ductor sec-
50GA-200
Materials
Tools used
Actual: 300,000 feeds
tion
2
3
Developing
Developing unit
section
50GA-300
Paper feed
Pick-up roller
section
40303005
Feed roller
40303005
(Tray 1, 2)
40300151
Bypass tray
Paper feed roller
section
41313001
40340151
11
3. PERIODIC CHECK
bizhub 500 / 420
D. Maintenance 4 (Every 1,250,000 prints)

No.
Unit
Description
Quantity
classification
1
Registration
Registration bearing /Rt
section
26NA4536
Registration bearing /Lt
Materials
Tools used
26NA4537
Loop roller
50GA3865
50GA3848
Loop bearing
26NA4082
2
Write section
Write unit
50GA-650
3.2.2
DF

No.
Unit
Description
classification
1
Preparations
Quantity
Materials
Tools used
Paper through, mage
condition
Appearance
2
Paper feed
Pick-up roller
Feed roller
Separation roller
Other rollers
Each sensor
Scanning guide
section
Actual: 50,000 faces

Blower brush
Paper con-
veyance sec-
tion
4
Final check
Paper through, image
check
Exterior cleaning
12
3. PERIODIC CHECK
No.
Unit
Description
Quantity
classification
1
Paper feed
Pick-up roller
section
43445003
Feed roller
Materials
Tools used
45823014
Separation roller
45823047
3.2.3
PC

No.
Unit
Description
Quantity
classification
Materials
Tools used
Preparations
Paper through check
Paper feed
Pick-up roller
section
Feed roller
Separation roller
Final check
Paper through check
Exterior cleaning

No.
Unit
Description
Quantity
classification
1
Paper feed
Pick-up roller
section
40303005
Feed roller
Materials
Tools used
40303005
40300151
13
bizhub 500 / 420
3. PERIODIC CHECK
3.2.4
LU
bizhub 500 / 420

No.
Unit
Description
Quantity
classification
Materials
Tools used
Preparations
Paper through check
Paper feed
Pick-up rubber
Feed rubber
Separation rubber
section
Final check
Paper through check
z
Exterior cleaning

No.
Unit
Description
Quantity
classification
1
Paper feed
Pick-up rubber
section
40LA1009
Feed rubber
Materials
Tools used
26NA4011
Separation rubber
26NA4012
3.2.5
FS

No.
Unit
Description
classification
Quantity
Materials
Tools used
Preparations
Paper through check
Conveyance
Each roller
Paddle
section, staple section

3
Staple
section
Final check
Paper through check

Exterior cleaning
14
z
z

MT

No.
Unit
Description
Quantity
classification
1
Preparations
Paper through check
Conveyance
Each roller
Materials
Tools used
z
section
3
Final check
Paper through check
Exterior cleaning
3.2.7
SD

No.
Unit
Description
Quantity
classification
1
Preparations
Paper through check
Conveyance
Each roller
Materials
Tools used
z
section
3
Final check
Paper through check
Exterior cleaning
3.2.8
RU

No.
Unit
Description
classification
1
Preparations
Paper through check
Conveyance
Each roller
Quantity
Materials
Tools used
z
section
3
Final check
Paper through check

Exterior cleaning
z
z
15
bizhub 500 / 420
3.2.6
3. PERIODIC CHECK
3. PERIODIC CHECK
bizhub 500 / 420
3.3
3.3.1
Replacement parts list

Periodically replacement parts list
Note
For the replacement procedure of periodically replaced parts, see "3.5 Maintenance procedure of
The parts count No. given in the table below represents the number of the fixed parts number in
the Service mode.
A. Main body
No.
Classification
Part name
Part number
Qt.
Actual replace- Parts count

ment cycle
Photo con-
ductor section Cleaning blade assy
3
4
Transfer/
Drum
No.
Page
referred to
DR510
250,000
P.28
50GA-209
250,000
P.42
Drum unit (without drum)
50GA-200
750,000
P.27
Transfer/separation unit
50GA-260
500,000
P.34
separation
section
5
Developing
Developer
DV511
250,000
P.36
section
Developing unit
50GA-300
750,000
P.35
Main body
Filter mounting plate assy
50GA-336
250,000
P.39
Ozon filter
50GA1031
250,000
P.19
40LA-318
250,000
P.20
10
Filter cover assy
50GA-314
250,000
P.20
11
50GA-311
250,000
P.40
Pick-up roller
40303005
300,000
P.44
13
Feed roller
40303005
300,000
P.44
14
40300151
300,000
P.49
41313001
200,000
P.66
12
Paper feed
section
P.51
P.51
(Tray 1, 2)
P.58
15
Bypass tray
Paper feed roller
16
section
40340151
200,000
P.63
17
Registration
Loop roller
50GA3865
1,250,000
P.69
18
section
50GA3848
1,250,000
P.69
19
Registration bearing /Rt
26NA4536
1,250,000
P.69
20
Registration bearing /Lt
26NA4537
1,250,000
P.69
21
Loop bearing
26NA4082
1,250,000
P.69
Fusing roller
50GE5303
250,000
P.86
22
Fusing
section
(bizhub 500)
50GA5303
(bizhub 420)
16
No.
Classification
3. PERIODIC CHECK
Part name
Part number
Qt.

ment cycle
23
Fusing
section
50GA5304
No.
Page
referred to
250,000
P.86
250,000
P.80
(bizhub 500)
50GA5304
(bizhub 420)
24
Fusing web
50GA-540
(bizhub 500)
50GA-540
(bizhub 420)
25
26NA5372
250,000
P.86
26
Fusing bearing /Up
26NA5371
250,000
P.86
27
Fusing bearing /Lw
50GA5359
250,000
P.86
28
Fusing sensor assy
50GA-544
500,000
P.89
29
Fuse holder assy
26NA-535
500,000
P.91
30
Fusing claw assy
50GA-533
500,000
P.78
31
Fusing driven roller /A assy
40400326
250,000
P.82
32
Fusing driven roller /B assy
40400328
250,000
P.82
33
50GA-546
500,000
P.86
50GA4406
250,000
P.22
Write unit
50GA-650
1,250,000
P.23
Part number
Qt.
34
Paper reverse
section
35
Write section
B. Option
No.
Classification
Part name

ment cycle
DF
2
3
4
PC
5
6
No.
Page
referred to
Pick-up roller
43445003
200,000
*1
Feed roller
45823014
200,000
*1
*2
Separation roller
45823047
200,000
Pick-up roller
40303005
300,000
*3
Feed roller
40303005
300,000
*4
*5
40300151
300,000
Pick-up rubber
40LA4009
200,000
*6
Feed rubber
26NA4011
200,000
*6
Separation rubber
26NA4012
200,000
*7
LU
*1
(See P.5 in "Field Service DF-607")
*2
(See P.6 in "Field Service DF-607")
*3
(See P.7 in "Field Service PC-202 (bizhub 500/420)" / See P.7 in "Field Service PC-402 (bizhub 500/420)")
*4
*5
*6
(See P.3 in "Field Service LU-201")
*7
(See P.7 in "Field Service LU-201")
17
bizhub 500 / 420
3. PERIODIC CHECK
bizhub 500 / 420
3.4
3.4.1
18
Life value
Life value of materials
Item
Number of prints
Drum
250,000
Developer
250,000
Remarks
The life value is defined only by the number of prints.
Maintenance procedure of the external section
3.5.1
bizhub 500 / 420
3.5
3. PERIODIC CHECK
Replacing the ozone filter
A. Periodically replaced part/cycle
Ozone filter: Every 250,000 prints
B. Procedure
1. Remove the right cover /Up.

(See P.122)
2. Remove the ozone filter [1].

Note
When removing the ozone filter, be sure to
pull it out by holding it at the section indicated
by [2].
3. Reinstall the above parts following the removal

steps in reverse.
[1]
[2]
50gaf2c014na
19
3. PERIODIC CHECK
3.5.2
Replacing the filter cover assy and the suction filter /A assy
bizhub 500 / 420
A. Periodically replaced parts/cycle
Filter cover assy: Every 250,000 prints
Suction filter /A assy: Every 250,000 prints
B. Procedure
1. Remove the screw [1] and then remove the filter

cover assy [2].
[1]
[2]
50gaf2c015na
2. Remove the suction filter /A assy [1].
[1]
20
50gaf2c016na
3. PERIODIC CHECK
Be sure to install the suction filter /A assy

with the white filter face [1] inside.

steps in reverse.
[1]
50gaf2c017na
21
bizhub 500 / 420
Note
3. PERIODIC CHECK
3.5.3
Replacing the paper exit suction filter
bizhub 500 / 420
Paper exit suction filter: Every 250,000 prints
B. Procedure
1. Remove the screw [1] and then remove the paper

exit suction filter cover [2].
[1]
[2]
50gaf2c018na
2. Remove the paper exit suction filter [1].

[1]
steps in reverse.
50gaf2c019na
22
Maintenance procedure of the write section
3.6.1
bizhub 500 / 420
3.6
3. PERIODIC CHECK
Replacing the write unit
Warning
Be sure not to turn on the write unit with it shifted from its regular installation position.
Be absolutely sure not to remove the write unit cover. Otherwise, laser beams get in your eyes and
you may suffer loss of sight.
Be absolutely sure not to remove the write unit for about 2 minutes after you turn off the main
power switch (SW1) or the power switch (SW2).
Write unite: Every 1,250,000 prints
B. Procedure
1. Remove the developing unit from the main body.
[1]
(See P.35)
2. Remove the drum unit from the main body.

(See P.27)
3. Pull out the dust-proof glass cleaning rod [1].

4. Remove the cleaning knob [4] from the dust-proof
glass cleaning rod [1] by rotating it in the arrowmarked direction [3] with the section indicated by
[2] as a fulcrum.
5. Replace the dust-proof glass cleaning rod [1] to its

original position.
Note
[2]
Be sure to push in fully the dust-proof glass

cleaning rod [1] so that it does not come in
contact with the main body frame when
[4]
removing the unit.
[3]
50gaf2c020na
23
3. PERIODIC CHECK
6. Remove the 6 screws [1] and then remove the
bizhub 500 / 420
[1]
write cover [2].

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

8. Remove the connector [2] and then remove the
[3]
drum cooling fan assy [3].
50gaf2c022na
9. Remove the screws [1], 1 each, and then remove
[1]
the 2 write section mounting member assy's [2].

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

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

Note
bizhub 500 / 420
[1]
When installing the write unit, be sure to set

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

steps in reverse.
[2]
26
50gaf2c026na
Maintenance procedure of the photosensitive material section
3.7.1
bizhub 500 / 420
3.7
3. PERIODIC CHECK
Replacing the drum unit
Note
When removing the drum unit, be sure to hold it at both ends.
When removing the drum unit, be sure to avoid holding it at the separation claw unit section.
Be sure to avoid touching the drum with bare hands, and also be careful not to damage it.
Be sure to avoid turning the drum in any direction other than in the specified direction.
When storing the drum unit, be sure to store it in the dark place with a drum cover attached.
Drum unit: Every 750,000 prints
B. Procedure
1. Open ADU.
(See P.122)
2. Pull the lock release lever [1] to open the conveyance unit [2].
[1]
[2]
50gaf2c027na

[2]
[1]
(See P.35)
4. Loosen the screw [1] and remove the drum unit

[2].

steps in reverse.
50gaf2c028na
27
3. PERIODIC CHECK
bizhub 500 / 420
3.7.2
Replacing the drum
Note
Be sure to avoid touching the drum and the cleaning blade with bare hands, and also be careful
not to damage them.
When storing the drum, be sure to store it in the dark place with a drum cover attached.
When installing the drum and the cleaning blade, be sure to apply setting powder to the circumference of the drum and the cleaning blade, regardless of these parts being new or used ones.
When setting powder is applied to the drum, be sure to conduct the following operations before
installing the drum unit to the main body.
1) With the charging corona unit removed, rotate the drum one full turn (to prevent setting powder
from splashing onto the charging corona unit and the image from getting defective.)
2) When installing a new drum, be sure to reset the drum counter in the service mode. Failing to
reset it may result in image fogging and toner splashing. (See P.187)
28
3. PERIODIC CHECK

Drum: Every 250,000 prints
bizhub 500 / 420
B. Procedure

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

[2]
[3]
50gaf2c029na
29
3. PERIODIC CHECK
bizhub 500 / 420
4. Remove the connector [1].

5. Open the lock lever [2] and remove the charging
corona unit [3].
[1]
[3]
[2]
50gaf2c030na
30
3. PERIODIC CHECK
OK
mounting plate [2].
7. Pull out the drum shaft [3] for removal.

Note
[2]
When installing the drum shaft, be sure to
[2]
insert the drum shaft until the shaft mounting

plate comes into contact firmly with it as
shown in the drawing.
[3]
[3]

[1]
bearing [5].
[2]
[3]
[4]
[5]
50gaf2c031na
31
bizhub 500 / 420
6. Remove the screw [1] and then remove the shaft
NG
3. PERIODIC CHECK
bizhub 500 / 420
9. Remove the seal blocks [1] and [2].

10. Hold the drum [3] at both ends and remove it.
Note
[1]
When removing the drum, be careful not to

damage the photosensitive surface.
When removing the drum, be careful not to hit
it against the metal frame section [4] of the
cleaning blade.
[3]
[4]
[2]
50gaf2c032na
32
3. PERIODIC CHECK
When installing the drum, using the attached

jig [2] with the drum unit cover [1] before
installing the charging corona unit, rotate the
[2]
drum 1 full turn in the arrow-marked direction

[3]. And then check to see if setting powder is
not scraped off, and also if the toner collection sheet and the cleaning blade do not
turned up.

steps in reverse.
[2]
[3]
50gaf2c033na
33
bizhub 500 / 420
Note
[1]
3. PERIODIC CHECK
bizhub 500 / 420
3.8
Maintenance procedure of the transfer/separation corona section
3.8.1
Replacing the transfer/separation corona unit
Transfer/separation corona unit: Every 500,000 prints
B. Procedure
1. Open ADU.
[3]
(See P.122)
2. Open the conveyance unit.

(See P.27)
3. Release the lock levers [1] and [2] and remove the
transfer/separation corona unit [3].

steps in reverse.
[1]
34
[2]
50gaf2c034na
Maintenance procedure of the developing section
3.9.1
bizhub 500 / 420
3.9
3. PERIODIC CHECK
Replacing the developing unit
Developing unit: Every 750,000 prints
B. Procedure
1. Open the front door [1].

2. Loosen the screw [2] and remove the developing
unit [3].

steps in reverse.
[3]
[1]
[2]
50gaf2c035na
35
3. PERIODIC CHECK
3.9.2
Replacing developer
bizhub 500 / 420
Developer: Every 250,000 prints
B. Procedure
[2]
(See P.35)
2. Release the locks [1] at 2 places and remove the

developing unit cover /1 [2].
[1]
50gaf2c036na
36
3. PERIODIC CHECK
When installing the developing unit cover /1

[1], be sure to install it so that the splash prevention sheet [2] does not get caught into the
[1]
[3]
[2]
[3]
[2]
50gaf2c037na
37
bizhub 500 / 420
Note
3. PERIODIC CHECK
bizhub 500 / 420
[1]
3. Tilt the developing unit [1], and rotate the develop-
[4]
ing gear [2] in the arrow-marked direction [3] to

discharge thoroughly developer in the developing
unit [1].
4. Clean developer and toner that adhere to the

Note
Be absolutely sure not to turn the developing
gear [2] in any direction other than in the
arrow-marked direction [3]. (Never rotate it
clockwise as seen from the direction indicated by [5].)
If there remains any used developer on the
developing roller, this may cause image fogging.
[5]
[3]
[2]
50gaf2c041na
5. Put in new developer [1] evenly from above the

[1]
[3]
agitator screw [2].
6. Rotate the developing gear [4] in the arrowmarked direction [5] so that developer [1] gets
deep into the developing unit [3].
7. Repeat steps 8 and 9 to put in the developer [1]

[2]
thoroughly.
8. Rotate the developing gear [4] in the arrowmarked direction [5] and check to see if the spik-
[6]
ing of developer is found on the entire surface of

the developing roller [6].

steps in reverse.
[5]
[4]
50gaf2c042na
Note
When developer [1] is replaced, be sure to
conduct the TCR adjustment in the service
mode.
(See P.169)
38
3. PERIODIC CHECK
3.10.1
bizhub 500 / 420
3.10 Maintenance procedure of the toner supply section

Replacing the filter mounting plate assy
Filter mounting plate assy: Every 250,000 prints
B. Procedure
[2]
[1]

(See P.35)
2. Open ADU.
(See P.122)

(See P.27)

(See P.27)
5. Release the lock levers [1] at 2 places and remove

the filter mounting plate assy [2].

procedure in reverse.
[1]
[2]
50gaf2c043na
39
3. PERIODIC CHECK
3.10.2
Replacing the suction cover /2 assy
bizhub 500 / 420
Suction cover /2 assy: Every 250,000 prints
B. Procedure

(See P.35)
2. Open ADU.
(See P.122)

(See P.27)

[3]
(See P.27)
5. Remove the screw [1] and then remove the rail [2].
Note
When installing the rail, be sure first to insert
the tip into the notch [3].
[2]
[1]
50gaf2c044na
40
3. PERIODIC CHECK
6. Remove the 2 suction cover /2 assy's [1].

[1]
steps in reverse.
50gaf2c045na
41
bizhub 500 / 420
3. PERIODIC CHECK
bizhub 500 / 420
3.11 Cleaning/toner recycle section

3.11.1
Replacing the cleaning blade assy
Note
Be sure to avoid touching the edge section of the cleaning blade assy with bare hands.
When installing the cleaning blade assy, be sure to apply setting powder to the circumference of
the drum and the cleaning blade, regardless of these parts being new or used ones.
When setting powder is applied to the drum, be sure to conduct the following operations before
installing the drum unit to the main body.
1) With the charging corona unit removed, rotate the drum 1 full turn (to prevent setting powder
from splashing onto the charging corona unit and the image from getting defective.)
Cleaning blade assy: Every 250,000 prints
B. Procedure

(See P.35)
[1]
2. Open ADU.
(See P.122)

(See P.27)

(See P.27)
5. Remove the drum from the drum unit.

[2]
50gaf2c046na
(See P.28)

cleaning blade presser plate [2].
7. Remove the cleaning blade assy [1].

[1]
50gaf2c047na
42
3. PERIODIC CHECK
When installing the cleaning blade assy [1], be

sure to insert the transparent sheet section
[2] of the unit the between the collection
screw [3] and the collection paddle [4].

steps in reverse.
[3]
[2]
[4]
[1]
50gaf2c048na
43
bizhub 500 / 420
Note
[1]
3. PERIODIC CHECK
bizhub 500 / 420
3.12 Maintenance procedure of the paper feed section

3.12.1
Replacing the feed roller/pick-up roller (tray 1)
Feed roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints)
Pick-up roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints)
B. Procedure
1. Remove the front cover.

(See P.128)
2. Remove the tray 1.

(See P.143)
3. Remove the connector [1] and the 2 screws [2],

and then remove the paper feed unit /1 [3].
[2]
[1]
[3]
[2]
50gaf2c108na
44

Note
[2]
When installing the paper feed unit /1 [1], be

sure to set the shafts [2] and [3] to the holes
[4] and [5].
[5]
[4]
[1]
50gaf2c109na
45
bizhub 500 / 420
[3]
3. PERIODIC CHECK
3. PERIODIC CHECK
bizhub 500 / 420

separation roller unit /1 [2].
[3][4]
Note
[1]
When installing the separation roller unit /1,

be sure to set the projections [3], 1 each, to
each of the holes [4].
[2]
[1]
[3][4]
50gaf2c110na
[2]

6. Detach the convex section [2] from the hole [3]
and remove the paper feed unit cover [4].
[3]
[1]
[4]
50gaf2c111na
46
3. PERIODIC CHECK
ing [2].
[1]
8. Detach the hook [4] of the spring [3] from the

oblong hole [5].
9. Remove the bearing [6] and then remove the

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

the 2 bearings [2].
14. Remove the pick-up roller assy [3].
[1]
[2]
[1]
[3]
[2]
50gaf2c164na
15. Remove the C-ring [1] and then remove the pick[2]
up roller [2].
[1]

steps in reverse.
50gaf2c113na
48

3.12.2
3. PERIODIC CHECK
Replacing the separation roller assy (tray 1)
bizhub 500 / 420

Separation roller assy: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints)
B. Procedure
1. Remove the tray 1.

(See P.143)
[1]
2. Remove the paper feed unit /1.

(See P.44)
3. Remove the separation roller unit /1.

(See P.44)

[2]
[3]
50gaf2c117na
separation roller mounting plate assy [2].

Note
When installing the separation roller mounting plate assy, be sure to fasten it with screws
while pressing it in the arrow-marked direction [3].
5. Remove the 2 C-rings [1] and pull out the shaft [2].
6. Remove the separation roller mounting plate [3].
[1]
Note
When removing the separation roller mounting plate, be careful that the spring [4] does
[2]
[1]
not get lost since it is apt to come off.

When installing the separation roller mounting plate, be sure to install it so that it comes
under the projection [5].
[5]
[4]
[3]
50gaf2c118na
49
3. PERIODIC CHECK
bizhub 500 / 420
7. Remove the guide [1].

8. Remove the C-ring [2] and then remove the separation roller assy [3].

steps in reverse.
[1]
[3]
[2]
50gaf2c119na
50

3.12.3
3. PERIODIC CHECK
Replacing the feed roller/pick-up roller (tray 2)
Pick-up roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints)
bizhub 500 / 420
B. Procedure
1. Remove the bypass unit.

(See P.60)
2. Pull out the tray 2 [1].
[1]
50gaf2c120na
3. Push the lever [1] to open the vertical conveyance

door [2].
4. Detach the fulcrum [3] of the vertical conveyance

[4]
door from the mounting plate [4] and remove the

vertical conveyance door.
[3]
[1]
[2]
50gaf2c121na
51
3. PERIODIC CHECK
bizhub 500 / 420

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

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

[2]
paper feed unit /2 [3].
[1]
[3]
[2]
50gaf2c124na
53
bizhub 500 / 420
3. PERIODIC CHECK
bizhub 500 / 420

separation roller unit /2 [2].
[1]
Note
When installing the separation roller unit /2,
be sure to set the projection [3] to the hole [4].
[3] [4]
[1]
[3] [4]
[2]
50gaf2c125na
[4]

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

clutch /2 (CL5) [3].
Note
When installing CL5, be sure to set the stopper [4] to the guide plate [5].
[3]
[2]
[5]
[4]
[1]
50gaf2c127na
55
bizhub 500 / 420
3. PERIODIC CHECK
14. Detach the hook [2] of the spring [1] from the
bizhub 500 / 420
[3]
[7]
oblong hole [3].

the 2 bearings [5].
16. Remove the paper feed roller unit [6].

[2]
Note
When attaching the spring, be sure to put the
[1]
hook into the oblong hole (not into the round

hole [7]).
[6]
[4]
[4]
[5]
50gaf2c165na
[4]
[1]
17. Remove the E-ring [1] and then remove the bearing [2].
18. Remove the bearing [3] and then remove the feed
roller assy [4].
[3]
56
[2]
50gaf2c166na
3. PERIODIC CHECK
bizhub 500 / 420
roller [2].
[1]
[2]
50gaf2c167na

the 2 bearings [2].
21. Remove the pick-up roller assy [3].
[1]
[2]
[1]
[3]
[2]
50gaf2c168na
22. Remove the C-ring [1] and then remove the pick[2]
[1]
up roller [2].

steps in reverse.
50gaf2c129na
57
3. PERIODIC CHECK
3.12.4
Replacing the separation roller assy (tray 2)
bizhub 500 / 420
B. Procedure

(See P.60)
2. Pull out the tray 2.

3. Remove the vertical conveyance door.
(See P.51)
4. Remove the conveyance roller cover.

(See P.51)
[1]
[2]
[1]
5. Remove the paper feed guide /2.

(See P.51)
6. Remove the paper feed unit /2.

(See P.51)
7. Remove the separation roller unit /2.

(See P.51)

separation roller mounting plate assy [2].
Note
[3]
When installing the separation roller mount50gaf2c133na
ing plate assy, be sure to fasten it with screws

while pressing it in the arrow-marked direction [3].
9. Remove the 2 C-rings [1] and pull out the shaft [2].
10. Remove the separation roller mounting plate [3].
[1]
Note
When removing the separation roller mount-
[2]
ing plate, be careful that the spring [4] does
[1]
not get lost since it is apt to come off.

When installing the separation roller mounting plate, be sure to install it so that it comes
under the projection [5].
[5]
58
[4]
[3]
50gaf2c134na
3. PERIODIC CHECK
11. Remove the guide [1].

12. Remove the C-ring [2] and then remove the separation roller assy [3].

steps in reverse.
[1]
[3]
[2]
50gaf2c135na
59
bizhub 500 / 420
3. PERIODIC CHECK
bizhub 500 / 420
3.13 Maintenance procedure of the bypass tray section

3.13.1
Removing/reinstalling the bypass unit
A. Procedure
[2]
1. Remove the right cover /Lw.
[1]
(See P.123)
2. Remove the screw [1] and then remove the

bypass cover /Fr [2].
3. Loosen the screw [3] and then remove the screw

[4] to remove the bypass cover /Rr [5].
[5]
[3]
60
[4]
50gaf2c001na
3. PERIODIC CHECK

[4]
ground terminal [3].

bypass unit [5].
[2]
[3]
[1]
[5]
[4]
50gaf2c002na
61
bizhub 500 / 420
3. PERIODIC CHECK
bizhub 500 / 420

steps in reverse.
8. After installing the bypass unit, open the tray 2

paper feed guide [1] and the bypass feed guide [2]
in the arrow-marked direction [3] to check to see if
they operate smoothly.
[1]
[3]
[2]
50gaf2c003na
62

Replacing the separation roller assy
Note
When replacing the separation roller assy, be sure also to replace the feed roller at the same time.
B. Procedure

[2]
[2]
(See P.60)
2. Remove the 2 springs [1].

[2]
[1]
50gaf2c004na
63
bizhub 500 / 420
3.13.2
3. PERIODIC CHECK
3. PERIODIC CHECK
4. Detach the hook [1] from the hole [2] and remove
bizhub 500 / 420
[3]
[1]
the push-up plate assy [3].
[2]
50gaf2c005na
[1]
[3]
[1]
Note
When installing the push-up plate assy, be
sure to install it while pressing the push-up
plate [3] so that each of the springs [1] does
not comes off each cross-headed boss [2].
[2]
64
[2]
50gaf2c006na
3. PERIODIC CHECK
[1]
bizhub 500 / 420
[2]
separation roller fixing plate assy [2].
50gaf2c007na
[3]
[5]
[4]
6. Detach the support axis [2] of the holder [1] from
[1]
the mounting plate [3] and remove the holder.

Note
When removing the holder [1], the spring [4]
provided under the holder is apt to come off.
Be careful that it does not get lost.
When installing the holder [1], be sure to
install it so that it comes under the projection
[5].
[2]
50gaf2c008na
[3]
[1]
7. Remove the C-ring [1] and then remove the separation roller assy [3] from the holder [2].

steps in reverse.
[2]
50gaf2c009na
65
3. PERIODIC CHECK
3.13.3
Replacing the feed roller
bizhub 500 / 420
Note
When replacing the feed roller, be sure also to replace the separation roller assy at the same time.
B. Procedure

(See P.60)
2. Remove the push-up plate assy.

(See P.63)
3. Press the conveyance guide [1] in the arrowmarked direction [2] to remove the support axis [3]
from the hole [4], and then remove the conveyance guide.
[4]
[3]
[1]
[2]
50gaf2c010na
4. Open the lever [1]. Remove the 2 screws [2] and
[3]
[2]
66
then remove the paper roller cover [3].
[1]
50gaf2c169na
[2]
[3]

clutch /BP (CL6) [2].
Note
When installing CL6, be sure to set the stopper [3] to the guide plate [4].
[4]
50gaf2c170na
6. Remove the gear [1].
[1]
50gaf2c171na
67
bizhub 500 / 420
[1]
3. PERIODIC CHECK
3. PERIODIC CHECK
bizhub 500 / 420
7. Remove the C-ring [1] and then remove the bearing [2].
8. Remove the bearing [3] and slide the shaft [4].
[3]
[4]
[2]
[1]
50gaf2c172na

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

steps in reverse.
[2]
[4] [1]
[3]
50gaf2c173na
68
3. PERIODIC CHECK
3.14.1
bizhub 500 / 420
3.14 Maintenance procedure of the registration section

Cleaning the paper dust removing brush
A. Periodic cleaning cycle
Paper dust removing brush: Every 250,000 prints
B. Procedure
1. Open ADU.
[2]
(See P.122)

(See P.27)

(See P.35)

(See P.27)
5. Remove the suction cover /2 assy.

(See P.40)
6. With the lever [1] pulled, remove the paper dust

removing brush [2] and clean the paper dust
removing brush with a blower brush.
[1]
50gaf2c174na
3.14.2

steps in reverse.
Replacing the loop roller, the loop bearing, the registration roller /Rt, and the registration
bearings /Rt and /Lt
Loop roller: Every 1,250,000 prints
Loop bearing: Every 1,250,000 prints
Registration roller /Rt: Every 1,250,000 prints
Registration bearing /Rt: Every 1,250,000 prints
Registration bearing /Lt: Every 1,250,000 prints
B. Procedure
1. Open ADU.
(See P.122)

(See P.27)

(See P.35)

(See P.27)
5. Remove the suction cover /2 assy.

(See P.40)

[1]
50gaf2c175na
69
3. PERIODIC CHECK
bizhub 500 / 420

ADU drive assy [2].
Note
When installing the ADU drive assy, be sure to
set the stopper [4] of the registration clutch
(CL1) [3] to the guide plate [5].
[2]
[1]
[3]
[1]
[3]
[4]
[5]
50gaf2c154na
70
[5]
3. PERIODIC CHECK
[6]
[1]

9. Remove the screw [2].
10. Remove the C-clip [3] and slide CL1 [4] in the
arrow-marked direction [5].
11. Remove the 2 C-clips [6] to release the bearing

[7].
Note
When installing the 2 C-clips [6], be sure to
install them with their collars come face to
face each other.
12. Remove the C-clip [8] and then remove the bearing [9].
[10]
[3]
[2]
[4]
13. Remove the registration unit [10].
[7]
[9]
[8]
50gaf2c155na
71
bizhub 500 / 420
3. PERIODIC CHECK
bizhub 500 / 420
[6]
[5]
[4]
[3]
14. Remove the bearing [1] and CL1 [2].

15. Remove the E-ring [3] and then remove the loop
clutch (CL2) [4].
Note
When installing CL2, be sure to set the stopper [5] to the screw [6].
16. Remove the screw [7] and then remove the registration main body assy [8].
[7]
[8]
72
[2]
[1]
50gaf2c156na
3. PERIODIC CHECK
loop bearings [2].
18. Remove the loop roller [3].

19. Remove the 2 loop bearings from the loop roller.
[2]
[1]
[2]
50gaf2c157na
73
bizhub 500 / 420
17. Remove the E-rings [1], 1 each, and release the 2
[3]
3. PERIODIC CHECK
bizhub 500 / 420
20. Remove the 2 springs [1].

21. Remove the E-rings [2], 1 each, and then remove
the 2 registration bearings /Lt [3].
22. Remove the registration roller /Lt [4].

Note
When attaching the spring, be sure to couple
the hook [5] of the spring at the position as
shown in the drawing left.
[4]
[1]
74
[3]
[5]
[2]
[2] [3]
[1]
50gaf2c158na
3. PERIODIC CHECK
the 2 registration bearings /Rt [2].
24. Remove the registration roller /Rt [3].

steps in reverse.
[1]
[2]
[1]
[2]
[3]
50gaf2c159na
75
bizhub 500 / 420
23. Remove the E-rings [1], 1 each, and then remove
3. PERIODIC CHECK
bizhub 500 / 420
3.15 Maintenance procedure of the fusing section

3.15.1
Removing/reinstalling the fusing unit
Caution
Since the fusing section gets hot immediately after turning off the main power switch (SW1) or the
power switch (SW2), you may suffer a burn. Be sure to conduct the operations when the temperature goes down sufficiently.
A. Procedure
[2]
1. Open ADU.
[1]
(See P.122)

(See P.122)

(See P.27)
4. Loosen the screw [1] and remove the front auxiliary cover [2].
50gaf2c085na
76
3. PERIODIC CHECK

6. Remove the screw [2] and then remove the filter
[4]
cover [3].
[1]

8. Loosen the 2 screws [5]. And after sliding the
entire reverse unit [6] in the arrow-marked direction [7], tilt the front side in the arrow-marked
direction [8] for removal.
[8]
[3]
[2] [5]
[6]
[5]
[7]
[4]
50gaf2c086na
77
bizhub 500 / 420
3. PERIODIC CHECK
bizhub 500 / 420
[2]
fusing unit [2].

Note
When lifting the fusing unit, be sure to hold it
at both ends.
When installing/removing it, be careful not to
damage rollers.

steps in reverse.
[1]
3.15.2
50gaf2c087na
Replacing the fusing claw assy
Fusing claw assy: Every 500,000 prints
B. Procedure
1. Remove the fusing unit.

(See P.76)
2. Remove the C-clip [1].

3. Open the fusing front guide assy [2].
[1]
[2]
50gaf2c088na
4. Slide the fusing front guide assy [1] for removal.
[1]
78
50gaf2c089na
3. PERIODIC CHECK

6. Remove the screw [2] and raise the fusing claw
assy [3].
7. Remove the connector [4] from the fusing claw

assy.
Note
The fusing claw assy varies for bizhub 500
[1]
and 420. Be sure to check a punch mark [5]

and replace it with a right fusing claw assy.
bizhub 500: 50 GA
bizhub 420: 42 GA
When installing the fusing claw assy, be careful not to neglect attaching the connector [4].
When installing the fusing claw assy, be sure
to insert the positioning sections [6] at 2
[2]
[5]
[4]
places into each of the projections [7].

When installing the fusing claw assy, be careful not to damage the roller surface with the
tip of the claw.

steps in reverse.
[3]
[7]
[6]
50gaf2c091na
79
bizhub 500 / 420
3. PERIODIC CHECK
3.15.3
Replacing the fusing web
bizhub 500 / 420
Fusing web: Every 250,000 prints
B. Procedure
[4]
[2]
(See P.76)
2. Remove the fusing claw assy.

(See P.78)

5. Apply pressure from the inside of the ducts [3] at 2
places to release the lock and remove the fusing
web [4].
Note
The fusing web varies for bizhub 500 and 420.
[1]
[5]
[3]
50gaf2c092na
Be sure to check a punch mark [5] and

replace it with a right fusing web.
bizhub 500: 50 GA
bizhub 420: 42 GA
When installing the fusing web, be sure to
install the screw [1] first.
Note
[2]
When installing the fusing web, be sure to

insert the projections [1] at 2 places into the
positioning holes [2].
[1]
80
50gaf2c093na
[2]
[5]
[8]
The performance of a new fusing web [1] is

guaranteed from the position at which a
brown line [2] is broken. When replacing the
fusing web, be sure to take up the fusing web
up to the position at which the distance [5]
from the nip section [4] of the fusing roller [3]
and the fusing web to the brown line becomes
0 to 10 mm or less.
When taking up the fusing web, be sure to
[4]
[3]
bring down the release lever [6] to release the

cleaner lock gear [7] and rotate the web drive
gear [8].
When replacing the fusing web, be sure to
reset the fusing web counter in the service
mode.
(See P.187)

step in reverse.
[1]
[7]
[6]
[6]
50gaf2c094na
81
bizhub 500 / 420
[1]
3. PERIODIC CHECK
3. PERIODIC CHECK
3.15.4
Replacing the fusing driven roller assy /A and /B
bizhub 500 / 420
Fusing driven roller assy /A: Every 250,000 prints
Fusing driven roller assy /B: Every 250,000 prints
B. Procedure
[1]
[2]
[4]
[3]

(See P.76)
2. Remove the fusing claw assy from the fusing unit.

(See P.78)
3. Remove the fusing web from the fusing unit.

(See P.80)
4. Remove the screw [1] and then remove the fusing

unit cover /Fr [2].

fusing unit cover /Rr [4].
Note
When removing the fusing unit cover /Rr, be
[8]
careful that the internal gear does not fall

down.
6. Remove the 2 screws [5] and the 2 screws [6].

7. Release the 2 envelope levers [7].
8. Remove the fusing casing [8] without touching the
envelope lever.
Note
When installing the fusing casing [8], be sure
to install first the screw [5] (upper side).
[6]
82
[7]
[5]
50gaf2c095na
[3]
3. PERIODIC CHECK
[2]
[3]

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

steps in reverse.
[1]
[4]
50gaf2c096na
83
bizhub 500 / 420
3. PERIODIC CHECK
bizhub 500 / 420
3.15.5
Removing/reinstalling the fusing heater lamps /1 (L2) and /2 (L3)
Note
Be careful not to touch the lamp sections of L2 and L3 with bare hands. When touched, be sure to
clean them with a roller cleaner.
A. Procedure
[1]
(See P.76)

(See P.78)

(See P.80)
4. Remove the fusing casing.

(See P.82)
5. Remove the fastons [1] and [2], 2 each.

Note
When removing the faston, be sure to remove
it by holding the connector section. Be absolutely sure not to pull out by holding the wiring
harness section.
[2]
84
50gaf2c097na
3. PERIODIC CHECK
6. Remove the screw [1] and then remove the lamp
[1]
fixing plate /Fr [2].
7. Pull out the fusing heater lamps /1 (L2) [3] and /2

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

(main) on the upper side with L3 [4] (sub) on
the lower side.

steps in reverse.
Note
When installing the fusing heater lamp, be
sure to take note of the direction of installation.
Lamp
Destination
North America
[7]
[6]
[4]
50gaf2c098na
Europe/Others
Fr
Rr
Fr
Rr
L2
Red
Red
Blue
Blue
L3
Red
Black
Blue
Black
85
bizhub 500 / 420
[8]
3. PERIODIC CHECK
3.15.6
Replacing the fusing roller, the fusing pressure roller, the heat insulating sleeve /A, the fusing
bizhub 500 / 420
bearings /Up and /Lw and the fusing input gear assy
Fusing roller: Every 250,000 prints
Fusing pressure roller: Every 250,000 prints
Heat insulating sleeve /A: Every 250,000 prints
Fusing bearing /Up: Every 250,000 prints
Fusing bearing /Lw: Every 250,000 prints
Fusing input gear assy: Every 500,000 prints
B. Procedure

[7]
[8]
[6]
[5]
(See P.76)

(See P.78)

(See P.80)

(See P.82)
[1]
[4]
5. Remove the fusing heater lamps /1 (L2) and /2

(L3).
(See P.84)

lamp fixing plate /Rr [2].

fusing input gear assy [4].
Note
When installing the fusing input gear assy, be
sure to set the D cut section [6] of the shaft
[5] to the D cut hole [8] of the frame [7].
8. Release the 2 envelope levers [9].

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

[2].
10. Remove the heat insulating sleeve /A [3] and the

fusing bearing /Up [4].
Note
When installing the heat insulating sleeve /A
[4] [3]
and the fusing bearing /Up, be sure to install
[10]
them with their respective collar [5] outside.

When installing the heat insulating sleeve /A,
be sure to apply Multemp FF-RM to its inside
and outside peripheries.
11. Remove the C-ring [6] and then remove the heat
insulating sleeve /A [7] and the fusing bearing /Up
[8].
Note
When installing the heat insulating sleeve /A
[12]
[11]
[7]
[8]
and the fusing bearing /Up, be sure to install

them with their respective collar [9] outside.
When installing the heat insulating sleeve /A,
be sure to apply Multemp FF-RM to its inside
and outside peripheries.
12. After sliding once the fusing roller [10] in the

[9]
[6]
50gaf2c100na
arrow-marked direction [11], remove it in the

Note
According to the model, the fusing roller varies in the diameter and the wall thickness.
When replacing it with a new one, be sure to
install one that is suitable for the model.
Model
Diameter
Wall thickness
bizhub 500
35 mm
t 2.0 mm
bizhub 420
35 mm
t 0.8 mm
87
bizhub 500 / 420
[5]
3. PERIODIC CHECK
bizhub 500 / 420
13. Remove the fusing pressure roller [1].

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

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

steps in reverse.
[1]
88
50gaf2c102na

Replacing the fusing sensor assy
Caution
After installing the fusing sensor assy, be sure to check to see if it is in touch with the fusing roller.
Fusing sensor assy: Every 500,000 prints
B. Procedure
[1]
[3]
[2]

(See P.76)

(See P.78)

(See P.80)

(See P.82)

(L3).
(See P.84)
6. Remove the fusing roller and the fusing pressure

roller.
(See P.86)
[4]
7. Remove the faston [1].

Note
it by holding its base section. Be absolutely
sure not to pull it out by holding the wiring
harness section.
[5]

10. Remove the web support assy /2 [4] and pull it
[3]
out in the arrow-marked direction [5].
50gaf2c104na
89
bizhub 500 / 420
3.15.7
3. PERIODIC CHECK
3. PERIODIC CHECK
bizhub 500 / 420
[2]
the fusing sensor assy [2].

Note
When installing the fusing sensor assy, be
careful not to deform the sensor section.
After installing the fusing sensor assy, be sure
to check to see if the wiring harness is not in
touch with the fusing roller.
Caution
[1]
After installing the fusing sensor assy, be sure

50gaf2c105na
to check to see if the thermistors /1 (TH1) and

/2 (TH2) are in touch with the fusing roller.
Note
[1]
The fusing sensor assy is made up of TH1 and

TH2. The sections of TH1 and TH2 have been
adjusted when they were assembled, and be
absolutely sure not to loosen the screw [1].

steps in reverse.
50gaf2c106na
90

Replacing the fuse holder assy
Caution
After installing the fuse holder assy, be sure to check to see if it is in touch with the fusing roller.
Fuse holder assy: Every 500,000 prints
B. Procedure
[1]
[4]
[3]
(See P.76)

(See P.78)

(See P.80)

(See P.82)

(L3).
(See P.84)
[2]
50gaf2c107na
6. Remove the fusing roller and the fusing pressure

roller.
(See P.86)
7. Pull out the web support assy /2.

(See P.89)
8. Remove the faston [1].

Note
it by holding its base section. Be absolutely
sure not to pull it out by holding the wiring
harness section.

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

steps in reverse.
91
bizhub 500 / 420
3.15.8
3. PERIODIC CHECK
4. SERVICE TOOLS
bizhub 500 / 420
4. SERVICE TOOLS
4.1
Service material list
Material No.
Name
Shape
Remark
000V-19-0
Setting powder
25 g
000V-18-0
Cleaning pad
10 pcs/1 pack
00GR0026
Multemp FF-RM
25 g
00GR0021
Solvest 240
Multemp FF-RM is recommended.
92
Jig list
Parts No.
Name
26NA2134
Drum rotation mem-
Shape
Quantity
1
ber
26NAJG01
Optic unit positioning
Remark
Mounted to the drum
unit
jig
40347940
Test chart
(A3 size)
40347942
Test chart
MINOLTA logo
(A3 size)
40347940
Test chart
Without a KONICA
Without a KONICA
MINOLTA logo
(11 x 17 size)
120A9711
Adjustment chart
For DF adjustment
For DF adjustment
For DF adjustment
For DF adjustment
(A3 size)
120AJG02
Adjustment chart
(11 x 17 size)
120A9712
White chart
(A4 size)
120AJG03
White chart
(81/2 x 11 size)
00VC-2-0
Drum cover
00VD-100
Blower brush
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4.2
4. SERVICE TOOLS
4. SERVICE TOOLS
bizhub 500 / 420
Parts No.
00VE-100
14G54631
Name
Shape
Quantity
Tester
Stapler unit position-
ing jig
4.3
Remark
For SD staple adjustment
Materials
A. Item
Parts name
94
Useful life
Type name
Toner bottle
32,200 prints
TN511
Drum
250,000 prints
DR510
Developer
250,000 prints
DV511
5. FIRMWARE VERSION UP
5.1
5.1.1
ISW
Outline
A. ISW (In-System Writer)

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

PC
Overall control board (OACB)
Printer control board (PRCB)
DF control board (DFCB)

FS control board (FSCB)
FAX control board (FK-502)
When executing the ISW over the entire system, be sure to execute it in the order given below. (To minimize the
occurrence of troubles resulting from the mismatch of the firmware version)
Step
Type of programs
Fax board controller 1, Fax board controller 2, Finisher, DF
Image controller
Operation panel message data
MFP controller
Note
When replacing the OACB, be sure to conduct the ISW of the MFP controller first. When the firmware of the MFP controller is not contained in the OACB, no display is shown on the touch panel.
The finisher above refers to the FS-510. The ISW of the FS-511 is conducted by changing the
EPROM.
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5.1.3
Settings on the main body side while in ISW
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Following the description given below, be sure to make appropriate settings on the main body side to conduct
the operations of the firmware version upgrade and writing.
A. Types of the setting
Power ON mode
This mode is used when the firmware of the MFP controller is not installed to the overall control board
(OACB) or when it is damaged. In a case like this, it is not possible to enter the service mode. The firmware
writing of the MFP controller can be made with the power switch ON.
Service mode
This mode is used when the firmware of the MFP controller is installed properly. Selecting [ISW] of [System
2] in the service mode allows you to write the firmware.
B. When upgrading the firmware

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

Data LED turns ON with nothing
Mode
Power ON mode
shown on the touch panel.

Other boards
ISW error displayed
Service mode
For the overall control board (OACB), when something is wrong with the firmware or no firmware is written, the
normal start-up cannot be made. In a case like this, when the power switch is ON, the data LED turns ON with
nothing shown on the touch panel, and the system is placed in the firmware stand-by mode.
For other boards, when the firmware of the MFP controller is normal and something is wrong with other firmware, an ISW error is shown on the touch panel section when the power is turned ON.
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ISWTrns
5.2.1
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5.2
Specifications
A. ISWTrns (PC software)

(1) Operating environment of the software
OS:
CPU:
Windows95/98/98SE/Me/NT4.0/2000/XP
Pentium 75 MHz or above
Memory:
16 MB or more
Free space in hard disk:
100 MB or more
Others:
PC provided with parallel (printer) or USB interface (type A)
(2) Transmission time
Varies according to each PC
(3) Parts required to conduct the ISW
Personal computer (PC): 1

IBM-compatible PC/AT, Provided with D-sub25 pin parallel (printer) interface or USB interface
ISWTrns setup program
Parallel cable or USB cable: 1
Firmware
Item
Specifications
Board to be rewritten
Overall control board (OACB), Printer control board (PRCB), FAX control
Rewritable firmware
MFP controller
board (FK-502), FS control board (FSCB), DF control board (DFCB)

Operation panel message data
Image controller
FAX board controller 1
FAX board controller 2
Finisher
ADU
Note
For boards other than the above, ROM replacement is required.
97
5.2.2
Installation of the ISWTrns
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Install the ISWTrns program to the PC.

(1) Procedure
Step
Operation
Start the PC.
Copy the setup files to the PC and double click the [Setup.exe] icon to start the install program.
Note
When there remains the ISWTrns of the old version, uninstall the old version first, and
then install the new version.
"ISWTrns setup screen"

Following the instructions on the screen, check the folder to which an installation is made, and then
click [Next].
Note
For default, "C:\Program Files\KONICA MINOLTA\ISWTrns" is set as a folder to which an
installation is made.
When changing the folder to which an installation is made, click [Browse] and specify
the folder.
4
Following the instructions on the screen, check the folder to which the ISWTrns program is stored
and then click [Next].
Note
For default, "ISWTrns" is set as a folder to which an installation is made.
When changing the folder to which an installation is made, enter the folder name
directly, or select one from the existing folder displayed.
5
Following the instructions on the screen, click [Finish].
The installation of the ISWTrns program is automatically completed.
Select [ISWTrns] from the start menu or double-click the [ISWTrns] icon on the desk top to start up
the ISWTrns program.
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Operation
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Step
"ISWTrns screen"
Click [OK] to set the storage folder of the firmware.
Note
This screen is shown only when the program is started for the first time after installing
the ISWTrns.
9
"Option screen"
Click [Make Folder]
Note
A folder (C:\Program Files\KONICA MINOLTA\ISWTrns) into which the ISWTrns program
is installed as a storage folder is set by default.
When changing the storage folder, click [Browse] to specify it arbitrarily or enter it
directly in the editor box in full path.
Clicking [Make Folder] creates hierarchical folders with the storage folder set above as
a route.
10
"Option screen"
Click [OK].
Note
This operation allows the data folder created in step 9 to be stored in the INI file of the
ISWTrns program.
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5.2.3
Usage of the ISWTrns
A. Installation of the USB driver (Windows2000/XP)
When a connection is made between the PC and the main body with a USB cable, the installation of the USB
driver is automatically started by the plug-and-play. However, this may result in the installation of the Windows
USB driver (USBPRINT.SYS) and be sure to set the USB driver following the steps given below.
(1) Procedure
Step
1
Operation
Connect the USB cable to the main body.
Connect the USB cable to the USB connector of the USB.
From the screen below, select "Install from a list or specific location," and then click [Next].
The driver is stored in the C:\WINDOWS\Drivers\Usb.
In the "Please choose your search and installation options" screen, select "Don't search. I will choose
the driver to install," and then click [Next].
Check the driver name and click [Next].

Driver name: KONICA MINOLTA 500/420 USB Driver for ISW
When the "Completing the Found New Hardware Wizard" screen is displayed, click [Finish] to exit the
Check the "Device Manager screen" to see if the USB driver has been correctly installed.
installation.
Driver name: KONICA MINOLTA 500/420 USB Driver for ISW
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B. Firmware copy
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By using the ISWTrns, firmware that transfers it to the main body is copied into the specified folder.
(1) Procedure
Step
Operation
Start the PC.
Select [ISWTrns] from the start menu or double click the [ISWTrns] icon on the desktop to start up the
Click [Option (O)] from the menu and then click [Option (O)].
"Option screen"
ISWTrns.
Click [Data Copy].
"File Copy screen"

Click [Browse].
Select the folder into which firmware is stored as a copied file.
Note
The folder selected is shown in the upper display section of the "Original Files."
In the lower display section of the "Original Files," the firmware related files stored in the
folder are shown.
Select a file you want to copy from the lower display section of the "Original Files."
Note
The plural transferred files (rewritten data) can be selected.
When copying all of the files that are displayed, skip this step and proceed to the step 7.
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Step
7

Operation
Click [Copy] automatically copies the selected file into the specified folder created by installing the
ISWTrns.
Note
When copying all of the files that are displayed in the lower display section of the "Original Files", click [Copy All] instead of [Copy].
In the upper display section of the "Copied Files", a folder name created at the setup of
the ISWTrns is displayed.
In the list shown in the lower display section of the "Copied Files," files the copy of
which has been successfully completed are listed in full path. In the "Failed to Copy
Files", files the copy of which have been failed are listed. As the causes of failure, following are considered.
A. There exists a file of the same name and "O/W" is not checked.
B. A folder into which a file is stored is not found.
C. An overwrite is made on an overwrite-prohibited file.
When changing a file that is currently stored into a new data, click the overwrite check
box to make a check mark.
After completion of copy, click [Refresh].
Click [Cancel] to get back to "option screen."
10
"Option screen"
Click [OK].
C. Preparation for transfer of the main body

(1) Checking the firmware version
Before rewriting firmware, be sure to check the current firmware version following the procedure given below.
Step
1
102
Operation
Enter the Service mode.
Press the [Firmware Version] in "Service mode screen".
Indication of "Firmware Version screen"
(2) ISW transfer standby
Step
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Open the Service mode of the main body to put the ISW transfer in the standby condition.
Operation
Enter the Service mode.
Press the [System 2] in "Service mode screen."
Press the [ISW] in the sub menu shown to the right of the screen.
"Board Type Selection screen"
Press the key corresponding to the firmware to be rewritten.

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

(1) When using the parallel cable
Preparations are made of the following when a connection is made.
PC which firmware have been copied.
Parallel cable
1)
Procedure
Step
1
Operation
Turn OFF the power of the main body.
Turn OFF the power of the PC.
Connect the parallel cable [2] to the IEEE1284 port [1] of the PC.
[1]
[2]
50gaf2c176na
Connect the parallel cable [1] of the PC to the ISW connector [2] of the main body.
[2]
[1]
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(2) When using the USB cable
PC which firmware have been copied.
UBS cable
1)
Procedure
Step
1
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Preparations are made of the following when a connection is made.
Operation
Connect the UBS cable [2] to the USB port [1] of the PC.
[1]
[2]
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Note
Be sure to connect the UBS cable to the ISW connector of the main body after the setting is made in the following condition.
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E. Rewriting of firmware
(1) Relationship between the ISW and the display of the operation panel
When the ISWTrns starts up, the main screen is displayed. In the main screen, the transmission file (firmware) is
selected, the information is diplayed, the checksum and the transmission file are sent out. For detailed information of the functions, refer to the following.
[3]
[2]
[4]
[1]
[5]
[6]
[7]
[8]
[9]
[10]
[1] File status information list

View detailed information about the version file when select firmware.
[2] Select type frame
Select condition for a transfer file. When selecting all of the 4 types of the combo boxes, a folder [4] is set
from the information set in the ISWTrns.INI file. The setting of the selected combo boxes are saved to the
ISWTrns.INI file and it is display initially when it is started next time.
[3] Version selection frame
This frame let you select which version of a transfer file you want transmitted when more than one version is
stored in a folder.
[4] Version storage folder edit box
When the select type frame of [2] is decided, a folder name is displayed in full path from the information of
the data folder set in the option window and the INI file. When the firmware is in a folder other than the
specified data folder, this can be changed by clicking [Browse] [6] to specify the file location or entering
directly the file location. A firmware corresponding to the INI file conditions in the folder shown here is displayed in the list box of [5].
[5] Version file selection list box
Displays files that is in the folder selected at [4]. When more than one version files are stored in the same
folder, all versions are displayed in this list box. The list displayed here is sorted in the order of names, and
an item displayed last is selected when the list is displayed. Changing the selected item decides a firmware
version to be transmitted.
[6] Version file [Browse]
This key is used when the firmware is in a folder other than the specified data folder. Display the folder
selection screen to select the folder of [4].
[7] Send file information frame
Display the list of firmware to be actually transmitted based on the information selected in the frames [2] and
[3], and click [FileCheck] [9] to display the checksum of the file and the consistency (OK, NG, ??) of the
checksum.
[8] Send file information display list
When version files are selected at [5], files to be actually transmitted are displayed. The number of files actually transmitted is described in the checksum attached to the firmware.
Click [FileCheck] at [9] to calculate the checksum of the entire displayed files. And compare the obtained
value with the checksum value stored in the checksum file (*.sum) attached to the firmware to display the
result.
106
With a transmission file displayed in "SendFile info" of [8], press this key to calculate the file checksum
(checksum of the entire file) of the displayed transmission file and show a result beside the transmission file.
And also, compare the result of the checksum with the checksum file attached to the firmware and display
the obtained result in the form shown below.
"OK": Accord
"NG": Not accord
"??": Checksum file (*.sum) not found
[10] [FileSend]
The transmission of the transferred file is started.
(2) Procedure
e.g.: When conducting the ISW of the MFP controller for bizhub 500.
Step
Operation
Start the ISWTrns program.
Click [Set-up (S)] from the menu and then click [Communication setting (C)].
"Set Communication screen"

Select a port through which the transmission is made and click [OK].
Note
When [Parallel] is selected, be sure also to specify [Port].
4
Select the machine type, the destination and the board types.
Machine type: 500, Country: EU, Board type: CONTROL (ALL)
The data to be used is displayed in the version selection frame and the send file information frame.
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[9] [FileCheck]
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Step

Operation
Press the [FileCheck] to check if the data to be used has any problem.
Place the main body in the ISW standby condition.
Check to see if "Please execute the data transfer. The data reading is begun." is displayed.
When a connection is made with a USB cable, connect the USB cable [2] to the USB connector [1] of
the main body.
[1]
[2]
50gaf2c179na
Note
Be sure to press the start key before connecting the USB cable. When connecting the
USB cable before the start key is pressed, the main body is put in the stand-by position
for the print data with no ISW data accepted.
10
108
Click [FileSend] of the ISWTrns.
Operation
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Step
11
The following window is displayed on the PC while in the data transfer.
12
When the data transfer is completed, the following window is displayed and click [OK].
"ISWTrns"
13
When the data writing is completed, the reboot is automatically made to show the trouble reset display. When conducting the ISW successively after that, press [Trouble reset]. And then, after checking to see if "OK" is displayed, press the key that sets the number of sheets in the order shown below
and start the service mode.
Stop -> 0 -> 0 -> Stop -> 0 -> 1
Note
When the ISW other than for the MFP controller is completed, no reboot is made automatically. In cases like this, when conducting the ISW for another board successively,
press [OK] on the screen showing a message "ISW completed," and select again a
board type that conducts the rewrite on the board type selection screen.
14
5.2.4
Check the firmware version in the service mode to see if the rewriting is completed successfully.
Error list
A. Overall control board firmware abnormality

When the main body detects an overall control board firmware abnormality after turning ON the power switch,
the data LED turns ON with nothing displayed on the LCD of the operation panel (ISW stand-by condition). For
details of the data LED display, refer to the table below.
No.
Operation
Data LED
CPU in initialization when the power is turned on
OFF
Flash memory in checking
OFF
When an error is detected while in memory check (ISW
ON
standby status)
4
ISW processing (data being received from the PC and flash

memory being written)
While in the data reception:

It flashes at high speed.
While in the flash memory write:
It flashes at low speed.
When an abnormality is detected while in data transmission
Start key LED (orange) turns ON
When an error is detected while in writing flash memory
Start key LED (orange) turns ON
Memory check successfully completed: while in rebooting
OFF
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B. ISWTrns error list

The ISWTrns displays messages when an error is shown or the operation is completed. The table below shows
the contents of the message and the status of the ISWTrns.
Message
Status of the ISWTrns
Cannot open a checksum file
Opening of a checksum file failed. Possible causes include a corrupted
Cannot read a checksum file
Loading of a checksum file into memory failed. Possible causes include
Cannot open a file
Opening of a send file failed. Possible causes include a corrupted file
Cannot open the LPT port
Opening of the LPT port failed.
Communications port setup
A call to GetCommState failed.
file and a file in use.

a shortage of memory and an OS problem.
and a file in use.
acquisition error
Communications port setup error
A call to SetCommState failed.
Cannot open a send file
Opening of a send file failed. Possible causes include a corrupted file

and a file in use.
Cannot send a Term Test file
Transmission of a communications test block failed.

1. The main body is not ready to receive.
2. The cable is out of position.
3. Transmission of the wrong send file was attempted.
Unsuccessful file transmission
The transmission of a send file failed. Possible causes include a cable

out of position.
Unsuccessful transmission to the
Output to the LPT port failed. Possible causes include a cable out of
LPT port
position.
Invalid folder name
An invalid folder name was entered. Start a folder name with a drive
name, such as C:\.
Default data folder is not set.
A data folder is not set in ISWTrns.INI. This message is displayed when
Please select folder.
ISW Trns launches for the fist time.
Unsuccessful thread creation
The creation of a thread failed.
No send file available
No file to copy file is selected or exists in the folder.
Unable to copy several files
1. The destination folder does not exist.

2. When the overwrite check box is not checked, an attempt is made to
copy to a file having the same file name.
3. An attempt is made to overwrite a protected file.
4. Any other cause (such as a file being used by another application or
OS problem)
Send file not found, or invalid file
The number of divisions of a send file recorded in the checksum file and
name in the folder. Check.
the number of files actually existing do not match.

1. A file having an invalid file name exists in the data folder. Delete possibly invalid file names from the folder list.
2. The number of files in a divided file is wanting. Identify the wanting
files in the folder list and recopy them.
3. When the checksum file is damaged, copy it to the folder again.
110
The following shows the error displays.

Error display
Descriptions
Finisher not connected
The finisher is in the condition in which no connection is made.
Parameter error
A parameter abnormality occurs on the program.
Sequence error
An abnormality occurs with the processing sequence on the program.
Memory full error
The memory is full.
Device initialization error
A USB or parallel device initialization error occurs.
Machine type/board incompatible
The data transferred from the PC is not the data for bizhub 500/420, or
Time-out error
While in the file transfer from the PC, a time-out error occurs.
Checksum error
A checksum error occurs with the ROM file.
Flash erasure error
An abnormality occurs while in the flash erasure.
Engine power source error
Printer control board (PRCB) power source abnormality. Other abnormal-
not for the board selected from the panel.
ities occur with PRCB (when selecting the image controller, finisher or
ADF).
Write error
An error occurs with the write answer check (when selecting the fax
board controller 1 or the fax board controller 2).
Task generation error
A task generation error occurs.
Other errors
Errors other than the above occur, such as an OS error.
D. ISWTrms troubleshooting
When an error occurs while in the execution of the ISWTrns program.
Condition
1
Cause
Measure taken
The ISWTrns does not
The ISWTrns.EXE file is damaged
Set it up again.
start up.
The setup files itself is damaged.
Check the setup files and set it up
When an item in the
The transferred file is not stored in the
Check to see if the firmware file is
combo box is selected,
specified folder.
stored in the folder displayed in the
again.
2
the transferred file is
"File" text box of "Version."
not displayed.
Use the "Data Copy" function if the file

storage location is unknown.
The data folder in the option screen is
Check the setting of the data folder.
set incorrectly.
The file name is illegal (or has been
The file name must be used with no
changed.)
change made. When the file name is

changed, the display or selection of
the file becomes unavailable. When
the file name is changed, return it to
former state.
The folder name is illegal (or has been
When the folder name created by the
changed.)
"Make Folder" in the option screen

has been changed, it cannot be
found. Return it to former state and
check it again.
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C. Main body error list
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Condition
Cause
Measure taken
"NG" is displayed while
The transferred firmware is damaged.
Copy the firmware and check it again.
in the file checksum.
When "NG" still recurs, contact the

supplier of the firmware.
"??" is displayed while
When the firmware was copied to the
Copy the checksum file to the same
in the file checksum.
PC, the copying of the checksum file
firmware as the one for the firmware
(*.sum) was forgotten.
at the same time. (If you use the "Data

Copy" function, a copy is made auto-
The transfer of the file failed.
matically.)
5
An error "Cannot
The file is being used by anther pro-
Exit another program. The error still
open a file" is dis-
gram or system.
recurs, reboot Windows.
An error "Cannot
The connection of the cable is loos-
Check the cable to see if it is con-
send a Term Test
ened.
nected securely or if there is any prob-
played.
file" is displayed.
lem found with the cable itself.

The main body is not in the receiving
Check the main body to see if it is in
condition.
the receiving condition.
An error "Unsuc-
The connection of the cable is loos-
Check the cable to see if it is con-
cessful transmis-
ened.
nected securely or if there is any problem found with the cable itself.
sion to the LPT

port" is displayed.
Wrong data has been sent.
Check the file status screen to see if

the receiving mode on the main body
side (type of receiving board) corresponds with the transferred file on the
PC side.
The length of the cable is out of spec- Use a cable the length of which is less
ifications.
than 2 m.
The parallel port of the PC is set to
See the PC manual to release the
the ECP mode.
ECP mode.
There is a compatibility problem
Conduct a test with a PC with an
between the parallel port of the PC
actual performance of transmission,
and the port on the main body side.
and check to see if there is a compatibility problem found.
112
6. OTHERS
6.1
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6. OTHERS
Items not allowed to be disassembled and adjusted
6.1.1
Scanner section
A. CCD unit
(1) Parts not allowed to be removed
7 screws that are used to assemble the CCD unit.
4 attaching screws of the lens reference plate assy
[3]
[1]
[5]
[2]
[2]
[4]
[3]
[1]
Screws not allowed to be removed
[4]
CCD unit
[2]
[5]
Lens reference plate assy
[3]
CCD unit attaching screws (Can be
50gaf2c136na
removed when replacing the CCD unit.)
(2) Reason for prohibition

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

(1) Positions not allowed to be adjusted
Positions at which the mirror unit and the exposure unit are installed
[2]
[1]
Mirror unit
[1]
[2]
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Exposure unit

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

6.1.2
6. OTHERS
Write section
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A. Write section cover

4 attaching screws of the write section cover
[1]
[2]
50gaf2c138na
[1]
[2]
Write section cover

The inside of the write section becomes a laser beam path. Opening the cover allows the entry of dust and dirt
into the inside and they may block the laser beam path. Therefore, the attaching screws of the write section
cover must not be removed.
115
6. OTHERS
bizhub 500 / 420
B. Write attaching plate

5 attaching screws of the write mounting board
[2]
[1]
[1]
[1]
50gaf2c139na
[1]
[2]
Write attaching plate

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

6.1.3
6. OTHERS
Developing unit
2 attaching screws of the developer restriction blade
1 fixing screw of the magnet adjustment plate
Ds adjustment screws
bizhub 500 / 420
Developing unit at 2 places (inside the cover)
[6]
[4]
[5]
[3]
[2]
[1]
[2]
Developing roller
[3]
[4]
Magnet adjustment plate
[1]
50gaf2c140na
[5]
[6]
(Ds adjustment screws)

Each of the developer restriction blade and the magnet adjustment plate is used to determine the height of
developer on the developing roller. And the Ds adjustment screws are also used to determine the distance
between the drum and the developing roller. These parts are adjusted to an appropriate value in advance.
Therefore do not remove these attaching screws and fixing screws.
117
6. OTHERS
bizhub 500 / 420
6.1.4

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

The Ds adjustment screws are used to determine the distance between the drum and the developing roller and
they are adjusted to an appropriate value in advance. Therefore, do not remove these fixing screws.
118
List of parts to be disassembled and reassembled
Note
This list shows the explanation of the disassembly and reassembly of the parts which are considered necessary to replace (other than periodically replaced parts). However, these parts except for
the covers are not required to be disassembled while in normal service operations.
For the method of replacing the periodically replaced parts, see "3.5 Maintenance procedure of
No.
1
Section
Cover
Part name
Page referred to
Rear cover /1
P.120
Rear cover /2
P.120
Rear cover /3
P.121
Right cover /Up
P.122
Right cover /Lw
P.123
Left cover
P.123
Front door
P.124
Upper cover /Rt
P.125
Original glass
P.125
10
Upper cover /Fr
P.127
11
Upper cover /Lt
P.127
12
Upper cover /Rr
P.127
13
Front cover
P.128
14
Operation panel
Operation panel
P.129
15
Scanner section
CCD unit
P.130
16
Exposure lamp
P.133
17
Exposure unit
P.134
18
Scanner wire
P.137
19
Toner supply section
Toner supply unit
P.139
20
Paper feed section
Tray 1
P.143
Tray 2
P.143
21
119
bizhub 500 / 420
6.2
6. OTHERS
6. OTHERS
bizhub 500 / 420
6.3
Disassembling/assembling procedure
Caution
When disassembling or assembling the parts, be sure the power cord has been unplugged from
the power outlet.
6.3.1
Removing/reinstalling the rear cover /1
A. Procedure
[1]
rear cover /1 [2].

steps in reverse.
[2]
6.3.2
[1]
50gaf2c049na
A. Procedure
1. Remove the rear cover /1.

(See P.120)

(See P.121)

the 2 handles [2].
[2]
[2]
120
[1]
50gaf2c050na
6. OTHERS
rear cover /2 [2].

steps in reverse.
[1]
6.3.3
50gaf2c051na
A. Procedure

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

rear cover /3 [4].

steps in reverse.
[1][2]
[4]
[3]
50gaf2c052na
121
bizhub 500 / 420
[2]
6. OTHERS
bizhub 500 / 420
6.3.4

Removing/reinstalling the right cover /Up
A. Procedure
1. Open the bypass tray.

(See P.123)
2. Pull the ADU release lever [1] to open ADU [2].
[2]
[1]
50gaf2c053na
[1]
[2]

right cover /Up [2].

steps in reverse.
50gaf2c054na
122

Removing/reinstalling the right cover /Lw
A. Procedure
1. Open the bypass tray [1].

right cover /Lw [3].

steps in reverse.
[1]
[3]
[2]
6.3.6
50gaf2c055na
Removing/reinstalling the left cover
A. Procedure
1. Loosen the 2 screws [1].

2. Remove the 4 screws [2] and then remove the left
[1]
cover [3].

steps in reverse.
[2]
[3]
50gaf2c056na
123
bizhub 500 / 420
6.3.5
6. OTHERS
6. OTHERS
bizhub 500 / 420
6.3.7

Removing/reinstalling the front door
A. Procedure

2. Remove the screw [2] and then remove the support plate [3] and the front door at the same time.
Note
[5]
When installing the front door, be sure first to

fit the installation hole [4] to the shaft [5].
[4]

steps in reverse.
[1]
[2]
[3]
50gaf2c057na
124

Removing/reinstalling the original glass
A. Procedure
[1]
[2]

upper cover /Rt [2].
50gaf2c058na

glass attaching plate /Up [2].
[1]
[2]
50gaf2c059na
125
bizhub 500 / 420
6.3.8
6. OTHERS
6. OTHERS
bizhub 500 / 420
[6]
[1]
3. Loosen the 2 screws [1] and slide the glass
[5]
attaching plate /Lw [2].
4. Loosen the screw [3] and slide the glass holding

plate [4].
5. Remove the original glass [5].

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

steps in reverse.
[2]
126
50gaf2c061na

Removing/reinstalling the upper covers /Fr and /Lt
A. Procedure
[4]
1. Remove the original glass.
[5]
(See P.125)
2. Loosen the screw [1].

upper cover /Fr [3].

upper cover /Lt [6].

steps in reverse.
[6]
[2]
6.3.10
[3]
[1]
50gaf2c062na
Removing/reinstalling the upper cover /Rr
A. Procedure
[2]
(See P.125)
2. Remove the upper covers /Fr and /Lt.

(See P.127)
3. Remove DF from the main body.

upper cover /Rr [2].

steps in reverse.
[1]
50gaf2c063na
127
bizhub 500 / 420
6.3.9
6. OTHERS
6. OTHERS
bizhub 500 / 420
6.3.11
Removing/reinstalling the front cover
A. Procedure
[1]

3. Remove the screw [3] and then remove the front
cover [4].

steps in reverse.
[4]
[2]
[3]
50gaf2c160na
128

Removing/reinstalling the operation panel
A. Procedure
1. Remove the 4 screw caps [1] and then remove

the 4 screws [2].
[1]
2. Remove the connector [4] of the operation board

(OB) [3] and then remove the operation panel [5].
Note
When installing the operation panel, be sure
to install the connector [4] without fail.

steps in reverse.
[2]
[5]
[3]
[4]
50gaf2c064na
129
bizhub 500 / 420
6.3.12
6. OTHERS
6. OTHERS
bizhub 500 / 420
6.3.13

Removing/reinstalling the CCD unit
A. Procedure
[2]
[1]
(See P.125)
2. Remove the 2 screws [1] and the remove the lens

light blocking cover assy [2].

lens light blocking cover [5].
5. Remove the 3 screws [6] and then remove the ribbon cable cover [7].
Note
Be careful not to damage the scanner wire.
[4]
[3]
[4]
[5]
[4]
[7]
[6]
50gaf2c066na
6. Remove the ribbon cable [2] from the CCD board

(CCDB) [1].
[1]
130
[2]
50gaf2c065na
6. OTHERS
When removing the ribbon cable [1], be sure

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

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

original position and lock the ribbon cable
[2].
[2]
[1]
50gaf2c069na
131
bizhub 500 / 420
Note
6. OTHERS
bizhub 500 / 420

CCD unit [2].

steps in reverse.
Note
After installing the CCD unit, be sure to conduct the image adjustment in the service
mode. (See P.163, P.164, P.165, P.166, P.167,
P.168)
[1]
132
[2]
50gaf2c070na

Replacing the exposure lamp
bizhub 500 / 420
6.3.14
6. OTHERS
Note
Be careful not to touch the lamp section of the exposure lamp (L1) with bare hands.
A. Procedure
[3]
[2]
[1]
1. Remove the original glass. At this time, remove

also the glass attaching plate /Lw.
(See P.125)

3. Remove the harness clamp [2].
4. Remove the 2 screws [3] and slide the exposure
lamp (L1) [4] for removal.

steps in reverse.
[4]
[3]
50gaf2c073na
133
6. OTHERS
bizhub 500 / 420
6.3.15

Removing/reinstalling the exposure unit
Note
When installing the exposure unit, be sure to use the optics unit positioning jig.
When installing the exposure unit, be sure to conduct the image adjustment in the service mode.
(See P.163, P.164, P.165, P.166, P.167, P.168)
A. Procedure for removal

[3]

(See P.125)

(See P.127)
3. Remove the upper cover /Rr.

(See P.127)
4. Remove the operation panel.

(See P.129)
5. Remove the wiring harness [2] from the 2 harness

clamps [1].

operation panel unit /Lw assy [4].
[2]
134
[1]
[4]
50gaf2c071na
[5]
[3]
7. Move the exposure unit [1] to the notch [2] of the

frame.

9. Remove the screws [4] and [5] and then remove
the exposure unit from the exposure unit mounting plates /Fr [6] and /Rr [7].
10. Slide the exposure unit [1] for removal.
[1]
[2]
[4]
[6]
50gaf2c074na
135
bizhub 500 / 420
[7]
6. OTHERS
6. OTHERS
B. Procedure for reinstallation
bizhub 500 / 420
1. Move the V-mirror unit [1] to the vicinity of the Vmirror positioning hole [2].
2. Insert the optics unit positioning jig [3] into the V[10]
mirror positioning hole and fix the V-mirror unit.

Note
Be sure to insert the optics unit positioning jig
[8]
from the front side and pass it through the Vmirror unit.
[6]
3. Insert the optics unit positioning jig [5] into the

exposure unit positioning hole [4].
4. Hit the exposure unit [6] against the optics unit

positioning jig [5].
5. Install the exposure unit to the exposure unit

mounting plates /Fr [7] and /Rr [8] with the screws
[9] and [10].
6. Pull off the 2 optics unit positioning jigs.

7. For the parts to be installed in the succeeding
steps, be sure install them following the removal
steps in reverse.
[1]
[2]
[3]
[4]
[5]
[9]
[7]
50gaf2c075na
136

Stretching the scanner wire
Note
Be sure to wind the scanner wire around the pulley closely with no scanner wire overlapping each
other.
When restretching or replacing the scanner wire, be sure to use the optics unit positioning jig.
When restretching or replacing the scanner wire, be sure to conduct the image adjustment in the
service mode. (See P.163, P.164, P.165, P.166, P.167, P.168)
A. Procedure
[1]

(See P.125)

(See P.127)

(See P.127)
4. Remove the operation panel.

(See P.129)
5. Remove the operation panel unit /Lw assy.

(See P.134)
6. Move the V-mirror unit [1] to the vicinity of the Vmirror positioning hole [2].
7. Insert the optics unit positioning jig [3] into the V[2]
[3]
50gaf2c076na
mirror positioning hole and fix the V-mirror unit.

Note
Be sure to insert the optics unit positioning jig
[3] from the operation panel side and pass it
through the V-mirror unit.
137
bizhub 500 / 420
6.3.16
6. OTHERS
6. OTHERS
bizhub 500 / 420
8. Loosen the 2 hexagon socket screws [3] of the

[8]
[7]
[6]
drive pulley on the side so that the drive pulley [1]
[1]
can rotate freely against the pulley shaft [2].
9. Drop the metal ball [5] provided at the intermediate section of the scanner wire [4] into the drive
[3]
pulley installation hole and, with this as a starting

point, wind the wire 6 turns [6] outwards and 5
[4]
[11]
[5]
turns [7] inwards.
[9]
Note
The scanner wires are color-coded. Be sure
[2]
to use the one painted black on the front side

with the one with no paint on the rear side.
[12]
For each scanner wire that is wound around

the pulley, be sure to use on the outside the
one at the end of which the metal ball [8] is
[12]
provided and on the inside the one at the end

of which the screw thread [9] is provided.
[1]
[6]
[7]
For each scanner wire, be sure to pull out the
[8]
[10]
one that is wound on the outside in the paper

feed direction [10] from the upper side of the
drive pulley and the one wound on the inside
in the paper exit direction [11] from the upper
[3]
side of the drive pulley.
[4]
10. After completion of the winding of the scanner

[9]
wire, be sure to fix it with the tape [12] so that it
[5]
50gaf2c077na
does not come off.
11. Pass the scanner wire [2] provided with the metal
ball [1] through the pulley [4] on the paper exit side
[1]
[3] [4]
[6]
[8]
[2]
after passing through under the V-mirror unit [3],

and pass further through the pulley [5] inside the
V-mirror unit. And then hook it to the notch [6] of
the frame.
12. Pass the scanner wire provided with the screw
[5]
[2]
thread through the pulley [7] on the paper feed

side. And then pass it from above through the pulley [8] on the outside of the V-mirror unit and fur-
[7]
ther through under the V-mirror unit and, with the

nut [9] and the washer [10], fix it at the tension of
[4]
1.3 kg to 1.7 kg.
[5]
[10]
[8]
138
[9]
50gaf2c078na
6. OTHERS
When fixing the screw thread side of the

scanner wire, be sure fix it with a tension of
1.3 to 1.7 kg applied by a spring balance in the
When fixing the scanner wire, be sure to
check to see if the V-mirror unit has been
fixed with the optics unit positioning jig.
[1]
50gaf2c079na
Be sure to tighten up the set screw of the

drive pulley that has been loosened.
Be sure to peel off the tape that has been
used for fixing.
13. Install the exposure unit.

(See P.134)
Note
Be sure to slide the exposure unit and check
to see if it operates smoothly.
6.3.17
Removing/reinstalling the toner supply unit
Note
Be sure to remove the toner bottle in advance.
A. Procedure
[1]
(See P.125)

(See P.127)

(See P.127)

(See P.122)

(See P.120)

system unit cover [2].
[1]
[2]
50gaf2c080na
139
bizhub 500 / 420
Note
6. OTHERS
7. Remove the 2 screws [1] and then remove the rib-
bizhub 500 / 420
[1]
bon cable cover [2].
8. Remove the ribbon cable [3].

overall control board mounting box [6].
[6]
[3]
[2]
[5]
140
[5]
[4]
50gaf2c081na
6. OTHERS

ozone filter mounting assy [3].
[2]
[3]
[1]
50gaf2c082na

15. Remove the board support [3] and the remove the
drum motor (M1) [4].
[2]
[3]
[1]
[4]
50gaf2c083na
141
bizhub 500 / 420
6. OTHERS
bizhub 500 / 420
[2]

[1]
toner supply unit [3].

steps in reverse.
[3]
[2]
[2]
50gaf2c084na
142

Removing/reinstalling the trays 1 and 2
Note
The trays 1 and 2 are of the same form and of the same mechanism. The procedure given here
shows mainly the operations employed for the tray 1.
When there remains paper in the tray, be sure to remove it thoroughly before starting operations.
A. Procedure

2. Remove the screw [2] and then remove the stopper [3].
[6]
Note
When installing the stopper, be sure to set the
positioning hole [4] to the projection [5].
3. While holding down the stopper [6], pull out the

tray 1 for removal.
Note
When installing the tray 1, be sure to check to
see if the tray can be pulled out and pushed in
smoothly.
When installing the tray 1, be sure to check to
see if the tray is not thoroughly pulled out.
[1]
[4] [5]
[3]
[2]
50gaf2c141na
143
bizhub 500 / 420
6.3.18
6. OTHERS
6. OTHERS
bizhub 500 / 420
6.4
6.4.1
Option counter
Configuration of the key counter
As shown below, the key counter is configured as a product so that it can be supplied according to the application. In principle, the key counter can be installed by obtaining the key counter kit 4.
[1] Cover
[2] Mounting
[3] Key
[4] Counter
[5] Screws
[6] Screws
[7] Screws
plate
counter
socket
for the
for the
for the
cover
counter
mounting
socket
plate
Key counter kit 4*
Key counter
z
z
mounting kit*
Key counter
In the kit, parts (such as a mounting plate, mylar, wire saddle and screws) that are not used for 500/420
are included.
[1]
[2]
[4]
[3]
[5]
[6]
[7]
50gaf2c183na
144

Installation procedure of the key counter
1. Remove the upper cover /Lt.

(See P.127)
2. Remove the split cover [1] of the upper cover /Lt.

3. Put the harness [2] for the key counter through the
upper cover /Lt.
[1]
4. Install the upper cover /Lt.
[2]
50gaf2c184na
5. Install the mounting plate [4] with the 3 screws [3].

[4]
[3]
50gaf2c185na
6. Hook up the connector of the key counter socket.

7. Install the counter socket [6] with the 2 screws [5].
[5]
[6]
50gaf2c186na
8. Install the cover [8] with the 2 screws [7].
[8]
[7]
50gaf2c187na
145
bizhub 500 / 420
6.4.2
6. OTHERS
bizhub 500 / 420
6. OTHERS
Blank page
146
7. HOW TO USE THE ADJUSTMENT/SETTING SECTION
bizhub 500 / 420
ADJUSTMENT/SETTING
7. HOW TO USE THE ADJUSTMENT/SETTING SECTION
7.1
Composition
This part "ADJUSTMENT/SETTING" describes items to be adjusted and the method of adjustment that is
required by this machine, it also gives detailed explanations.
A. Checking before starting work
When conducting claims in the field, it is necessary to check first the following:
1. Are the power supply and voltage secured in accordance with the specifications?
2. Is the power supply properly grounded?
3. Is any equipment that repeatedly consumes a lot of electricity connected to the same power supply? (e.g.:
Electric noise sources such as elevator and air conditioner)
4. Are environmental conditions suitable for the machine?
High temperature and high humidity, direct sunlight, air ventilation, etc.
Levelness of the location on which the machine is installed.
5. Does the cause of poor images lie in the original itself?

6. Is density selected properly?
7. Is the original glass stained?
8. Is proper paper used for copy?
9. Are copy consumable replaced with new ones at their life? (e.g.: Developer, drum, cleaning blade, etc)
10. Is toner filled?
B. Checkpoints when conductions on-site service
Due attention should be paid to the following when repairing the machine.
1. Be sure to unplug the power cord from the power outlet. Also, when operating the machine with the power
supplied, be careful of the scan of the exposure unit and be sure not to get caught by the gear.
2.
3.
4.
5.
The fusing section may be very hot. Be careful not to get burnt when handling it.
The developing unit is strongly magnetized. Be careful not to bring a watch and instrument near to the unit.
Be careful not to damage the drum with a tool.
Be careful not to touch IC directly with bare hands.
147
8. UTILITY MENU
bizhub 500 / 420
8. UTILITY MENU
8.1
List of utility mode
Note
For detail on the utility mode, refer to "User's guide".
[1] One-Touch
[1] Scan
Registration
[1] Address
[1] E-Mail
Book
[2] FTP
[3] SMB
[4] User Box
[2] Group
[3] Program
[2] Fax
[4] Subject/Text
[1] Subject
(for E-mail)
[2] Text
[1] Address
[1] Abbr. Dial
Book
[2] E-Mail
[3] User Box
[2] Group
[3] Program
[3] User Box
[4] Subject/Text
[1] Subject
(for E-mail)
[2] Text
[1] Public/Personal User Box (HDD installed) /Confidential RX User Box

(HDD not installed)
[2] Bulletin Board User Box
[2] User Setting
[1] System Set-
[1] Language Selection
ting
[2] Measurement Unit Setting

[3] Paper Tray
[1] Paper Type
Setting
[2] Auto Tray Select Setting

[3] Auto Tray Switch ON/OFF
[4] No Matching Paper in Tray Setting
[5] Print Lists
[4] Reset Set-
[1] System Auto Reset
ting
[2] Auto Reset

[3] Job Reset
[2] Display Set-
[1] Sub Screen Display ON/OFF
ting
[2] Scan Basic Screen Default Setting

[3] Fax Basic Screen Default Setting
[4] Copy Screen
[5] Fax Active Screen
[3] Initial Setting

[4] Copier Setting
[5] Scanner Setting
148
[2] User Setting
8. UTILITY MENU
[6] Printer Set-
[1] Basic Setting
ting
[2] Paper Setting

[3] PCL Setting
bizhub 500 / 420
[1] Typeface
[2] Symbol Set
[3] Font Size
[4] Line/Page
[5] CR/LF Mapping
[4] PS Setting
[5] Print Report
[3] Administrator
[1] System Set-
[1] Power Save Setting
Setting
ting
[2] Output Set-
[1] Print/Fax Output Setting
ting
[2] Output Tray Setting
[3] Date/Time Setting

[4] Daylight Saving Time Setting
[5] Weekly
[1] Weekly Timer ON/OFF Setting
Timer Setting
[2] Time Setting

[3] Date Setting
[4] Select Time for Power Save
[5] Password for Non-Business Hours
[6] Restrict User
[1] Restrict Access to Saved Program Jobs
Access
[2] Delete Saved Program Jobs

[3] Restrict Access to Job Settings
[7] Expert
[1] Original Image Density
Adjustment
[2] Erase Adjustment

[3] Finisher
[1] Center Staple Position
Adjustment
[2] Half-Fold Position

[3] Punch Horizontal Position
[4] Punch Resist Loop Size
[8] List/Counter
[1] Management List

[2] Paper Size/Type Counter
[0] Standard Size Setting

[2] Administra-
[1] Administrator Registration
tor/Machine
[2] Input Machine Address
Setting
[3] One-Touch
Registration
[1] Scan
[1] Address
[1] E-Mail
Book
[2] FTP
[3] SMB
[4] User Box
[2] Group
[3] Program
[4] Subject/Text
[1] Subject
(for E-mail)
[2] Text
149
bizhub 500 / 420
8. UTILITY MENU
[3] Administrator
[3] One-Touch
Setting
Registration
[2] Fax
[1] Address
[1] Abbr. Dial
Book
[2] E-Mail
[3] User Box
[2] Group
[3] Program
[3] User Box
[4] Subject/Text
[1] Subject
(for E-mail)
[2] Text
[1] Public/Personal Use Box

[2] Bulletin Board User Box
[4] One-Touch
[1] Address Book List
Registration List
[2] Group List

[3] Program List
[4] E-Mail Subject/Text List
[4] User
[1] Authentication Method
Authentication/
[2] User Authentication Setting
Account Track
[3] Account Track Setting

[4] Print without Authentication
[5] Counter List
[5] Network
[1] Network Setting
Setting
[2] TCP/IP Setting

[3] Netware Setting
[4] IPP Setting
[5] FTP Setting
[6] SMB Setting
[7] AppleTalk Setting
[8] LDAP Set-
[1] Enabling LDAP
ting
[2] Setting Up LDAP
[9] E-Mail Set-
[1] E-Mail TX (SMTP)
ting
[2] E-Mail Rx (POP)
[0] Detail Set-
[1] Device Setting
ting
[2] Time Adjustment Setting

[3] Status Notifi-
[1] Notification Address Setting
cation Setting
[2] Notification Item Setting

[3] Notification Time Setting
[4] PING Confirmation

[5] PSWC Setting
[6] SLP Setting
[7] LPD Setting
[8] SNMP Setting
[6] Copier Setting

[7] Printer Setting
150
[1] I/F Timeout
[9] Prefix/Suffix
[1] ON/OFF Setting
Setting
[2] Prefix/Suffix Setting

[8] Fax Setting
Setting
[1] Header Information
bizhub 500 / 420
[3] Administrator
8. UTILITY MENU
[2] Header/Footer Position

[3] Telephone Line Setting
[4] TX/RX Setting
[5] Function
[1] Function ON/OFF Setting
Setting
[2] Dial-In Setting

[3] Memory RX
[4] Closed Network RX
[5] Forward TX Setting
[6] Remote RX
[7] Confidential RX Password Check
[8] PC-Fax RX Setting
[9] TSI User Box Setting
[6] PBX CN Set

[7] Report Settings
[8] Job Settings List
[9] System
[1] IS OpenAPI Setting
Connection
[3] Prefix/Suffix Auto Setting
[0] Security Set-
[1] Administrator Password
ting
[2] User Box Admin. Setting

[3] Administrator Security Level
[4] Security Details
[5] HDD Setting
[1] Check HDD Capacity

[2] Delete Unused User Box
[3] Delete Secure Print Documents
[5] Overwrite All Data
[6] HDD Lock Password
[6] Manage-
[3] Network Fuction Setting
ment Function
Setting
151
9. LIST OF ADJUSTMENT ITEMS
Machine
Imaging
Process
Adjustment
Counter
ADF
Finisher
Print Positioning: Leading Edge

Print Positioning: Side Edge
Paper Feed Direction Adj.
Printer Resist Loop
Bypass Tray Adjustment
Image Position: Leading Edge
Scan
Image Position: Side Edge
Area
Cross Direction Adjustment
Feed Direction Adjustment
Lead Edge Erase Adjustment
Non-Image Area Erase Check
TCR Adjustment
Toner Density Adjustment
Laser Diameter Adjustment
LD1 Offset Adj.
LD2 Offset Adj.
Present Parts Life (Reset)
PM Counter (Reset)
PM Counter (Set)
Paper Feed Direction
Lead Edge
Side Edge
Resist Loop Adj.
Original Size Adj.
Density Adj.
Scan Position Adjustment
Sensor Auto Adjustment
Center Staple Position
Half-Fold Position
Punch Horizontal Position
Punch Resist Loop
Printer
Area
P.157
P.158
P.159
P.161
P.162
P.163
P.164
P.165
P.166
P.167
P.168
P.169
P.170
P.171
P.172
P.178
P.189
P.212
P.213
P.214
P.215
P.215
P.216
P.217
P.218
P.219
P.220
P.221
P.222
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e g
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d
e
f
NVRAM board
CCD unit
Roller parts related

to paper feed
DF
Scanner wire, exposure/mirror unit
Slit glass
Write unit
Replacement parts
related to fusing unit
Developer
Drum
Adjustment/setting items
After completion of PM
Replacement parts/Others
Page referred to
bizhub 500 / 420
9. LIST OF ADJUSTMENT ITEMS
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Note
After changing developer, be sure to avoid the printing operation before completion of the TCR
adjustment.
When replacing the NVRAM board (NRB), be sure to conduct the TCR adjustment after changing
developer.
When replacing the overall control board (OACB) due to the board being damaged, the NRB that
has been provided on the damaged OACB should be reused on a new OACB in principle. When the
NRB is considered to be damaged and replaced with a new one, be sure to refer to the support
division of the authorized distributor.
In the NRB, all sorts of various adjustment data, setting data and counter data are stored. Accordingly, when replacing the NRB, be sure to conduct all of the adjustments and the settings and then
replace the parts (drum, developer, cleaning blade, fixing web) the control of which are adjusted
by the counter. Be sure to refer to the support division of the authorized distributor for particulars.
152
10. SERVICE MODE
10.1 List of service mode

Machine
Printer Area
P.157
Print Positioning: Side Edge
P.158
Paper Feed Direction Adj.
P.159
Printer Resist Loop
P.161

Scan Area
page
Print Positioning: Leading Edge
P.162
Image Position: Leading Edge
P.163
Image Position: Side Edge
P.164
Cross Direction Adjustment
P.165
Feed Direction Adjustment
P.166
Lead Edge Erase Adjustment
P.167
Non-Image Area Erase Check
P.168
Imaging Process
Charging Main Manual Adj.
P.169
Adjustment
Transfer Manual Adj.
P.169
Separation (AC) Manual Adj.
P.169
Separation (DC) Manual Adj.
P.169
Grid Charging Manual Adj.
P.169
Bias Voltage Manual Adj.
P.169
TCR Adjustment
P.169
Toner Auto Supply
P.169
P.170
Laser Diameter Adjustment
P.171
LD1 Offset Adj.
P.172
LD2 Offset Adj.

LD1 Bias Adj.
P.172
LD2 Bias Adj.

System 1
Marketing Area
P.173
Tel/Fax Number
P.174
Serial Number
P.174
Trouble Isolation
P.175
No Sleep
P.175
Foolscap Size Setting

Original Size Detection
P.175
Original Glass Original Size Detect
P.176
ADF Original Size Detect

Original Glass Small Size Detect
Detected Size Setting
P.176
Install Date
P.177
153
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10. SERVICE MODE
10. SERVICE MODE
bizhub 500 / 420
System 1
Initialization
page
Utility/Administrator
Job memory Setting
Setting Data
Data
P.177
FAX Setting Data

Network Setting Data
Destination Storage Data
CS Remote Care Setting Data
Service Mode Setting
Image Process Adj.
(Adj.) Data
Data
Machine and ADF
Adjustment Data
All History Data

Counter
State Confirmation
Total Service
P.179
Fax Communication Error
P.179
Mode
P.179
ADF Counter
P.181
Service Call
P.181
JAM
P.183
Present Parts Life
P.187
Optional Parts Life
P.178
PM
P.189
Reuse
P.184
Each Size
P.186
Pape Jam History
P.184
Jam Counter History
P.183
Time Series Trouble (SC)
P.183
Each Section Trouble (SC)
P.181
Sensor Check
P.190
Load Check
P.198
Memory/HDD Condition
ADF
154
P.205
Memory/HDD Adjust-
Memory Check
P.205
ment
HDD R/W Check
P.205
HDD Format
P.206
Adj. Data Table
P.206
P.212
Lead Edge
P.213
Side Edge
P.214
Resist Loop Adj.
P.215
Original Size Adj.
P.215
Density Adj.
P.216
P.217
Sensor Auto Adjustment
P.218
10. SERVICE MODE

Finisher
P.219
Half-Fold Position
P.220
Punch Horizontal Position
P.221
Punch Resist Loop
P.222
Firmware Version
P.223
CS Remote Care
System 2
page
Center Staple Position
P.224
Data Capture
Paper Size Setting
P.238
Tray3
P.238
LCT
DipSW Setting
P.238
ISW
P.253
Option
P.253
Trouble Reset
List Output
P.253
Machine Management List
P.254
Adjustments List
Service Parameter
Protocol Trace
Fax Setting List
Test Mode
Full Image Halftone
P.255
Gradation Pattern (No.2)

Beam Gap Check
Line Check Pattern
Test Pattern Output Mode
Running Mode
Test Fax
FAX
P.262
P.263
Line1
Modem/NCU
*1
*1
NetWork
System
Fax File Format
Communication
List Output
Function Parameter
Initialization
Enhanced Security
Billing Setting
*1
CE Password
P.266
Administrator Password
P.266
Administrator Feature Level
P.267
CE Authentication
P.267
Counter Setting
P.269
Management Function Choice
P.270
(See the FK-502 Service Manual)
155
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10. SERVICE MODE
bizhub 500 / 420
10.2 Setting Method

This machine is provided with a service mode for various types of adjustments/settings. Data adjusted and/or
set in this mode are stored in the NVRAM board (NRB).
10.2.1
Start and exit of the service mode
You can access the service mode while the power is both turned ON and OFF. In either way, the started service
mode is the same, but how to exit differs.
A. Starting and exiting service mode while the power is ON
1. Check to see if the regular copy screen is displayed.

2. Press the Utility/Counter key.
3. "Meter Count/ Utility screen"
Press [Details].
4. "Meter Count screen"

Press the Stop key and key pad in the order shown below.
Stop 0 0 Stop 0 1
Note
When the CE password is set, a password is required to input to enter the service mode.
5. "Service Mode screen"

The service mode is in the start-up condition.
6. Select an item to set.

The setup screen of each item is displayed.
7. Conduct required operations, and press [END/OK] after completion of the operations.
The setting made at step 6 becomes effective.

Press [Exit] to return to the regular copy screen.
B. Starting and exiting service mode while the power is OFF
1. While pressing the Utility/Counter key, turn ON the power switch (SW2).
2. Trouble reset screen appears.
3. Press the [Trouble reset].
4. On the Operation panel, press the following keys.
Stop 0 0 Stop 0 1
5. Service Mode screen appears.

Note
When the CE password has been set, you must enter the password to enter the service mode.
6. Press the key for an item you want to configure.

The setting screen for each item appears.
7. Conduct necessary operations and turn OFF the SW2 after completion of operations.
8. The new settings become effective after restart.
156
10. SERVICE MODE
10.3.1
Print Positioning: Leading Edge (Printer Area)
Adjusts the leading edge timing of the printer image.

This adjustment is used to change the restart timing of paper of the registration roller and adjust the relative
position in the sub scan direction of the image against the paper.
The adjustment can be made for each paper feed (each tray, bypass feed and ADU). And for the bypass feed, it
is possible to make an adjustment for each type of paper (plain paper, thick paper, thin paper, OHP, envelope
and label).
Note
Be sure to complete the Paper Feed Direction Adj. (Printer Area) before starting this adjustment.
(See P.159)
A. Procedure

Press [Machine].
2. "Machine Adjust screen"

Press [Printer Area].
3. "Printer Area screen"

Press [Print Positioning: Leading Edge].
4. "Print Positioning: Leading Edge screen"

Select an item to adjust and then press [Test Copy].
Note
When [Batch] is pressed, no test copy is available.
5. "Test Copy screen"

With paper set in the tray selected, press the Start key to output the test pattern (No. 16).
When paper is fed from the bypass feed, set the corresponding type of paper. And then press the Start
key to output the test pattern (No. 16).
6. Press [END].
7. Measure the leading edge timing with a scale.
Standard value [1]: 20 0.5 mm
[1]
50gaf3c001na
8. "Print Positioning: Leading Edge screen"

Enter a value through the [+]/[] or numeric keys and press [Setting].
Setting range: 12.8 (shorter) to + 12.7 mm (longer)
1 step = 0.1 mm
Press [Restore] to return to a value before change.
9. Repeat steps 4 to 8 until it gets within the standard value.

10. Press [END].
157
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10.3 Machine Adjust
10. SERVICE MODE
bizhub 500 / 420
10.3.2
Print Positioning: Side Edge (Printer Area)
Changes the laser write timing and also changes the image position on the drum in the main scan direction to
adjust the mis-centering of the printer image.
For each paper feed (each tray, bypass feed, ADU) and for each paper size (common, small size, large size), the
adjustment can be made.
Note
Be sure to complete the Cross Direction Adjustment (Scan Area) before making this adjustment.
(See P.159)
A. Procedure

Press [Machine].


Press [Printer Positioning: Side Edge].
4. "Print Positioning: Side Edge screen"

Select an item to adjust and press [Test Copy].
Note

With paper set in the tray selected, press the Start key to output the test pattern (No. 16).
6. Press [END].
7. Fold the output paper into two in the main scan direction to check it for any discrepancy against the
center line of the print.
Standard value: 0 1.5 mm or less
8. "Print Positioning: Side Edge screen"

Setting range: 12.8 (image: to the rear) to + 12.7 (image: to the front) mm
1 step = 0.1 mm

10. Press [END].
158

Paper Feed Direction Adj. (Printer Area)
A. Printer
Adjusts the magnification of the printer in the sub scan direction.
This adjustment is used to change uniformly the process speed of the drum and the registration roller and
change the magnification in the sub scan direction of the image on the drum.
The adjustment can be made for each type of paper (normal paper, OHP, thick paper, envelope, label and custom paper)
Note
The background of the test pattern to be output is fogging. However, this is not abnormal.
For thin paper, the setting of normal paper is applicable.
(1) Procedure

Press [Machine].


Press [Paper Feed Direction Adj.]
4. "Paper Feed Direction Adj. screen"

Press [Printer].
5. Select an item for the type of paper and press [Test Copy].
Set A3 (for metric) or 11 x 17 (for inch) paper that is the type of paper selected. And then press the Start
key to output the test pattern (No. 16).
7. Press [END].
8. Measure the magnification in the sub scan direction with a scale.
Standard value [1]: 0.5% or less (190 1 mm or
less)
[1]
50gaf3c002na

Setting range (normal paper): 5.0 (smaller) to + 5.0 % (larger)
Setting range (other than the above): 2.0 (smaller) to + 2.0 % (larger)
1 step = 0.1 %

11. Press [END].
159
bizhub 500 / 420
10.3.3
10. SERVICE MODE
10. SERVICE MODE
bizhub 500 / 420
B. Fixing motor clock

Makes appropriate a paper feed loop amount between the registration roller and the fusing roller to prevent the
transfer slippage at the position about 20 mm from the trailing edge of the transfer paper.
The adjustment can be made for each type of paper (normal paper, OHP, thick paper, envelope, label, custom
paper and user paper).
Note
Printer magnification in the paper through direction: The adjustment of the printer should have
been completed. (See P.159)
For thin paper, the setting of normal paper is applicable.
(1) Procedure

Press [Machine].


Press [Paper Feed Direction Adj.]

Press [Fixing Motor Clock].
5. Select an item for the type of paper and press [Test Copy].
Set A3 (for metric) or 11 x 17 (for inch) paper that is the type of paper selected. With the print count set at
5, press the Start key to output the test pattern.
7. Press [END].
8. Check all of the 5 output sheets of paper to see if
there occurs no transfer jitter.
Approx.20mm
50gaf3c018na

Setting range (normal paper): 5.0 (smaller) to + 5.0 % (larger)
Setting range (user paper): 0.5 (smaller) to + 0.5 % (larger)
Setting range (other than the above): 2.0 (smaller) to + 2.0 % (larger)
1 step = 0.1 %
Press [Restore] to return to the value before change.

11. Press [END].
160

Printer Resist Loop
Adjusts the paper loop amount at the registration roller section to adjust a paper skew, wrinkles, or a jam at the
registration section.
The adjustment can be made for each paper feed (each tray, bypass feed and ADU) and for each paper size
(large size, intermediate size and small size). And for the bypass feed, it is also possible to make an adjustment
for each type of paper (normal paper, thick paper, thin paper, OHP, envelope, and label).
A. Procedure

Press [Machine].

Press [Printer Resist Loop].
3. "Printer Resist Adjustment screen"

Select an item to adjust and press [Test Copy].
Note

With the paper selected set in the tray, press the Start key to output the test pattern (No. 16).
5. Press [END].
6. Check to see if there occurs no paper skew, wrinkle, or jam at the registration section.
7. "Printer Resist Adjustment screen"
Setting range:
For bypass feed thick paper (large/small), bypass feed thin paper (large/small), bypass feed OHP (large/
small), bypass feed envelope (large/small), and bypass feed label (large/small):
16.64 (smaller) to + 16.51 mm (larger)
1 step = 0.13 mm
For other than the above:
Setting range for bizhub 500: 32.00 to + 31.75 mm 1 step = 0.25 mm
Setting range for bizhub 420: 26.88 to + 26.67 mm 1 step = 0.13 mm

9. Press [END].
161
bizhub 500 / 420
10.3.4
10. SERVICE MODE
10. SERVICE MODE
bizhub 500 / 420
10.3.5
Conduct this adjustment when the paper size of the bypass tray is not detected correctly.
A. Procedure

Press [Machine].

Press [Bypass Tray Adjustment].
3. "Bypass Tray Adjustment screen"

Press [Max. Width] to expand the guide plate of the bypass tray to the maximum, and then press the Start
key.
4. When the adjustment is completed normally, "OK" is displayed in the "Result" area.
5. Press [Min. Width] to narrow the guide plate of the bypass tray to the minimum, and then press the Start
key.
6. When the adjustment is completed normally, "OK" is displayed in the "Result" area.
7. Press [Test Copy].
Check to see if the size of paper set in the bypass tray is detected correctly and then press [END].
9. Repeat steps 3 to 8 when the paper size is not correct.

10. Press [END].
162

Image Position: Leading Edge (Scan Area)
Adjusts the leading edge timing while in the scan in the platen mode.
This adjustment is used to adjust the position at which the read is started in the sub scan direction while the
original is being scanned by the exposure unit.
A. Procedure

Press [Machine].

Press [Scan Area].
3. "Scan Area screen"

Press [Image Position: Leading Edge].
4. "Scan Area (Image Position: Leading Edge) screen"

Press [Test Copy].

With the test chart set on the original glass, select A3 (for metric) or 11 x 17 (for inch) paper and press the
Start key.
6. Press [OK].
7. Check the scanner leading edge position (original glass).
Standard value: a. Envelope 0 2.5 mm or less
b. Other paper 0 1.5 mm or less
8. "Scan Area (Image Position: Leading Edge) screen"

Setting range: 2.0 (shorter) to +2.0 mm (longer)
1 step = 0.1 mm

10. Press [END].
163
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10.3.6
10. SERVICE MODE
10. SERVICE MODE
bizhub 500 / 420
10.3.7
Image Position: Side Edge (Scan Area)
Adjusts the mis-centering of the image in the main scan direction while in the scan in the platen mode.
Note
Be sure that the adjustment of the Print Position: Side Edge has been completed.
(See P.158)
A. Procedure

Press [Machine].

Press [Scan Area].

Press [Image Position: Side Edge].
4. "Scan Area (Image Position: Side Edge) screen"

Press [Test Copy].

Start key.
6. Press [OK].
7. Fold the output paper into two at the center in the main scan direction and check it for discrepancy
against the center line of the print.

Setting range: 2.96 (image: to the rear) to + 2.96 mm (image: to the front)
1 step = 0.04 mm

10. Press [END].
164

Cross Direction Adjustment (Scan Area)
Adjusts the magnification of the image in the main scan direction while in the scan in the platen mode and in the
DF mode.
A. Procedure

Press [Machine].

Press [Scan Area].

Press [Cross Direction Adjustment].
4. "Scan Area (Cross Direction Adjustment) screen"

Press [Test Copy].

With the test chart set on the original glass or ADF, select A3 (for metric) or 11 x 17 (for inch) paper and
press the Start key.
6. Press [OK].
7. Measure the magnification in the main scan direction with a scale.
Standard value [1]: 0.5 % or less (200 1 mm
or less)
[1]
50gaf3c003na

Setting range: 5,0 (smaller) to + 5.0% (larger)
1 step = 0.1%

10. Press [END].
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bizhub 500 / 420
10.3.8
10. SERVICE MODE
10. SERVICE MODE
bizhub 500 / 420
10.3.9
Feed Direction Adjustment (Scan Area)
Adjusts the magnification of the image in the sub scan direction while in the scan on the original glass.
This adjustment is used to change the scan speed of the exposure unit.
A. Procedure

Press [Machine].

Press [Scan Area].

Press [Feed Direction Adjustment].
4. "Scan Area (Feed Direction Adjustment) screen"

Press [Test Copy].

Start key.
6. Press [OK].
7. Measure the magnification in the sub scan direction with a scale.
Standard value [1]: 0.5 % or less (200 1 mm
or less)
[1]
50gaf3c004na
8. "Scan Area (Feed Direction Adjustment) screen"

Setting range: 1.00 (smaller) to + 1.00% (larger)
1 step = 0.05%

10. Press [END].
166
10. SERVICE MODE
10.3.10 Lead Edge Erase Adjustment
bizhub 500 / 420
Adjusts the leading edge erasure amount.

A. Procedure

Press [Machine].

Press [Lead Edge Erase Adjustment].
3. "Lead Edge Erase Adjustment screen"

Press [Test Copy].

With A3 (for metric) or 11 x 17 (for inch) paper selected, press the Start key to output the test pattern (No.
16).
5. Press [OK].
6. Check the printer leading edge erasure amount.
Standard value [1]: 3.5 mm or less
[1]
50gaf3c005na
7. "Lead Edge Erase Adjustment screen"

Setting range: 2.0 (erasure: smaller) to + 2.0 mm (erasure: larger)
1 step = 0.1 mm

9. Press [END].
167
10. SERVICE MODE
bizhub 500 / 420
10.3.11 Non-Image Area Erase Check

When installing this machine, or when moving its installation location, check to see if the non-image area erase
check mechanism of the copy applied setting operates correctly in its installation location, and adjust automatically the sensitivity with which the non-image area is detected.
Pre-arrangements:
Open DF fully to the limit.
Avoid putting anything on the original glass.
Clean the original glass.
A. Procedure

Press [Machine].

Press [Non-Image Area Erase Check].
3. "Non-Image Area Erase Check screen"

4. Check to see if "OK" is displayed.

5. Press [OK].
When anything other than "OK" is displayed, see "B. Problems and their countermeasures" to check again
the non-image area erase setting.
B. Problems and their countermeasures

When a problem is detected by checking the non-image area erase check, an error number is displayed as
shown below.
(1) Error 1
Countermeasure - 1
When the non-image area erase function is not used very frequently, or when copy originals that have a dark
background are not copied very frequently in non-image area erase, the copier can be used in the current installation location. However, when copy originals that have a dark background are frequently copied, install the
copier in a location where less external light gets in (darker) than the present location, and check the non-image
area erase check mode again.
(2) Error 2
Countermeasure - 2
When the non-image area erase function is not used very frequently, the copier can be used in the current installation location. However, if the non-image area erase function is frequently used, install the copier in a location
where less external light gets in (darker) than the present location, and check the non-image area erase check
mode again. At this time, when there is a bright light source such as a fluorescent light installed directly above
the copier, reconsider the installation location, or take some measures to shield the light source and check the
mode again.
168
10. SERVICE MODE
10.4.1
bizhub 500 / 420
10.4 Imaging Process Adjustment

Charging Main Manual Adj.
Do not conduct this adjustment in the field.

10.4.2
Transfer Manual Adj.

10.4.3
Separation (AC) Manual Adj.

10.4.4
Separation (DC) Manual Adj.

10.4.5
Grid Charging Manual Adj.

10.4.6
Bias Voltage Manual Adj.

10.4.7
TCR Adjustment
When changing developer, conduct this adjustment before starting the copy operation. The developer counter
is automatically reset.
Note
When changing developer, be sure not to conduct the copy operation before completion of the
TCR adjustment.
A. Procedure

Press [Imaging Process Adjustment].
2. "Process screen"
Press [TCR Adjustment].
3. "TCR Adjustment screen"

4. Check to see if "OK is displayed, and also check the TCR adjustment data value.
Note
The adjustment is completed in about 180 seconds.
When there occurs a TCR adjustment error due to the developer agitating operation not completed successfully, the message "operating ..." disappears and an error code is displayed.
(See P.285)
5. Press [OK].
10.4.8
Toner Auto Supply
Since this is normally conducted automatically, do not conduct this adjustment in the field.
169
10. SERVICE MODE
bizhub 500 / 420
10.4.9
This adjustment can be used to increase and/or decrease the toner density of developer.
Use this adjustment when an image fogging occurs due to the increased toner density of developer and you
want to decrease the toner density.
A. Procedure

2. "Process screen"
Press [Toner Density Adjustment].
3. "Toner Density Adjustment screen"

Enter a value through the [+]/[] or numeric keys.
Setting range: 2 (toner density reduced) to + 2 (toner density increased)
1 step = 1
Note
The set value is a value relative to the present set value. When the set value is set to "0," this
returns the toner density back to the normal level.
4. Press the Start key.

5. While in the adjustment, a message "operating ..." is displayed. And after completion of the adjustment, it
disappears.
Note
The toner density is automatically adjusted according to a value set.
When an error code is displayed while in the toner density adjustment, be sure to check the
expected defective parts given in the error code list and then conduct again the toner density
adjustment.
(See P.285)
6. Press [OK].
170
10. SERVICE MODE
The MPC value can be corrected by entering a set value to change the image density (dot diameter).
Major cases in which this adjustment is used.
When you want to change the image density.
When replacing the write unit or TCSB (toner control sensor board), or when cleaning the dust proof glass.
A. Procedure

2. "Process screen"
Press [Laser Diameter Adjustment].
3. "Laser Diameter Adjustment screen"

Setting range: 3 (thinner) to + 3 (denser)
1 step = 1
Note
When an adjustment is made in the denser direction, this increases the dot diameter with the
toner consumption also increased.

5. While in the adjustment, a message "operating ..." is displayed. And after completion of the adjustment, it
disappears.
6. Press [OK].
171
bizhub 500 / 420
10.4.10 Laser Diameter Adjustment
10. SERVICE MODE
bizhub 500 / 420
10.4.11 LD1 Offset Adj. / LD2 Offset Adj.

Adjusts the 2 laser beam amount (LD1/LD2) equally.
Be sure to make this adjustment when replacing the write unit, drum and developer.
Note
Make sure that the TCR adjustment, the toner density adjustment and the dot diameter adjustment have been completed.
A. Procedure

2. "Process screen"
With an item displayed by [ ]/[ ], press "LD1 Offset Adj." / "LD2 Offset Adj.".
3. "LD1 Offset Adj. screen" / "LD2 Offset Adj. screen"

Select "Normal Paper" or "Thick Paper" and press [Test Copy].

With corresponding A3 (for metric) or 11 x 17 (for inch) paper set, press the Start key to output the test
pattern.
5. Press [END].
6. Check the test pattern.
Standard value: Check to see if the density of the
image patterns created by LD1/LD2 is the same,
and if the starts of the patterns in the high-lighted
[1]
section are aligned between the 2 reference lines

[1] ( 1 gap is OK).
[1] Reference lines
LD1 LD2 LD1 LD2 LD1 LD2 LD1 LD2
50gaf3c006na
7. "LD1 Offset Adj. screen" / "LD2 Offset Adj. screen"

When outside the standard value, enter a value through the [+]/[] or numeric keys and press [Setting].
Setting range: 128 (thinner) to + 127 (denser)
1 step = 1 (Pressing the button for a long period allows the value to be changed in increments of 10
steps.)
8. Repeat steps 2 to 7 until it gets inside the standard value.

9. Press [OK].
10.4.12 LD1 Bias Adj. / LD2 Bias Adj.

172
10. SERVICE MODE
10.5.1
bizhub 500 / 420
10.5 System 1
Marketing Area
Sets the marketing area of the main body and the fax.
Marketing area of the main body:
Japan, US, Europe, Other 1, Other 2, Other 3, Other 4
Fax Target:
US (America), CA (Canada), JP (Japan), AU (Australia), NZ (New Zealand), EU (Europe), DE (Germany), GB

(England), FR (France), CH (Switzerland), NL (Netherlands), BE (Belgium), AT (Austria), NO (Norway), SE (Sweden), FI (Finland), IE (Ireland), DK (Denmark), IT (Italy), ES (Spain), PT (Portuguese), PL (Poland), ZA (South
Africa), TW (Taiwan), SA (Saudi Arabia), CN (China), MY (Malaysia), SG (Singapore), KR (Korea), HK (Hong
Kong), OT (Argentine)
A. Procedure

Press [System 1].
2. "System Input screen"

Press [Marketing Area].
3. "Marketing Area screen"

Press [Japan] to [Other 4] to select a marketing area.
4. When no FK-502 is provided, press [END] to complete the marketing area.

When FK-502 is provided, press [Fax Target].
5. "Fax Target screen"

Select the marketing area of the fax by [+]/[].
6. Press [END] for registration.

7. "Marketing Area screen"
Press [END] to complete the marketing area.
173
10. SERVICE MODE
bizhub 500 / 420
10.5.2
Tel/Fax Number
Sets the telephone number and the fax number of the service station that are displayed on the screen when a
service call occurs.
These telephone and fax numbers are also displayed as the service center contact of the basic screen help of
the user screen.
A. Procedure

Press [System 1].

Press [Tel/Fax Number].
3. "Service Telephone/Fax Number Setting"

Press [TEL] or [FAX].
4. Enter the telephone number or fax number through the copy count setting key.
5. When setting both the telephone number and the fax number, repeat steps 3 to 4.
6. Press [END].
Note
Pressing the Clear key erases all the figures of the items selected.
10.5.3
Serial Number
Sets and displays the serial numbers of the main body and the optional devices.
Caution
Be absolutely sure not to change the serial numbers of the main body set when installing them.
Otherwise, a fusing temperature abnormality may result.
A. Procedure

Press [System 1].

Press [Serial Number].
A serial number that is registered is displayed.
3. "Serial Number Input screen"

Press a device to be registered: [Printer (Body)], [Option Tray], [LCT], [Finisher], [Fax #1], [Fax #2], [Punch
Kit], [Suddle Kit], [Mail Bin Kit].
4. "Soft Keyboard screen"

Enter a serial number through the alphabet and numeric keys.
5. Press [OK].
Press [Clear] if you want to make the settings entered invalid.
6. Repeat steps 3 to 5 to enter the serial number of each device.

7. Press [OK].
174

10.5.4
10. SERVICE MODE
Trouble Isolation
bizhub 500 / 420
When each function (device) is in trouble, isolating a trouble allows the limited use of this machine.
A. Procedure

Press [System 1].

Press [Trouble Isolation].
3. "Trouble Isolation screen"

Press [1] or [2] to display an item and set the isolation by [Set] or [Unset] of each item.
4. Press [END].
10.5.5
No Sleep
Sets the availability/unavailability of the sleep while in the administrator mode.

A. Procedure

Press [System 1].

Press [No Sleep].
3. "No Sleep screen"

Set the availability/unavailability of the sleep by [Permit] or [Prohibit].
4. Press [END].
10.5.6
Foolscap Size Setting
Sets the Foolscap size.

A. Procedure

Press [System 1].

Press [Foolscap Size Setting].
3. "Foolscap Size Setting screen"

Press [81/2 x 13], [81/4 x 13], [81/8 x 131/4] or [8 x 13] to set a Foolscap size.
4. Press [END].
175
10. SERVICE MODE
bizhub 500 / 420
10.5.7
Original Size Detection
Sets the detection size of the original size on the original glass and ADF.
A. Procedure

Press [System 1].

Press [Original Size Detection].
3. Press [Original Glass Original Size Detect] of the menu.

4. "Original Glass Original Size Detect screen"
Press one of the 4 types to set a size series to be detected on the original glass.
5. Press [ADF Original Size Detect] of the menu.

6. "ADF Original Size Detect screen"
Press one of the 4 types to set a size series to be detected on ADF.
7. Press [Original Glass Small Size Detect] of the menu.

8. "Original Glass Small Size Detect screen"
Press either [Detected Size] or [A4S / 81/2 x 11S] to set the minimum size to be detected on the original
glass.
9. Press [OK].
10.5.8
Detected Size Setting
Sets the size detection of the bypass tray and those other than the bypass tray in B series or K size (8K/16K
size).
A. Procedure

Press [System 1].

Press [Detected Size Setting].
3. "8K/16K Select screen"

Press [B series] or [K size] to set the size series to be detected.
4. Press [END].
176

10.5.9
10. SERVICE MODE
Install Date
bizhub 500 / 420
Sets the start date of the total counter.

A. Procedure

Press [System 1].

Press [Install Date].
3. "Install Date screen"

Press Year (4 digits), Month (2 digits), Day (2 digits) with the copy count setting key and press [Entry].
4. Check the display "The present contents of a setting" to see if it is replaced with a set value that has been
input.
5. Press [END].
10.5.10 Initialization
Initializes the setting/adjustment data controlled in non-volatile memory to the value set when shipped from the
factory.
Data that can be initialized are as follows.
Data classification
Utility/Administrator Setting Data
Data
Job Memory Setting Data
FAX Setting Data
Network Setting Data
Destination Storage Data

CS Remote Care Setting Data
Service Mode Setting (Adj.) Data
Image Process Adj. Data

Machine and ADF Adjustment Data
All History Data
A. Procedure

Press [System 1].

Press [Initialization].
3. "Initialize screen"
Press either one of the data items in the data classification.
4. "Utility / Administrator Setting Data" / "Destination Storage Data" / "CS Remote Care Setting Data" /
"Service Mode Setting (Adj.) Data" / "Counter Data"
Select a data to initialize.
Pressing [All Select] selects all the data items in the data classification.
5. Pressing the Start key initializes the data selected of the data classification selected.
6. When initializing the data of each classification, repeat steps 3 to 5.
7. Press [OK].
177
10. SERVICE MODE
bizhub 500 / 420
10.6 Counter
10.6.1
Display of the Counter
Displays the following data held by this machine on the touch panel.
The counter can be also checked by the output list, CSRemoteCare.
Total Service
Fax Communication Error
Mode
ADF Counter
Service call
JAM
Present parts life
Optional parts life
PM
Reuse
Each size
Paper Jam History
Jam counter history
Time series trouble (SC)
Each section trouble (SC)
A. Procedure

Press [Counter].
2. "Counter screen"
Press a counter item you want to check.
The counter spread over 2 pages. The displayed page can be switched over by [ ] or [ ].
3. Each "Counter screen"

When there are two or more pages of items, the page can be switched over by [ ] or [ ].
Note
For the individual data check screens of "JAM Counter History" and "Each Section Trouble
(SC)," [Clear Counter] is displayed.
Pressing [Clear Counter] displays "Clear Counter Check screen" and pressing [Yes] clears the block data.
Pressing [No] returns to the previous screen with no block data cleared. While in the visit to the user for the
PM execution, clear these data to check the JAM and SC counts that have occurred since the previous
visit.
4. Press [OK].
178
10. SERVICE MODE
B. Total Service
bizhub 500 / 420
Displays the total copy count printed in the service mode and the user mode.
Note
The maximum count is 99,999,999.
No.
CSRC parameter
Item collected
Total Service
Count condition
Number of paper printed and exited in
the single and double sided copy
modes.
Total Service (2-Sides)
Of the above, the number of paper

printed and exited in the double sided
print mode.
C. FAX Communication Error

Displays the number of errors that occurred while in sending and receiving FAX with errors while in sending separated from those while in receiving.
Note
The maximum count is 999,999.
No.
CSRC parameter
FAX TX Error
Item collected
FAX RX Error
Count condition
Number of errors that occurred while in
the FAX sending.
Number of error that occurred while in
the FAX receiving.
D. Mode
Displays the use condition for each of the modes used by the copier/scanner/printer/FAX.
Note
No.
CSRC parameter
Item
Count condition
(F1)
1
01
No. of Prints in Half-Fold Mode
02
No. of Prints in Center Staple Mode
1 count made while in the folding exit.

1 count made while in the stitch-andfold exit.
05
No. of Staples 1
1 count for 1 staple when stapling in

the 1-staple mode.
06
No. of Staples 2
1 count for 1 staple when stapling in

the 2-staple mode.
07
No. of Punches
1 count made while in the punch.
179
10. SERVICE MODE
bizhub 500 / 420
No.
CSRC parameter
Item
Count condition
(F1)
6
08
BOX Housing: Copy Proof Print
09
BOX Housing: Copy BOX Hold
0A
BOX Housing: Print Proof Print
0B
BOX Housing: Print BOX Hold
10
0C
BOX Housing: Print
11
0D
BOX Housing: Scanner BOX Hold
12
0E
BOX Housing: FAX Scanning
1 count for each completion of a job.
Classified Document
1 count for each completion of a job
BOX Hold
13
0F
BOX Housing: FAX RX
14
10
BOX Housing: FAX RX Distribute by TSI
15
11
BOX Housing: FAX RX BOX Hold
Distribute by F-Code
1 count for each completion of a job. F
code and other than TSI.
16
12
Output from Box: Copy Image Print

Except for the print for checking.
17
13
Output from Box: Copy Image
E-Mail TX
18
14
19
15
Output from Box: Copy Image FTP TX

Output from Box: Copy Image SMB TX
20
16
Output from Box: Print Image
Except for the print for checking.

1 count for each completion of a job
21
17
Output from Box: Print Image E-Mail TX
22
18
Output from Box: Print Image FTP TX
23
19
Output from Box: Print Image SMB TX
24
1A
Output from Box: Scan Image Print
25
1B
Output from Box: Scan Image
26
1C
Output from Box: Scan Image FTP TX
27
1D
Output from Box: Scan Image SMB TX
28
1E
Output from Box: FAX Scan Image
29
1F
30
20
31
21
Output from Box: FAX RX Image Print
32
22
Output from Box: FAX RX Image
33
23
Output from Box: FAX RX Image
E-Mail TX
Print
FAX TX
E-Mail/IFAX TX
FAX TX
E-Mail/IFAX TX
180
Print (Except Proof Print)
10. SERVICE MODE
E. ADF Counter
bizhub 500 / 420
Displays the number of the paper through by modes of ADF.

Note
1 count for the single sided copy and 2 counts for the double sided copy.
No.
CSRC parameter
Item
Remarks
(F0)
1
00
01
N of originals fed in ADF mode

N of originals fed in RADF mode
02
N of originals fed in RDH mode
No count is made with "0" at all times.
03
N of originals fed in RRDH mode
07
N of originals fed in mixed original ADF mode
08
N of originals fed in mixed original RADF
0C
mode
F.
N of 2 sided SDF original fed
Service Call
Displays troubles that have occurred for each SC.

Note
The block trouble count is not available for CSRC.
When the service mode DipSW3-1 is set to "1" (latched), SC34, 35 and 36 make no count.
No.
CSRC
SC cord
No.
parameter
CSRC
SC cord
No.
parameter
(E0)
CSRC
SC cord
parameter
(E0)
(E0)
001
00
02
01
018
11
11
07
035
22
22
02
002
01
02
02
019
12
11
08
036
23
23
01
003
02
02
03
020
13
11
09
037
24
23
02
004
03
02
04
021
14
11
10
038
25
23
03
005
04
02
05
022
15
11
11
039
26
24
01
006
05
02
06
023
16
11
12
040
27
24
02
007
06
02
07
024
17
11
13
041
28
24
03
008
07
03
01
025
18
11
14
042
29
27
01
009
08
10
01
026
19
11
15
043
2A
27
02
010
09
10
02
027
1A
11
16
044
2B
27
03
011
0A
10
03
028
1B
11
17
045
2C
28
01
012
0B
11
01
029
1C
11
18
046
2D
28
02
013
0C
11
02
030
1D
11
19
047
2E
28
03
014
0D
11
03
031
1E
11
20
048
2F
28
04
015
0E
11
04
032
1F
11
21
049
30
32
01
016
0F
11
05
033
20
20
01
050
31
33
01
017
10
11
06
034
21
22
01
051
32
33
02
181
10. SERVICE MODE
bizhub 500 / 420
No.
CSRC

SC cord
No.
parameter
(E0)
182
CSRC
SC cord
No.
parameter
CSRC
SC cord
parameter
(E0)
(E0)
052
33
35
01
093
5C
B1
11
134
85
B1
64
053
34
35
02
094
5D
B1
12
135
86
B1
65
054
35
37
01
095
5E
B1
13
136
87
B1
66
055
36
38
01
096
5F
B1
14
137
88
B1
67
056
37
38
02
097
60
B1
15
138
89
B1
68
057
38
38
03
098
61
B1
16
139
8A
B1
69
058
39
38
04
099
62
B1
17
140
8B
B1
70
059
3A
38
05
100
63
B1
18
141
8C
B1
71
060
3B
38
06
101
64
B1
19
142
8D
B1
72
061
3C
38
07
102
65
B1
20
143
8E
B1
73
062
3D
38
08
103
66
B1
22
144
8F
B1
74
063
3E
39
01
104
67
B1
23
145
90
B1
75
064
3F
39
02
105
68
B1
25
146
91
B1
76
065
40
39
03
106
69
B1
26
147
92
B1
77
066
41
39
04
107
6A
B1
27
148
93
B1
78
80
067
42
40
01
108
6B
B1
28
149
94
B1
068
43
41
01
109
6C
B1
29
150
95
B1
81
069
44
44
01
110
6D
B1
30
151
96
B1
82
070
45
47
01
111
6E
B1
31
152
97
B1
83
071
46
50
01
112
6F
B1
32
153
98
B1
84
072
47
50
02
113
70
B1
33
154
99
B1
85
073
48
50
03
114
71
B1
34
155
9A
B1
86
074
49
50
04
115
72
B1
35
156
9B
B1
87
075
4A
53
01
116
73
B1
36
157
9C
B1
88
076
4B
53
02
117
74
B1
37
158
9D
C1
03
077
4C
53
03
118
75
B1
40
159
9E
C1
81
078
4D
54
01
119
76
B1
41
160
9F
C1
82
079
4E
54
02
120
77
B1
42
161
A0
C1
83
080
4F
60
01
121
78
B1
43
162
A1
C2
84
081
50
60
02
122
79
B1
44
163
A2
C2
85
082
51
60
03
123
7A
B1
45
164
A3
C2
86
083
52
61
01
124
7B
B1
46
165
A4
C2
87
084
53
62
01
125
7C
B1
50
166
A5
C2
88
085
54
67
01
126
7D
B1
51
167
A6
D0
01
086
55
67
02
127
7E
B1
52
168
A7
D0
02
087
56
80
01
128
7F
B1
53
169
A8
D2
01
088
57
83
01
129
80
B1
54
170
A9
D2
03
089
58
B0
01
130
81
B1
60
171
AA
D2
81
82
090
59
B0
02
131
82
B1
61
172
AB
D2
091
5A
B0
03
132
83
B1
62
173
AC
E0
01
092
5B
B1
10
133
84
B1
63
174
AD
E0
02
No.
CSRC
10. SERVICE MODE
SC cord
No.
parameter
CSRC
SC cord
No.
parameter
(E0)
CSRC
SC cord
parameter
(E0)
(E0)
175
AE
E0
03
193
C0
E0
8E
211
D2
E0
176
AF
E0
04
194
C1
E0
8F
212
D3
E0
A0
A1
177
B0
E0
05
195
C2
E0
90
213
D4
E0
A2
178
B1
E0
06
196
C3
E0
91
214
D5
E0
A3
179
B2
E0
07
197
C4
E0
92
215
D6
E0
A4
180
B3
E0
81
198
C5
E0
93
216
D7
E0
A5
181
B4
E0
82
199
C6
E0
94
217
D8
E0
A6
182
B5
E0
83
200
C7
E0
95
218
D9
E0
A7
183
B6
E0
84
201
C8
E0
96
219
DA
E0
A8
184
B7
E0
85
202
C9
E0
97
220
DB
E0
A9
185
B8
E0
86
203
CA
E0
98
221
DC
E0
AA
186
B9
E0
87
204
CB
E0
99
222
DD
E0
AB
187
BA
E0
88
205
CC
E0
9A
223
DE
E0
AC
188
BB
E0
89
206
CD
E0
9B
224
DF
E0
AD
189
BC
E0
8A
207
CE
E0
9C
225
E0
E0
AE
190
BD
E0
8B
208
CF
E0
9D
226
E1
E0
AF
191
BE
E0
8C
209
D0
E0
9E
227
E2
E0
B0
192
BF
E0
8D
210
D1
E0
9F
228
E3
E0
B1
G. Time Series Trouble (SC)

For the latest 50 SC's, displays the SC code of cause, the total count, the date of occurrence, the time of occurrence, and the firmware version.
Note
Press the corresponding SC item to display a firmware version.
H. JAM Counter History
Displays the number of occurrences for each jam code. (Except for stationary jams)
Note
The jam code is a code that is displayed when DipSW10-7 is set at "1."
No.
CSRC
Jam cord
No.
parameter Upper Lower

(J0)
CSRC
Jam cord
No.

(J0)
CSRC
Jam cord

(J0)
01
00
10
07
06
13
13
0C
13
02
01
11
08
07
13
14
0D
14
11
0
03
02
12
09
08
13
15
0E
14
04
03
12
10
09
13
16
0F
15
05
04
13
11
0A
13
17
10
15
06
05
13
12
0B
13
18
11
20
183
bizhub 500 / 420
10. SERVICE MODE
bizhub 500 / 420
No.
CSRC

Jam cord
No.

(J0)
CSRC
Jam cord
No.

(J0)
CSRC
Jam cord

(J0)
19
12
20
40
27
61
61
3C
66
20
13
20
41
28
61
62
3D
66
21
14
20
42
29
61
63
3E
66
22
15
20
43
2A
61
64
3F
66
23
16
20
44
2B
62
65
40
66
24
17
20
45
2C
62
66
41
66
25
18
20
46
2D
62
67
42
66
26
19
20
47
2E
62
68
43
72
16
27
1A
20
10
48
2F
62
69
44
72
17
28
1B
30
49
30
62
70
45
72
18
29
1C
31
50
31
62
71
46
72
21
30
1D
32
51
32
62
72
47
72
25
31
1E
33
52
33
63
73
48
72
43
32
1F
34
53
34
63
74
49
72
81
33
20
50
54
35
63
75
4A
72
82
34
21
60
55
36
63
76
4B
72
84
35
22
60
56
37
63
77
4C
72
85
36
23
61
57
38
63
78
4D
72
90
37
24
61
58
39
63
79
4E
97
38
25
61
59
3A
63
80
4F
97
39
26
61
60
3B
66
81
50
97
I.
Paper Jam History
For the latest 100 jams, displays JAM code, Total Count, Date of Occurrence, Paper Tray, Paper Size, and
Zoom.
J.
Reuse
Displays the accumulated hours of the parts and the number of occurrences of the job that uses the parts.
Note
No.
CSRC parameter
Item
Count condition
(F5)
1
00
Power condition /1 (Total Power ON
1 count for 1 minute.
time)
2
01
Power condition /2 (EN-5V ON time)
02
Low power mode time

03
WUP time
Accumulated hours during which the

fusing heater turns on in the warm-up
condition. 1 count for 1 second.
184

CSRC parameter
Item
Count condition
(F5)
5
04
Print operating time (single sided mode)
Accumulated hours from start to stop

of the print. 1 count for 1 second (not
including the time period during which
the counter stops due to a jam).
05
Print operating time (double sided mode)
Accumulated hours from start to stop

of the print. 1 count for 1 second (not
including the time period during which
the counter stops due to a jam).
06
Correction operation count
Number of counts the image stabilization control (the fusing temperature

lower than 50 C) is executed. 1 count
for each execution.
07
APS sensor ON time
Accumulated hours during which the

APS sensor turns ON. 1 count for 1
second.
08
Platen scan count
Counts the number of occasions in

which the scan is made in the platen
mode.
10
09
The number of occurrences of the stop
Counts the number of occasions in
due to toner running out.
which the system stops due to no

toner.
11
0A
12
0B
Polygon stop operation time

The number of occurrences of the Main
Counts the number of NMI's.
Power OFF
13
0C
The number of occurrences of the feed
1 count is made each time the feed
door closed
door is closed.
14
0D
The number of starting all print jobs
15
0E
Tray 1 paper feed count
1 count is made when paper is fed

from the tray 1 each time 1 sheet of
paper is exited.
16
0F

paper is exited.
17
10

paper is exited.
18
11

paper is exited.
19
12
The number of prints made by selecting
the bypass paper feed tray
from the bypass tray each time 1 sheet

of paper is exited.
20
13
The number of prints made by selecting
the LCT paper feed tray
from LCT each time 1 sheet of paper is

exited.
185
bizhub 500 / 420
No.
10. SERVICE MODE
10. SERVICE MODE
bizhub 500 / 420
K. Each Size
Displays the number of print of each paper size.
Note
1 count each time paper is exited (0 count for a blank sheet and 2 counts for the double sided
print).
No.
186
CSRC parameter
Paper size
01
A3
02
A4
03
A5
04
A6
05
B4
06
B5
07
B6
08
12 x 18
09
11 x 17
10
0A
81/2 x 14
11
0B
81/2 x 11
12
0C
71/4 x 101/2
13
0D
51/2 x 81/2
14
0E
Foolscap
15
0F
Post card
16
10
4x6
17
11
8K
18
12
16K
19
13
Others
Remarks
Not used
Not used
Not used
Not used

Present Parts Life
Displays the counter of an intended part.

And, when replacing an intended part, the counter of the replaced part is reset to manage the service history.
A. Procedure for the display/reset

Press [Counter].
2. "Counter/Data screen"
Press [Present Parts Life].
3. "Parts Counter (Fixed) screen"

Press [ ]/[ ] to check the counter or display a part to be reset.
4. "Parts Counter (Fixed) screen"

Check the count value of an intended part.
When resetting it, press a part to be reset and then press the Clear key.
5. Press [OK].
B. Fixed parts counter list

No.
CSRC
Unit
Parts name
Parts No.
parameter
(Z1)
1
00
01
DC (including charge unit)
Drum
Cleaning blade assy
50GA-209
02
Drum unit (including charge unit)
50GA-200
03
Transfer/separation section
Transfer/separation unit
50GA-260
04
Developing unit
Developer
05
06
Filter mounting plate assy
50GA-336
07
Ozon filter
50GA1031
08
40LA-318
10
09
Filter cover assy
50GA-314
50GA-311
11
0A
12
0B
13
0C
14
15
Developing unit
Main body
Paper feed unit
50GA-300
Tray 1 pick-up roller
40303005
Tray 1 paper feed roller
40303005
0D
Tray 1 separation roller
40300151
0E
40303005
16
0F
40303005
17
10
40300151
18
11
Bypass paper feed roller
41313001
19
12
20
13
Bypass unit
Registration section
Bypass separation roller
40340151
Paper feed connection roller
50GA3865
21
14
Registration roller /A
50GA3848
22
15
Registration bearing /1
26NA4536
23
16
Registration bearing /2
26NA4537
24
17
Paper feed slide bearing
26NA4082
187
bizhub 500 / 420
10.6.2
10. SERVICE MODE
10. SERVICE MODE
bizhub 500 / 420
No.
CSRC
Unit
Parts name
Parts No.
parameter
(Z1)
25
26
27
188
18
Fusing unit
19
1A
Fusing roller (bizhub 500)
50GE5303
Fusing roller (bizhub 420)
42GA5303
Fusing pressure roller (bizhub 500)
50GA5304
Fisung pressure roller (bizhub 420)
42GA5304
Fusing cleaner assy (bizhub 500)
50GA-540
Fusing cleaner assy (bizhub 420)
42GA-540
26NA5372
28
1B
29
1C
Fusing bearing /Up
26NA5371
30
1D
Fusing bearing /Lw
50GA5359
31
1E
Fusing sensor assy
50GA-544
32
1F
Fuse holder assy
26NA-535
33
20
Fusing claw assy (bizhub 500)
50GA-533
Fusing claw assy (bizhub 420)
42GA-533
34
21
Fusing driven roller A assy
40400326
35
22
Fusing driven roller B assy
40400328
36
23
Reverse unit
50GA4406
50GA-650
37
24
Write unit
Write unit
38
25
LU-201
Pick-up rubber
40LA4009
39
26
Paper feed rubber
26NA4011
40
27
Separation rubber
26NA4012
41
28
42
29
DF-607
Pick-up roller
43445003
Paper feed roller
45823014
Separation roller
45823047
43
2A
44
2B
PC-202 (tray 3/tray 4)
40303005
45
2C
PC-402 (tray 3 only)
40303005
46
2D
40300151
47
2E
40303005
48
2F
40303005
49
30
50
31
Fusing unit
40300151
50GA-546

PM
Sets the PM execution cycle or resets the PM counter.

Note
The PM cycle setting has been input in advance and be sure not to change this setting normally.
A. Procedure for the counter reset

Press [Counter].
Press [PM].
3. "PM Counter screen"

Check the PM counter.
When resetting it, press the Clear key.
4. Press [OK].
B. Procedure for the cycle setting

Press [Counter].
Press [PM].
3. "PM Counter screen"

Enter a PM cycle value (1 to 999999) through the copy count setting button and press [Set].
4. Press [OK].
189
bizhub 500 / 420
10.6.3
10. SERVICE MODE
10. SERVICE MODE
10.7.1
Sensor Check
This machine is provided with an input/output check function as a self-diagnostic function. For the sensor check
(input check), the state confirmation of each signal can be made.
A. Procedure

Press [State Confirmation].
2. "State Confirmation screen"

Press [Sensor check].
3. "Sensor Check screen"

Press [Check Code] and, when entering the sensor check code in 3 digit through the copy count setting
button, a state (ON/OFF or value) is displayed in the Result area.
4. For the multi mode, press [Multi Code] and enter a three-digit multi code through the copy count setting
key.
5. When conducting the sensor check of other signal sources, repeat steps 3 to 4.
Analog signal
Symbol
TCRS
Drum temperature
TCRS
TCR sensor
TCRS
TCR sensor
TH1
Thermistor /1
TH2
Thermistor /2
IDCS
IDC sensor
HUMS
Humidity sensor
VR1
Paper size VR/BP (bypass)
10
ON
Name
11
190
Display and signal source
Multi code
Code
Classification
B. List of sensors
Paper feed
bizhub 500 / 420
10.7 State Confirmation
OFF
0 to 255 *1
PS18
paper empty sensor /BP (bypass)
No paper
PS23
Lift sensor (bypass)
Up position
Paper
Down position
Connect detection signal (bypass)
Connection
Non-connection
PS19
Paper size sensor /BP1 (bypass)
Paper
No paper
PS20
PS21
PS22
PS5
Paper empty sensor /1
No paper
Paper
PS9
Near-empty sensor /1
Near-empty
Non-near-empty
PS6
Upper limit sensor /1
Upper limit
Not at upper limit
PS8
Tray set sensor /1
Set
Not set
PS10
Paper size sensor /Rr1
*2
PS11
Paper size sensor /Fr1
10. SERVICE MODE
Symbol
12
PS12
No paper
Paper
PS15
Near-empty
Non-near-empty
PS13
Upper limit
Not at upper limit
PS14
Tray set sensor /2
Set
Not set
PS16
*2
PS17
PS115
Paper empty sensor /3 (PC-202)
No paper
Paper
PS113
Near-empty sensor /3 (PC-202)
Near-empty
Non-near-empty
PS114
Upper limit sensor /3 (PC-202)
Upper limit
Not at upper limit
PS112
Tray set sensor /3 (PC-202)
Set
Not set
PS116
Paper feed sensor /3 (PC-202)
Paper
No paper
PS117
Vertical conveyance sensor /3 (PC-202)
PS118
Paper size sensor /Rr3 (PC-202)
PS119
Paper size sensor /Fr3 (PC-202)
PS124
Paper empty sensor /4 (PC-202)
No paper
Paper
PS122
Near-empty sensor /4 (PC-202)
Near-empty
Non-near-empty
PS123
Upper limit sensor /4 (PC-202)
Upper limit
Not at upper limit
PS121
Tray set sensor /4 (PC-202)
Set
Not set
PS125
Paper feed sensor /4 (PC-202)
Paper
No paper
PS126
Vertical conveyance sensor /4 (PC-202)
PS127
Paper size sensor /Rr4 (PC-202)
PS128
Paper size sensor /Fr4 (PC-202)
PS153
Paper empty sensor (LU)
No paper
Paper
PS155
LU exit sensor (LU)
Paper
No paper
PS152
Upper limit sensor (LU)
Upper limit
Not at upper limit
PS154
Remaining paper sensor /1 (LU)
*3
PS151
Remaining paper sensor /2 (LU)
MS151
Upper door interlock switch (LU)
Open
Close
PS156
LU set sensor (LU)
Not set
Set
13
14
15
16
ON
Name
OFF
*2
*2
Connect detection signal (LU)
Connection
Non-connection
PS5
Right door open/close sensor (PC-402)
Open
Close
PS6
Tray set sensor (PC-402)
Not set
Set
PS7
Lower limit over run sensor (PC-402)
Over run
Not over run
PS2
Vertical conveyance sensor (PC-402)
Paper
No paper
PS1
Paper feed sensor (PC-402)
Upper limit
Not at upper limit
MEB
Main tray empty board (PC-402)
PS9
Sub tray empty sensor (PC-402)
PS3
Paper empty sensor (PC-402)
PS4
Upper limit sensor (PC-402)
191
bizhub 500 / 420
Multi code
Code
Paper feed
Classification
Paper feed
16

Symbol
Multi code
Code
bizhub 500 / 420
Classification
10. SERVICE MODE
ON
Name
OFF
10
PS13
Lower limit sensor (PC-402)
Lower limit
Not at lower limit
11
PS12
Shift home sensor (PC-402)
Home position
Other than
12
PS11
Shift position sensor (PC-402)
Shift position
home position
Not at shift
position
17
13
PS14
Shift gate position sensor (PC-402)
Gate lock
14
PS10
Paper lift motor encoder sensor (PC-402)
0 to 255
15
SW1
Tray release switch
ON
PS19,
Paper size sensor /BP1, /BP2, /BP3, /BP4
0 to 15 *4
PS20,
(bypass)
Gate release
OFF
PS21,
Paper size board /1
PSB/2
Paper size board /2
PSDB3
Paper size detect board /3 (PC-202)
PSDB4
Paper size detect board /4 (PC-202)
PS1
Registration sensor
PS2
Vertical conveyance sensor
22
PS3
Fusing exit sensor
23
MS
Interlock switch
24
PS7
Feed door open/close sensor
25
PS111
Right door open/close sensor (PC-202)
Optical device
40
PS30
Scanner home sensor
50
Conveyance
PSB/1
Specific function
PS22
2
20
0 to 15 *5
Paper
No paper
Open
Close
Other than
Home position
home position
2
PS31
APS timing sensor
DF close
DF open
Serial communication check when the
OK
NG
power is turned ON (DF)

2
Main body identification signal
bizhub 420
bizhub 500
Machine type code
"129" =
"128" =
bizhub 420
bizhub 500
JS connection detection
Connection
Non-connection
PS1
Paper full sensor
Full
Other than full
power is turned ON (FS)

power is turned ON (SubCPU)
power is turned ON (Main body)
JS
51
192
52
PS4
Toner bottle sensor
TH1/
The higher value of thermistor /1 and ther-
TH2
mistor /2
Analog signal
DF
60
70
ON
Name
PS5
Original empty sensor
PS6
Original feed sensor
PS9
Original registration sensor
PS8
Original detection sensor
PS10
Original exit sensor
PS7
Cover open/close sensor
SW3
DF open/close switch (Main body side)
MOSDB
Mix original size detection board
MOSDB
Detected
OFF
Not detected
0 to 255
Original
No original
Close
Open
Original
No original
10
MOSDB
11
PS1
Original size sensor /1
12
PS2
13
PS3
14
PS4
15
VR1
Original size VR
0 to 255 *1
PS4
Entrance sensor
Paper
No paper
PS5
Conveyance sensor
PS6
Alignment sensor /1
Home position
Other than
PS7
Alignment sensor /2
SW3
Tray overrun switch
home position
Not at upper
Upper limit/
limit/lower limit
lower limit
Close
SW2
Shutter switch
Not open
SW1
Door switch
Close
Open
PS4
Encoder sensor (PU)
Light blocking
Light passing
through
10
PS23
Paper guide home sensor (SD)
Home position
Other than
home position
193
bizhub 500 / 420
Multi code
PZS
Symbol
Code
58
FS-510
10. SERVICE MODE
57
Toner supply
Analog signal
Classification
FS-510
70

Symbol
Multi code
Code
bizhub 500 / 420
Classification
10. SERVICE MODE
ON
Name
OFF
11
PS14
Lower limit sensor
Lower limit
Not at lower limit
12
PS15
Upper limit sensor
Upper limit
Not at upper limit
13
OT-601 connection detection
Connection
Non-connection
14
PS3
Tray position sensor
Tray detected
Tray not
detected
15
PS16
Shutter home sensor
Close
Open
16
Home position
Other than
17
PS11
Exit paddle home sensor
18
PS12
Exit roller home sensor
19
PS8
Stacker sensor
Paper
No paper
20
PS10
Stapler home sensor
Other than
Home position
21
Stapler ready sensor
Ready
22
Staple empty sensor
No staple
Staple
23
Staple home sensor
Home position
Other than
24
25
PS2
Punch position sensor /1 (PU)
Home position at
Home position
odd numbered
at initialization
home position
home position
Unready
home position
times
26
PS3
Punch position sensor /2 (PU)
At the center
Not at the
of stroke
center of stroke
27
PS1
Punch scraps full sensor (PU)
Full
Other than full
28
PS22
Folding roller home sensor (SD)
Home position
Other than
29
SW4
Guide plate switch
Close
Open
30
PS23
Paper guide home sensor (SD)
Home position
Other than
31
PS20
Exit sensor (SD)
Paper
No paper
32
PS21
Tray empty sensor (SD)
33
Staple home sensor /Rr (SD)
Home position
Other than
34
Stapler ready sensor /Rr (SD)
Ready
35
Staple empty sensor /Fr (SD)
No staple
Staple
36
Staple home sensor /Fr (SD)
Home position
Other than
37
Stapler ready sensor /Fr (SD)
Ready
38
Staple empty sensor /Fr (SD)
No staple
Staple
39
SW4
SD interlock switch (SD)
Set
Not set
40
PS18
Exit home sensor (SD)
Open
Close
41
PS1
Paper detection sensor /1 (MT)
No paper
Paper
home position
home position
home position
Unready
home position
194
Unready
10. SERVICE MODE
42
PS5
Paper full sensor /1 (MT)
Full
Other than full
43
PS2
No paper
Paper
44
PS6
Full
Other than full
45
PS3
No paper
Paper
46
PS7
Full
Other than full
47
PS4
No paper
Paper
48
PS8
Full
Other than full
PS1
Sub tray exit sensor
Paper
No paper
PS3
Intermediate conveyance sensor
PS4
Main route conveyance sensor
PS2
Bypass route conveyance sensor
PS6
Sub tray full sensor
Full
Other than full
PS7
Main tray full sensor
PS9
Alignment home sensor
Home position
Other than
PS14
Stapler home sensor
PS12
Roller release home sensor
10
PS13
11
PS5
Alignment tray sensor
Paper
No paper
12
PS22
Stapler home sensor /Rr
Home position
Other than
13
PS20
Staple empty sensor /Rr
No staple
14
PS21
Stapler ready sensor /Rr
Ready
Unready
15
PS25
Stapler home sensor /Fr
Home position
Other than
16
PS23
Staple empty sensor /Fr
No staple
Staple
17
PS24
Stapler ready sensor /Fr
Ready
Unready
18
PS19
Main tray upper limit sensor
Paper surface
Paper surface
70
ON
Name
OFF
home position
Released
Pressed
home position
Staple
home position
detected
not detected
19
PS8
Main tray reset sensor
Other than
Paper
paper removal
removal
20
SW2
Main tray upper limit switch
Upper limit
Not at upper limit
21
PS10
Shift home sensor
Front home
Rear home
position
position
22
Light blocking
23
PS15
Punch encoder sensor
Light passing
24
PS11
Shift encoder sensor
through
25
26
27
PS2
Path sensor (RU)
Paper
No paper
195
bizhub 500 / 420
70
Symbol
Multi code
Code
FS-511
FS-510
Classification
80
PS24
ADU conveyance sensor /1
PS25
PS27
Reverse sensor
PS26
ADU open/close sensor
81
Symbol
Multi code
Code
ADU/Reverse
bizhub 500 / 420
Classification
10. SERVICE MODE
ON
Name
Paper
OFF
No paper
Open
Close
Set
Not set
*1
Resolution 1024 is also displayed as resolution 256.
*2
The size in the main scan direction is shown by the combination of the ON/OFF of the paper size sensors
/Rr and /Fr.
Sensor check
Tray 1
11-5
11-6
Tray 2
12-5
12-6
Tray 3
13-7
13-8
Tray 4
14-7
14-8
ON
OFF
A3, B4, A4, B5
ON
ON
11 x 17
OFF
ON
A4S, 81/2 x 11S
OFF
OFF
A5S, B5S, 81/2 x 11S
Sensor check display
*3
ON/OFF combination of remaining paper sensor /1 (PS154) and /2 (PS151) represents an amount of
paper remained in LU.
196
Paper size
Sensor check
15-4
Remaining paper sensor
/1 (PS154)
15-5
/2 (PS151)
Full amount
ON
OFF
Medium amount
ON
ON
Small amount
OFF
ON

*4
10. SERVICE MODE
The combination of the ON/OFF of the paper size sensors /BP1 (PS19), /BP2 (PS20), /BP3 (PS21) and
*5
PS19
PS20
PS21
OFF
OFF
OFF
OFF
ON
OFF
OFF
OFF
OFF
ON
OFF
OFF
ON
ON
OFF
OFF
OFF
OFF
ON
OFF
ON
OFF
ON
OFF
OFF
ON
ON
OFF
ON
ON
ON
OFF
OFF
OFF
OFF
ON
ON
OFF
OFF
ON
10
OFF
ON
OFF
ON
11
ON
ON
OFF
ON
12
OFF
OFF
ON
ON
13
ON
OFF
ON
ON
14
OFF
ON
ON
ON
15
ON
ON
ON
ON
bizhub 500 / 420
/BP4 (PS22) is shown in 4-bit data (0 to 15).

PS22
The combination of the ON/OFF of the paper size boards and the paper size detection boards (4 in all) is
shown in 4-bit data (0 to 15).
State of each of the 4 sensors on the paper size boards
17-2 (tray 1), 17-3 (tray 2),
/1 (PSB /1) and /2 (PSB /2) and the paper size detect
17-4 (tray 3), 17-5 (tray 4)
boards /3 (PSDB /3) and /4 (PSDB /4)

1
OFF
OFF
OFF
OFF
ON
OFF
OFF
OFF
OFF
ON
OFF
OFF
OFF
ON
ON
OFF
OFF
OFF
ON
OFF
ON
OFF
ON
OFF
OFF
ON
ON
OFF
ON
ON
ON
OFF
OFF
OFF
OFF
ON
ON
OFF
OFF
ON
10
OFF
ON
OFF
ON
11
ON
ON
OFF
ON
12
OFF
OFF
ON
ON
13
ON
OFF
ON
ON
14
OFF
ON
ON
ON
15
ON
ON
ON
ON
197
10. SERVICE MODE

Load Check
This machine is provided with an input/output check function as a self-diagnostic function. For the load check,
the check and adjustment (output check) of the load operation can be made.
A. Procedure


Press [Load check].
3. "Load Check screen"

Press [Check Code] and enter a load check code in 3 digits through the copy count setting key.
4. For the multi mode, press [Multi Code] and enter a multi code in 3 digits through the copy count setting
key.

The load check operation starts with a message "Operating" displayed.
6. Press the Stop key.

The load check is completed with a message "Fin" displayed.
7. When conducting other load operations or the output check of signals, repeat steps 3 to 6.
Multi code
L1
Exposure lamp
M4,
Toner supply motor, toner solenoid
SD5
turn ON at the same time
20
21
Symbol
Code
High voltage/image Classification
B. List of loads
Paper feed
bizhub 500 / 420
10.7.2
Name
CL4
Feed clutch /1
CL5
Feed clutch /2
CL6
Feed clutch /BP
SD1
Pick-up solenoid /BP
SD151
Pick-up solenoid (LU)
M9
Feed motor (LS250)
Same as 55-003
Feed motor (LS210)
3
4
Restrictive conditions
Feed motor (LS125)

M122
Paper feed motor /3 (LS250) (PC-202)
Valid only when the paper empty sen-
sor /3 (PS115) detects a no paper

condition.
6
7
M123
sor /4 (PS124) detects a no paper

condition.
198
M150
9
11
12
10. SERVICE MODE
Name
bizhub 500 / 420
Symbol
21
Multi code
Code
Paper feed Classification
Feed motor (LS250) (LU)

M9,
Feed motor (LS250), registration
CL1,
clutch, loop clutch turn ON at the
CL2
same time
M122
Valid only when the paper empty sensor /3 (PS115) detects a no paper
condition.
13
M123
Valid only when the paper empty sensor /4 (PS124) detects a no paper
condition.
22
14
M150
M120
Vertical conveyance motor /3 (LS250)

(PC-202)

(PC-202)

(PC-202)
M121

(PC-202)

(PC-202)

(PC-202)
M120,
Vertical conveyance motor /3, /4
M121
(LS250) (PC-202)

(LS210) (PC-202)

(LS125) (PC-202)
10
M2
Vertical conveyance motor (LS250)

(PC-402)
11
12
(PC-402)
(PC-402)
23
M7
Paper lift motor /1
The upper limit sensor /1 (PS6) turns

ON, or it is stopped by the stop button.
M8
Paper lift motor /2
The upper limit sensor /2 (PS13) turns

199
Multi code
Symbol
Code
bizhub 500 / 420
Paper feed Classification
10. SERVICE MODE
23
M124
Name
Paper lift motor /3 (PC-202)
The upper limit sensor /3 (PS114)

turns ON, or it is stopped by the stop
button.
M125
Paper lift motor /4 (PC-202)

turns ON, or it is stopped by the stop
button.
M151
Paper lift motor (LU)
The upper limit sensor (PS152) turns

M9,
Feed motor, pick-up solenoid /BP turn
SD1
ON at the same time
sor/BP (PS18) detects a no paper
CL1
Registration clutch
CL2
Loop clutch
CL3
Vertical conveyance clutch
CL151
Feed clutch (LU)
29
SD2
Drum claw solenoid ON
31
M2, L1
Scanner motor, exposure lamp
After home position search, A3
Scanner motor, exposure lamp
After home position search, A3
condition.
Optical device
25
makes a single scan operation.

2
makes a continuous scan operation.

32
M5
Polygon motor (LS250)

Polygon motor (LS210)
34
M2, L1
Shading correction operation
36
LDB
Laser PWM (0 to 255)
37
LDB,
Laser turns ON forcibly
M5
38
LDB,
The polygon motor (M5) turns ON

and OFF at the same time.
LD alarm check
M5
The polygon motor (M5) turns ON at

the same time and the results are displayed when it turns OFF.
999
LD alarm, data clear
39
L1
Platen stop APS
40
M11
Fusing motor (LS250)
The exposure lamp turns ON with
Main body
APS processed forcibly.

2
3
41

M1
Drum motor (LS250)
The charging corona turns ON at the
Drum motor (LS210)
Drum motor (LS125)
same time.
same time.
same time.
200
Symbol
M1
43
44
Drum motor (LS250)

Drum motor (LS125)
FM3,
Exhaust fan /Fr, /Rr turn ON at the
FM9
same time
FM4
Drum cooling fan
FM2,
Fusing cooling fan /Fr, /Rr turns ON at
FM8
the same time
FM1
Power supply cooling fan
FM6
Developing suction fan
FM5
Coveyance suction fan
FM7
Developing cooling fan
TCT
Total counter 1 count up
KCT
Key counter 1 count up
M3
Developing motor (LS210)
3
45
Name
Drum motor (LS210)
6
42
10. SERVICE MODE
bizhub 500 / 420
41
Multi code
Code
Main body Classification
Developing motor (LS125)
L2
Fusing heater lamp /1
L3
L2, L3
Fusing heater lamp /1, /2 turn ON at
detection is made, be careful
the same time
not to turn on for more than 10
L2,
Fusing heater lamp /1, fusing motor
seconds. Otherwise, the fusing
M11
L3,
Fusing heater lamp /2, fusing motor
M11
L2, L3,
Fusing heater lamp /1, /2, fusing
M11
motor turn ON at the same time

Operation panel check (panel key-
Operation panel
48
PKB
49
LCD
Operation panel check
Specific function
51
Caution
Since
no
high
temperature
roller may deform, thus causing a fire.
board LEDs all turm ON)
EL
Only erase lamp 24V ON
EL
Erase lamp
52
TSL
Transfer exposure lamp
53
SD4
Web solenoid
55
M4
Toner supply motor
SD5
Toner solenoid
M4,
Toner supply motor, toner solenoid
SD5
201
DF
Multi code
Symbol
Code
bizhub 500 / 420
Specific function Classification
10. SERVICE MODE
56
M10
Toner bottle motor (CW)
PZS
Toner remaining sensor ON/OFF
2
57
Name
Toner bottle motor (CCW)
Toner remaining sensor ON
59
RL1
60
M1
Original feed motor
M2
Original conveyance motor
FM3
Cooling fan
SD1
Pressure roller release solenoid
SD2
Stamp solenoid
LB
Print lamp (LED board) green ON
LB
Print lamp (LED board) red ON
M1,
1 side original scan continuous opera-
M2,
tion (no original)
SD1
2 sides original scan continuous oper-
Main relay
ation (no original)

10
1 side original scan continuous opera-
Operates according to the original
tion (original)
size set.
11
1 side mixed original scan continuous
12
2 sides original scan continuous oper-
operation (original)
FS-510
ation (original)
70
M2
Conveyance motor (10 seconds ON)
M4,
After alignment motor /Rr, /Fr opera-
M5
tion, home position search
M11
Tray lift motor up
Stops when the upper limit sensor

(PS15) turns ON after the tray position sensor (PS3) detects the tray 2.
M11
Tray lift motor initial operation
After the tray goes down, it goes up

when the lower limit sensor (PS14)
turns ON and it stops when PS15
turns ON. It becomes valid after executing the load check 70-5.
M12
Shutter close/open operation once
At the same time, the paper exit roller

release/pressure operation is made
by the paper exit roller release motor
(M6).
202
10
11
M6
Name
bizhub 500 / 420
Multi code
70
10. SERVICE MODE
Symbol
Code
FS-510 Classification
Release/press operation of exit roller

once
12
M9
Open/close operation once of paper

exit opening (SD)
13
14
15
16
17
M7
After 2-staple positioning, home posi-
18
19
20
21
22
23
M10,
Folding once (SD)
tion search
M14
24 to 52
M1,
SD1
paddle solenoid ON/OFF
54
M1,
Exit motor (1 second ON), exit paddle
SD2
solenoid ON/OFF
55 to 77
ADU/Reverse
78
80
53
M1
Exit motor (1 second ON), stacker
Punching once (PU)
79
M2
Switching the number of punches
M6
Reverse motor (LS250) rotating for-
Inch only
ward
2
Reverse motor (LS210) rotating forward
Reverse motor (LS125) rotating forward
Reverse motor (LS250) rotating backward
81
CL7
ADU conveyance clutch /Up
CL8
ADU conveyance clutch /Lw
M9,
Feed motor, ADU conveyance clutch
CL7
/Up turn ON at the same time
203
Adjustment/special mode
204
81
4
5
Symbol
Multi code
Code
bizhub 500 / 420
ADU/Reverse Classification
10. SERVICE MODE
M9,
Name
CL8
/Lw turn ON at the same time
M9,
CL7,
/Up, /Lw turn ON at the same time
CL8
83
SD3
Reverse solenoid
90
PM counter clear
91
Process counter clear
No use allowed in the field.
Drum counter clear
No use allowed in the field.

No operation available in the field.
92
NVRAM board data reset
93
Field initial set

10.7.3
10. SERVICE MODE
Memory/HDD Condition
bizhub 500 / 420
Displays the memory capacity and the hard disc capacity (total/free space).
A. Procedure


Press [Memory/HDD condition].
The memory package capacity, and the total capacity and the free capacity of HDD are displayed.
3. Press [END].
10.7.4
Memory Check (Memory/HDD Adjustment)
Checks the memory operation.

A. Procedure


Press [Memory/HDD Adjustment].
3. Press [Memory Check] from the menu.

4. "Memory Check screen"
Press [Rough Check] or [Detail Check].

When completed normally, it is displayed that the memory check result is "OK."
6. Press [END].
10.7.5
HDD R/W Check (Memory/HDD Adjustment)
Conducts the read/write check of the hard disc.

A. Procedure


3. Press [HDD R/W Check] from the menu.

4. "HDD R/W Check screen"
When completed normally after checking, it is displayed that the check result is "OK."
5. Press [END].
205
10. SERVICE MODE
bizhub 500 / 420
10.7.6
HDD Format (Memory/HDD Adjustment)
Formats HDD.
Note
When formatting HDD, all the data stored in HDD gets lost and becomes unrecoverable.
A. Procedure


3. Press [HDD Format] from the menu.

The screen for confirmation is display.
4. Press [Yes].
When formatting is executed and completed, a message "The formatting of HDD is completed" is displayed.
5. Turn OFF the power switch (SW2) and the main power switch (SW1) in this order.
6. After waiting for 10 seconds or more, turn ON SW1 and SW2 in this order.
Note
Turning ON SW1 not waiting for 10 seconds or more after turning it OFF may damage HDD. Be
sure to turn ON SW1 10 seconds or more after turning it OFF.
10.7.7
Adj. Data Table
Displays the adjustment data set for this machine.

A. Procedure


Press [Adj. Data Table].
3. "Adj. Data Table screen"

Press [ ] or [ ] to display necessary items.
4. Pressing [NVRAM Value] switches the display into the step number display set and pressing also [Adjust
Value] switches the display into the adjustment value (the value of 1 step x the number of steps).
5. Press [OK].
206

Adj. Data Table
Display
1/28
bizhub 500 / 420
10.7.8
10. SERVICE MODE
Adjustment item
Print position adjustment: leading edge (tray 1)
Print position adjustment: leading edge (LCT)
Print position adjustment: leading edge (bypass (normal paper))
Print position adjustment: leading edge (bypass (thick paper: large))
2/28
Print position adjustment: leading edge (bypass (thick paper: small))

Print position adjustment: leading edge (bypass (thin paper))
Print position adjustment: leading edge (bypass (OHP))
Print position adjustment: leading edge (bypass (envelope))
Print position adjustment: leading edge (bypass (label: large))
Print position adjustment: leading edge (bypass (label: small))
Print position adjustment: leading edge (ADU)
3/28
Print position adjustment: side edge (tray 1 (common))

Print position adjustment: side edge (tray 1 (small size))
Print position adjustment: side edge (tray 1 (large size))
4/28

Print position adjustment: side edge (LCT)
Print position adjustment: side edge (ADU (common))
5/28
Print position adjustment: side edge (ADU (small size))

Print position adjustment: side edge (ADU (large size))
Print position adjustment: side edge (bypass (common))
Print position adjustment: side edge (bypass (small size))
Print position adjustment: side edge (bypass (large size))
Magnification in the printer feed direction (printer: normal paper)
Magnification in the printer feed direction (printer: OHP (large))
207
10. SERVICE MODE
bizhub 500 / 420
Display
6/28

Adjustment item
Magnification in the printer feed direction (printer: OHP (small))

Magnification in the printer feed direction (printer: thick paper (large))
Magnification in the printer feed direction (printer: thick paper (small))
Magnification in the printer feed direction (printer: envelope)
Magnification in the printer feed direction (printer: label (large))
Magnification in the printer feed direction (printer: label (small))
Magnification in the printer feed direction (printer: custom paper)
7/28
Magnification in the printer feed direction (fixing motor clock: normal paper)
Magnification in the printer feed direction (fixing motor clock: OHP (large))
Magnification in the printer feed direction (fixing motor clock: OHP (small))
Magnification in the printer feed direction (fixing motor clock: thick paper (large))
Magnification in the printer feed direction (fixing motor clock: thick paper (small))
Magnification in the printer feed direction (fixing motor clock: envelope)
Magnification in the printer feed direction (fixing motor clock: label (large))
8/28
Magnification in the printer feed direction (fixing motor clock: label (small))
Magnification in the printer feed direction (fixing motor clock: custom paper)
Magnification in the printer feed direction (fixing motor clock: user paper)
Printer registration loop amount (tray 1 (small))
Printer registration loop amount (tray 1 (large))
Printer registration loop amount (tray 2 (middle1))
9/28
Printer registration loop amount (tray 2 (middle2))

Printer registration loop amount (tray 3 (middle))
Printer registration loop amount (tray 4 (middle))
10/28

Printer registration loop amount (option tray)
Printer registration loop amount (LCT)
Printer registration loop amount (bypass (normal (small)))
Printer registration loop amount (bypass (normal (middle)))
Printer registration loop amount (bypass (normal (large)))
Printer registration loop amount (bypass (thick paper: small))
11/28
Printer registration loop amount (bypass (thick paper: large))

Printer registration loop amount (bypass (thin paper: small))
Printer registration loop amount (bypass (thin paper: large))
Printer registration loop amount (bypass (OHP: small))
Printer registration loop amount (bypass (OHP: large))
Printer registration loop amount (bypass (envelope))
Printer registration loop amount (bypass (label: small))
208
12/28
Adjustment item
bizhub 500 / 420
Display
10. SERVICE MODE
Printer registration loop amount (bypass (label: large))
Printer registration loop amount (ADU (small))

Printer registration loop amount (ADU (large))
Tray adjustment (maximum width)
Tray adjustment (minimum width)
Scan area (scanning position: leading edge)
13/28
Scan area (scanning position: side edge)

Magnification in the scanner feed crossover direction
Magnification in the scanner feed direction
Printer leading edge erasure amount adjustment
Charging main manual
Transfer manual
Separation AC manual
14/28
Separation DC manual
Carging grid manual
Developing grid manual
TCR
Toner density
Dot diameter
LD1 offset (normal paper)
15/28
LD1 offset (thick paper)

LD2 offset (normal paper)
LD2 offset (thick paper)
LD1 bias (normal paper)
LD1 bias (thick paper)
LD2 bias (normal paper)
LD2 bias (thick paper)
16/28
Magnification in the ADF feed direction (single sided: 50%)

Magnification in the ADF feed direction (double sided: 50%)
17/28

ADF leading edge (single sided)
ADF leading edge (double sided (front side))
ADF leading edge (double sided (back side))
ADF side edge (single sided)
ADF side edge (double sided (front side))
ADF side edge (double sided (back side))
209
10. SERVICE MODE
bizhub 500 / 420
Display
18/28

Adjustment item
ADF registration loop amount (single sided)

ADF registration loop amount (double sided)
ADF original size (maximum width)
ADF original size (minimum width)
ADF density
ADF scan position
Center staple position (B5S)
19/28
Center staple position (A4S)

Center staple position (B4)
Center staple position (A3)
Center staple position (81/2 x 11S)
Center staple position (11 x 17)
Center staple position (8K)
Center staple position (81/2 x 14)
20/28
Half-fold position (B5S)

Half-fold position (A4S)
Half-fold position (B4)
Half-fold position (A3)
Half-fold position (81/2 x 11S)
Half-fold position (11 x 17)
Half-fold position (8K)
21/28
Half-fold position (81/2 x 14)

Punch horizontal position
Punch registration loop amount (B5S)
Punch registration loop amount (B5)
Punch registration loop amount (A4S)
Punch registration loop amount (A4)
Punch registration loop amount (B4)
22/28
Punch registration loop amount (A3)

Punch registration loop amount (81/2 x 11S)
Punch registration loop amount (81/2 x 11)
Punch registration loop amount (81/2 x 14S)
Punch registration loop amount (11 x 17)
Punch registration loop amount (8K)
Punch registration loop amount (16K)
23/28
Punch registration loop amount (16KS)

Punch registration loop amount (FLS)
Test pattern density
DipSW No.01
DipSW No.02
DipSW No.03
DipSW No.04
210
24/28
Adjustment item
bizhub 500 / 420
Display
10. SERVICE MODE
DipSW No.05
DipSW No.06
DipSW No.07
DipSW No.08
DipSW No.09
DipSW No.10
DipSW No.11
25/28
DipSW No.12
DipSW No.13
DipSW No.14
DipSW No.15
DipSW No.16
DipSW No.17
DipSW No.18
26/28
DipSW No.19
DipSW No.20
DipSW No.21
DipSW No.22
DipSW No.23
DipSW No.24
DipSW No.25
27/28
DipSW No.26
DipSW No.27
DipSW No.28
DipSW No.29
DipSW No.30
DipSW No.31
DipSW No.32
28/28
DipSW No.33
DipSW No.34
DipSW No.35
DipSW No.36
DipSW No.37
DipSW No.38
DipSW No.39
211
10. SERVICE MODE
bizhub 500 / 420
10.8 ADF
10.8.1
Adjusts the magnification in the sub scan direction while in the DF original scan.
This adjustment adjusts the magnification of the image data in the sub scan direction by changing the scan
speed of DF.
The adjustment is made for each mode (single sided, double sided (front/rear)) and expansion/reduction ratio
(50%, 100%, 200%, 400%).
Note
Make sure that the adjustment of the magnification in the printer paper feed direction has been
completed.
(See P.159)
A. Procedure

Press [ADF].
2. "ADF Adjustment screen"

Press [Paper Feed Direction].
3. "Paper Feed Direction screen"

Press the magnification that adjusts the 1-Sided or 2-Sided.

Select A3 (for metric) or 11 x 17 (for inch) paper, and press the Start key with the adjustment chart set to
DF.
6. Press [OK].
7. Measure the magnification in the paper feed direction with a scale.
Standard value (while in the life size): 0.5% or less (200 1 mm or less)
8. "Paper Feed Direction screen"

Setting range: 2.0 (shorter) to + 2.0% (longer)
1 step = 0.1%

10. Repeat steps 3 to 9 for each magnification.
11. Press [OK].
212

Lead Edge
Adjusts the position at which the image read is started while in the DF original scan.
This adjustment adjusts the leading edge position of the image by changing the image read start timing after the
leading edge of the original passes through the read position.
The adjustment is made for each mode (1-Sided, 2-Sided (Front/Back)).
A. Procedure

Press [ADF].

Press [Lead Edge].
3. "ADF Adjustment: Lead Edge screen"

Press [1-Sided], [2-Sided (Front)], or [2-Sided (Back)] to select the mode.

DF.
6. Press [END].
7. Measure the leading edge position of the image with a scale.
8. "ADF Adjustment: Lead Edge screen"

Setting range: 5.0 (slower start of read) to + 5.0 mm (faster start of read)
1 step = 0.1 mm

10. Repeat steps 3 to 9 for each mode.
11. Press [OK].
213
bizhub 500 / 420
10.8.2
10. SERVICE MODE
10. SERVICE MODE
bizhub 500 / 420
10.8.3
Side Edge
Adjusts the mis-centering of the image in the main scan direction while in the DF original scan.
The adjustment is made for each mode (1-Sided, 2-Sided (Front/Back)).
Note
Make sure that the adjustment of the printer position: side edge has been completed.
(See P.158)
A. Procedure

Press [ADF].

Press [Side Edge].
3. "ADF Adjustment: Side Edge screen"

Press [1-Sided], [2-Sided (Front)], or [2-Sided (Back)] to select the mode.

DF.
6. Press [END].
7. Fold the output paper into two at the center in the main scan direction, and check the discrepancy of the
print center line.
Standard value: 3.0 mm or less
8. "ADF Adjustment: Side Edge screen"

Setting range: 2.96 (image: to the rear) to + 2.96 mm (image: to the front)
1 step = 0.04 mm

11. Press [OK].
214

Resist Loop Adj.
Adjusts the original loop amount (1-Sided or 2-Sided) at the registration roller section of DF to adjust a paper
skew, wrinkles or an original jam at the registration section.
This adjustment adjusts the re-start timing of the DF registration roller.
A. Procedure

Press [ADF].

Press [Resist Loop Adj.].
3. "Resist Loop Adj. screen"

Press [1-Sided] or [2-Sided] to select the mode.

5. Select paper according to the item selected at step 3. Set A3 (for metric) or 11 x 17 (for inch) original that
is used more frequently set to DF and press the Start key.
6. Press [END].
Return to the registration loop amount adjustment screen.
7. "Resist Loop Adj. screen"

Setting range: 5.0 (smaller) to + 5.0 mm (larger)
1 step = 0.5 mm
8. Repeat steps 5 to 7 until it becomes appropriate.

10. Press [OK].
10.8.5
Original Size Adj.
This adjustment is made when the original size detection does not function properly at DF.
A. Procedure

Press [ADF].

Press [Original Size Adj.].
3. "Original Size Adj. screen"

Press [Max. Width].
4. With A3 (for metric) or 11 x 17 (for inch) paper set to DF, press the Start key.
5. Check to see if the result is OK.
6. Press [Min. Width].
7. With B6S (for metric) or 5.5 x 8.5S (for inch) size paper set to DF, press the Start key.
8. Check to see if the result is "OK".
9. Press [OK].
215
bizhub 500 / 420
10.8.4
10. SERVICE MODE
10. SERVICE MODE
bizhub 500 / 420
10.8.6
Density Adj.
This adjustment is made when the slit glass is replaced.

The slit glass at the scanner section is coated, and therefore, its transmittance of the exposure lamp is different
when compared to the original glass.
Prearrangements
Clean the slit glass.
Check the whole area of the white chart to see if it is not soiled.
A. Procedure

Press [ADF].

Press [Density Adj.].
3. "Density Adj. screen"

Set the white chart to DF.
Note
Be sure to set the white chart in the A4 direction.

When the white chart is scanned and the auto adjustment of density is completed successfully, "OK" is
displayed.
5. When an error message is displayed, turn OFF and ON the power switch (SW2) of the main body and
repeat steps 3 to 4 until it is completed successfully.
6. Press [OK].
216

10.8.7
10. SERVICE MODE
bizhub 500 / 420
Adjusts the read start position of the exposure unit in the sub scan direction.
A. Procedure

Press [ADF].

Press [Scan Position Adjustment].
3. "Scan Position Adjustment screen"

Press [Test Copy].

ADF.
5. Press [END].
6. Check the read position.
[1]
50gaf3c012na
7. "Scan Position Adjustment screen"

Setting range: 2.0 (faster) to + 2.0 mm (slower)
1 step = 0.1 mm

10. Press [OK].
217
10. SERVICE MODE
bizhub 500 / 420
10.8.8
Sensor Auto Adjust
This adjustment is made when an erroneous detection occurs with the reflective sensor, or after the DF control
board (DFCB) and each of the reflective sensors are replaced. Conducting this adjustment backs up the sensitivity value of each of the reflective sensors to RAM in DFCB.
Prearrangement
Clean each of the reflective sensors of DF.
Note
After conducting [Initialization + Auto Adjust], the value of the original size VR (VR1) is reset. Be
sure to conduct [Original Size Adjustment].
A. Procedure

Press [ADF].

Press [Sensor Auto Adjust].
3. "ADF Sendor Adjustment screen"

Press [Initialize And Sensor Auto Adj.] or [ADF Sensor Auto Adj.].

Check the check results, the initialization, and the sensors 1 to 4 to see if they are "OK."
5. Press [END].
218
10. SERVICE MODE
10.9.1
bizhub 500 / 420
10.9 Finisher
Center Staple Position (SD-502)
Adjusts the stapling position in the sub scan direction while in the stitch-and-fold by SD-502.
Note
Before conducting this adjustment, make sure that the adjustment of the half-fold position has
been completed.
(See P.220)
A. Procedure

Press [Finisher].
2. "Finisher Adjustment screen"

Press [Center Staple Position].
3. "Center Staple Position Adj. screen"

Press each key and select the paper size to be adjusted.

With 5 or more originals (2 or more sheets at the finish of the stitch-and-fold) set to DF, select suitable
paper and press the Start key.
6. Press [END].
7. Check the stitch-and-fold position of paper and
the position of the staple in the sub scan direction.
[1]
4511f3c005na
8. "Center Staple Position Adj. screen"

Setting range: 5.0 (to the right) to + 5.0 mm (to the left)
1 step = 0.5 mm

10. Press [OK].
219
10. SERVICE MODE
bizhub 500 / 420
10.9.2
Half-Fold Position (SD-502)
Adjusts the folding position while in the stitch-and-fold print by SD-502.

A. Procedure

Press [Finisher].

Press [Half-Fold Position].
3. "Half-Fold Position Adjustment screen"

Press each key to select the paper size to be adjusted.

With the original set to DF, select a paper size and press the Start key.
6. Press [END].
7. Fold the output paper along the folding line and
check the paper edge to see if it is not shifted [1].
[1]
4511f3c006na
8. "Half-Fold Position Adjustment screen"

Setting range: 5.0 (to the right) to + 5.0 mm (to the left)
1 step = 0.5 mm
Note
When there occurs a shift shown at step 7, enter a value on the minus () side.

10. Press [OK].
220

10.9.3
10. SERVICE MODE
Punch Horizontal Position (PU)
bizhub 500 / 420
Adjusts the position of the punch holes by PU-501 in the sub scan direction.
A. Procedure

Press [Finisher].
2. "Finisher Adjustment"
Press [Punch Horizontal Position].
3. "Punch Horizontal Position Adj. screen"

Press [Test Copy].
4. With the original set to DF, select a suitable paper size and press the Start key.
5. Press [END].
Return to the punch horizontal position adjustment screen.
6. Check the distance between the paper edge and

the center of the punch hole.
[1]
Standard value [1]: 11 mm (metric) , 9.5 mm (inch)

and 10.5 mm (swedish)
4512f3c003na
7. "Punch Horizontal Position Adj. screen"

Setting range: 5.0 (shorter) to + 5.0 mm (longer)
1 step = 0.5 mm

9. Press [OK].
221
10. SERVICE MODE
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10.9.4
Punch Resist Loop (PU)
Adjusts the registration loop amount while in the punch by PU-501.

This adjustment is made when there occurs a tilt with the punch hole, or when a jam occurs frequently in the
punch mode.
A. Procedure

Press [Finisher].

Press [Punch Resist Loop].
3. "Punch Resist Loop screen"

Press [Test Copy].
4. With the original set to DF, select a suitable paper size and press the Start key.
5. Press [END].
6. Check the punch holes to see if they are parallel
with the paper edge. And also check to see if a
jam occurs.
4512f3c004na
7. "Punch Resist Loop screen"

Setting range: 4 (longer) to + 4 mm (shorter)
1 step = 1 mm
Note
When a jam occurs in the punch mode, set a value to the minus () side.
When the line of punch holes is slanted, set a value to the plus (+) side.

9. Press [OK].
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10. SERVICE MODE
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10.10 Firmware Version

Displays the version of the firmware (main body and optional).
MFP Controller
Image Controller
Operation Panel Message Data
Finisher
ADF
Fax board controller 1
Fax board controller 2
MFP Controller BOOT Program
Image Controller BOOT Program
A. Procedure

Press [Firmware Version].
2. "Firmware Version screen"

Press [1] or [2] to display the intended item.
3. Press [END].
223
10. SERVICE MODE
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10.11 CS Remote Care

10.11.1 Outlines
CS Remote Care enables the machine and the computer at CS Remote Care center to exchange data
through telephone line in order to control the machine.
CS Remote Care enables the machine to call the computer at the center when trouble occurs. It also enables the computer at the center to contact the machine for the necessary data.
Data which CS Remote Care handles can be divided into the following groups.
a. Data which show the status of use of the machine such as Total count, PM count.
b. Data which show the abnormal situation on the machine such as where and how often errors occur.
c. Data on adjustment
d. Data on setting
10.11.2 Setting Up the CS Remote Care

Note
At this moment on February 2006, the use of the communication means other than the modem is
unavailable.
For resetting up the machine which CS Remote Care has already been set up, clear the RAM for
CS Remote Care before resetting.
For clearing RAM, see "(3) RAM Clear" in "C. Detail Setting" in "10.11.8 Detail on settings".
(See P.232)
When using the telephone line for connection, use the recommended modem.
(For recommended modem, contact responsible person of KONICA MINOLTA.)
Step
0
Procedure
Register the device ID to the application at CS Remote Care Center.
The initial connection is not available unless the device ID is registered.
Connecting the modem

Turn the power for the modem OFF. Connect the machine and the modem with a modem cable.
Connect the modem and the wall jack with a modular cable.
* For connecting the modular cable, see the manual for the modem.
Clearing the RAM
1. Select [Service Mode] [CS Remove Care], and touch [Detail Setting].
2. Touch [RAM Clear].
3. Select Set, and touch [END].
(See P.233)
3
Selecting the CS Remote Care function

Select [Service Mode] [CS Remove Care] [System Selection], and touch [Modem].
Inputting the ID Code
1. Select [Service Mode] [CS Remote Care] [ID Code], and touch [ID Code].
2. Input the seven digits ID of the service person, and touch [ID Code] again.
(See P.232)
5
Setting the date and time for CS Remote Care
1. Select [Service Mode] [CS Remote Care], and touch [Detail Setting].
2. Touch [Date & Time Setting].
3. Input the date, time and the time zone using the 10-Key Pad, and touch [Set].
(See P.232)
224
Procedure
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Step
10. SERVICE MODE
Setting the Center ID
2. Touch [Machine Setting] [Center ID], and input the Center ID (five digits).
(See P.232)
7
Setting the Device ID
2. Touch [Machine Setting] [Device ID], and input Device ID (nine digits).
(See P.232)
8
Setting the telephone number of the Center
2. Touch [Machine Setting] [Center Telephone Number].
3. Input the telephone number of the Center using the 10-Keys Pad and [P], [T], [W], [-] keys.
(See P.232)
9
Inputting the Device telephone number
2. Touch [Machine Setting] [Device Telephone Number].
3. Input the Device telephone number using the 10-Key Pad and [P], [T], [W], [-] keys.
(See P.232)
10
Inputting the AT command for initializing the modem
1. Select [Service Mode] [CS Remote Care] and touch [Detail Setting].
2. Touch [AT Command].
3. Input AT Command.
Note
Change this Command only when it is necessary. (They do not need to be changed in
normal condition.)
For details on AT Command, see the manual for the modem.
(See P.234)
11
Setting the DIPSW for CS Remote Care

Note
This setting is not normally necessary. Take this step only when necessary in a specific connecting condition.
12
Executing the initial transmission

Select [Service Mode] [CS Remote Care], and touch [Detail Setting].
Touch [initial transmission] on the right bottom of the screen to start initial transmission.
When the machine is properly connected with the Center, CS Remote Care setting screen will be
displayed.
Note
The initial transmission key at the right bottom of the screen will be displayed only
when the Center ID, the Device ID, Telephone number of the Center and the Device
telephone number have been input.
(See P.232)
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10.11.3 Software SW setting for CS Remote Care

Note
SW bits data are written into the NVRAM every time a change is made. In case you changed bit
data by accident, be sure to restore the previous state.
A. Input procedure
1. Select [Service Mode] [CS Remote Care] [Detail Setting], and touch [Software Switch Setting].
2. Touch [Switch No.], and input the SW number (two digits) using the 10-Key Pad.
3. Touch [Bit Assignment], and select SW bit number using the arrow keys, and input 0 or 1 using the 10-Key
Pad.
(For setting by hexadecimal numbers, touch [HEX Assignment] key, and input using the 10-Key Pad or A
to F keys.)
4. Touch [Fix].
Note
About functions of each switch, see to "B. List of software SW for CS Remote Care".
B. List of software SW for CS Remote Care

Note
Do not change any bit not described on this table.
SW No.
Bit
SW 01
Dial Mode
SW 02
Functions
Pulse
Tone
Default
1
Reservation
Reservation
Reservation
Baud rate
*1
*1
*1
*1
*1
*1
*1
*1
Emergency transmission
Do not call
Call
Auto call on date specification
Do not call
Call
Reservation
Reservation
Reservation
Auto call on the IC Life
Do not call
Call
Auto call on CCD Clamp/Gain
Do not call
Call
Adjustment failure
7
226
Reservation
10. SERVICE MODE
SW No.
Bit
SW 03
Reservation
Auto call on the toner empty
Reservation
0
1
0
Reservation
Modem redial interval
*2
*2
*2
*2
*2
*2
*2
*2
Reservation
Modem redial times
*3
*3
*3
*3
*3
*3
*3
*3
*3
*3
*3
*3
*3
*3
Do not redial
Redial
Reserved
Retransmission interval on E-Mail deliv-
*4
*4
ery error
4 to 7
0
Reservation
Redial for response time out
1 to 7
*4
*4
*4
*4
*4
*4
Reservation
Retransmission times on E-Mail
*5
*5
delivery error
4 to 7
SW 10
Call
SW 09
Do not call
Call
0 to 7
SW 08
Default
SW 05
SW 07
Do not call
SW 04
Auto call on the waste toner bottle full
Reservation
4 to 7
SW 06
Functions
*5
*5
*5
*5
*5
*5
*5
*5
*5
*5
*5
*5
Reservation
0 to 7
Reservation
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10. SERVICE MODE
SW No.
Bit
SW 11
Timer 1
*6
*6
RING reception CONNECT
*6
*6
reception
SW 12
Default
*6
*6
*6
*6
*6
*6
*6
*6
*6
*6
*6
*6
Timer 2
*7
*7
Dial request completed CONNECT
*7
*7
reception
*7
*7
*7
*7
*7
*7
*7
*7
*7
*7
*7
*7
Reservation
Timer 4
*8
*8
Line connection Start request
*8
*8
telegram delivery
*8
*8
*8
*8
*8
*8
*8
*8
*8
*8
*8
*8
SW 13
0 to 7
SW 14
SW 15
Functions
Timer 5
*9
*9
Wait time for other side's response
*9
*9
*9
*9
*9
*9
*9
*9
*9
*9
*9
*9
*9
*9
0
0
SW 16
0 to 7
Reservation
SW 17
0 to 7
Reservation
SW 18
Do not call
Call
Attention display
To set weather to give the alarm display
when using the modem but the power
for the modem is OFF.
1 to 7
Reservation
SW 19 to SW 0 to 7
Reservation
40
228
*2
*3
Baud rate
Mode
01-7
01-6
01-5
9600 bps
19200 bps
"38400 bps"
05-0
01-4
Modem redial interval

Mode
05-3
05-2
05-1
1 minute
2 minutes
"3 minutes"
4 minutes
5 minutes
6 minutes
7 minutes
8 minutes
9 minutes
10 minutes
Modem redial times

Mode
06-6
06-5
0 to 9 times
"10 times"
06-4
06-3
06-2
06-1
06-0
000 0000 to 000 1001

0
11 to 99 times
*4
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*1
10. SERVICE MODE
000 1011 to 110 0011
Retransmission interval on E-Mail delivery error

Mode
08-3
08-2
08-1
0 minute
08-0
0
10 minutes
20 minutes
30 minutes
40 minutes
50 minutes
"60 minutes"
70 minutes
80 minutes
90 minutes
100 minutes
110 minutes
120 minutes
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10. SERVICE MODE
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*5
Retransmission times on E-Mail delivery error

Mode
09-6
09-5
09-4
0 to 9 times
"10 times"
11 to 99 times
*6
11-7
11-6
11-5
"32 sec"
11-4
11-3
11-2
11-1
11-0
12-2
12-1
12-0
14-2
14-1
14-0
15-2
15-1
15-0
0010 0001 to 1111 1111
Timer 2 (Dial request completed CONNECT reception)

Mode
12-7
12-6
12-5
0 to 63 sec
"64 sec"
12-4
12-3
0000 0000 to 0011 1111

0
65 to 255 sec
0100 0001 to 1111 1111
Timer 4 (Line connection Start request telegram delivery)

Mode
14-7
14-6
14-5
0 to 31 (x 100 msec)
"32 (x 100 msec)"
14-4
14-3
0000 0000 to 0001 1111

0
33 to 255 (x 100 msec)
0010 0001 to 1111 1111
Timer 5 (Wait time for other side's response)

Mode
15-7
15-6
15-5
0 to 29 sec
"30 sec"
31 to 255 sec
230
09-0
0000 0000 to 0001 1111
33 to 255 sec
*9
09-1
Timer 1 (RING reception CONNECT reception)

Mode
*8
09-2
000 1011 to 110 0011
0 to 31 sec
*7
09-3
000 0000 to 000 1001
15-4
15-3
0000 0000 to 0001 1101

0
0001 1111 to 1111 1111
10. SERVICE MODE
10.11.4 Setup confirmation

Follow the steps below to make sure that CS Remote Care has been properly set up.
bizhub 500 / 420
1. Call the Service Mode to the screen.

2. Touch [CS Remote Care].
3. Check to make sure that only selected item is displayed.
10.11.5 Calling the Maintenance
When CE starts maintenance, inputting the ID code of CE (seven digits: numbers which CE can identify.
They are controlled by the distributor.) will transmit the information to the Center side and tells that the maintenance has started. When the maintenance is finished, touching [Maintenance Complete] key will transmit
the information to the Center and tells that it is finished.
A. When starting the Maintenance
1. Select Service Mode and touch [CS Remote Care].

2. Touch [ID Code], and input ID Code.
3. Touch [ID Coke].
* The Start key blinks while maintenance is being carried out.
B. When finishing the Maintenance
1. Select Service Mode and touch [CS Remote Care].

2. Touch [Maintenance Complete].
10.11.6 Calling the Center from the Administrator
When the CS Remote Care setup is complete, the administrator can call the CS Remote Care center.
1. Select [Administrator Setting], and touch [System Connection].

2. Touch [Admin. transmission].
When the setup is not complete or another transmission is being carried out, the Admin. transmission key
will not be displayed, and the transmission is not available.
Note
For transmitting data of the machine by calling the center on the specified date and time, refer to
the manual for CS Remote Care Center.
10.11.7 Checking the transmission log
The transmission log list will be output to be checked.
1. Select [Service Mode] [CS Remote Care], and touch [Detail setting].
2. Touch [Communication Log Print].
3. Load Tray 1 or Bypass tray with A4S paper.
4. Press the Start key to output transmission log.
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10. SERVICE MODE
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10.11.8 Detail on settings

A. System Selection
Functions
To select the system type for remote diagnosis.
Use
Use to newly build or change the system.
Setting/
Select E-Mail, Modem, or Fax.
Procedure
Fax is available only when the optional Fax kit is being installed.
E-Mail (Not Used)
Modem
Fax (Not Used)
B. ID Code
Functions
To register the Service ID.
Use
Use when registering and changing Service ID.
Setting/
Enter a 7-digit code from the 10-Key Pad. (0000001 to 9999999)
Procedure
<Registration>
Touch ID Code and enter the Service ID.
Touch [ID code] to register the ID.
The [Detail Setting] will appear when the ID has been registered.
C. Detail Setting
(1) Basic Setting
Functions
Execute the primary setting.
Use
Use to change the set contents.

Use to register the machine to the CS Remote Care Center.
Setting/
Procedure
1. Call the Service Mode to the screen.

2. Touch [CS Remote Care].
3. Touching the [Detail Setting] will display the primary setting.
Primary Setting
Set the Center ID, Device ID, and the phone No.
When e-mail is selected for system and all setup procedures are completed, E-mail
address of the Center is displayed.
* When entering the phone No, 10-Keys and keys on the screen have following meanings.
[] Pose
: Waits to start transmitting after dialing
[W] Wait
: Detects the dial tone of the other end
[T] Tone dial
: Carry out tone dialing
[P] Pulse dial
: Carry out pulse dialing
[*], [#]
: To be used as necessary
Initial Transmission
Touching the Initial Transmission key will sent the information to the CS Remote Care
Center to register the machine.
(Only when the Modem or Fax is selected on the system Input.)
232
10. SERVICE MODE
Functions
To set the data and time-of-day
Use
Use to set or change the date and time-of-day.
Setting/
Procedure
1.
2.
3.
4.
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(2) Date & Time Setting
Call the Service Mode to the screen.

Touch [CS Remote Care].
Touch [Detail Setting] to access Date & Time Setting.
Enter the date (month, day and year), time-of-day, and the time zone from the 10-Key
Pad.
5. Touch [SET] to start the clock.
(3) RAM Clear

Functions
To clear the following data at the Center

ID Code, Primary Setting, Date/Time Input (Time Zone), Software SW Setting and AT
Command.
Use
To be used for setting CS Remote Care.

To be used for reset the every data of the Center to default.
Note
If RAM Clear is selected during transmission, RAM clear processing will be
implemented at the time the transmission is completed regardless of whether it
is done properly or not.
Setting/
The default setting is Unset.
Procedure
Set
Unset
(4) Communication Log Print

Functions
To print out the Communication Log.
Use
Use to output and use the Communication Log.
Setting/
Procedure
1.
2.
3.
4.
5.
Call the Service Mode on the screen.

Touch [CS Remote Care].
Touch [Detail Setting] to access Communication Log Print.
Load Tray 1 or Bypass Tray with A4S or 81/2 x 11 paper.
Press Start key to print out the Communication Log.
(5) Software Switch Setting

Functions
To change the CS Remote Care settings.
Use
To change the settings for CS Remote Care as necessary.
Setting/
For procedures on settings, see "10.11.3 Software SW setting for CS Remote Care".
Procedure
(See P.226)
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10. SERVICE MODE
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(6) Response Time Out

Functions
Use
Setting/
Not Used. (To be used when connected by E-mail.)
Procedure
D. AT Command
Functions
To set the command to be issued at the time of Modem Initialization.

This setting is available only when [Modem] is selected for the system setting.
Use
To set the command to be issued at the time of Modem Initialization.
Setting/
Enter the command and touch [SET] to register.
Procedure
E. Server set
Functions
Use
Setting/
Not Used.
Procedure
10.11.9 List of the CS Remote Care error code

Note
Error codes in the shaded region may occur when transmitting from the machine to the center.
Error code
Error
Solution
0001
The line is busy (Busy detection)
Transmit again manually.
0002
Failure of the Modem default setting at transmitting
Check if the power of the modem
(When the transmission completes with modem initial setting failed)
is ON.
Check the connecting condition
between the modem and the
main unit.
0003
Timeout of CONNECT at transmitting
Transmit again manually
(No response to ATD)

is ON.
main unit.
0004
Timeout of Incoming request response

(No response to incoming (starting) request MSG)
234
Contact responsible person of

KONICA MINOLTA.
0005
Error
Timeout of CONNECT at receiving
(No response to ATA)
Solution
is ON.
main unit.
0006
Shut down of the data modem line (Host)

(Carrier OFF is detected)
0007
Shut down of the data modem line (Main unit)

(Line is shut down forcibly due to event)
0008
Timeout of start request telegram delivery
No solution, because the line is

shut down at the host side.
KONICA MINOLTA.
(Start request telegram is not delivered after line connection)

0009
Timeout of finish request telegram delivery
(Finish request telegram is not delivered (Start of

shut down).)
000A
Receiving rejection
(Receiving is made when the main unit is set to reject
Check the setting condition of the

host side.
receiving.)
Check the setting condition of the
RS232C Driver Over Run
If the same error is detected sev-
main unit side.

000B
(When the modem detects Over Run.)
eral times, turn the modem power

OFF and ON.
000C
If the same error is detected several times, turn the
modem power OFF and ON.
Break Interrupt (BI) Indicator
OFF and ON.

000D
(When the modem detects Break Interrupt (BI) Indicator.)

000E
Receiving RING Buffer Full
000F
Transmitting RING Buffer Full
(When the Receiving RING Buffer is full.)

(When the Transmitting RING Buffer is full.)
0010
RX FIF0 ERROR
(when Read / Write error occurs at RX FIF0)
0011
Baud Rate ERROR

(When selected Baud Rate is out of the specification

OFF and ON.
KONICA MINOLTA.
KONICA MINOLTA.
KONICA MINOLTA.
Check the Baud rate of the software DipSW.
(9600 bps to 38400 bps).)

0012
TX FIF0 Level Error

(When the threshold of the selected TX FIF0 is not

KONICA MINOLTA.
error value (1, 3, 9, 13).)

0013
RX FIF0 Level Error

(When the threshold of the selected RX FIF0 is not

KONICA MINOLTA.
error value (0, 4, 8, 14).)

0014
Receiving Data Over Error

(When the data whose size exceeds the transmitting

KONICA MINOLTA.
RING buffer is requested.)
235
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Error code
10. SERVICE MODE
10. SERVICE MODE
bizhub 500 / 420
Error code
Error
Solution
0015
Status Error
0016
Status Error (During receiving)
0017
Status Error
(During modem operation is being confirmed)

KONICA MINOLTA.
KONICA MINOLTA.
(During line is being shut down)

0018
Machine ID has already been registered

(Request telegram 2 (SET-UP) comes from the main
KONICA MINOLTA.
Set the initial registrations again
for all including the host side.
unit that has already registered Machine ID.)

0019
Center ID Error
(Center ID of the host is not identical with the one of
Check Center ID setting of the

main unit side.
start request telegram.)
Check Center ID setting of the
Device ID inconsistency
Check Device ID setting of the
main unit side.

001A
(Device ID of the host is not identical with the one of
main unit side.
start request telegram.)
Check the setting of the host
Device ID Unregistered
Check Device ID setting of the
side.
001B
(Request telegram 2 (Constant data transmitting,

Emergency call) comes from the main unit that has
not registered Machine ID yet.)
001C
Grammar Error
(Received response telegram is unregulated format.)
001D
Impossible to change (Unchangeable items)

(Host requests to change the setting of items which
main unit side.

Check the setting of the host
side.
KONICA MINOLTA.
KONICA MINOLTA.
are not allowed to change.)

001E
Impossible to change (During printing)

(Setting cannot be changed because the setting
Try again when the machine is not

printing.
change is made during the machine is printing or

starts printing.)
001F
Impossible to change (Unread items)

(The host tries to make writing on the items the cur-

KONICA MINOLTA.
rent value has not been read.)

0020
Timeout of Telegram Delivery
Try communication again.
(At waiting mode of telegram delivery the machine

fails to receive the telegram in a given time.)
0021
Telegram Size Over

(The machine receives the telegram whose size

KONICA MINOLTA.
exceeds the specification.)

0022
Transmitting Phase Response NG

(Transmitting phase response MSG is not appropri-

KONICA MINOLTA.
ate.)
0023
Timeout of Transmitting Phase Response MSG

(Transmitting phase response MSG is timeout.)
236

KONICA MINOLTA.
0024
Error
Solution
Event Data Acquisition Function Error
KONICA MINOLTA.
(Although the transmitting phase response MSG is

OK, the function for Data acquisition shows No
event,.)
0025
Timeout of Driver transmitting check MSG
(Transmitting check MSG from the driver task is tim-
KONICA MINOLTA.
eout.)
0026
Detection of Internal Contradiction
(Unknown event is detected. Condition value is not
KONICA MINOLTA.
correct or so on.)
0027
Transmission / Receiving collision
Try communication again.
(Receiving is detecting during transmitting processing)
10.11.10 Troubleshooting for CS Remote Care

If communication is not done properly during use of the modem, check the condition by following the procedures shown below.
1. Shift the screen in the order of [Service Mode] [CS Remote Care] [Detail Setting].
At this time, in the cases of Initial transmitting / Administrator transmitting / Maintenance Start transmitting
/ Maintenance Finish transmitting, the communication result will be displayed at the top of the screen.
* For the communication result, the following message will be displayed based on its success or failure.
Display of
Cause
Solution
Communication result
Communicating
Communication
Although the machine tries to commu-
trouble with the
nicate with the Center, there is any
Center
trouble and the communication com-
Complete success-
See the list of error message and

confirm the corresponding point.
(See P.234)
pletes unsuccessfully.
fully
Modem trouble
Although the machine tries to communicate with the Center, there is any
trouble in the modem.
Check if the Power of modem in

ON.
Check if there is any problem in
connection between the modem
and the main unit.
Busy line
Although the machine tries to communicate with the Center, the line to the
Communicate with the Center

again.
Center is busy.
No response
Although the machine tries to communicate with the Center, there is no

response from the Center.
Communicate with the Center

again.
Check the communication environment of the Center side.
237
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Error code
10. SERVICE MODE
10. SERVICE MODE
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10.12 System 2
10.12.1 Data Capture
Set the availability/unavailability of the capture of the print job data.
Keeping the print data captured allows the reproduction of a print with which a trouble occurred.
(For particulars, see "IV. Troubleshooting" of "Field Service IC-204.")
10.12.2 Paper Size Setting
Set the paper size of LU.
A. Procedure

Press [System 2].

Press [Paper Size Setting].
3. "Paper Size Setting screen"

Select [Tray 3] or [LCT] and press [Paper size].
4. Press [A4] or [81/2 x 11].

5. Press [OK] twice to return to [System Input screen].
10.12.3 DipSW Setting

Set the software DipSW.
Note
Be sure not to change the setting of DipSW that is not given in this service manual.
A. Procedure

Press [System 2].

Press [DipSW Setting].
3. "Software Switch Setting screen"

Press [SW No.].
4. Press the [+]/[] or numeric keys to enter the DipSW No.

In "SW Setting value", 8-bit data of the DipSW number selected is displayed in binary digit and hexadecimal digit.
5. Press [Bit No.].

6. Press the [+]/[] or numeric keys to enter the bit number.
7. Press either of [OFF (0)] or [ON (1)] of "Bit Data" to set a value.
8. Press [Set].
9. Repeat steps 3 to 8 to set necessary software DipSW.
10. Press [OK].
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10. SERVICE MODE
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B. List of software DipSW

Note
Be sure not to change bits with no particular reference made of the function.
DIPSW No. Bit
DipSW1
Function
Operation at key counter
0
Ignore.
removal
1
PM counting method of A3 (11
1
Decide promptly
Default setting
Japan
Inch
Metric
as a jam.
1 count
2 counts
x 17)
2
Restriction of the FS-510 sta-
None
Stop once at 20
No toner stop condition 1
Decided by
Stop at once
DipSW3-2
after paper exit.
pled copy count

DipSW2
DipSW3
DipSW4
copies.
SC latch (fusing SC)
Latch released
Latched`
No toner stop condition 2
When a job
Stop at the break
completed
of the copy print.
Detection of the toner level
*1
*1
(toner supply display)
*1
*1
Print stop condition after toner
*2
*2
1
1
supply display
*2
*2
Job stop when there remains
Not stop
Stop
no toner
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10. SERVICE MODE
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DIPSW No. Bit

DipSW5
Function
Default setting
Japan
Inch
Metric
Toner save setting
*3
*3
*3
*3
Not rotate
Rotate
6
DipSW6
Preliminary drum rotation of

when the power is on
DipSW7
DipSW8
Selection of K size for machine
Metric series
Corresponding
dispatched to Taiwan (bypass)
size
to K size
Selection of the non-image
Square erase
Diagonal erase
Print inhibition when getting at
auto erase mode
Invalid
Valid
PM
240
DIPSW No. Bit

DipSW9
DipSW10
DipSW11
DipSW12
DipSW13
10. SERVICE MODE

Function
Default setting
Japan
Inch
Metric
Jam code display
Not displayed
Displayed
Print count setting up to the
*4
*4
print inhibition when getting at
*4
*4
PM
*4
*4
Jaggy filter selection
OFF
ON
Discrimination level of the non-
*5
*5
image auto erase mode
*5
*5
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10. SERVICE MODE
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DIPSW No. Bit

DipSW14
DipSW15
Function
Default setting
Japan
Inch
Metric
Stop/non-stop due to overload
Stop at 400
Not stop
when not connected to FS/job
sheets
tray.
DipSW16
Fusing temperature while in the
*6
*6
low power mode
*6
*6
Heater operation
Print permission before con-
Heater turns ON Heater is OFF while

at all times.
in the sleep mode.
Permit
Prohibit
1
0
ducting TCR adjustment
DipSW17
Dot diameter adjustment con-
*7
*7
trol
*7
*7
0/1
Foolscap size setting
*8
*8
*8
*8
1
2
*8
*8
Separation claw operation OFF
Normal
OFF
mode (for destination to China)
242
DIPSW No. Bit

DipSW18
10. SERVICE MODE

Function
Separation of a defective part
Default setting
Japan
Inch
Metric
Normal
Separated
Normal
Separated
from the tray 1 (upper stage of

the main body)
1

from the tray 2 (lower stage of
the main body)
Normal
Separated
Normal
Separated
Normal
Separated
from the tray 3 (PC-202 upper

stage/PC-402)
5

from the tray 4 (PC-202 lower
stage)

from the tray 5 (LU)
DipSW19
Normal
Separated
Normal
Separated
from the printer controller (IC)

1

from the FAX kit (FK)
Normal
Separated
from HDD
4
Normal
Separated
Normal
Separated
Normal
Separated
Normal
Separated
0
0
from DF
DipSW20

from the network

from IEEE1284

from USB
Normal
Separated
from SD
6
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DIPSW No. Bit

DipSW21
Function
Default setting
Japan
Inch
Metric
Platen/ADF size recognition
81/2 x 14
Foolscap
0
0
switchover
3
Platen small size (81/2 x 11/A4
*9
*9
Tray full detection at the exit of
Not detected
Detected
Not detected
Detected
or less) setting
DipSW22
DipSW23
100 sheets while in the FS

non-staple (FS-510)
5
Tray full detection at the exit of

100 sheets while in the FS staple (FS-510)
DipSW24
244
Mixed original direction setting
Not detected
Detected
DIPSW No. Bit

DipSW25
10. SERVICE MODE

Function
Default setting
Japan
Inch
Metric
Switchover of the TSL control
Normally
All OFF
Polygon motor stop timer
15 seconds
30 seconds
Reference image position for
At the center
On the rear
Density setting when the
*10
*10
printer toner save function is
*10
*10
selected.
*10
*10
Image leading edge position
*11
*11
adjustment while in the image
*11
*11
rotation
*11
*11
*11
*11
ON/OFF
DipSW26
bypass custom paper
DipSW27
DipSW28
side of paper
Image leading edge position
*12
*12
adjustment while in the platen
*12
*12
memory copy
*12
*12
*12
*12
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DIPSW No. Bit

DipSW29
DipSW30
DipSW31
DipSW32
DipSW33
Function
Default setting
Inch
Metric
Transfer/separation output
*13
*13
selection of the user paper
*13
*13
(tray)
*13
*13
TSL (transfer exposure lamp)
*14
*14
control of the user paper (tray)
*14
*14
Transfer/separation output
*15
*15
selection of the user paper
*15
*15
(bypass)
*15
*15
TSL control of the user paper
*16
*16
(bypass)
*16
*16
FCOT-EE setting
No pre-scan
Pre-scan
Switchover of the punch hole
*17
*17
number (PU)
*17
*17
Mixplex function provided/not
Provided
Not provided
provided
246
Japan
DIPSW No. Bit

DipSW34
10. SERVICE MODE

Function
System ON/OFF while in the
0
ON
1
OFF
Default setting
Japan
Inch
Metric
sleep or the power switch

(SW2) OFF
1
FS-510 paper exit tray position
2
3
4
Print start permission when
USB function
*18
*18
*18
*18
*18
*18
Permit
Prohibit
0
0
SD-502 is supplied with paper.
DipSW35
ISW mode
Printer mode
Engine power source control
Power OFF
Power not OFF
IPX used or not used
Not used
Used
Telnet used or not used
Not used
Used
Fusing temperature setting
*19
*19
by the SC detection
DipSW36
when normal paper is selected
*19
*19
*20
*20
*21
*21
when thick paper, envelope or

label is selected
5

when thin paper is selected.
*22
*22
when OHP is selected.
*22
*22
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10. SERVICE MODE
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*1
Toner level detection (toner supply display)
Set the copy count that is printed until the print operation is terminated from the toner near empty is displayed after the toner level sensor (PZS) detects toner
empty for a certain period of time.
Mode
4-1
4-0
After 0 print or its equiva-
4-3
4-2
5-6
5-5
lent
After 100 print or its
equivalent
equivalent
equivalent
*2
Print stop condition after the toner supply display
Set the copy count that is printed until the print is prohibited after a message set by DipSW4-0/1 is displayed.
Mode
100 prints or its equivalent
*3
Toner save setting
Toner consumption can be reduced by bringing the

developing bias and the charging grid potential down
below 50V (20 steps). And it is also possible to
increase the image density a little by bringing the
potential up above 50V (20 steps).
Mode
No adjustment made
Toner consumption
increased (Image density

increased)
Toner consumption
reduced (Image density
reduced)
No adjustment made
*4
Setting of the print count made up to the time of

the print inhibition when gettint to PM
When getting at DipSW8-2PM with the print inhibition

set to "1," the print stops after getting at the PM
count shown on the right.
248
12-5
12-4
12-3
1000 prints
Mode
2000 prints
3000 prints
4000 prints
5000 prints
*5
10. SERVICE MODE
Discrimination level of the non-image auto erase

mode
This setting is made in the non-image erase mode of

an applicable function. The image area detection
threshold value is set when the non-image erase
function set by the administrator is set to no limit.
Mode
Corresponding to dark
mode.
Standard
Corresponding to light
interference
Fusing temperature while in the low power
Set the fusing temperature while in the low power
13-6
original
*6
13-7
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Mode
16-1 16-0
The fusing heater lamps /1 (L2) and /2
(L3) turn on when the thermistors /1

(TH1) and /2 (TH2) are respectively at
70 C, and turn OFF when they are at
80 C.
(L3) turn ON when the thermistors /1
130 C.
160 C.
80 C.
*7
Change the timing when the dot diameter adjustment

is made.
Mode
16-7
16-6
At all times
None
The humidity is 60% or

more and the power
switch turns OFF for more
than 8 hours.
The power switch turns
OFF for more than 8
hours.
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10. SERVICE MODE
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*8
Foolscap size setting
Set the definition of the foolscap size.
17-2
17-1
17-0
81/2 x 13
Mode
8 /4 x 13
8 /8 x 13 /4
8 x 13
1
1
*9
Platen small size (81/2 x 11/A4 or less) setting
Default setting is "1" for inch and "0" for metric.
Mode
21-5
A notice is made in a size detected by
APS.
1
A notice is made as A4 (Japan) /

81/2 x 11 (inch) size.
*10 Density setting when selecting the printer toner

save function.
When "Toner save mode" for the printer driver turns
ON, set the printer density in the range shown in the
table.
27-7
27-6
27-5
Standard
Mode
4 (thin)
+1
+2
+ 3 (dense)
*11 Adjustment of the image leading edge while in

the image rotation
Mode
28-3 28-2 28-1 28-0
+ 0 mm
+ 0.5 mm
occurs a leading edge slippage of 3 to 4 mm on the
0.5 mm
back page.
+ 3.5 mm
3.5 mm
While in the location in the 1-sided/2-sided copy,

adjust the slippage at the leading edge when there
*12 Adjustment of the image leading edge position

while in the platen memory copy
Mode
28-7 28-6 28-5 28-4
+ 0 mm
+ 0.5 mm
Adjust the discrepancy when the image leading edge
0.5 mm
position is slipped.
+ 3.5 mm
3.5 mm
While in the platen copy, the paper exit direction is

reversed for the normal print and the memory print.
250
10. SERVICE MODE
*13 Selection of the transfer/separation output of the

user paper (tray)
Set the transfer/separation output that is applicable
when selecting the user paper in [Paper type] of [Utility menu].
29-2
29-1
Normal paper (Japan)
Mode
Normal paper (inch)
Normal paper (metric)
Thick paper
Thin paper
Recycled paper
*14 TSL control of the user paper (tray)

Set the TSL control that is applicable when selecting
the user paper in [Paper type] of [Utility menu]. When
selecting "Switch over depending on the environment," conduct the TSL control by switching over
"Normal ON control"/"All OFF" according to the
29-0
Mode
29-4
29-3
Normal ON control
All OFF
Switching over depending
on the environment
humidity detected by the humidity sensor (HUMS).

*15 Selection of the transfer/separation output of the
user paper (bypass)
When selecting the bypass tray, set the transfer/separation output that is applicable when the user paper
30-2
30-1
Normal paper (Japan)
Mode
30-0
0
Normal paper (inch)
is selected in [Specialty paper] of "Change Tray set-
Normal paper (metric)
tings" or when it is selected in [Paper type] of [Utility
Thick paper
menu].
Thin paper
Recycled paper
*16 TSL control of the user paper (bypass)

When selecting the bypass tray, set the TSL control
that is applicable when the user paper is selected in
[Specialty paper] of "Change Tray settings" or when it
is selected in [Paper type] of [Utility menu].
When selecting "Switch over depending on the envi-
Mode
30-4
30-3
Normal control
All OFF
Switching over depending
33-1
33-0
on the environment
ronment," conduct the TSL control by switching over

"Normal control"/"All OFF" according to the humidity
detected by the humidity sensor (HUMS).
*17 Switchover of the punch hole number (PU)
While in the use of PU-501, set the number of punch
holes to be displayed on the operation board. This
can be set regardless of the destination of the main
Mode
2 holes (Japan)
3 holes (inch)
body.
4 holes (metric)
Default setting is 3 holes for inch and 4 holes for met-
4 holes (Sweden)
ric.
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10. SERVICE MODE
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*18 FS-510 paper exit tray position

Set the stop position of the paper exit tray.
34-3
34-2
34-1
Not fixed
Mode
Tray 1
Tray 2
Tray 3
Folding/stitch-and-fold
tray (SD)
Not fixed
*19 Fusing temperature setting while in the selection

of plain paper
When there occurs a problem (insufficient fusing,
large paper curl) with fusibility while in the selection of
plain paper, change the fusing set temperature.
Countermeasure
36-3
36-2
Standard
Mode
Standard + 10 C
Standard + 5 C
Standard 10 C
1) Increase the temperature: To suppress a jam

due to an insufficient fusing and the wind-up of
paper around the roller.
2) Decrease the temperature: To suppress a
paper curl and the undulation of paper.
of thick paper, envelope, label.
When there occurs a problem (insufficient fusing) with
fusibility while in the selection of thick paper, envelope
Mode
36-4
Standard
Standard + 10 C
and label, change the fusing set temperature. (For

countermeasure, see *19.)
of thin paper
When there occurs a problem (insufficient fusing) with
fusibility while in the selection of thin paper, change
Mode
36-5
Standard
Standard + 10 C
the fusing set temperature. (For countermeasure, see

*19.)
of OHP
When there occurs a problem (insufficient fusibility
and large paper curl) with fusibility while in the selection of OHP, change the fusing set temperature. (For
countermeasure, see *19.)
252
36-7
36-6
Standard
Mode
Standard + 10 C
Standard 20 C
Standard 10 C
10. SERVICE MODE
10.12.4 ISW
bizhub 500 / 420
For particulars, see "5. FIRMWARE VERSION UP".

(See P.95)
10.12.5 Option
Let the main body recognize the installing condition of the optional HDD and FAX.
A. Procedure

Press [System 2].

Press [Option].
3. "Option screen"
Press [Installed] or [Not Installed] to select the installation or non-installation of the HDD and FAX.
4. Press [OK].
10.12.6 Trouble Reset

After completion of the handling of a trouble related to the fusing system, release the trouble.
Note
When a trouble related to the fusing system occurs, the software DipSW3-1 (SC latch) is set to "1"
("0" for default). This adjustment is used to return this to the default condition (normal operation).
When an SC code is displayed on the touch panel, you cannot enter the service mode. Accordingly, the following shows the method for resetting a trouble from the power-off condition.
A. Procedure
1. Turn ON the main power switch (SW1).

2. With the Utility/Counter key pressed, turn ON the power switch (SW2).
3. Press [Trouble reset] to release a trouble with [OK] displayed.
4. Turn OFF and ON the power switch (SW2).
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10. SERVICE MODE
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10.13 List Output

10.13.1 List output
Outputs various types of lists.
Lists that can be output are as shown below.
Machine Management List
Adjustment List
Service Parameter
Protocol Trace Last
Protocol Trace Error
Fax Setting List
A. Prearrangement
Set A4S (for metric) or 8.5 x 11S (for inch) size paper in one of the trays.
B. Procedure

Press [List Output].
2. "List Output screen"

Press the list to output for selection.

The list selected is output.
4. "List Output screen"

When outputting other lists, repeat steps 2 to 3.
5. Press [END].
Service Mode screen appears.
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10.14 Test Mode

10.14.1 Test pattern list
The following test patterns can be output.
Full Image Halftone (No. 1)
Gradation Pattern (No. 2)
Beam Gap Check (No. 11)
Line Check Pattern (No. 16)
Note
Be sure not to output a test pattern that is not given in this service manual.
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10. SERVICE MODE
No.1
Overall halftone (8-bit output)
[Check item]
When the density is set at 70 (halftone)
When there are white stripes or black stripes, check to see if an abnormality is found with the scanner
system or process system
[Recommended sections to be checked]: Developing unit, cleaning glass, charging corona, transfer/separation corona, scanner mirror, slit glass and original glass
When the density is set at 0 (white)
When an image fogging occurs, check the process system to see if an abnormality is found with it.
[Recommended sections to be checked]: Charging corona, and the contact of a high voltage power
source
When the density is set at 255 (black)
When the density is thin, check the process system to see if an abnormality is found with it.
[Recommended sections to be checked]: Write unit
Test pattern
When the density is set at 70.
50gaf3c007na
256
No.2
10. SERVICE MODE
Gradation pattern
[Check item]
When fogging appears or density is thin, check the process system and the gamma correction to see if which
is defective.
Regardless of this test pattern being normal, any trouble is found with the print image, the image processing
system or scanner system is considered defective.
Test patterns
50gaf3c013na
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10. SERVICE MODE
No.3
Gradation pattern (8-bit output)
[Check item]
Check to see if the laser output of LD1/LD2 is uniform and if the gradation is reproduced without a break.
[Recommended sections to be checked]: Write unit, and LD offset adjustment
*
For LD offset adjustment, see "10.4.11 LD1 Offset Adj. / LD2 Offset Adj.".
(See P.172)
Test pattern
LD1 LD2
50gaf3c008na
258
No.5
10. SERVICE MODE
Gradation pattern (8-bit output)
[Check item]
Check the pattern to see if the laser output of LD1/LD2 is uniform with the gradation continuously reproduced.
[Recommended checkpoints]: Write unit, LD offset adjustment
*
For LD offset adjustment, see "10.4.11 LD1 Offset Adj. / LD2 Offset Adj.".
(See P.172)
Test pattern
LD1 LD2
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10. SERVICE MODE
No.11
Beam check (8-bit output)
[Check item 1]
Check to see if there is a difference in density found with the solid black pattern in the main scan and sub
scan directions.
[Recommended sections to be checked]: Charging corona, transfer/separation corona, developing unit,
and write dust-proof glass.
[Check item 2]
Check to see if an image crawling occurs with the gradation pattern at the leading edge and/or trailing
edge of the test pattern in the sub scan direction.
[Recommended sections to be checked]: Transfer/separation corona
Test pattern
[1]
[2]
50gaf3c010na
[1] Solid black pattern
260
[2] Gradation pattern
No.16
10. SERVICE MODE
Linearity evaluation pattern (1-bit error diffusion output)
[Check item]
Judge from this test pattern whether the scanner system or the printer system is abnormal.
Items that can be checked include main scan magnification, sub scan magnification, image skew, and leading
edge timing of the printer system. If the copy image is defective despite no abnormality being visible on the
test pattern, the scanner system is defective.
Test pattern
[1]
237mm
20mm
31mm
190mm
0m
28
205.7mm
28
0m
190mm
[1]
190mm
50gaf3c011na
[1] Edge of paper
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10. SERVICE MODE
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10.14.2 Test pattern output

There are two methods provided for the test pattern output.
Output it by selecting the item of each test pattern. (Procedure A)
Output it by specifying the test pattern number. (Procedure B)
Note
Be sure not to output a test pattern that is not given in this service manual.
A. Procedure for a test pattern output

Press [Test Mode].
2. "Test Mode screen"

Press either of the following: [Full Image Halftone], [Gradation Pattern (No. 2)], [Gradation Pattern (No. 3)],
[Gradation Pattern (No. 5)], [Beam Gap Check] and [Line Check Pattern].
3. Screen for each pattern

When specifying any density, enter a density value through [+]/[] keys and press [Setting].
When selecting an overall halftone, it is possible to select a halftone density by [0 (White)], [70 (Halftone)]
and [255 (Black)].

Select A3 (for metric) or 11 x 17 (for inch) paper and press the Start key.
6. Check the test pattern and press [END].

7. When outputting other test patterns, repeat steps 2 to 6.
8. Press [OK].
B. Procedure for any test pattern output

Press [Test Mode].

Press [Test pattern output mode].
3. "Test Pattern Output Mode screen"

Press [Pattern No.] and specify a test pattern number through the [+]/[] keys.
When specifying any density, press [Density Setting], enter a density value through the [+]/[] keys and
press [Setting].

With A3 (for metric) or 11 x 17 (for inch) paper selected, press the Start key.
6. Check the test pattern and press [END].

7. When outputting other test patterns, repeat steps 3 to 7.
8. Press [OK].
262
10. SERVICE MODE
Conduct a continuous print operation test.

In this mode, the following items can be selected.
Intermittent Copy Mode
The machine shifts into the ready condition after completion of the print operation of the set copy count and
conducts the same operation after waiting for 0.5 sec.
Paperless Running Mode
In this mode, no paper is fed and none of the paper detection/jam detection is made while in the operation. The
print operation is made nearly at the same timing as the usual operation with no transfer/separation control
made. The machine shifts into the ready condition after completion of the print operation of the set copy count
and conducts the same operation after waiting for 0.5 sec.
Paperless Mode
With no paper fed and none of the paper detection/jam detection made, the print operation is made nearly at
the same timing as the usual operation.
Paperless Endless Mode
The operation is made with the set copy count automatically set with no limit. Like the paperless mode, the print
operation is made nearly at the same timing as the usual operation with no paper fed and none of the paper
detection/jam detection made.
Progress Running Mode
The combined operation of the paperless endless mode plus the scan operation and the stepped change of the
auto paper feed is made. This is not use in the field.
A. Procedure

Press [Test Mode].

Press [Running mode].
3. "Running Mode screen"

Press [Intermittent Copy] to [Paperless Endless] and select a test mode to be conducted.
4. Press the Start key to start the running test.

5. Press the Stop key to stop the running test.
6. Turn off and on the power switch (SW2) to exit the running test mode.
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10.14.3 Running Mode
10. SERVICE MODE
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10.15 Fax setting

For particulars of the setting, see FK-502 Service Manual.
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10. SERVICE MODE
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10.16 Enhanced Security

10.16.1 List of the security setting
Adjustment/setting item
Enhanced Security
CE Password
Administrator Password
Administrator Feature Level
Level 1
Level 2
Prohibit
CE Authentication
ON
OFF
10.16.2 Start and termination of the security mode

Security setting is made on "Enhanced security screen" in the security mode.
A. Procedure

With none of the service mode items selected, press the copy count setting keys in the order shown
below.
Stop 0 C
2. "Enhanced Security screen"

The security mode is put in the start-up condition and the security setting is available.

When selecting either of the service mode items, the selected service mode item screen is displayed and
the security mode terminates.
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10. SERVICE MODE
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10.16.3 CE Password
Set a password to enter the service mode.
Note
Be sure to avoid using as a password the name and the birth day that can be easily suspected by
other people.
CE must not leak the password to other people.
The CE password is valid when the CE authentication function is valid.
(See P.267)
A. Procedure

Press [CE Password].
2. "CE Password Setting screen"

Enter 8 digits of a password currently set in the alphanumeric characters and press [END]. "92729272" is
set for default.
3. Enter 8 digits of a new password in the alphanumeric characters and press [END].
4. Enter 8 digits of the re-entered password in the alphanumeric characters and press [END] to make the
setting valid with [Enhanced Security screen] displayed.
If you want to make the entered setting invalid, press [Cancel].
10.16.4 Administrator Password

Set a password to enter the administrator setting of the set-up menu.
The administrator password can also be set from the administrator setting of the set-up menu.
Note
Be sure to avoid using as a password the name and the birth day that can be easily suspected by
other people.
A. Procedure

Press [Administrator Password].
2. "Administrator Password Setting screen"

Enter 8 digits of a new password in the alphanumeric characters and press [END]. "12345678" is set for
default.
3. Enter 8 digits of the re-entered password in the alphanumeric characters and press [END] to make the
setting valid with [Enhanced Security screen] displayed.
If you want to make the entered setting invalid, press [Cancel].
266
10. SERVICE MODE
Set the range of the administrator feature to be displayed in Administrator Setting in the Utility menu. When the
setting is made to [Prohibit] in this feature, the following features are not displayed.
A. Features not diaplayed
[3] Administrator setting
[1] System setting
[0] Standard Size setting
B. Procedure

Press [Administrator Feature Level].
2. "Administrator Feature Level Setting screen"

Select either of [Level 1]/[Level 2]/[Prohibit].
3. Press [END] to register the feature selected.
10.16.6 CE Authentication
Set the request or non-request of the password entry to enhance the security level in the service mode.
A. Procedure

Press [CE Authentication].
2. "CE Authentication screen"

Press [ON] or [OFF].
3. Press [END] to decide the setting with [Enhanced Security screen] displayed.
267
bizhub 500 / 420
10.16.5 Administrator Feature Level
10. SERVICE MODE
bizhub 500 / 420
10.17 Billing Setting

10.17.1 List of the billing setting
Adjustment/setting item
Billing Setting
Counter Setting
Management Function Choice
10.17.2 Start and termination of the billing setting mode

The billing setting is made in [Billing Setting screen] in the billing setting mode.
A. Procedure

With none of the service mode items selected, press the copy count setting keys in the order shown
below.
Stop 9
2. "Billing Setting screen"

The billing mode is put in the start-up condition and the billing setting is available.

When selecting either of the service mode items, the billing setting mode is terminated and the selected
service mode item screen is displayed.
268
10. SERVICE MODE
10.17.3 Counter Setting
Total Counter Mode
Large Size Counter Mode
bizhub 500 / 420
Set the counter mode of the counters of 2 types.
A. Procedure

Press [Counter Setting].
2. "Counter Setting screen"

Select a count mode of the total counter in either of [Mode 1] or [Mode 2].
Total counter count mode ([Mode 1] for the initial setting)
[Mode 1]: 1 count for each print
[Mode 2]: 2 counts depending on the paper size and the print mode.
3. Select a count mode of the large size counter from among the following items.
Large size counter count mode ([No Count] for the initial setting)
[No Count]
[A3/11 x 17]
[A3/B4/11 x 17/81/2 x 14]
[A3/11 x 17/B4/81/2 x 14/Foolscap]
Note
When selecting other than [No count], the count-up is as shown below in the combination of the
total counter and the counter mode.
Copy mode
1-sided copy
Print paper size
Other than the
2-sided copy
Specified size
specified size
Count mode selection of the total counter
Other than the
Specified size
specified size
Mode 1 Mode 2 Mode 1 Mode 2 Mode 1 Mode 2 Mode 1 Mode 2
Number of
Total counter
counts
Size counter
2-sided total counter
4. Press [END].
269
10. SERVICE MODE
bizhub 500 / 420
10.17.4 Management Function Choice

Set the installation/non-installation of the key counter and the management device.
A. Procedure

Press [Management Function Choice].
2. "Management Function Choice screen"

Select the management device.
Note
The initial setting is [Unset].
3. Select the message type.

4. Press [END].
270
11. MECHANICAL ADJUSTMENT
bizhub 500 / 420

11.1 Mis-centering adjustment of the trays 1 and 2
This adjustment is made when there occurs a mis-centering that cannot be adjusted in the service mode.
A. Procedure
1. Pull out the tray [1].

2. If there remains any paper, remove it thoroughly.
3. When the paper guide [2] is set to the small size
position, expand it.

5. Move the paper guide [2] and adjust the center
position with the marking-off [4] as a guide.
6. Tighten the 2 screws [3].
[4]
[3]
[1]
[2]
50gaf3c014na
7. Set the tray with paper put in it.

8. Conduct the copy/print operation and check to
see if the mis-centering between the center [1] of
[2]
the paper and the center [2] of the copied image

is within a standard value ( 3 mm or less [3]).
[3]
9. When the value is not within the standard value,

repeat steps 1 to 8 until the standard value can be
[1]
obtained.
50gaf3c015na
271
bizhub 500 / 420
11.2 Mis-centering adjustment of the bypass tray

This adjustment is made when there occurs a mis-centering that cannot be adjusted in the service mode.
A. Procedure
1. Open the bypass tray [1].

2. If paper is set, remove it.
3. When the paper guide [2] is set to the small size
position, expand it.

5. Move the paper guide [2] and adjust the center
position with the marking-off [4] as a guide.
[4]
[2]
[2]
[1]
[3]
50gaf3c016na
7. Set paper in the bypass tray.

8. Conduct the copy/print operation and check to
see if the mis-centering between the center [1] of
[2]
the paper and the center [2] of the copied image

is within a standard value ( 3 mm or less [3]).
[3]
9. When the value is not within the standard value,

repeat steps 1 to 8 until the standard value can be
[1]
obtained.
50gaf3c017na
272
12. JAM CODE
bizhub 500 / 420
TROUBLESHOOTING
12. JAM CODE
12.1 Jam code list
Classification Jam code
Cause
Resulting
Correction
Bypass
Tray 1
Tray 2
J-1000
J-1100
J-1200
During operation
operation
The vertical conveyance sensor (PS2)
If there is a
Pull out the paper from
does not turn ON within a specified
sheet of paper
the bypass tray and
period of time after the feed clutch
being printed
remove jammed paper
/BP (CL6) turns ON.
when a jam
if any.
The registration sensor (PS1) does
occurs, the main
Open the vertical con-
not turn ON within a specified period
body completes
veyance door and ADU
of time after the feed clutch /1 (CL4)
the paper exit
and remove jammed
turns ON.
before stopping
paper if any.
operations.
Pull out the tray and
remove jammed paper
period of time after the feed clutch /2
if any.
(CL5) turns ON.

J-1201

of time after the vertical conveyance
sensor (PS2) turns ON.
PC-202
J-1300
PC-402
PC-202
J-1301
The vertical conveyance sensor /3
Open the right door of
(PS117) does not turn ON a specified
PC and the vertical
period of time after the paper feed
conveyance door of the
motor /3 (M122) turns ON.
main body and remove
jammed paper if any.
does not turn ON a specified period
of time after the paper feed motor
remove jammed paper
(M1) turns ON.
if any.

of the main body does not turn ON
within a specified period of time after
the vertical conveyance sensor /3
(PS117) of PC-202 turns ON.
PC-402
J-1302

the vertical conveyance sensor (PS2)
of PC-402 turns ON.
J-1305
The paper feed sensor (PS1) does not

turn ON within a specified period of
time after the paper feed motor (M1)
turns ON.
273
12. JAM CODE
bizhub 500 / 420
Cause
Resulting
Correction
PC-402
J-1306
J-1307
J-1308
During operation
operation
If there is a
turn OFF within a specified period of
sheet of paper
PC and the vertical
time after the PS1 turns ON.
being printed
when a jam
occurs, the main
period of time after the paper feed
body completes
sensor (PS1) turns ON.
the paper exit
remove jammed paper
before stopping
if any.
operations.

J-1309
When a paper feed start signal is sent

out to PC-402 from the main body, a
recieve signal from PC-402 is not sent
out within a specified period of time
after that.
J-1311
The shift position sensor (PS11) does

of time after shift home sensor (PS12)
turns OFF.
PC-202
J-1400

(PS126) does not turn ON within a
specified period of time after the
paper feed motor /4 (M123) turns ON.
J-1401

specified period of time after the vertical conveyance sensor /4 (PS126)
turns ON.
LU
J-1500
J-1501
The LU exit sensor (PS155) does not
Open the upper door of
LU and the vertical
time after the feed clutch (CL151)
turns ON.

the LU exit sensor (PS155) turns ON.
Other
J-2001
Emergency stop jam of the system
The main body
Remove jammed paper
J-2002
While in the print, the vertical convey-
and the optional
if any from optional
ance door opens.
device stop
device / main body.
The ADU door is opened while in
immediately.
J-2003
printing.
J-2004
PC
J-2005
The ADU is opened while in printing.

While in the print, the right door
opens.
274
12. JAM CODE

Cause
Resulting
Correction
FS
FS-510
J-2006
J-2007
During operation
operation
While in the print, the front door
The main body
Remove jammed paper
opens.
and the optional
if any from optional
While in the print, the guide plate
device stop
device / main body.
switch (SW4) turns OFF.
immediately.
While in the up drive operation of the

tray, the shutter switch (SW2) turns
ON.
FS-511
J-2008
RU
J-2009
While in the print, FS-511 comes off

from the main body.
While in the print, the front door
opens.
FS-511
J-2010
While in the print, the upper door

opens.
MT
While in the print, the right door

opens.
SD
While in the print, the saddle-stitching

section opens.
Conveyance
J-3000
The printer sec-
Open ADU and remove
not turn OFF within a specified period
tion stops
of time after the registration clutch
immediately.
(CL1) turns ON.

J-3100
The fusing exit sensor (PS3) does not

time after the registration clutch (CL1)
turns ON.
Fusing
J-3200
The fusing exit sensor (PS3) does not

Reversing
J-3300
The reverse sensor (PS27) does not

time after the fusing exit sensor (PS3)
turns ON.
J-3400
The reverse sensor (PS27) does not

Other
J-5001
A print start signal is not sent out from
The main body
the overall control board (OACB)
and the optional
PC, the vertical convey-
device stop
ance door of the main
the registration sensor (PS1) turns
immediately.
body and ADU and
ON.
remove jammed paper

if any.
275
bizhub 500 / 420
12. JAM CODE
bizhub 500 / 420
Cause
Resulting
Correction
DF
J-6001
J-6002
J-6101
During operation
operation
The DF open/close switch (SW3)
The DF stops
Open the open/close
turns OFF while in the DF operation.
immediately. If
cover and remove
The cover open/close sensor (PS7)
there is paper
turns OFF while in the DF operation.
being trans-
While in the single sided mode, the
ferred or having
original feed sensor (PS6) does not

time after the original feed motor (M1)
turns ON.
J-6102
When feeding the first original in the

mode other than the single sided
mode, the original feed sensor (PS6)
period of time after the original feed
motor (M1) turns ON.
J-6103
When feeding the second original in

the mode other than the single sided
J-6104
When feeding the third original in the

J-6105

original feed sensor (PS6) does not
J-6106

does not turn OFF within a specified
period of time after the PS6 turns ON.
J-6107

period of time after the PS6 turns ON.
276
been transferred, the main

body completes
the paper exit
before stopping
operations.
12. JAM CODE
Cause
Resulting
Correction
DF
J-6108
J-6201
During operation
operation
The DF stops
Open the open/close
immediately. If
cover and remove
there is paper
being trans-
period of time after the PS6 turns ON. ferred or having

original registration sensor (PS9) does
of time after the feed motor (M1) turns
ON.
J-6202
been transferred, the main

body completes
the paper exit
before stopping
operations.

mode, the original registration feed
sensor (PS9) does not turn ON within
a specified period of time after the
feed motor (M1) turns ON.
J-6203

mode, the original registration sensor
(PS9) does not turn ON within a specified period of time after the feed
J-6204

(PS9) does not turn ON within a specified period of time after the feed
J-6205

original registration sensor (PS9) does
of time after the PS9 turns ON.
J-6206

(PS9) does not turn OFF within a
specified period of time after the PS9
turns ON.
J-6207

turns ON.
277
bizhub 500 / 420
12. JAM CODE
bizhub 500 / 420
Cause
Resulting
Correction
DF
J-6208
J-6301
J-6302
During operation
operation
The DF stops
Open the open/close
immediately. If
cover and remove
there is paper
being trans-
ferred or having
turns ON.
been trans-
ferred, the main
original detection sensor (PS8) does
body completes
the paper exit
of time after the original coveyance
before stopping
operations.

mode, the original detection sensor
(PS8) does not turn ON within a specified period of time after the original
coveyance motor (M2) turns ON.
J-6303

J-6304

J-6305

original detection sensor (PS8) does
J-6306

turns ON.
J-6307

turns ON.
278
12. JAM CODE
Cause
Resulting
Correction
J-6501
J-6502
During operation
J-6308
The DF stops
Open the open/close
immediately. If
cover and remove
there is paper
being trans-
ferred or having
turns ON.
been trans-
While in the idle, the original feed sen-
ferred, the main
sor (PS6) is ON.
body completes
While in the idle, the original registra-
the paper exit
tion sensor (PS9) or the original

detection sensor (PS8) is ON.
J-6503
before stopping
operations.
While In the idle, either of the original

feed sensor (PS6), the original registration sensor (PS9) and the original
detection sensor (PS8) is ON.
J-6504
While in the idle, the original exit sensor (PS10) is ON.
J-6505
While in the idle, the original registration sensor (PS6) or the original exit
sensor (PS10) is ON.
J-6506
While in the idle, any of the original

registration sensor (PS9), the original
detection sensor (PS8) or the original
exit sensor (PS10) is ON.
J-6507
While in the idle, any of the original

feed sensor (PS6), the original registration sensor (PS9), the original
detection sensor (PS8) or the original
exit sensor (PS10) is ON.
J-6601
J-6602
During operation
DF
When idling
operation

original exit sensor (PS10) does not
time after the original coveyance
mode, the original exit sensor (PS10)
period of time after the original coveyance motor (M2) turns ON.
J-6603

period of time after the original coveyance motor (M2) turns ON.
279
bizhub 500 / 420
12. JAM CODE
bizhub 500 / 420
Cause
Resulting
Correction
DF
J-6604
During operation
operation
J-6605
J-6606
The DF stops
Open the open/close
immediately. If
cover and remove
there is paper
being trans-
period of time after the original covey- ferred or having

ance motor (M2) turns ON.
been trans-
ferred, the main
original exit sensor (PS10) does not
body completes
the paper exit
before stopping
operations.

period of time after the PS10 turns
ON.
J-6607

ON.
J-6608

J-7201
FS-511
FS-510
J-7202
When idling
ON.
FS-510
While in the idle, the entrance sensor
FS, RU, MT, SD,
Remove jammed paper
(PS4) is ON.
main body stop
if any from the FS/main
While in the idle, the passage sensor
immediately.
body.
(PS2) of RU turns ON.

While in the idle, the conveyance sensor (PS5) or the stacker sensor (PS8)
is ON.
FS-511
While in the idle, any of the sub tray

exit sensor (PS1), the bypass route
conveyance sensor (PS2), the intermediate conveyance sensor (PS3),
the main route conveyance sensor
(PS4) or the alignment tray sensor
(PS5) is ON.
FS-510
J-7203
SD
J-7204
While in the idle, the stacker sensor

(PS8) is ON.
While in the idle, the the paper exit
sensor (PS20) is ON.
280
12. JAM CODE

Cause
Resulting
Correction
FS-510
J-7205
J-7216
FS-511
When idling
MT
While in the idle, the conveyance sen-
FS, RU, MT, SD,
Remove jammed paper
sor /Up (PS9) or /Lw (PS10) is ON.
main body stop
immediately.
body.
During operation
operation
The entrance sensor (PS4) of FS does

of time after the fusing exit sensor
(PS3) of the main body turns ON.
The path sensor (PS2) of RU does not
time after the fusing exit sensor (PS3)
of the main body turns ON.
FS-510
J-7217
The entrance sensor (PS4) does not

The conveyance sensor (PS5) does
of time after the entrance sensor
(PS4) turns ON.
FS-511
The path sensor (PS2) of RU does not

The sub tray paper exit sensor (PS1)
of FS does not turn ON within a specified period of time after the path sensor (PS2) of RU turns ON.
The main route conveyance sensor
(PS4) of FS does not turn ON within a
specified period of time after the path
sensor (PS2) of RU turns ON.
The bypass route conveyance sensor
(PS2) of FS does not turn ON within a
specified period of time after the path
sensor (PS2) of RU turns ON.
The main route conveyance sensor
turns ON.
The bypass route conveyance sensor
turns ON.
281
bizhub 500 / 420
12. JAM CODE
bizhub 500 / 420
Cause
Resulting
Correction
FS-511
J-7217
During operation
operation
The intermediate conveyance sensor
FS, RU, MT, SD,
Remove jammed paper
(PS3) does not turn ON within a spec-
main body stop
ified period of time after the main
immediately.
body.
route conveyance sensor (PS4) turns

ON.
bypass route conveyance sensor
(PS2) turns ON.
FS-510
J-7218
The conveyance sensor (PS5) does

FS-511
The sub tray exit sensor (PS1) does

turns ON.
FS-510
J-7221
After completion of stapling, the

stacker sensor (PS8) does not turn
OFF within a specified period of time
after the paper exit motor (M1) turns
ON.
FS-511
After completion of stapling, the alignment tray sensor (PS5) does not turn
OFF within a specified period of time
after the paper exit motor (M3) turns
ON.
SD
J-7225
Folding jam
PU
J-7243
Punch jam
FS-510
J-7281
The stapler motor does not return to

the home position within a specified
period of time after the stapler motor
turns ON.
FS-511
The stapler home sensor /Fr (PS22)

/Fr (M16) turns ON.
FS-511
J-7282
The stapler home sensor /Rr (PS25)

/Rr (M17) turns ON.
282
12. JAM CODE

Cause
Resulting
Correction
SD
J-7284
J-7285
During operation
operation
The clincher motor /Fr does not return
FS, RU, MT, SD,
Remove jammed paper
to the home position within a speci-
main body stop
fied period of time after the clincher
immediately.
body.
The registration sensor (PS1) turns
The printer sec-
Open the vertical con-
ON while in idling.
tion stops
veyance door and ADU
immediately.
and remove jammed
motor /Fr turns ON.

The clincher motor /Rr does not
return to the home position within a
clincher motor /Rr turns ON.
MT
J-7290
The conveyance sensor /Up (PS9) or

/Lw (PS10) of MT does not turn ON
the conveyance sensor (PS5) of FS
turns ON.
The conveyance sensor /Up (PS9) or
/Lw (PS10) do not turn OFF within a
specified period of time after PS9 or
J-8100
feed
J-8200
PC-202
When idling
PS10 turn ON.

Paper
J-8300
PC-402
turns ON while in idling.
paper if any.
Open the right door
(PS116) turns ON while in idling.
and remove jammed
paper if any.
turns ON while in idling.

PC-202
J-8400

LU
J-8500
The LU exit sensor (PS155) turns ON
Open the upper door
while in idling.
and remove jammed

paper if any.
Fusing
J-9000
The fusing exit sensor (PS3) turns ON
Open ADU and remove
while in idling.
Reverse
J-9100
The reverse sensor (PS27) turns ON
ADU
J-9200
The ADU conveyance sensor /1
while in idling.
J-9300
J-9701
During operation

reverse motor (M6) turns ON for
reverse rotation.
283
bizhub 500 / 420
12. JAM CODE
bizhub 500 / 420
Cause
Resulting
Correction
ADU
J-9702
J-9703
During operation
operation
The printer sec-
Open ADU and remove
tion stops
specified period of time after the ADU
immediately.
conveyance sensor /1 (PS24) turns

ON.
of time after the ADU conveyance
sensor /2 (PS25) turns ON.
284
13. MALFUNCTION CODE
bizhub 500 / 420

13.1 Malfunction code list
A. Note for use
Turn OFF/ON the power switch (SW2) of the main body when releasing an abnormal condition.
B. Code list
NOTE
For codes with "*" given in the error code column, a message "Turn off the power and turn it on
again" is displayed on the operation panel.
For codes with no "*" given in the error code column, a message "Contact the service" is displayed.
Classification
Code
Causes
Resulting
Estimated abnormal parts
Main body
operation
Drive
C-0201
C-0202
The main body
does not turn ON within a speci-
stops immedi-
fied period of time after the paper
ately to turn OFF
lift motor /1 (M7) turns ON.
the main relay
(RL1).
PC-202

C-0203
LU
C-0204
C-0205
(PS114)
PC control board (PCCB)
(PS123)
The upper limit sensor (PS152)
LU drive board (LTDB)
PC-402
lift motor (M151) turns ON.

C-0206
Paper lift motor (M5) abnormality.
Shift motor (M4) abnormality.
Shift motor (M4)
Shift gate motor (M3) abnormality.
Shift gate motor (M3)

285

Code
Causes
Resulting
Bypass
operation
Drive
C-0207
While in the paper feed, there
The main body
occurs a condition twice in suc-
stops immedi-
Lift sensor (PS23)
cession in which the lift sensor
ately to turn OFF
Feed motor (M9)
the main relay
(RL1).
pick-up solenoid /BP (SD1) turns

ON.
While in the power switch (SW2)
ON, there occurs a condition
twice in succession in which
PS23 does not turn OFF within a
specified period of time after SD1
Main body
turns ON.
Fan
C-0301
Conveyance suction fan (FM5)
Conveyance suction fan
abnormality.
(FM5)
Communication abnormality
nication
between the engine control of the
abnor-
overall control board (OACB) and
mality
that of the printer control board
abnormality
Commu-

C-1001*
(PRCB).
While in the stand-by, an FS
Ready signal cannot be detected
for a specified period of time.
FS
bizhub 500 / 420
Classification
FS
C-1002
FS communication abnormality.
A serial communication is unavail-
able between the FS control

board (FSCB) and the printer
control board (PRCB).
FS-510
C-1003
Flash ROM abnormality.
A checksum error of the flash

ROM is detected.
FS-511
C-1101
Shift motor (M8) drive abnormal-
Shift motor (M8)
ity.
When starting the home position movement, the shift

home sensor (PS10) does not
turn ON a specified period of
time after M8 turns ON.
When starting the shift position movement, PS10 does
not turn OFF a specified
period of time after M8 turns
ON.
286
Classification
Code
Causes
Resulting
FS
operation
FS-511
C-1102
Tray lift motor (M7) drive abnor-
The main body
mality.
stops immedi-
ately to turn OFF
(PS19)
drive, the main tray upper limit
the main relay
sensor (PS19) does not turn
(RL1).
While in the main tray up
ON within a specified period

of time after M7 turns ON.
While in the main tray down
drive, the lock signal of M7 is
detected.
While in the M7 ON, the main
tray upper limit switch (SW2)
or the main tray lower limit
switch (SW3) turns ON.
C-1103
Alignment motor (M5) drive
abnormality.
While in the alignment home

position search, the alignment
(PS9)

turn ON within a specified
ON.
While in the alignment operation, PS9 does not turn OFF
within a specified period of
C-1104
Paper exit roller release motor
Paper exit roller release
(M13) drive abnormality.
motor (M13)
When starting the pressure
position drive, the exit roller
(PS13)
turn ON within a specified

ON.
When starting the separation
position drive, PS13 does not
turn OFF within a specified
ON.
287
bizhub 500 / 420

Code
Causes
Resulting
operation
FS
bizhub 500 / 420
Classification
FS-511
C-1105
The main body
Intermediate conveyance
release motor (M12) drive abnor-
stops immedi-
roller release motor (M12)
mality.
ately to turn OFF
the main relay
(PS12)
(RL1).
When starting the pressure

position drive, the roller
release home sensor (PS12)
does not turn ON within a
specified period of time after
M12 turns ON.
When starting the separation
position drive, PS12 does not
ON.
C-1106
Stapler movement motor (M6)
Stapler movement motor
drive abnormality.
(M6)
While in the home position

search, the stapler home sen-
Stapler home sensor (PS14)

sor (PS14) does not turn ON

While in the 1-staple position
movement, PS14 does not
ON.
C-1107
Stapler motor /Rr (M16) drive
Stapler motor /Rr (M16)
abnormality.
The stapler home sensor /Rr

(PS22) does not turn OFF
PS22 does not turn ON within
a specified period of time
after the OFF of PS22 is
detected.
after M16 turns ON for
reverse rotation.
288
(PS22)
Classification
Code
Causes
Resulting
bizhub 500 / 420
FS
operation
FS-511
C-1108
Stapler motor /Fr (M17) drive
The main body
Stapler motor /Fr (M17)
abnormality.
stops immedi-
ately to turn OFF
(PS25)
(PS25) does not turn OFF
the main relay
(RL1).
The stapler home sensor /Fr

after the OFF of PS25 is
detected.
after M17 turns ON for
reverse rotation.
SD
C-1109
Saddle stapler motor /Fr drive
Saddle stapler motor /Fr
abnormality.
SD control board (SDCB)
When the saddle stapler

motor /Fr is ON, it does not
get off from the home position
time.
After its getting off from the
home position is detected, it
does not get to the home
position within a specified
period of time.
After the saddle stapler motor
/Fr turns ON for reverse rotation, it does not get to the
home position within a specified period of time.
289

Code
Causes
Resulting
operation
FS
bizhub 500 / 420
Classification
SD
C-1110
Saddle stapler motor /Rr drive
The main body
Saddle stapler motor /Rr
abnormality.
stops immedi-
When the saddle stapler
ately to turn OFF
motor /Rr turns ON, it does
the main relay
not get off from the home
(RL1).

period of time.
After its getting off from the
home position is detected, it
does not get to the home
period of time.
After the saddle stapler motor
/Rr turns ON for reverse rotation, it does not get to the
home position within a specified period of time.
C-1111
Paper guide motor (M13) drive
Paper guide motor (M13)
abnormality.
Paper guide home sensor
When M13 turns ON for protrusion, the paper guide
(PS23)

period of time.
When M13 turns ON for evacuation, PS23 does not turn
of time.
C-1112
Staple guide motor (M14) drive
Staple guide motor (M14)
abnormality.
Staple guide home sensor

return operation, the staple
guide home sensor (PS26)
M14 turns ON.
When starting a retraction
operation, PS26 does not
ON.
290
(PS26)
Classification
Code
Causes
Resulting
FS
operation
SD
C-1113
Exit open/close motor (M9) drive
The main body
Exit open/close motor (M9)
abnormality.
stops immedi-
Saddle exit home sensor
ately to turn OFF
(PS18)
contact operation, the sad-
the main relay
dle exit home sensor (PS18)
(RL1).
When starting a pressure

M9 turns ON.
When starting a separation
ON.
C-1114
Folding motor (M10) drive abnor-
Folding motor (M10)
mality.
Folding roller home sensor
The folding roller home sensor
(PS22)
specified period of time after M10

turns ON.
C-1115
Conveyance motor (M8) drive
Conveyance motor (M8)
abnormality.
Within a specified period of

time after M8 turns ON, the
ON of a motor lock signal is
detected for a prescribed
period of time in succession.
A specified period of time
after M8 turns OFF, the OFF
of a motor lock signal is
detected for a prescribed
period of time in succession.
FS-510
C-1116
Exit roller release motor (M6) drive
Exit roller release motor (M6)
abnormality.
Shutter home sensor (PS16)
When the shutter is closed,
the shutter home sensor

(PS16) does not turn ON
When the shutter is open,
PS16 does not turn OFF
291
bizhub 500 / 420

Code
Causes
Resulting
operation
FS
bizhub 500 / 420
Classification
FS-510
C-1117
Alignment motor /Fr (M5) drive
The main body
Alignment motor /Fr (M5)
abnormality.
stops immedi-
Alignment home sensor /Fr
ately to turn OFF
(PS7)
search, the alignment home
the main relay
sensor /Fr (PS7) does not turn
(RL1).

search, PS7 does not turn
OFF within a specified period
C-1118
Exit paddle solenoid (SD2) drive
Exit paddle solenoid (SD2)
abnormality.
While in the paddle evacuation, the exit paddle home
(PS11)
sensor (PS11) does not turn

of time after SD2 turns ON.
While in the paper hold-down
period of time after SD turns
ON.
FS-511
C-1119
Punch motor (M11) drive abnor-
Punch motor (M11)
mality.
The punch encoder sensor

specified period of time after M11
turns ON.
C-1120
drive abnormality (inch system
Hole punch selector motor
only)
(M14)
When starting the punch 2hole position switch drive, the

hole punch position switch
(SW4) is not turned ON in the
the M14 is turned ON.
When starting the punch 3hole position switch drive, the
SW4 is not turned OFF in the
the M14 is turned ON.
292
Classification
Code
Causes
Resulting
Main body
FS
operation
PU
C-1121
Punch motor (M1) drive abnor-
The main body
Punch motor (M1)
mality.
stops immedi-
Punch position sensor /1
The punch position sensors /1
ately to turn OFF
(PS2)
(PS2) and /2 (PS3) do not turn
the main relay
OFF within a specified period of
(RL1).
(PS3)
process
commu-
nication
abnor-
(PRCB)
mality
While in the stand-by, a process
Image
C-2001

Developing motor (M3) speed
speed
abnormality.
abnor-
While M3 is ON, an EM error sig-
mality
nal has been detected 5 times in
Motor
C-2201
succession within a specified

period of time.
C-2202
Drum motor (M1) speed abnor-
Drum motor (M1)
mality.
While M1 is ON, an EM error signal has been detected 5 times in

period of time.
Drum cooling fan (FM4) abnor-
lock
mality.
abnor-
While FM4 is ON, an EM error
mality
signal has been detected 5 times
Fan
C-2301
in succession within a specified

period of time.
C-2302
Developing suction fan motor
(FM6) abnormality.
motor (FM6)

period of time.
C-2303
abnormality.

period of time.
293
bizhub 500 / 420

Code
Causes
Resulting
operation
Main body
bizhub 500 / 420
Classification
High machine inside temperature
The main body
TCR sensor (TCRS)
mality
abnormality.
stops immedi-
around
When the temperature around the
ately to turn OFF
drum is above 58 C
the main relay
Erase lamp (EL) connector slip-off
(RL1).
Abnor-
C-2401
the drum
C-2402
Erase lamp (EL)

abnormality.
When EL turns ON before starting
an initial charging, EL abnormality
has been detected 15 times in
succession at prescribed intervals
after a specified period of time.
Toner bottle phase detection
bottle
abnormality.
Toner bottle position sensor
abnor-
While in the power switch (SW2)
(PS28)
mality
ON, the toner bottle position sen-
Toner
C-2403
sor (PS28) does not turn ON

within a specified period of time
after the toner bottle motor (M10)
turns ON.
Charging abnormality.
If there is a
Charging corona
voltage
An error signal is detected 5
sheet of paper
High voltage unit (HV)
power
times in succession at pre-
being printed,
source
scribed intervals.
the main body
High
C-2701
abnor-
completes the
mality
paper exit to
stop operations. The main
relay (RL1) turns
OFF.
C-2702
C-2703
Transfer lightning abnormality.
The main body
Transfer/separation charger
There occurs a phenomenon 5
stops immedi-
High voltage unit (HV)
times in a job, in which an error
ately to turn OFF
signal is detected 3 times in suc-
the main relay
cession at prescribed intervals.
(RL1).
Separation lightning abnormality.

There occurs a phenomenon 5
times in a job, in which an error
signal is detected 5 times in succession at prescribed intervals.
C-2801
TCR output abnormality.
TCR sensor (TCRS)
When the TCR output is in
excess of 3.0 V.
C-2802

When the TCR sensor (TCRS)
maximum output is 1.0 V or less.
294
Classification
Code
Causes
Resulting
Main body
operation
The main body
TCR sensor (TCRS)
voltage
When the output ripple voltage of
stops immedi-
power
the TCR sensor (TCRS) is less
ately to turn OFF
than 0.5 V.
the main relay
Toner density abnormality.
(RL1).
High
C-2803
source
abnor-
C-2804
mality
When the L detection output is in
(PZS)
excess of 2.6 V before the toner
TCR sensor (TCRS)
remaining sensor (PZS) detects a
no toner condition, toner density

does not recover even when
toner is automatically supplied.
Fusing motor (M11) speed abnor-
Fusing motor (M11)
speed
mality.
abnor-
When M11 is ON, an EM error
mality
signal is detected 30 times in
Motor
C-3201

period of time.
lock
abnormality.
abnor-
When FM2 is ON, an EM error
mality
signal is detected 3 times in suc-
Fan
C-3301
cession within a specified period

of time.
C-3302
abnormality.
When FM8 is ON, an EM error

signal is detected 3 times in succession within a specified period
of time.
Fusing main sensor high temper-
The main body
Thermistor /1 (TH1)
high
ature abnormality.
stops immedi-
temper-
The thermistor /1 (TH1) detects a
ately to turn OFF
ature
temperature higher than 236 C
the main relay
abnor-
for more than a specified period
(RL1). All the
mality
of time.
keys are not
Fusing sub sensor high tempera-
taken in.
Fusing
C-3501
C-3502
ture abnormality.
Thermistor /2 (TH2)
The thermistor /2 (TH2) detects a

temperature higher than 236 C
of time.
295
bizhub 500 / 420

Code
Causes
Resulting
operation
Main body
bizhub 500 / 420
Classification
Fusing main sensor low tempera-
The main body
Thermistor /1 (TH1)
low
ture abnormality.
stops immedi-
temper-
While in the idle or in the low
ately to turn OFF
ature
power mode, the fusing heater
the main relay
abnor-
lamp /1 (L2) turns on for more
(RL1). All the
mality
than 12 seconds in succession.
keys are not
Fusing main sensor low tempera-
taken in.
Fusing
C-3801
C-3802
ture abnormality.
While in other than the warm-up,
the thermistor /1 (TH1) detects a
temperature lower than 130 C
for more than 10 seconds.
C-3803
Fusing main sensor low temperature abnormality.

The detection temperature of the
thermistor /1 (TH1) does not get
to the prescribed temperature
after it starts the warm-up.
C-3804
Fusing sub sensor low tempera-
Thermistor /2 (TH2)
ture abnormality.
While in the idle, the fusing heater

lamp /2 (L3) turns on for more
than 12 seconds in succession.
C-3805
Fusing sub sensor low temperature abnormality.

While in other than the warm-up,
the thermistor /2 (TH2) detects a
temperature lower than 130 C
for more than 10 seconds.
C-3806
Fusing sub sensor low temperature abnormality.

The detection temperature of the
thermistor /2 (TH2) does not get
to the prescribed temperature
after it starts the warm-up.
C-3807
Fusing main sensor high temper-
Thermistor /1 (TH1)
ature abnormality (sub CPU
detection)
In the sub CPU, the thermistor /1
(TH1) detects a temperature
higher than 236 C for more than
a specified period of time.
296
Classification
Code
Causes
Resulting
Main body
operation
Fusing sub sensor high tempera-
The main body
Thermistor /2 (TH2)
low
ture abnormality (sub CPU detec-
stops immedi-
temper-
tion)
ately to turn OFF
ature
In the sub CPU, the thermistor /2
the main relay
abnor-
(TH2) detects a temperature
(RL1). All the
mality
higher than 236 C for more than
keys are not
taken in.
Fusing
C-3808
Inferior contact of the thermistor
Thermistor /1 (TH1)
sensor
/1 (TH1)
abnor-
While in the warm-up condition,
mality
when the thermistor /2 (TH2)
Fusing
C-3901
detection temperature gets to the

Ready temperature before the
TH1 detection temperature, the
TH1 detection temperature does
not get to the Ready temperature
a specified period of time after
the TH2 detection temperature
got to the Ready temperature.
C-3902
Inferior contact of the thermistor
Thermistor /2 (TH2)
/2 (TH2)
While in the warm-up condition,

when the thermistor /1 (TH1)
detection temperature gets to the
Ready temperature before the
TH2 detection temperature, the
TH2 detection temperature does
not get to the Ready temperature
a specified period of time after
the TH1 detection temperature
got to the Ready temperature.
C-3903
Thermistor /1 (TH1) open abnor-
Thermistor /1 (TH1)
mality (sub CPU detection)
In the sub CPU, the TH1 detection temperature detects a temperature between -8 and 20 C
of time.
C-3904
Thermistor /2 (TH2) open abnor-
Thermistor /2 (TH2)
mality (sub CPU detection)
In the sub CPU, the TH2 detection temperature detects a temperature between -8 and 20 C
of time.
297
bizhub 500 / 420

Code
Causes
Resulting
operation
Main body
bizhub 500 / 420
Classification
Image
C-4001
proces-
Index board (INDEXB) contact
The main body
abnormality.
stops immedi-
sing
ately to turn OFF
abnor-
the main relay
mality
(RL1).
Polygon motor (M5) speed abnor-
Polygon motor (M5)
speed
mality.
abnor-
When M5 is ON, an error signal is
mality
detected 3 times in succession
Motor
C-4101
within a specified period of time.

Laser drive board (LDB) abnor-
proces-
mality.
sing
When an overcurrent flows for
Image
C-4401
abnormality
laser output.
C-4701
Laser index abnormality.
When the cycle of the index is dif-
ferent from an expected value.

Main body control board commu-
nication
nication abnormality 1
Scanner drive board (SDB)
abnor-
mality
between the overall control board
Commu-
C-5001
(OACB) and the scanner drive

board (SDB).
C-5002
Main body control board communication abnormality 2

Communication abnormality,
incoming command abnormality,
platen operation sequence
abnormality to the sub CPU in the
overall control board (OACB).
C-5003
Sub CPU A/D conversion abnormality.

There is no response 2 times in
succession to the A/D conversion
request of the overall control
board (OACB).
298
Classification
Code
Causes
Resulting
Main body
operation
Exhaust fan /Fr (FM3) conversion
The main body
lock
abnormality.
stops immedi-
abnor-
When FM3 is ON, an error signal
ately to turn OFF
mality
is detected 5 times in succession
the main relay
(RL1).
Fan
C-5301
C-5302
Exhaust fan /Rr (FM9) conversion
abnormality.

C-5303
conversion abnormality.
(FM1)

OS
C-5401*
error
There occurs an OS error with the
Engine section
engine control section in the
power OFF.
printer control board (PRCB).

System
C-5402*
control
Time out for tuning off the power
Engine section
switch (SW2)
power OFF.
commu-
Operation panel
nication
display all ON.
abnormality
Image
C-6001
process
CCD board (CCDB) connection
Scanner sec-
CCD board (CCDB)
abnormality.
tion stops
communication
immediately.
Engine section
abnor-
power OFF.
mality
C-6002*

(PRCB).
While in the stand-by, a scanner
C-6003*

(PRCB).
Time out for the notice time of the
platen original size.
299
bizhub 500 / 420

Code
Causes
Resulting
Main body
operation
While in the exposure unit initial
Scanner sec-
Scanner motor (M2)
abnor-
search, the scanner home sensor
tion stops
Scanner home sensor
mality
(PS30) does not turn on within a
immediately.
(PS30)
Scanner
C-6101
specified period of time. And

also, while in the return scan,
PS30 does not turn on within a
specified period of time.
C-6201
Exposure lamp (L1) abnormality.
Exposure lamp (L1)
A specified period of time after L1
L1 inverter (L1 INVVB)
turns on, an L1 abnormality signal
is detected in succession for a

specified period of time.
Image
C-6701
processing
C-6702
abnor-
AOC abnormality.
CCD board (CCDB)
AOC counter overflow
Exposure lamp (L1)
AGC abnormality.
L1 inverter (L1 INVVB)
AGC counter overflow
Scanner motor (M2)
DF
mality

DF control board (DFCB) commu-
The main body
nication
nication abnormality.
stops immedi-
abnor-
ately to turn OFF
mality
between the printer control board
the main relay
(PRCB) and DFCB.
(RL1).
Commu-
Fan
C-8001
C-8301
Cooling fan (FM3) abnormality.
Cooling fan (FM3)

lock
abnormality
FAX
bizhub 500 / 420
Classification
FAX
C-B001
FAX ROM checksum error
board
C-B002
A FAX board hardware error is
abnormality
detected.
C-B003
A FAX file initialization abnormality

is detected.
FAX
C-B110
driver
error
Instance generation error or an

observer registration error
C-B111
Initialization failure of the configuration space
C-B112
A semaphore is obtained; release

error
C-B113
Sequence error between the

tasks on the main body side.
C-B114
C-B115
Message queue control error

Sequence error between the
main body and the FAX board
C-B116
FAX board no response (no

response after initialization)
300
FAX breakdown
FK-502
Classification
Code
Causes
Resulting
bizhub 500 / 420
FAX
operation
FAX
C-B117
Time out error for ACK standby
driver
C-B118
Undefined frame reception
error
C-B119
DMA transfer error
JC
C-B120
JC software error
C-B122
Device error (GA LOCAL SRAM)
C-B123
Device error (DRAM)
C-B125
Device error (GA)
C-B126
FAX breakdown
FK-502
While in the interruption processing, there occurs a time out error

due to no response from DC.
C-B127

due to no response from CC.
C-B128

due to no response from Line.
C-B129

due to no response from the File
system/File Driver.
MIF
C-B130
Driver software error
software
C-B131
Length error of the frame received
C-B132
Header error of the frame receive
error
from the main side.

from the main side.
C-B133
232C I/F sequence error
C-B134
DPRAM I/F sequence error
C-B135
DPRAM CTL/STS register abnormality.
C-B136
Time out for ACK standby
C-B137
DPRAM RESET received
C-B140
MSG I/F error with JC
C-B141
I/F error with driver
I/F
C-B142
Undefined command received
error
C-B143
Command frame length error
C-B144
Command parameter length error
C-B145
Undefined parameter
C-B146
Command/response sequence
error
301

Code
Causes
Resulting
operation
FAX
bizhub 500 / 420
Classification
Line
C-B150
control
External class instance acquisition error
C-B151
Job start-up error (start-up JOB

parameter/slave job generation
error)
C-B152
Doc access error (report Buf

access error)
C-B153
Time out for a response from the

external task
C-B154
Internal Que table control error
1 des-
C-B160
Instance generation error
tination
C-B161
Time out error
control
C-B162
Interface error
C-B163
Message queue control error
(create/enque/deque)
C-B164
A semaphore is obtained: release

error.
C-B165
Observer registration error
C-B166
Incoming resource check error
C-B167
Outgoing image information

expansion error
Page
C-B168
Incoming image serialization error
C-B169
Quick memory data access error
C-B170
Internal Que table control error
C-B171
Instance generation error
control
(create/enque/deque)
C-B172
Time out error
C-B173
Interface error
C-B174
A semaphore is obtained: release

error.
C-B175
Observer registration error
C-B176
TTI area cannot be secured.
C-B177
Error return from TTI_Rasterizer
C-B178
Incoming Job generation error
C-B180
Quick transfer memory data

access error
C-B181
Block Buff acquisition error
C-B182
Outgoing block image error (Req,
C-B183
Incoming block image error (Req,
Restore)
Store)
C-B184
Incoming image information storage error
302
FAX breakdown
FK-502
Classification
Code
Causes
Resulting
bizhub 500 / 420
FAX
operation
Page
C-B185
control
Incoming data size logic error
FAX breakdown
FK-502
(The incoming data is not a multiple number of DotLine.

C-B186
Image Buff acquisition (alloc) error
C-B187
Error return from Compressor
C-B188
Band Buff control error (new
ISW
Instance/get/free)
While in the completion of the
Engine section
panel
reception from the control of the
power OFF.
commu-
operation panel, either of the fol-
nication
lowing is detected or after starting
abnor-
the transmission, the transmis-
mality
sion cannot be completed within
Operation
C-C103

Data checksum error
Communication GA generates an error vector.
Machine
C-C181
The machine type mentioned in
type
the software is different from the
detection
machine type information given
abnor-
on the main body drive board.
mality
Flash
C-C182
A flash ROM checksum error of
ROM
the image control board is
abnor-
detected.
mality
Software
C-C183
The machine type mentioned in
abnor-
the software is different between
mality
the overall control and the image
Main body
control.
Non-
C-C284
volatile
memory
C-C285
abnormality
Non-volatile memory abnormality
It stops immedi-
*1
ately.
NVRAM board (NRB)
HD-505

*1
C-C286

*1
C-C287

*1
C-C288

*1
HDD
C-D001
HDD initialization abnormality.
Engine section
C-D002
JOB RAM retention abnormality.
power OFF.
303

Code
Causes
Resulting
operation
Main body
bizhub 500 / 420
Classification
Overall control board cooling fan
The main body
(FM8) abnormality.
stops immedi-
Overall control board cool-
abnor-
ately to turn OFF
ing fan (FM8)
mality
the main relay
Fan
C-D201
lock
Commu-
C-D203
nication
between the main body control
abnor-
board and IC-204
mality
C-D282*
(RL1).

IC-204
between the overall control board
(OACB) and the scanner drive

board (SDB).
When the power switch (SW2)
turns on, there is no SDB
response.
System
C-E001
Message queue abnormality.
Engine section
control
C-E002
Incorrect parameters of the mes-
power OFF.
C-E003
Incorrect task
C-E004
Incorrect event
C-E005
Memory access abnormality.
C-E006
Header access abnormality.
C-E007
DIMM initialization abnormality.
C-E081
DRAM initialization abnormality.
communication
abnormality
sage and the method
C-E082*
Image abnormality.
If there is a
Image processing abnormality on
sheet of paper
the overall control side
being printed,
the main body
completes the
paper exit to
stop operations. The main
relay (RL1) turns
OFF.
C-E083*
Copy sequence abnormality.
Engine section
Job object pointer abnormality
power OFF.
(For some reason, the acquisition

of the page management object
is unavailable.)
C-E084*

Memory copy sequence abnormality (the one the cause of which
cannot be identified.)
304
Classification
Code
Causes
Resulting
Main body
operation
Engine section
control
Through copy sequence (FCOT)
power OFF.
commu-
abnormality (the one that the
nication
cause of which cannot be identi-
System
C-E085*
abnormality
fied.)
C-E086*

The memory scanner stop is not
completed. (A stop completion
notice is not sent from the engine
side.)
C-E087*

The memory printer stop is not
completed. (A stop completion
notice is not sent from the engine
side.)
C-E088*
Unrecoverable error (The count is

made by C-5402.)
An error occurs when the timer is
set.
C-E089*

made by C-5402.)
An error occurs when the timer is
cancelled.
C-E08A*

made by C-5402.)
An abnormal operation occurs
when an interrupt copy is made
(printer user job).
C-E08B*

made by C-5402.)
(printer job 0).
C-E08C

made by C-5402.)
(printer job 1).
C-E08D*

made by C-5402.)
(FCOT print user job).
305
bizhub 500 / 420

Code
Causes
Resulting
operation
Main body
bizhub 500 / 420
Classification
Engine section
control
made by C-5402.)
power OFF.
commu-
nication
System
C-E08E*
abnormality
(FCOT print job).

C-E08F*

made by C-5402.)
(copy print user job).
C-E090*

made by C-5402.)
(copy print job 0).
C-E091*

made by C-5402.)
(copy print job 1).
C-E092*

made by C-5402.)
An error occurs when the task 0
is deleted with the queue 1 generation not allowed.
C-E093*

made by C-5402.)
An error occurs when the queue
0 is deleted with the queue 1
generation not allowed.
C-E094*

made by C-5402.)
n is deleted with the task n generation not allowed.
C-E095*

made by C-5402.)
An error occurs when the task 0
is deleted with the task 1 generation not allowed.
C-E096*

made by C-5402.)
0 is deleted with the task 1 generation not allowed.
306
Classification
Code
Causes
Resulting
Main body
operation
Engine section
control
made by C-5402.)
power OFF.
commu-
An error occurs when the task n
System
C-E097*
nication
abnor-
is started.
C-E098*
mality

made by C-5402.)
An error occurs when the task n
is deleted.
C-E099*

made by C-5402.)
n is deleted.
C-E09A*

made by C-5402.)
A scheduling abnormality occurs
when the FAX print cannot be
started due to a memory shortage (queue operation abnormality).
C-E09B*

made by C-5402.)
A scheduling abnormality occurs
when the FAX print cannot be
started due to a memory shortage (message transmission error).
C-E09C*

made by C-5402.)
A printer scheduling abnormality
occurs due to memory being full
(message transmission error)
C-E09E*

made by C-5402.)
(scanner scan user job).
C-E09F*

made by C-5402.)
(scanner mixed original scan job
0).
C-E0A0*

made by C-5402.)
(scanner z-folding scan job 0).
307
bizhub 500 / 420

Code
Causes
Resulting
operation
Main body
bizhub 500 / 420
Classification
Engine section
control
made by C-5402.)
power OFF.
commu-
nication
System
C-E0A1*
abnormality
(scanner normal scan job 0).

C-E0A2*

made by C-5402.)
(scanner scan job 1).
C-E0A3*

made by C-5402.)
(FAX scan user job).
C-E0A4*

made by C-5402.)
(FAX mixed original scan job 0).
C-E0A5*

made by C-5402.)
(FAX z-folding scan job 0).
C-E0A6*

made by C-5402.)
(FAX normal scan job 0).
C-E0A7*

made by C-5402.)
(FAX scan job 1).
C-E0A8*

made by C-5402.)
(FCOT scan user job).
C-E0A9*

made by C-5402.)
(FCOT scan job).
308
Classification
Code

Causes
Resulting
Main body
operation
Engine section
control
made by C-5402.)
power OFF.
commu-
nication
System
C-E0AA*
abnormality
(copy scan user job).

C-E0AB*

made by C-5402.)
(copy mixed original scan job 0).
C-E0AC*

made by C-5402.)
(copy z-folding scan job 0).
C-E0AD*

made by C-5402.)
(copy normal scan job 0).
C-E0AE*

made by C-5402.)
(copy scan job 1).
C-E0AF*

made by C-5402.)
A SUSPEND occurs.
C-E0B0*

made by C-5402.)
An EXCEPTION occurs.
*1
NVRAM board (NRB) error code display priority

When two or more error codes related to NRB occur at the same time, a code with the highest precedence is displayed according to the priorities shown below.
C-C287
C-C288
C-C286
C-C284
C-C285
309
bizhub 500 / 420
bizhub 500 / 420
C. Function to separate defective sections

For setting of DipSW that is specified for the following items, it is possible to use them with a failed section separated. After setting DipSW, however, no abnormality detection is made on the separated section.
NOTE
This function is employed to make temporary use of sections that are not affected. So, be sure
that this is limited only to a provisional use until a defective section is repaired.
(1) DipSW setting
Turning the main power switch (SW1) OFF and ON after setting the specified software DipSW bit allows you to
make a limited use of it until the bit setting is released next time.
Classification Malfunction
Causes
Control while detatched
DipSW
code
Main
C-0201
body
Paper feed in tray 1 is unavailable
abnormality
(There remains no paper, and on the
DipSW18-0
operation panel, the tray 1 is displayed

in hatching.)
C-0202
abnormality
DipSW18-1

in hatching.)
PC-202
C-0203
abnormality
DipSW18-4

in hatching.)
C-0204
abnormality
DipSW18-5

in hatching.)
LU
C-0205
Paper feed in LU is unavailable
abnormality
DipSW18-6
operation panel, LU is displayed in

hatching.)
PC-402
C-0206
Paper lift motor (M5) abnor-
mality
Shift motor (M4) abnormality
Shift gate motor (M3) abnor-
in hatching.)
DipSW18-4
mality
FK
C-B001
FK-502 abnormality
FAX mode is unavailable
DipSW19-1
HD-505 abnormality
HDD is unavailable
DipSW19-3
to B188
HDD
C-D001
to D002
DF
SD
C-8001
C-1109
to 1115
310
(HD-505 is not connected)

DF communication abnormal-
DF mode is unavailable
ity
(DF connection is not recognized)
SD drive abnormality
SD is unavailable
(SD connection is not recognized)
DipSW19-7
DipSW20-5
14. PARTS LAYOUT DRAWING
bizhub 500 / 420
APPENDIX
14.1 Main body
14.1.1
Switch/sensor
A. Main body rear side
[4]
[3]
[1]
[2]
50gaf5c017na
[1]
Toner bottle sensor (PS4)
[3]
Humidity sensor (HUMS)
[2]
Toner bottle position sensor (PS28)
[4]
Toner remaining sensor (PZS)
311
bizhub 500 / 420
B. Main body front side
[1]
[3]
[2]
50gaf5c018na
[1]
Power switch (SW2)
[2]
Interlock switch (MS)
[3]
Main power switch (SW1)
C. Main body upper surface
[3]
[4]
[1]
[2]
50gaf5c019na
312
[1]
DF open/close switch (SW3)
[3]
APS timing sensor (PS31)
[2]
[4]
APS sensor (PS32)
bizhub 500 / 420
D. Developing section
[1]
50gaf5c020na
[1]
TCR sensor (TCRS)
E. Paper feed section

(1) Tray 1
[5]
[6]
[1]
[2]
[4]
[3]
[1]
[4]
[2]
[5]
[3]
[6]
50gaf5c034na
313
bizhub 500 / 420
(2) Tray 2
[7]
[8]
[1]
[2]
[3]
[6]
[4]
[5]
50gaf5c035na
[1]
[5]
[2]
Feed door open/close sensor (PS7)
[6]

[3]
[7]
[4]
[8]
(3) Registration
[1]
[1]
314
50gaf5c036na

Bypass tray section
[6]
[5]
[7]
[1]
bizhub 500 / 420
F.
[2]
[4]
[3]
50gaf5c037na
[1]
Paper size VR/BP (VR1)
[5]
Paper size sensor /BP4 (PS22)
[2]
Paper empty sensor /BP (PS18)
[6]
[3]
Lift sensor (PS23)
[7]
[4]
G. ADU section
[1]
[2]
[3]
50gaf5c038na
[1]
ADU open/close sensor (PS26)
[2]
[3]
315
bizhub 500 / 420
H. Fusing section
[1]
[4]
[3]
[2]
50gaf5c021na
I.
[1]
[3]
Thermistor /1 (TH1)
[2]
Thermistor /2 (TH2)
[4]
Thermostat (TS)
Reverse/paper exit section
[1]
50gaf5c039na
[1]
316

14.1.2
Load
bizhub 500 / 420
[11]
[10]
[1]
[9]
[2]
[7]
[3]
[6]
[5]
[4]
[8]
50gaf5c022na
[1]
Toner supply motor (M4)
[7]
[2]
[8]
Feed motor (M9)

Drum motor (M1)
[3]
Toner solenoid (SD5)
[9]
[4]
[10]
Fusing motor (M11)
[5]
Overall control board cooling fan (FM10)
[11]
Scanner motor (M2)
[6]
317
bizhub 500 / 420
B. Main body inside
[4]
[1]
[2]
[3]
50gaf5c023na
[1]
[3]
[2]
[4]
C. Main body right side
[1]
[2]
50gaf5c024na
[1]
318
Web solenoid (SD4)
[2]
Coveyance suction fan (FM5)
bizhub 500 / 420
D. Write section
[1]
50gaf5c025na
[1]
Polygon motor (M5)
E. Photo conductor section
[1]
50gaf5c026na
[1]
319
bizhub 500 / 420
F.
Paper feed section
(1) Tray 1
[2]
[1]
50gaf5c040na
[1]
[2]
(2) Tray 2
[3]
[1]
[2]
320
[1]
[2]
[3]
50gaf5c041na
bizhub 500 / 420
(3) Registration
[1]
[2]
50gaf5c042na
[1]
[2]
Loop clutch (CL2)
G. Bypass tray section
[1]
[2]
[1]
[2]
50gaf5c043na
321
bizhub 500 / 420
H. ADU section
[1]
[2]
50gaf5c044na
[1]
I.
[2]
Reverse/paper exit section
[1]
[4]
322
[2]
[3]
[1]
Reverse motor (M6)
[3]
[2]
[4]
50gaf5c045na

14.1.3
Boards and others
bizhub 500 / 420
[1]
[2]
[9]
[3]
[8]
[7]
[4]
[6]
[5]
50gaf5c027na
[1]
L1 inverter (L1 INVB)
[6]
[2]
[7]
[3]
[8]
[4]
Circuit breaker /1 (CBR1)
[9]
NVRAM board (NRB)
[5]
Circuit breaker /2 (CBR2)
323
bizhub 500 / 420
B. Main body front side
[1]
50gaf5c028na
[1]
Total counter (TCT)
C. Main body inside
[1]
[2]
50gaf5c029na
[1]
324
DC power supply (DCPS)
[2]
Hight voltage unit (HV2)
bizhub 500 / 420
D. Operation panel and main body upper surface
[8]
[7]
[6]
[1]
[5]
[4]
[2]
[3]
50gaf5c030na
[1]
CCD board (CCDB)
[5]
Operation board (OB)
[2]
Panel key board (PKB)
[6]
Speaker (SP) (option)
[3]
OB inverter (OB INVB)
[7]
Exposure lamp (L1)
[4]
LCD board (LCDB)
[8]
L1 relay board (L1 RLB)
E. Write section
[2]
[1]
50gaf5c031na
[1]
[2]
325

Photo conductor section
bizhub 500 / 420
F.
[2]
[1]
50gaf5c032na
[1]
IDC sensor (IDCS)
[2]
Erase lamp (EL)
G. ADU section
[1]
50gaf5c046na
[1]
326
bizhub 500 / 420
H. Fusing section
[2]
[1]
50gaf5c033na
[1]
[2]
327
bizhub 500 / 420
14.2 DF
A. Front side
[1]
[2]
16eaf5c001na
[1]
Pressure roller release solenoid (SD1)
[2]
LED board (LB)
B. Rear side
[5]
[1]
[4]
[2]
[3]
328
16eaf5c002na
[1]
Cover open/close sensor (PS7)
[4]
Cooling fan (FM3)
[2]
Original conveyance motor (M2)
[5]
[3]
Original feed motor (M1)
[7]
[6]
[8]
[5]
[4]
[3]
[9]
[2]
[10]
[11]
[1]
16eaf5c003na
[1]
Original size sensor /2 (PS2)
[7]
Original empty sensor (PS5)
[2]
Stamp solenoid (SD2)
[8]
Original registration sensor (PS9)
[3]
Original exit sensor (PS10)
[9]
[4]
Original detection sensor (PS8)
[10]
[5]
Original feed sensor (PS6)
[11]
[6]
Mix original size detection board (MOSDB)
D. Paper feed tray
[1]
[2]
16eaf5c004na
[1]
Tray board (TB)
[2]
Original size VR (VR1)
329
bizhub 500 / 420
C. Upper surface
bizhub 500 / 420
14.3 PC
14.3.1
PC-202
[21]
[20]
[19]
[22]
[23]
[18]
[24]
[17]
[25]
[16]
[26]
[15]
[14]
[1]
[13]
[12]
[2]
[11]
[3]
[10]
[9]
[4]
[8]
[5]
[7]
[6]
330
4061f5c001na
[1]
Vertical conveyance sensor /4 (PS126)
[14]
[2]
Paper feed sensor /4 (PS125)
[15]
Paper size detect board /3 (PSDB3)

[3]
[16]
[4]
[17]
[5]
Vertical conveyance motor /4 (M121)
[18]
[6]
Paper feed motor /4 (M123)
[19]
[7]
[20]
Paper feed motor /3 (M122)
[8]
[21]
Vertical conveyance motor /3 (M120)
[9]
[22]
Right door open/close sensor (PS111)
[10]
[23]
[11]
Paper size detect board /4 (PSDB4)
[24]
Vertical conveyance sensor /3 (PS117)
[12]
[25]
Paper feed sensor /3 (PS116)
[13]
[26]

PC-402
bizhub 500 / 420
14.3.2
[20]
[19]
[21]
[18]
[17]
[22]
[16]
[23]
[24]
[1]
[15]
[2]
[3]
[14]
[4]
[5]
[13]
[6]
[7]
[8]
[12]
[9]
[10]
[11]
4061f5c201na
[1]
[13]
[2]
Main tray empty board (MEB)
[14]
Shift gate motor (M3)

Shift gate position sensor (PS14)
[3]
[15]
Rely board (RLB)
[4]
Paper lift motor encoder sensor (PS10)
[16]
[5]
Lower limit over run sensor (PS7)
[17]
Tray lock solenoid (SD1)
[6]
Shft motor encoder sensor (PS8)
[18]
Tray set sensor (PS6)
[7]
Shift motor (M4)
[19]
Paper feed motor (M1)
[8]
Tray release switch (SW1)
[20]
Vertical conveyance motor (M2)
[9]
Shift position sensor (PS11)
[21]
[10]
Lower limit sensor (PS13)
[22]
[11]
Sub tray empty sensor (PS9)
[23]
[12]
[24]
Paper feed sensor (PS1)
331
bizhub 500 / 420
14.4 LU
[8]
[7]
[10]
[11]
[12]
[13]
[6]
[5]
[1]
[2]
[4]
[3]
[9]
16aaf5c001na
[1]
[7]
[2]
[8]
Feed clutch (CL151)
[3]
Dehumidifier heater (HTR101)

parts setting
(Service
)
P/N 56AA-710#
[9]
LU set sensor (PS156)
[10]
[11]
Feed motor (M150)
[5]
[12]
LU drive board (LUDB)
[6]
LU exit sensor (PS155)
[13]
Upper door interlock switch (MS151)
[4]
332
14.5.1
bizhub 500 / 420
14.5 FS
FS-510
[27]
[26]
[28]
[25]
[20]
[24]
[21]
[29]
[30]
[23]
[1]
[22]
[19]
[18]
[17]
[16]
[2]
[13]
[12]
[11]
[10]
[9]
[15]
[4]
[3]
[5]
[6]
[7]
[14]
[8]
4349f5c001na
[1]
[16]
[2]
Guide plate switch (SW4)
[17]
Lower limit sensor (PS14)
[3]
Door switch (SW1)
[18]
[4]
Stacker paddle solenoid (SD1)
[19]
Shutter switch (SW2)
[5]
[20]
Tray overrun switch (SW3)
[6]
Exit motor (M1)
[21]
Shutter home sensor (PS16)
[7]
Stapler movement motor (M7)
[22]
Shutter motor (M12)
[8]
Alignment sensor /Fr (PS7)
[23]
[9]
Alignment motor /Fr (M5)
[24]
Exit roller release motor (M6)
[10]
Alignment motor /Rr (M4)
[25]
Alignment sensor /Rr (PS6)
[11]
Exit paddle home sensor (PS11)
[26]
Exit roller home sensor (PS12)
[12]
[27]
Conveyance sensor (PS5)
[13]
Exit paddle solenoid (SD2)
[28]
Entrance motor (M3)
[14]
Tray lift board (TLB)
[29]
Stacker sensor (PS8)
[15]
Tray position sensor (PS3)
[30]
Entrance sensor (PS4)
333
bizhub 500 / 420
14.5.2
FS-511
A. Front side
[1]
[2]
[4]
[3]
334
4521f5c001na
[1]
[3]
[2]
Front door sensor (PS17)
[4]
Main tray upper limit LED (LED19)
[10]
[11]
[12]
[13]
bizhub 500 / 420
B. Rear side
[14]
[1]
[9]
[2]
[8]
[3]
[7]
[4]
[6]
[5]
4521f5c002na
[1]
Main tray lower limit switch (SW3)
[8]
[2]
[9]
[3]
[10]
[4]
[11]
[5]
[12]
[6]
Interlock switch (SW1)
[13]
Main tray full sensor (PS7)
[7]
[14]
Paddle solenoid /Up (SD3)
motor (M12)
335
bizhub 500 / 420
C. Punch section
336
[1]
Punch motor (M11)
[2]
Punch clutch (CL1)
[3]
[3]
[1]
[2]
4521f5c003na
Punch encoder sensor (PS15)
bizhub 500 / 420
D. Conveyance section
[13]
[14]
[12]
[15]
[16]
[11]
[1]
[10]
[2]
[3]
[9]
[4]
[8]
[5]
[6]
[7]
4521f5e001na
[1]
Hole punch position switch (SW4)
[9]
[2]
[10]
Roller release home sensor (PS12)
[3]
[11]
[4]
Alignment tray sensor (PS5)
[12]
Exit roller home sensor (PS13)
[5]
Main tray reset sensor (PS8)
[13]
Upper door sensor (PS18)
[6]
Alignment home sensor (PS9)
[14]
Sub tray full sensor (PS6)
[7]
Main tray upper limit switch (SW2)
[15]
[8]
[16]
337
bizhub 500 / 420
E. Stapler section
[1]
[2]
4521f5c005na
[1]
338
[2]

Main tray section
bizhub 500 / 420
F.
[3]
[1]
[2]
4521f5c006na
[1]
[2]
Shift encoder sensor (PS11)
[3]
Shift motor (M8)
339
bizhub 500 / 420
14.6 PU-501
[1]
[2]
[3]
[5]
[4]
4512f5c001na
340
[1]
Punch scraps full sensor (PS1)
[4]
Encoder sensor (PS4)
[2]
Punch position sensor /1 (PS2)
[5]
Punch motor (M1)
[3]
[14]
bizhub 500 / 420
14.7 SD-502
[1]
[13]
[12]
[11]
[10]
[9]
[8]
[2]
[7]
[3]
[6]
[4]
[5]
4511f5c001na
[1]
Folding motor (M10)
[8]
[2]
Folding roller home sensor (PS22)
[9]
Tray empty sensor (PS21)

Paper guide motor (M13)
[3]
SD interlock switch (SW4)
[10]
Exit motor encoder sensor (PS25)
[4]
Staple guide home sensor (PS26)
[11]
[5]
Paper guide home sensor (PS23)
[12]
Saddle exit home sensor (PS18)
[6]
Exit sensor (PS20)
[13]
Exit open/close motor (M9)
[7]
Staple guide motor (M14)
[14]
341
bizhub 500 / 420
14.8 MT-501
[12]
[11]
[13]
[14]
[10]
[15]
[16]
[1]
[9]
[2]
[3]
[8]
[7]
[6]
[4]
[5]
4510f5c001na
342
[1]
Conveyance sensor /Up (PS9)
[9]
[2]
Paper full sensor /1 (PS5)
[10]
Gate solenoid /2 (SD2)

[3]
Conveyance sensor /Lw (PS10)
[11]
[4]
Paper detection sensor /1 (PS1)
[12]
[5]
[13]
[6]
[14]
[7]
[15]
[8]
MT control board (MTCB)
[16]
[2]
bizhub 500 / 420
14.9 RU-502
[1]
16faf5c001na
[1]
Path sensor (PS2)
[2]
Door sensor (PS1)
343
bizhub 500 / 420
14.10 JS-502
[1]
[2]
4347f5c001na
[1]
344
Paper full sensor (PS1)
[2]
Not used
15. CONNECTOR LAYOUT DRAWING
bizhub 500 / 420

15.1 Main body
15.1.1
Connector in the board
A. Overall control board
44 (BN : 28 pin) 43 (BN: 20 pin)

46 (BK : 50 pin)
51 (BN : 5 pin)
50 (BN : 24 pin)
42 (BN : 8 pin)
57 (BK : 9 pin)
47 (BN : 2 pin)
41 (W : 5 pin)
58 (W : 20 pin)
52 (BN : 2 pin)
49 (BK : 36 pin)
40 (W : 4 pin)
NC
59 (W : 24 pin)
1000 (BN : 8 pin)
NC
NC
803 (BN : 6 pin)
500 (BK : 44 pin)

NC
804 (BK : 20 pin)

55 (BK : 100 pin)
45 (Silver Metal : 4 pin)

48 (Silver Metal : 12 pin)
504 (BN : 144 pin)

56 (BN : 3 pin)
50gaf5c001na
345
bizhub 500 / 420
B. Printer control board
29 (BN : 28 pin)
34 (BN : 32 pin)
28 (BN : 24 pin)
38 (BN : 20 pin)
27 (GY : 22 pin)
37 (W : 8 pin)
91 (BN : 2 pin)
35 (W : 5 pin)
36 (W : 10 pin)
NC
NC
NC
21 (W : 11 pin)
NC
18 (BN : 12 pin)
20 (W : 6 pin)
90 (W : 8 pin)
69 (BN : 3 pin)
17 (BN : 10 pin)
25 (W : 6 pin)
24 (W : 7 pin)
26 (W : 13 pin)
23 (W : 12 pin)
16 (W : 6 pin)
11 (W : 3 pin)
39 (W : 5 pin)
12 (BK : 68 pin)
15 (BN : 17 pin)
33 (W : 11 pin)
32 (BN : 28 pin)
31 (BN : 34 pin)
19 (BN : 24 pin)
346
22 (BN : 38 pin)
NC
30 (BN : 40 pin)
50gaf5c002na
bizhub 500 / 420
C. Scanner drive board
62 (BK : 3 pin)
63 (W : 10 pin)
65 (W : 2 pin)
64 (W : 9 pin)
61 (BN : 24 pin)
50gaf5c003na
D. CCD board
60 (BN : 50 pin)
50gaf5c004na
347
bizhub 500 / 420
E. DC power supply
10 (W : 2 pin)
9 (W : 3 pin)
1 (W : 4 pin) 4 (W : 8 pin) 5 (W : 10 pin) 6 (W : 8 pin)
2 (W : 5 pin)
3 (W : 12 pin)
7 (W : 6 pin)
50gaf5c005na
348

High voltage unit
bizhub 500 / 420
F.
71 (W : 11 pin)
70 (W : 6 pin)
72 (W : 3 pin)
50gaf5c006na
G. Index board
51 (BN : 5 pin)
50gaf5c007na
349
bizhub 500 / 420
H. L1 inverter
930 (W : 3 pin)
931 (W : 4 pin)
I.
50gaf5c008na
L1 relay board
97(2 pin)
97 (2 pin)
50gaf5c009na
J.
Laser drive board
50 (BN : 24 pin)
50gaf5c010na
K. Operation board
2 (W : 3 pin)
56 (BK : 22 pin)
1 (BN : 28 pin)
7 (NC)
3 (BN : 4 pin)
4 (BK : 17 pin)
50gaf5c011na
350

OB inverter
bizhub 500 / 420
L.
8 (BN : 3 pin)
9 (W : 4 pin)
50gaf5c012na
M. NVRAM board
1 (BN : 20 pin)
2 (BN : 24 pin)
50gaf5c013na
N. Panel key board
6 (BK : 22 pin)
50gaf5c014na
351
bizhub 500 / 420
O. Paper size board /1, /2
87,88 (W : 5 pin)
50gaf5c015na
P.
Toner control sensor board
1 (W: 7 pin)
50gaf5c016na
352
15.2.1
bizhub 500 / 420
15.2 DF
A. DF control board (DFCB)
10 (W : 5 pin) 9 (W : 3 pin)
1 (W : 2 pin)
8 (W : 6 pin)
7 (W : 6 pin)
11 (W : 2 pin)
4 (W : 7 pin)
3 (W : 4 pin)
13 (W : N.C.)
2 (W : 13 pin)
6 (W : 12 pin)
5 (W : 11 pin)
16eaf5c005na
B. Tray board (TB)
3 (W : 3 pin)
2 (W : 12 pin)
1 (W : 7 pin)
16eaf5c006na
C. LED board (LB)
1 (W : 4 pin)
16eaf5c007na
353
bizhub 500 / 420
15.3 PC
15.3.1
A. PC-202
(1) PC control board (PCCB)
5 (W : 8 pin)
6 (W : 15 pin)
3 (W : 14 pin)
4 (W : 5 pin)
1 (W : 12 pin)
8 (W : 13 pin)
2 (W : 2 pin)
7 (W : 7 pin)
9 (W : 9 pin)
11 (W : 6 pin) 10 (W : 10 pin)
4061f5c002na
(2) Paper size detect board /3, /4 (PSDB3, PSDB4)
1 (W : 5 pin)
4061f5c003na
354
B. PC-402
3 (W : 11 pin)
4 (W : 13 pin)
7 (W : 5 pin)
bizhub 500 / 420
(1) PC control board (PCCB)
5 (W : 15 pin)
6 (W : 8 pin)
1 (W : 12 pin)
2 (W : 2 pin)
N.C
4061f5c202na
(2) Relay board (RLB)
1 (W : 22 pin)
2 (W : 22 pin)
4061f5c203na
(3) Main tray empty board (MEB)
1 (W : 3 pin)
4061f5c204na
355
bizhub 500 / 420
15.4 LU
15.4.1
A. LU drive board (LUDB)
112 (W : 12 pin)
114 (W : 4 pin)
113 (GY : 22 pin)
111 (W : 2 pin)
110 (GY : 19 pin)

16aaf5c002na
356
15.5.1
bizhub 500 / 420
15.5 FS
A. FS-510
(1) FS control board (FSCB)
7 (W : 5 pin)
5 (W : 3 pin)
3 (W : 10 pin)
8 (W : 2 pin)
10 (W : 3 pin)
6 (W : 7 pin)
4 (W : 4 pin)
12 (W : 11 pin)
1 (W : 6 pin)
2 (W : 8 pin)
11 (W : 6 pin)
9 (W : 7 pin)
14 (W : 9 pin)
26 (W : 2 pin)
13 (W : 10 pin)
16 (W : 11 pin)
18 (W : 6 pin)
20 (W : 10 pin)
15 (W : 8 pin)
25 (W : 5 pin)
17 (W : 7 pin)
19 (W : 4 pin)
4349f5c002na
(2) Tray lift board (TLB)
2 (W : 15 pin)
1 (W : 7 pin)
4349f5c003na
357
bizhub 500 / 420
B. FS-511
(1) FS control board (FSCB)
7 (W : 8 pin)
9 (W : 12 pin)
11 (W : 8 pin) 13 (W : 9 pin)
8 (W : 6 pin)
10 (W : 4 pin) 12 (W : N.C.)
6 (W : 2 pin)
5 (W : 4 pin)
4 (W : 2 pin)
15 (W : 8 pin)
3 (W : 2 pin)
16 (W : 6 pin)
2 (W : 2 pin)
17 (W : N.C.)
1 (W : 6 pin)
18 (W : 12 pin)
19 (W : 15 pin)
22 (W : 3 pin)
24 (W : 7 pin)
25 (W : 15 pin)
358
20 (W : 9 pin)
23 (W : 7 pin) 21 (W : 4 pin)
4521f5c007na
15.6.1
bizhub 500 / 420
15.6 SD
A. SD control board (SDCB)
5 (W : 4 pin)
6 (W : 3 pin)
8 (W : 7 pin)
7 (W : 8 pin)
4 (W : 9 pin)
2 (W : 3 pin)
3 (W : 2 pin)
12 (W : 5 pin)
1 (W : 6 pin)
10 (W : 10 pin)
11 (W : 4 pin)
9 (W : 9 pin)
4511f5c002na
359
bizhub 500 / 420
15.7 MT
15.7.1
A. MT control board (MTCB)
101 (W : 9 pin)
100 (W : 13 pin)
102 (W : 12 pin)
103 (W : 7 pin)
107 (W : 8 pin)
104 (W : 2 pin)
105 (W : 2 pin)
106 (W : 2 pin)
4510f5c002na
360

Separation (HV)
Transfer (HV)
Charging (HV)
Erase lamp (EL)
P-VV (Valid)
Loop clutch (CL2)
Fusing motor (M11)

Feed motor (M9)
Drum motor (M1)
Start key ON
16.1 Main body
A. A4, 2 single sided originals, single sided copy (1 copy), paper feed tray 1
bizhub 500 / 420

16. TIMING CHART
16. TIMING CHART
50gaf5c047na
361
362
Reverse
Forward
Transfer (HV)
Separation (HV)
Charging (HV)
Erase lamp (EL)


P-VV (Valid)

Loop clutch (CL2)
Reverse motor (M6)
Feed motor (M9)
Fusing motor (M11)
Drum motor (M1)
Start key ON
bizhub 500 / 420

16. TIMING CHART
B. A4, 3 double sided original, double sided copy (1 copy), paper feed tray 1
50gaf5c048na
Original conveyance
motor (M2)
Original feed
motor (M1)
NEXTPAGE signal
VD signal
DSET signal
Pressure roller release

solenoid (SD1)
ON
OFF
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
High speed
Low speed
Stop
Low speed
High speed
Middle speed
Stop
Low speed
High speed

(PS8)

(PS9)
Start key ON / 1st sheet feed start
Original set
1st sheet scan start
2nd sheet scan start
1st sheet scan complete
2nd sheet feed start

2nd sheet scan complete
A. Single sided original mode (A4, 2 sheets feed)
bizhub 500 / 420

16. TIMING CHART
16.2 DF
16eaf5c009na
363
364
High speed
Low speed
Stop
Middle speed
High speed
Low speed
Stop
Low speed
High speed
Original
conveyance
motor (M2)
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
Original feed
motor (M1)
NEXTPAGE signal
VD signal
DSET signal

solenoid (SD1)

(PS10)
Original detection
sensor (PS8)
Original registration
sensor (PS9)

(PS6)

(PS5)
Original set
2nd sheet
feed start
1st sheet exit start
Reverse
complete
Reverse start
1st sheet back face scan complete
1st sheet back face scan start
Reverse complete
Reverse start
1st sheet front face scan complete
1st sheet front face scan start
2nd sheet exit

complete
bizhub 500 / 420

16. TIMING CHART
B. Double sided original mode (A4, 2 sheets feed)
16eaf5c010na
ON
OFF
ON
OFF
ON
OFF
Original detection
sensor (PS8)

(PS10)

solenoid (SD1)
Original
conveyance
motor (M2)
Original feed
motor (M1)
Stop
Low speed
High speed
ON
OFF
ON
OFF
ON
OFF
High speed
Low speed
Stop
Low speed
High speed
Middle speed
NEXTPAGE signal
VD signal
DSET signal
ON
OFF
ON
OFF
sensor (PS9)

(PS6)
ON
OFF
ON
OFF

(PS5)
Continued from previous page
2nd sheet exit start
Reverse complete
Reverse start
2nd sheet back face scan complete
2nd sheet back face scan start
Reverse complete
Reverse start
2nd sheet front face scan complete
2nd sheet front face scan start
bizhub 500 / 420
2nd sheet exit complete

16. TIMING CHART
16eaf5c011na
365
366
Original conveyance
motor (M2)
Original feed motor

(M1)
NEXTPAGE signal
VD signal
DSET signal

solenoid (SD1)
ON
OFF
ON
OFF
OFF
ON
ON
OFF
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
High speed
Low speed
Stop
Low speed
High speed
Middle speed
Stop
Low speed
High speed

(PS8)
sensor (PS9)
Stamp operation is executed only when "trailing edge" or "leading edge and trailing edge" specified.
2nd sheet feed start

Original set
bizhub 500 / 420

16. TIMING CHART
C. FAX fine mode (A4, 2 sheets feed)
16eaf5c012na
Original conveyance
motor (M2)
Original feed motor

(M1)
NEXTPAGE signal
VD signal
DSET signal

solenoid (SD1)
ON
OFF
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
ON
OFF
High speed
Low speed
Stop
Low speed
High speed
Middle speed
Stop
Low speed
High speed
Original detection
sensor (PS8)
sensor (PS9)
Command received / 2nd sheet feed start

Stamp operation is executed only when "trailing edge" or "leading edge and trailing edge" specified.
When the communication completes normally, the trailing edge is stamped on.

Original set
Command received
bizhub 500 / 420

16. TIMING CHART
D. FAX immediate send mode (A4, 2 sheets feed)
16eaf5c013na
367
368
Main body fusing exit sensor (PS3)
Main body registration sensor (PS1)
Main body vertical conveyance sensor (PS2)
PC vertical conveyance sensor (PS2)
Print signal
Main body registration clutch (CL1)
Main body loop clutch (CL2)
Main body vertical conveyance clutch (CL3)
Main body feed motor (M9)
PC vertical conveyance motor (M2)
LU feed clutch (CL151)
LU pick-up solenoid (SD151)
LU feed motor (M150)
Start key ON
Loop
Loop
Loop
bizhub 500 / 420

16. TIMING CHART
16.3 LU
A. A4, life size, 1-1 mode, 3 originals
16aaf5c003na
Exit motor (M1)
Conveyance motor
(M2)
Entrance motor (M3)
Forward
Stop
High speed
Low speed
Stop
Forward
Stop
ON
OFF
16.4.1
Conveyance sensor (PS5)
A. Non-sort, A4, 1 sheet setting
FS-510
bizhub 500 / 420

16. TIMING CHART
16.4 FS
4349f5c004na
369
370
Entrance motor (M3)
Forward
Stop
Reverse
Forward
Stop
Reverse
Forward
Stop
Forward
Stop
Alignment motor
/Rr (M4)
Alignment motor /Fr

(M5)
Stapler movement
motor (M7)
Stapler motor
ON
OFF
Forward (release)
Stop
Reverse (pressure)
Stacker paddle
solenoid (SD1)
Exit roller
release
motor (M6)
Punch motor (M1)
Forward
Reverse
ON
OFF
Forward
Stop
Reverse
Exit motor (M1)
High speed
Low speed
Stop
ON
OFF
Forward
Stop
Stacker sensor (PS8)
Conveyance
motor (M2)
ON
OFF

bizhub 500 / 420

16. TIMING CHART
B. 1 stapling, punch, A4, 2 originals, 2 copies setting
4349f5c005na
ON
OFF
ON
OFF
L
H
ON
OFF
ON
OFF
L
H
Entrance conveyance
motor (M1)
FS operation start signal ON
A. No-sort, 1 original, 1 copy setting
bizhub 500 / 420
16.4.2
Item

16. TIMING CHART
FS-511
4521f5c008na
371
372
Shift motor (M8)
sensor (PS3)
Entrance conveyance
motor (M1)
Item
Forward
Stop
Reverse
H
L
ON
OFF
L
H
ON
OFF
L
H
Shift position
bizhub 500 / 420

16. TIMING CHART
B. Sort, 2 originals, 2 copies setting
4521f5c009na
ON
OFF
ON
OFF
L
H
L
H
sensor (PS3)
ON
OFF
Shift motor (M8)
roller release motor (M12)
ON
OFF
ON
OFF
ON
OFF
ON
OFF
Stapler motor /Rr (M17)
Paper exit roller release

motor (M13)
ON
OFF
ON
OFF
Paddle solenoid /Up (SD3)
Forward
Stop
Reverse
ON
OFF
H
L
Bypass route conveyance

sensor (PS2)
Forward
Stop
Reverse
L
H
Main route conveyance

sensor (PS4)
Release
Forward
Conveyance motor /Lw (M2) Stop
Reverse
Entrance conveyance
motor (M1)
Item
1
Staple
Conveyance to tray
Alignment operation
Switch back
Release
Alignment operation
Shift
Pressure
Staple
Conveyance to tray
Release
Shift
Pressure
bizhub 500 / 420

16. TIMING CHART
C. 1 staple /Rr, A4S, 2 originals, 2 copies setting
4521f5c010na
373
374
ON
OFF
ON
OFF
Punch motor (M11)
Punch clutch (CL1)
L
H
ON
OFF
ON
OFF
ON
OFF
ON
OFF
L
H
Entrance conveyance
motor (M1)
Item
Punch operation
bizhub 500 / 420

16. TIMING CHART
D. Non-sort, punch, 1 original, 1copy setting
4521f5c011na

bizhub 500 / 420

17.1 Main body 1/4
10
11
12
13
A
RL24V
FT3
FT5
NF
Inlet
FT1
Plug
FT2
Circuit breaker /2
FT6
FT4
J13-2
J21-02
RL1 CNT

J21-03
FT28
J13-4
CN9-3 L3 DRIVE
Sub relay
BT3
L2
FT25
CR002
CN10-2 AC(N)
FT26
J13-3
CN9-2 L2 DRIVE
RL1 POWER
FT22
CR001
RL1
FT21
TS
Thermostat
AC DRIVE
AC(H)
Noise filter
Main relay
BT1
CN10-1 AC(H)
CBR 1
FT20
J21-01
CN9-1 AC(H)
FT24
RL1 CNT
FT23
RL1 POWER
Circuit breaker /1
L3
FT27
AC(N)
CBR 2
J13-1
RL2
CN8-1 SW IN(H)
RT4
4
CR003
RT3
4
CN8-3 SW IN(N)
AC(H)
BT2
24V
5V
12V
Main power switch
DCPS(1/2)
E
for FNS
24V
F3
F1
63 64
62: 1 - 1
62: 2 - 2
62: 3 - 3
62: 4 - 4
63
64
for DCPS
24V
P.GND
LU-201
6-1 24V
6-5 P.GND
5V2
5V2
S.GND
S.GND
12V2
S.GND
S.GND
12V2
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
24V
7-1
MS
J23-1
300:B11- B11
300:B10- B10
300:B9 - B9
300:B8 - B8
300:B7 - B7
300:B6 - B6
300:B5 - B5
300:B4 - B4
300:B3 - B3
300:B2 - B2
300:B1 - B1
FS-511
+RU-502
M
1
J23-3
J24-2B
J23-4
SWD24V
SWD24V
G
3-1
-2
-3
-4
32
33
34
35
36
37
38
39
40
41
42
43
300:A10- A10
300:A9 - A9
300:A8 - A8
300:A7 - A7
300:A6 - A6
300:A5 - A5
300:A4 - A4
300:A3 - A3
300:A2 - A2
300:A1 - A1
300:A11- A11
21
22
23
24
25
26
27
28
29
30
31
11
12
13
14
15
16
19
20
17
18
LCDB LCD
OB INVB
(CN2)
2-3 S.GND
2-2 INV ON
2-1 5V
for ENGINE
FS_TXD
S.GND
NC
FS_RTS
S.GND
FS_RXD
NC
S.GND
FS_CTS
S.GND
S.GND
for DCPS
24V2
24V2
24V2
P.GND
P.GND
P.GND
5V2
5V2
S.GND
S.GND
OB
4-17
-16
-15
-14
-13
-12
-11
-10
-9
-8
-7
-6
-5
-4
-3
-2
-1
Backlight
or
-1B
7-2
PKB
PC-202
or
PC-402
FS-510
J24-1A
J23-2 J24-2A
(J23:NMF)
Interlock switch
for
SDB
44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62
2-5
2-4
2-3
2-2
2-1
1 2
for
DF
EN5V2
EN12V1
NMI
12V1
S.GND
24V
J60: 1 - 1
J60: 2 - 2
for
LU
3 4
5-1 24V
5-2 24V
5-3 24V
5-4 P.GND
5-5 P.GND
5-6 P.GND
5-7 S.GND
5-8 S.GND
5-9 5V2
5-10 5V2
1-1
1-2
1-3
1-4
80-A14
80-A13
80-A12
80-A11
80-A10
80- A9
80- A8
80- A7
80- A6
80- A5
80- A4
80- A3
80- A2
80- A1
34-A1 DB3
34-A2 S.GND
34-A3 DB1
34-A4 XSCL
34-A5 S.GND
34-A6 YD
34-A7 OPTXD
34-A8 S.GND
34-A9 OPRTS
34-A10 OPRXD
34-A11 S.GND
34-A12 OPCTS
34-A13 DF_INT
34-A14 APS_INT
80-B14
80-B13
80-B12
80-B11
80-B10
80- B9
80- B8
80- B7
80- B6
80- B5
80- B4
80- B3
80- B2
80- B1
34-B1 DB2
34-B2 S.GND
34-B3 DB0
34-B4 LP
34-B5 S.GND
34-B6 LCDENB
34-B7 RST
34-B8 S.GND
34-B9 OPINT
34-B10 /FAX_RING
34-B11 5V
34-B12 5V
34-B13 /SYS_STOP
34-B14 /UTY
9-1 FL HOT
-4 FL GND
(CN8)
8- 3
-2
-1
OACB(1/3)
I
Battery
OPERATION UNIT
SP
514: 1 - 2
514: 2 - 1
SW2
CN52
47-1 MONIT
47-2 S.GND
PSWB
S.GND 500- 4
S.GND 500- 3
5V1 500- 2
5V1 500- 1
6-3 24V
6-4 24V
6-8 P.GND
6-7 P.GND
6-2 24V
6-6 P.GND
F2
11
12
13
14
15
16
17
18
19
20
5V1
5V1
S.GND
S.GND
40- 4
40- 3
40- 2
40- 1
BT4
S.GND
S.GND
5V1
5V1
AC(N)
58-1 F8.DRV
58-2 F8.LCK
58-3 GND
CN8-2 SW OUT(H)
-12V 31- 7
S.GND 31- 6
12V1 31- 5
NMI
31- 4
EN24V 31- 3
EN5V2 31- 2
ENPWR 31- 1
CN8-4 SW OUT(N)
FT10
41- 5
41- 4
41- 3
41- 2
41- 1
FT10
S.GND
12V1
/NMI
EN12V1
EN5V2
SW1
12V2(LD) 42- 9
S.GND 42- 8
-12V 42- 7
S.GND 42- 6
12V2 42- 5
S.GND 42- 4
S.GND 42- 3
5V2
42- 2
5V2
42- 1
FT9
12V2(LD) 42- 8
S.GND 42- 7
S.GND 42- 6
12V2 42- 5
S.GND 42- 4
S.GND 42- 3
5V2
42- 2
5V2
42- 1
FT9
FM10
Speaker
OACB cooling fan
M
6
10
11
12
13
bizhub 500 / 420
Main Body location list

Symbol
CBR1
Part name
Circuit breaker /1
Location
3-B
CBR2
Circuit breaker /2
3-C
DCPS
DC power supply
4-A
FM10
Overall control board cooling fan
12-K
L2
11-B
L3
11-B
LCD
LCD
6-H
LCDB
LCD board
6-H
MS
Interlock switch
8-F
NF
Noise filter
4-B
OACB
11-F
OB
Operation board
8-G
OB INVB
OB inverter
6-K
PKB
Panel key board
6-G
PSWB
Power switch board
8-L
RL1
Main relay
6-B
RL2
Sub relay
6-B
SP
Speaker
11-L
SW1
Main power switch
3-D
SW2
Power switch
9-L
TS
Thermostat
11-B
FS-510
3-K
FS-511
3-K
LU-201
1-I
PC-202
3-H
PC-402
3-H
RU-502
3-K
Inlet
2-B
Backlight
6-J
Battery
12-I
Plug
2-B
15
16
17
LDB
18
19
19
20
Memory Board
SC-502
57- 1 DCD
- 2 RXD
- 3 TXD
- 4 DTR
- 5 GND
- 6 DSR
- 7 RTS
- 8 CTS
- 9 RI
INDEXB
45-1
45-2
45-3
45-4
20
VDD
-Data
+Data
GND
21
CSRC I/F
-35 +OUT_CLK
-36 S.GND
-37 S.GND
-38 ADRST
-39 APR
-40 S.GND
-41 +5V
-42 +5V
-43 +5V
-44 +5V
-45 S.GND
-46 +12V
-47 +12V
-48 +12V
-49 +12V
-50 S.GND
-27 +AD_D0
-28 S.GND
-29 S.GND
-30 -AD_D1
-31 +AD_D1
-32 S.GND
-33 S.GND
-18 GND
-19 GND
-20 SCLK
-21 *SEN
-22 SDI
-23 SDO
-24 S.GND
-25 S.GND
18
49- 1 STROBE
- 2 DATA0
- 3 DATA1
- 4 DATA2
- 5 DATA3
- 6 DATA4
- 7 DATA5
- 8 DATA6
- 9 DATA7
-10 ACK
-11 BUSY
-12 PERROR
-13 SLCT
-14 AUTOFD
-15 N.C.
-16 GND
-17 GND
-18 PERIHERAL
-19 GND
-20 GND
-19 GND
-22 GND
-23 GND
-24 GND
-25 GND
-26 GND
-27 GND
-28 GND
-29 GND
-30 HLOGIC
-31 INIT
-32 FAULT
-33 GND
-34 N.C.
-35 N.C.
-36 SELECTIN
+5V
S.GND
/HSENSE
S.GND
/INDPR
IC-204
431- 5
431- 4
431- 3
431- 2
431- 1
CN500
J52: 5 - 1
J52: 4 - 2
J52: 3 - 3
J52: 2 - 4
J52: 1 - 5
HD-505
-14 GND
-15 GND
-16 +IN_CLK
60- 1 S.GND
- 2 TG
- 3 CLAMP
- 4 ACLAMP
- 5 PRD_KEEP
- 6 GND
- 7 GMD
- 8 +TCK
- 9 -TCK
-10 S.GND
-11 S.GND
-12 +RCK
17
51-1
-2
-3
-4
-5
432-B1 LOAD
-B2 DACLK
-B3 DI
-B4 S.GND
-B5 /ALM2
-B6 /BIAS2
-B7 /S/H2
-B8 /ALMRST
-B9 S.GND
-B10 -VIDEO1
-B11 +VIDEO1
-B12 S.GND
E
46- 1
46- 2
46- 3
46- 4
46- 5
46- 6
46- 7
46- 8
46- 9
46-10
46-11
46-12
46-13
46-14
46-15
46-16
46-17
46-18
46-19
46-20
46-21
46-22
46-23
46-24
46-25
46-26
46-27
46-28
46-29
46-30
46-31
46-32
46-33
46-34
46-35
46-36
46-37
46-38
46-39
46-40
46-41
46-42
46-43
46-44
46-45
46-46
46-47
46-48
46-49
46-50
J50: B1 - B12
J50: B2 - B11
J50: B3 - B10
J50: B4 - B9
J50: B5 - B8
J50: B6 - B7
J50: B7 - B6
J50: B8 - B5
J50: B9 - B4
J50:B10 - B3
J50:B11 - B2
J50:B12 - B1
I
432-A1 /ENB1
-A2 /ALM1
-A3 /BIAS1
-A4 /S/H1
-A5 S.GND
-A6 LD+5V
-A7 LD+5V
-A8 +5VRN
-A9 S.GND
-A10 -VIDEO2
-A11 +VIDEO2
-A12 S.GND
16
21
NRB
CN35
OACB(2/3)
(CN55:FX2)
55-A 1 +12V
-A 2 GND
-A 3 +5V(main)
-A 4 GND
-A 5 GND
-A 6 WAKEUP
-A 7 GND
-A 8 GND
-A 9 AD1
-A10 +5V(STBY)
-A11 AD3
-A12 GND
-A13 AD5
-A14 +5V(STBY)
-A15 AD7
-A16 AD8
-A17 GND
-A18 AD10
-A19 AD12
-A20 GND
-A21 AD14
-A22 C/BE#1
-A23 PERR#
-A24 GND
-A25 SERR#
-A26 GND
-A27 GND
-A28 IRDY#
-A29 C/BE#2
-A30 AD17
-A31 GND
-A32 AD19
-A33 AD21
-A34 GND
-A35 AD23
-A36 C/BE#3
-A37 GND
-A38 AD25
-A39 AD27
-A40 GND
-A41 AD29
-A42 AD31
-A43 3.3V
-A44 REQ#
-A45 GND
-A46 CLK
-A47 GND
-A48 GND
-A49 MONITOR
-A50 INTA#
55-B 1 +5V(main)
-B 2 IORST1
-B 3 +5V(main)
-B 4 SBDM2
-B 5 SBDP2
-B 6 GND
-B 7 SBDM1
-B 8 SBDP1
-B 9 +5V(main)
-B10 +5V(stby)
-B11 AD0
-B12 AD2
-B13 AD4
-B14 AD6
-B15 +5V(stby)
-B16 C/BE#0
-B17 AD9
-B18 GND
-B19 AD11
-B20 AD13
-B21 AD15
-B22 GND
-B23 DEVSEL#
-B24 3.3V
-B25 STOP#
-B26 TRDY#
-B27 FRAME#
-B28 GND
-B29 AD16
-B30 AD18
-B31 PAR
-B32 AD20
-B33 AD22
-B34 GND
-B35 IDSEL
-B36 AD24
-B37 AD26
-B38 AD28
-B39 3.3V
-B40 AD30
-B41 GND
-B42 PME#
-B43 GND
-B44 CNT#
-B45 3.3V
-B46 RST#
-B47 +12V
-B48 3.3V
-B49 CLKEN
-B50 LINESEL
22
CN55 Board to Board Connector(100pin)
14
15
50-B12
-B11
-B10
- B9
- B8
- B7
- B6
- B5
- B4
- B3
- B2
- B1
J
J50: A1 - A12
J50: A2 - A11
J50: A3 - A10
J50: A4 - A9
J50: A5 - A8
J50: A6 - A7
J50: A7 - A6
J50: A8 - A5
J50: A9 - A4
J50:A10 - A3
J50:A11 - A2
J50:A12 - A1
14
USB
K
50-A12
-A11
-A10
- A9
- A8
- A7
- A6
- A5
- A4
- A3
- A2
- A1
17.2 Main body 2/4
22
23
CCDB
23
24
24
25
25
26
A
A
Symbol
B
Connector
Faston
Crimp
Relay connector
D
D
MK-708+FK-502
G
L
L
M
M
26
bizhub 500 / 420

bizhub 500 / 420

Symbol
Part name
Location
CCDB
CCD board
17-B
INDEXB
Index board
18-K
LDB
Laser drive board
16-K
NRB
NVRAM board
20-F
FK-502
23-E
HD-505
15-F
IC-204
15-G
MK-708
23-E
SC-502
17-G
1
LD-6
2
3
LD-6
M3
P.G-9
P.G-8
24V-11
24V-10
4
FM7
Z
5
RT3
3
6
B
RT3
3
B
7
RT3
3
8
B
RT3
3
B
TCT
10
11
PS7
TCRS
12
-3
-2
969-1
CL4
-3
-2
968-1
J10: 1 - 11
J10: 2 - 10
J10: 3 - 9
J27: 1 - 3
J27: 2 - 2
J27: 3 - 1
J14: 1 J14: 2 J14: 3 J14: 4 -
J08:10 - 3
J08:11 - 2
J08:12 - 1
J08: 7 - 6
J08: 8 - 5
J08: 9 - 4
4
3
2
1
TDS_CONT
12V
TDS_SIG
S.GND
30-B10 5V_R
30-B11 S.GND
30-B12 MULTI_SIZE1
30-B7 5V_R
30-B8 S.GND
30-B9 MULTI_EMPTY_PS
30-B5 24V2
30-B6 TRAY1_FEED_CL_DRV(UPPER)
30-B1
30-B2
30-B3
30-B4
30-A18 5V_R
30-A19 S.GND
30-A20 SIDE DOOR
30-A15 5V_R
30-A16 S.GND
30-A17 V_FEED_PS
30-A12 5V_R
30-A13 S.GND
30-A14 TRAY2_FULL_PS(LOWER)
35-1
35-2
35-3
35-4
35-5
TXD
S.GND
CTS
RXD
NC
RTS
S.GND
5V
37-1
37-2
37-3
37-4
37-5
37-6
37-7
37-8
/M1 36-1
/PF 36-2
/PS0 36-3
/PS1 36-4
/PS2 36-5
/PS3 36-6
/SIDE 36-7
/CPF0 36-8
/CPF1 36-9
P.GND 36-10
24V2
/KEY.SIG
S.GND
KC.DRV
P.GND
35-2
35-3
937:2 - 1
937:1 - 2
J16-12
J16-18
Erase lamp
Drum claw solenoid
12
paper size sensor /BP1
PS2
Paper empty sensor /BP
PS13
924: 1 - 2
924: 2 - 1
PS12
Feed clutch /1
PS6
TCR sensor
-3
-2
957-1
PS5
J17-2
J17-3
J17-9
J17-5
-3
-2
952-1
J08: 4 - 9
J08: 5 - 8
J08: 6 - 7
30-A9 5V_R
30-A10 S.GND
30-A11 TRAY2_EMPTY_PS(LOWER)
24V2 33-10
PCL_DRV 33-11
932:2 - 1
932:1 - 2
J16-15
J16-16
11
989-1
-2
-3
-4
-5
-3
-2
963-1
J08: 1 - 12
J08: 2 - 11
J08: 3 - 10
30-A6 5V_R
30-A7 S.GND
30-A8 TRAY1_FULL_PS(UPPER)
CLAW_SD_DRV 33-8
24V2 33-9
988-7
-6
-5
-4
-3
-2
-1
10
-3
-2
962-1
J07: 6 - 3
J07: 7 - 2
J07: 8 - 1
30-A3 5V_R
30-A4 S.GND
30-A5 TRAY1_EMPTY_PS(UPPER)
J11: 7 - 1
J11: 6 - 2
J11: 5 - 3
J11: 4 - 4
J11: 3 - 5
J11: 2 - 6
J11: 1 - 7
Fusing cooling fan/Rr
SD2
J04: 4 - 3
J04: 5 - 2
J04: 6 - 1
-3
-2
956-1
FM5
J07: 3 - 6
J07: 4 - 5
J07: 5 - 4
PRCB(1/2)
J04: 1 - 6
J04: 2 - 5
J04: 3 - 4
J16-4
J16-5
J16-6
J16-7
J16-8
J16-2
J16-3
Fusing cooling fan/Fr
IDCS
-3
-2
955-1
30-A1 24V2
30-A2 TC_DRV
33-1
33-2
33-3
33-4
33-5
33-6
33-7
SD5
J07: 1 - 8
J07: 2 - 7
5V
DRUM_TH
12V
TNRIF
TNOUT1
TNOUT2
S.GND
911: 3 - 1
911: 2 - 2
911: 1 - 3
911: 2 - 2
911: 1 - 3
IDC sensor
939-2
939-1
CL8
31-B15 F5.DRV
31-B16 P.GND
31-B17 /F5.LCK(DI/H)
J28: 3 - 4
J28: 2 - 5
J28: 1 - 6
J28: 6 - 1
J28: 5 - 2
J28: 4 - 3
Toner solenoid
Feed door
open/close sensor
M9
J33: 1 - 3
J33: 2 - 2
J33: 3 - 1
31-B12 24V2
31-B13 DUP_CL2_DRV
31-B14 N.C.
/F2.DRV 34-B14
/F8.LCK(DI/H) 34-B15
P.GND 34-B16
/F2.DRV 34-B11
/F2.LCK(DI/H) 34-B12
P.GND 34-B13
935:2 - 1
935:1 - 2
Web solenoid
FM8
915: 1 - 3
915: 2 - 2
915: 3 - 1
J03:12 - 3
J03:13 - 2
J03:14 - 1
31-B10 24V2
31-B11 DUP_CL1_DRV
31-A7 5V_R
31-A8 S.GND
31-B9 DUP_COVER
24V2 34-B9
TNR_SD_DRV 34-B10
934:2 - 1
934:1 - 2
FM2
Total counter
CL7
928: 1 - 2
928: 2 - 1
J03:10 - 5
J03:11 - 4
J03: 7 - 8
J03: 8 - 7
J03: 9 - 6
31-B4 5V_R
31-A5 S.GND
31-B6 DUP_PS2
J29:2 - 1
J29:1 - 2
Toner bottle motor
Toner supply motor
FT33
PS26
PS25
927: 1 - 2
927: 2 - 1
PS24
ADU conveyance
clutch /Up
-3
-2
976-1
J03: 4 -11
J03: 5 -10
J03: 6 - 9
24V2 34-B7
WEB_SD_DRV 34-B8
905:6 - 1
905:5 - 2
905:4 - 3
905:3 - 4
905:2 - 5
905:1 - 6
SD4
ADU open
/close sensor
-3
-2
975-1
CL5
31-B1 5V_R
31-B2 S.GND
31-B3 DUP_PS1
J03: 1 -14
J03: 2 -13
J03: 3 -12
34-B1
34-B2
34-B3
34-B4
34-B5
34-B6
BTLM_A
BTLM_AB
BTLM_B
BTLM_AB
24V2
24V2
903:6 - 1
903:5 - 2
903:4 - 3
903:3 - 4
903:2 - 5
903:1 - 6
-3
-2
987-1
M10
-3
-2
974-1
31-A16 24V2
31-A17 TRAY2_FEED_CL_DRV(LOWER)
34-A11
34-A12
34-A13
34-A14
34-A15
34-A16
TNR_A
TNR_AB
TNR_B
TNR_BB
24V2
24V2
J05:3 - 1
J05:2 - 2
J05:1 - 3
Fusing exit sensor
Thermistor /2
FT32
ADU conveyance
sensor /2
CL3
J35: 3 - 2
J35: 4 - 1
31-A14 24V2
31-A15 V_FEED_CL_DRV
31-A9 5V_R
31-A10 S.GND
31-A11 MULTI_POSITION_PS
31-A12 MULTI_SET
31-A13 S.GND
S.GND 34-A8
/T_LEVEL(DI) 34-A9
TLEV_5V 34-A10
-3
-2
953-1
PZS
PS23
925: 1 - 2
925: 2 - 1
W
(J35:CT 2PIN)
J35: 1 - 4
J35: 2 - 3
J15: 9 - 5
J15:10 - 4
J15:11 - 3
J15:12 - 2
J15:13 - 1
31-A6 S.GND
31-A7 MULTI_WIDTH_PS(MULTI)
31-A8 5V
J18: 3 - 1
J18: 2 - 2
J18: 1 - 3
M4
Feed clutch /2
VR1
923: 1 - 2
923: 2 - 1
-3
-2
973-1
SD1
J15: 6 - 8
J15: 7 - 7
J15: 8 - 6
J13:B4 - B1
J13:B3 - B2
J13:B2 - B3
980:3 - 3
980:4 - 4
J13:A2 - A3
J13:A1 - A4
Thermistor /1
FT30
FT31
PS22
Lift sensor
36: 1 - 3
36: 2 - 2
36: 3 - 1
X
-3
-2
985-1
J12: 3 - 5
J12: 2 - 6
J12: 1 - 7
J12: 5 - 3
J12: 4 - 4
980:1 - 1
980:2 - 2
J13:A4 - A1
J13:A3 - A2
PS3
Paper size VR/BP
5V_R 34-A5
S.GND 34-A6
(DI/H?) FIX_PS 34-A7
(AI/0-5V) TH2.S 34-A3

S.GND 34-A4
J12: 7 - 1
J12: 6 - 2
916: 3 - 1
916: 2 - 2
916: 1 - 3
FM6
31-A4 24V2
31-A5 MULTI_PICKUP_SD_DRV(MULTI)
31-A1 5V_R
31-A2 S.GND
31-A3 MULTI_SIZE4(MULTI)
(AI/0-5V) TH1.S 34-A1

S.GND 34-A2
/F6.DRV 15-15
(DI/H) /F6.LCK 15-16
P.GND 15-17
TH2
J15: 4 - 10
J15: 5 - 9
J15: 1 - 13
J15: 2 - 12
J15: 3 - 11
N.C.
FEED_GAIN
P.GND
P.GND
24V2
24V2
TH1
931: 1 - 2
931: 2 - 1
-3
-2
972-1
24V-11
24V-10
P.G-9
P.G-8
32-B6
32-B5
32-B4
32-B3
32-B2
32-B1
Drum cooling fan
FT37
FT36
FT40
Pick-up solenoid
/BP
LD-6
H/L-7
FM4
Paper size sensor

/BP4
CLK-4
CONT-3
CW/CCW-5
32-B11 5V
32-B10 S.GND
32-B9 FEED_ON(DO/L)
32-B8 FEEDM_CLK
914: 3 - 1
914: 2 - 2
914: 1 - 3
FT39
J16-11
J16-20
FT38
72- 1
72- 5
F4
Feed motor
FM1
5V-1
/F4.DRV 15-12
(DI/H) /F4.LCK 15-13
P.GND 15-14
71-11
71-10
71- 9
71- 8
71- 7
71- 6
71- 5
71- 4
71- 3
71- 2
71- 1
HV
S.G-2
32-B14 GND
32-B13 /F7.LCK(DI/H)
32-B12 F7.DRV
(DI/L)/S_FB 15-1
(AO/4-10V) SDC_SIG 15-2
(AO/4-10V) SAC_SIG 15-3
(DO/L)/S_CONT 15-4
(DI/L)/T_FB 15-5
(AO/4-10V) T_SIG 15-6
(DO/L) /T_CONT 15-7
(DI/L)/C_FB 15-8
(AO/4-10V) GRID_SIG 15-9
(AO/4-10V) CHG_SIG 15-10
(DO/L)/C_CONT 15-11
70- 2
70- 1
To guide plate bias
32-A3 GND
32-A2 /F1.LCK(DI/H)
32-A1 F1.DRV
/DEVM_LCK
DEVM_GAIN
P.GND
P.GND
24V2
24V2
J17-12
J25-5
3-1 5V2
3-2 5V2
3-3 S.GND
3-4 S.GND
3-5 12V2
3-6 EN24V
3-7 L2CONT
3-8 L3CONT
3-9 L3CONT2
3-10 RLCONT
3-11 RL_PGND
3-12 RL_PWR
RL24V
24V
917: 3 - 2
917: 2 - 3
917: 1 - 4
911: 3 - 1
911: 2 - 2
911: 1 - 3
32-A9
32-A8
32-A7
32-A6
32-A5
26-A4
J17-7
Grid biass
FT35
Charging
H/L-7
J25-1
70- 6
70- 5
70- 4
70- 3
To developing bias
CW/CCW-5
P.GND 16- 5
24V2 16- 6
CLK-4
5 6
CONT-3
16- 1
16- 2
16- 3
16- 4
32-A14 5V
32-A13 S.GND
32-A12 /DEV_ON(DO/L)
32-A11 DEV_CLK
24V1
P.GND
(DO/L)/BIAS1
(AO/2-8V)B_SIG
Charging
J62-4
J62-3
S.G-2
27-B1 5V
27-B2 F_MTYPE
27-B3 FIXM_ON(DO/L)
27-B4 FIXM_CLK
27-B5 S.GND
27-B6 /FIXM_LCK(DI/H)
27-B7 FIXM_GAIN
27-B8 P.GND
27-B9 P.GND
27-B10 24V2
27-B11 24V2
24V2 21- 11
5V 21- 10
5V 21- 9
S.GND 21- 8
S.GND 21- 7
12V2 21- 6
/EN24V2 21- 5
/HEATER1_CNT 21- 4
/HEATER2_CNT 21- 3
HEATER2_CNT2 21- 2
/RELAY_CNT 21- 1
5V-1
24V-11
24V-10
P.G-9
P.G-8
H/L-7
LD-6
CW/CCW-5
CLK-4
CONT-3
S.G-2
5V-1
24V-11
24V-10
P.G-9
P.G-8
H/L-7
7-6 P.GND
7-5 P.GND
7-4 P.GND
M11
Developing motor
CLK-4
CONT-3
20- 1
20- 2
20- 3
20- 4
20- 5
20- 6
M1
Fusing motor
Y
CW/CCW-5
V
24V2
24V2
P.GND
P.GND
P.GND
24V1
27-A11 5V
27-A10 S.GND
27-A9 /DRM_ON(DO/L)
27-A8 DRM_CLK
27-A7 F_MTYPE
27-A6 /DRAM_LCK(DI/H)
27-A5 DRM_GAIN
27-A4 P.GND
27-A3 P.GND
27-A2 24V
27-A1 24V
Drum motor
5V-1
S.G-2
17.3 Main body 3/4
13
13
bizhub 500 / 420

DCPS(2/2)
O
Separation
Transfer
Coin vendor/2
EL
PS18
PS19
bizhub 500 / 420

Symbol
CL3
Part name
Location
7-Y
CL4
Feed clutch /1
12-Y
CL5
Feed clutch /2
7-Y
CL7
ADU conveyance clutch /Up
9-Y
CL8
9-Y
EL
Erase lamp
10-Q
FM1
4-X
FM2
Fusing cooling fan /Fr
8-Q
FM4
Drum cooling fan
5-Q
FM5
9-X
FM6
5-Q
FM7
4-X
FM8
Fusing cooling fan /Rr
9-Q
HV
Hight voltage unit
3-Q
IDCS
IDC sensor
9-Q
M1
Drum motor
1-X
M3
Developing motor
3-X
M4
Toner supply motor
7-R
M9
Feed motor
5-X
M10
Toner bottle motor
7-R
M11
Fusing motor
2-X
PRCB
Printer control board
1-T
PS2
11-Y
PS3
Fusing exit sensor
6-Q
PS5
10-Y
PS6
10-Y
PS7
Feed door open/close sensor
12-Y
PS12
11-Y
PS13
11-Y
PS18
Paper empty sensor /BP
13-Y
PS19
Paper size sensor /BP1
13-Y
PS22
6-Y
PS23
Lift sensor
7-Y
PS24
8-Y
PS25
8-Y
PS26
ADU open/close sensor
8-Y
PZS
6-Q
SD1
Pick-up solenoid /BP
6-Y
SD2
Drum claw solenoid
10-Q
SD4
Web solenoid
8-R
SD5
Toner solenoid
8-R
TCRS
TCR sensor
12-Y
TCT
Total counter
10-Y
TH1
Thermistor /1
6-Q
TH2
Thermistor /2
6-Q
VR1
Paper size VR /BP
6-Y
DF-607
14-O
Guide plate bias
3-P
Grid
3-Q
Developing
3-O
Coin vendor /2
11-Q
Charging
3-Q
Transfer
4-P
Separation
4-P
14
15
16
17
18
M7
PS15
PS14
PS16
PS17
PSB/2
19
CL1
CL2
PS1
Registration sensor
HUMS
20
BK
RT3
3
21
RT3
3
BK
-5
-4
-3
-2
904-1
RT3
3
22
TSL
BK
RT3
3
BK
23
44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62
24
25
J64-2
J64-1
J48:3 - 1
J48:2 - 2
J48:1 - 3
-3
-2
978-1
-3
-2
954-1
Toner bottle sensor
25
PS4
PS28
21 22 23 24 25 26 27 28 29 30 31
11-1 DH_REM
11-3 24V
11-2 NC
5V_R 69-1
S.GND 69-2
TNRB.PS(DI/H) 69-3
J06:3 - 1
J06:2 - 2
J06:1 - 3
Exposure lamp
5V_R 29-B12
S.GND 29-B13
TNRB.PS(DI/H) 29-B14
Reverse sensor
PS27
J32: 2 - 10
J32: 1 - 11
-3
-2
977-1
SD3
REVERSE_UNIT_SET 29-B10
S.GND 29-B11
J32: 5 - 7
J32: 4 - 8
J32: 3 - 9
Reverse solenoid
Reverse motor
24
19-B1 FS_TXD
19-B2 S.GND
19-B3 N.C
19-B4 FS_RTS
19-B5 S.GND
19-B6 FS_RXD
19-B7 N.C
19-B8 S.GND
19-B9 FS_CTS
19-B10 S.GND
19-B11 S.GND
15-B12 N.C
5V_R 29-B7
S.GND 29-B8
REVERSE_PS 29-B9
933:2 - 1
933:1 - 2
906-4
-3
-2
-1
M6
J32: 7 - 5
J32: 6 - 6
J32:11 - 1
J32:10 - 2
J32: 9 - 3
J32: 8 - 4
Exhaust fan /Rr
Exhaust fan /Fr
OACB(3/3)
24V2 29-B5
REVERSE_SD 29-B6
29-B1
29-B2
29-B3
29-B4
919: 3 - 1
919: 2 - 2
919: 1 - 3
FM9
REVERSE_M_XB
REVERSE_M_B
REVERSE_M_XA
REVERSE_M_A
J30: 3 - 4
J30: 2 - 5
J30: 1 - 6
FM3
19-A1 LCC_FLM
19-A2 S.GND
19-A3 S.GND
19-A4 5V2
19-A5 5V2
19-A6 LCC_RTS
19-A7 LCC_RXD
19-A8 LCC_TXD
19-A9 LCC_CLK
19-A10 N.C.
19-A11 P.GND
19-A12 P.GND
/F9.DRV 29-A12
P.GND 29-A13
/F9.LCK(DI/H) 29-A14
Key counter
913: 3 - 1
913: 2 - 2
913: 1 - 3
PS32
J30: 6 - 1
J30: 5 - 2
J30: 4 - 3
J31: 3 - 6
J31: 2 - 7
J31: 1 - 8
JOB TRAY JOB TRAY

EMPTY PS FULL PS
/F3.DRV 29-A9
P.GND 29-A10
/F3.LCK(DI/H) 29-A11
5V_R 29-A6
S.GND 29-A7
JOB_TRAY_FULL_PS 29-A8
LAN
23
J61 : 1 - 12
J61 : 2 - 11
J61 : 3 - 10
J61 : 4 - 9
J61 : 5 - 8
J61 : 6 - 7
J61 : 7 - 6
J61 : 8 - 5
J61 : 9 - 4
J61 :10 - 3
J61 :11 - 2
J61 :12 - 1
U
J31: 6 - 3
J31: 5 - 4
J31: 4 - 5
J31: 8 - 1
J31: 7 - 2
L1
5V_R 29-A3
S.GND 29-A4
JOB_TRAY_EMPTY_PS 29-A5
JOB_TRAY_SET 29-A1
S.GND 29-A2
43-11
43-10
43- 9
43- 8
43- 7
43- 6
43- 5
43- 4
43- 3
43- 2
43- 1
JS-502
24V1(POLYGON) 39-1
P.GND 39-2
/PLY.ON 39-3
/PLY.LCK 39-4
PLY.CLK 39-5
22-A1 S.GND
22-A2 LT_TRAY_UP_M_ON
22-A3 LU_CLOSE_IN
22-A4 LU_FEED_M_H/L
22-A5 LU_FEED__M_CLK
22-A6 LU_FEED_M_ON
22-A7 LU_SD_DRIVE
22-A8 LU_CL_DRIVE
22-A9 LU_JAM_IN
22-A10 LU_FULL_PS_IN
22-A11 LU_EMPTY_PS_IN
22-A12 LU_SET1_IN
22-A13 LU_SET2_IN
22-A14 LU_SET_IN
22-A15 LU_TYPE_IN
22-A16 5V
22-A17 5V
22-A18 S.GND
22-A19 S.GND
22-B18 TSL_DRV
22-B19 P.GND
38-10
38-11
38-12
38-13
38-14
38-15
38-16
38-17
38-18
38-19
38-20
43-20
43-19
43-18
43-17
43-16
43-15
43-14
43-13
43-12
22
(J51:CT)
J51:5 - 1
J51:4 - 2
J51:3 - 3
J51:2 - 4
J51:1 - 5
J63: 1 - 19
J63: 2 - 18
J63: 3 - 17
J63: 4 - 16
J63: 5 - 15
J63: 6 - 14
J63: 7 - 13
J63: 8 - 12
J63: 9 - 11
J63:10 - 10
J63:11 - 9
J63:12 - 8
J63:13 - 7
J63:14 - 6
J63:15 - 5
J63:16 - 4
J63:17 - 3
J63:18 - 2
J63:19 - 1
J02: 1 - 2
J02: 2 - 1
22-B15 5V_R
22-B16 S.GND
J54: - 3
J54: - 2
J54: - 1
EG_RXD
S.GND
S.GND
5V1
S.GND
/EG_RST
APS_TIM_IN
NMI_SIG
FIX_OK_IN
DDF_VV
ADF_EMPTY_PS
38-1
38-2
38-3
38-4
38-5
38-6
38-7
38-8
38-9
21
Polygon motor
938:2 - 1
1-2
22-B12 5V_R
22-B13 S.GND
B_VV
TONYY
P_VV
S_VV
EE_VV
S.GND
/EG_RTS
EG_TXD
/EG_CTS
2
1
20
J54: - 6
J54: - 5
J54: - 4
22-B9 S.GND
22-B10 RESI.PS(DI/H)
22-B11 5V
22-B7 24V2
22-B6 LOOP_CL_DRV
DF-607
J01: 3 - 3
J01: 4 - 2
J01: 5 - 1
J01: 1 - 5
J01: 2 - 4
65- 2 P.GND
65- 1 24V2
48-1 TX+
48-2 TX48-3 RX+
48-4 RX+
48-5 CT
48-6 RX48-7 NC
48-8 FG
48-9 VDD1
48-10 LED1
48-11 LED2
48-12 VDD2
-3
-2
951-1
922: 1 - 2
922: 2 - 1
22-B5 24V2
22-B8 RESIST_CL_DRV
N.C.
S.GND
HUMS_SIG
5V
61- A12
61- A11
61- A10
61- A9
61- A8
61- A7
61- A6
61- A5
61- A4
61- A3
61- A2
61- A1
61- B12
61- B11
61- B10
61- B9
61- B8
61- B7
61- B6
61- B5
61- B4
61- B3
61- B2
61- B1
SDB
Loop clutch
J39: 1 - 7
J39: 2 - 6
22-B1
22-B2
22-B3
22-B4
KC_24V
KC.DRV
/KEY.SIG
S.GND
64-7 APS_5V
64-8 APS_DATA1
64-9 S.GND
64-3
64-4
64-5
64-6
64-1 ADF_CLOSE_SIG
64-2 S.GND
63-7 24V
63-8 LAMP_ON/OFF
63-9 LAMP_EM
63-10 P.GND
for DCPS
921: 1 - 2
921: 2 - 1
J09 1 - 4
J09 2 - 3
J09 3 - 2
J09 4 - 1
26-A12 24V2
26-A13 LIFT_UP_M_DRV(LOWER)
KC_24V 28-A1
APS_SIG_IN 28-A2
APS_5V 28-A3
S_DA_DATA 28-A4
OPM_EN 28-A5
S.GND 28-A6
OPM_CLK 28-A7
OPM_MODE_C 28-A8
DF_CLOSE_SIG 28-A9
XENON_EM 28-A10
S.GND 28-A11
HPPS_IN 28-A12
APS_TIM_IN 28-B1
5V1 28-B2
XENON_ON 28-B3
5V2 28-B4
5V2 28-B5
OPM_DIR 28-B6
OPM_MODE_B 28-B7
OPM_MODE_A 28-B8
S_DA_LATCH 28-B9
S_DA_CLK 28-B10
/KC_DRV 28-B11
KCSIG_IN 28-B12
982-3
-2
-1
J22: 2 - 1
(J22:CT)
J22: 1 - 2
931-4
-3
-2
-1
3
4
19
Registration clutch
-3
-2
-1
986-4
M8
Humidity sensor
J03: 7 - 5
908- 1
26-A7 FD_SIZE1(LOWER)
26-A11 S.GND
26-A4 5V_R
26-A5 S.GND
26-A6 WIDTH_PS2(LOWER)
-4
-3
-2
985A-1
-1
930-2
L1 inverter
930-1 L.V.
-3 H.V.
63-4 5V1
63-5 S.GND
63-6 TIMING1
20: 1 - 1
20: 2 - 2
18
Paper lift motor /2
-5
-4
-3
-2
98-1
-3
-2
967-1
APS sensor
936B-1
936B-2
DF open/close switch
SW3
26-A1 5V_R
26-A2 S.GND
26-A3 WIDTH_PS1(LOWER)
96-1
96-3
981-3
-2
-1
63-1 S.GND
63-2 OPT_HOME
63-3 5V2
62-1 U
-2 V
-3 W
200: 1 - 1
200: 4 - 4
17
-3
-2
966-1
25-A4 5V_R
25-A5 S.GND
25-A6 CASETTE_SET(LOWER)
L1 RLB
980-3
-2
-1
L1 relay board
97-3
97-1
APS timing sensor
Scanner home sensor
L1 INVB
-3
-2
964-1
25-A1 5V_R
25-A2 S.GND
25-A3 NEAR_EMPTY_PS(LOWER)
-3
-2
965-1
FD_SIZE1(UPPER)
FD_SIZE2(UPPER)
FD_SIZE3(UPPER)
FD_SIZE4(UPPER)
S.GND
PS31
24-A6 24V2
24-A7 LIFT_UP_M_DRV(UPPER)
24-A1
24-A2
24-A3
24-A4
24-A5
PS30
907- 2
907- 1
-5
-4
-3
-2
97-1
Scanner motor
M2
Paper size board /2
PSB/1
Paper size board /1
23-A10 5V_R
23-A11 S.GND
23-A12 WIDTH_PS2(UPPER)
PS11
-3
-2
961-1
PS10
24V
P.GND
23-A7 5V_R
23-A8 S.GND
23-A9 WIDTH_PS1(UPPER)
-3
-2
960-1
201B: 1- 12
201B: 2- 11
201B: 3- 10
201B: 4- 9
201B: 5- 8
201B: 6- 7
201B: 7- 6
201B: 8- 5
201B: 9- 4
201B:10- 3
201B:11- 2
201B:12- 1
16
Tray set sensor /2
PS8
23-A4 5V_R
23-A5 S.GND
23-A6 CASETTE_SET(UPPER)
ADS_BUSY 18-12
ADF_VV 18-11
ADF_DSET 18-10
ADF_SIZE1 18-9
ADF_SIZE2 18-8
ADF_SIZE3 18-7
ADF_NEXTPAGE 18-6
N.C. 18-5
ADF_EMPTY_PS 18-4
5V1 18-3
ADF_READY 18-2
SGND 18-1
15
Near-emptysensor/2
-3
-2
958-1
PS9
Tray set sensor /1
23-A1 5V_R
23-A2 S.GND
23-A3 NEAR_EMPTY_PS(UPPER)
30-B19 24V2
30-B20 MULTI_FEED_CL_DRV(MULTI)
201A: 1- 10
201A: 2- 9
201A: 3- 8
201A: 4- 7
201A: 5- 6
201A: 6- 5
201A: 7- 4
201A: 8- 3
201A: 9- 2
201A:10- 1
14
Paper lift motor /1
-3
-2
959-1
CL6
Near-emptysensor/1
J10:10 - 2
J10:11 - 1
30-B16 5V_R
30-B17 S.GND
30-B18 MULTI_SIZE3
N.C. 17-10
ADF_RXD 17-9
N.C. 17-8
ADF_TXD 17-7
N.C. 17-6
N.C. 17-5
ADFOPEN 17-4
N.C. 17-3
N.C. 17-2
N.C. 17-1
J10: 7 - 5
J10: 8 - 4
J10: 9 - 3
30-B13 5V_R
30-B14 S.GND
30-B15 MULTI_SIZE2
926: 1 - 2
926: 2 - 1
PS21
Feed clutch /BP
Z
PS20
Y
-3
-2
971-1
J10: 4 - 8
J10: 5 - 7
J10: 6 - 6
-3
-2
970-1
17.4 Main body 4/4
26
for DCPS
REVERSE UNIT
for DH
M5
26
bizhub 500 / 420

PRCB(2/2)
V
32 33 34 35 36 37 38 39 40 41 42 43
for DB/LCC UNIT

For Finisher
bizhub 500 / 420

Symbol
CL1
Part name
Registration clutch
Location
20-Y
CL2
Loop clutch
20-Y
CL6
Feed clutch /BP
14-Y
FM3
Exhaust fan /Fr
23-Q
FM9
Exhaust fan /Rr
24-Q
HUMS
Humidity sensor
20-Y
KCT
Key counter
18-R
L1
Exposure lamp
17-S
L1 INVB
L1 inverter
17-Q
L1 RLB
L1 relay board
17-R
M2
Scanner motor
16-Q
M5
Polygon motor
23-X
M6
Reverse motor
24-Q
M7
Paper lift motor /1
17-Y
M8
Paper lift motor /2
19-Y
PS1
Registration sensor
21-Y
PS4
Toner bottle sensor
25-R
PS8
Tray set sensor /1
15-Y
PS9
15-Y
PS10
16-Y
PS11
16-Y
PS14
Tray set sensor /2
18-Y
PS15
17-Y
PS16
18-Y
PS17
18-Y
PS20
14-Y
PS21
14-Y
PS27
Reverse sensor
25-Q
PS28
26-R
PS30
Scanner home sensor
16-Q
PS31
APS timing sensor
17-Q
PS32
APS sensor
18-Q
PSB/1
Paper size board /1
16-Y
PSB/2
Paper size board /2
19-Y
SD3
Reverse solenoid
24-Q
SDB
Scanner drive board
16-N
SW3
DF open/close switch
17-Q
TSL
22-Y
JS-502
22-Q
PS8
PS10
PS7

PS3
PS4
PS2
Original size
sensor/4
Original size
sensor/2
PS1 ON
PS3 ON
PS4 ON
PS2 ON
VR ON
PS1 ON
PS3 ON
PS4 ON
PS2 ON
VR ON
Cooling fan
Original feed motor
17.5 DF
M2
M1
bizhub 500 / 420

solenoid
LB
FM3
CN18
VR ON
PS2 ON
PS4 ON
PS3 ON
PS1 ON
FM3
SD1
SD2
CN14
CN16
CN15
SD1
Original size VR
PS1
Original size
sensor/3
PS6
PS6 ON
PS2 ON
PS7 ON
PS10 ON
PS8 ON
PS9 ON
SD2
Original size
sensor/1
PS5
MOSDB
PS9

DFCB
CN17
TB
CN19
bizhub 500 / 420
DF-607 location list

Symbol
DFCB
Part name
Location
DF control board
3-D
FM3
Cooling fan
5-B
LB
LED board
5-B
M1
Original feed motor
6-B
M2
6-B
MOSDB
Mix Original size detection board
5-F
PS1
6-H
PS2
6-H
PS3
6-H
PS4
6-H
PS5
5-G
PS6
5-G
PS7
4-G
PS8
3-G
PS9
3-G
PS10
3-G
SD1
Pressure roller release solenoid
5-B
SD2
Stamp solenoid
5-B
TB
Tray board
6-F
VR1
Original size VR
6-H
1
2
I
3
M125
PS122
4
PS128

PS127
5
PS124
Paper lift motor /3

Tray set sensor/3
PS116
PS117
PS111
M122
M120
PS113
M124
PS118
PS119
PS112
PS125
PS126
M123
M121
Vertical conveyance motor /4
Near-emptysensor /3
PS115
PSDB3
Paper size detect board /3
PS114
C
PSDB3
Paper feed motor /3
Vertical conveyance sensor /4
Paper feed sensor /4
PS123
Right door open/close sensor
Lift sensor /4
PS121
Tray set sensor/4
F
F
G
G
PSDB4
PSDB4
Near-emptysensor/4
Paper lift motor /4
17.6.1
17.6 PC
PC-202
PCCB
Symbol
Faston
Connector
Crimp
Relay connector
bizhub 500 / 420

bizhub 500 / 420
PC-202 location list

Symbol
M120
Part name
Location
4-C
M121
7-G
M122
Paper feed motor /3
4-C
M123
Paper feed motor /4
6-G
M124
Paper lift motor /3
5-C
M125
Paper lift motor /4
3-G
PCCB
PC control board
3-D
PS111
4-C
PS112
Tray set sensor/3
6-C
PS113
5-C
PS114
3-C
PS115
3-C
PS116
3-C
PS117
4-C
PS118
5-C
PS119
5-C
PS121
Tray set sensor /4
4-G
PS122
4-G
PS123
5-G
PS124
5-G
PS125
6-G
PS126
6-G
PS127
5-G
PS128
5-G
PSDB3
6-C
PSDB4
4-G
1
2
PS12
PS11
I
4
PS9
PS8
PS7
M5
M4
M3
PS14
Shft motor encoder sensor

Lower limit over run sensor
Paper lift motor
Shift motor
Shift gate motor
Shift gate position sensor
PS10
Sub tray empty sensor
RLB
5
6
PS4
PS3
PS2
PS1
M2
M1
SD1
PS6
Vertical conveyance motor
Paper feed motor
Tray lock solenoid

Tray set sensor
D
PS5
Paper feed sensor
Paper empty sensor
Upper limit sensor
RLB
Paper lift motor encoder sensor
E
E
F
F
G
G
MEB
MEB
Main tray empty board
PS13
Shift position sensor
H
SW1
Shift home sensor
Lower limit sensor
6
7
PCCB
Symbol
Connector
Faston
Crimp
Relay connector
bizhub 500 / 420
17.6.2
Tray release switch

PC-402
bizhub 500 / 420
PC-402 location list

Symbol
M1
Part name
Location
Paper feed motor
8-C
M2
Vertical conveyance motor
7-C
M3
Shift gate motor
6-G
M4
Shift motor
6-G
M5
Paper lift motor
5-G
MEB
Main tray empty board
4-G
PCCB
PC control board
3-A
PS1
Paper feed sensor
7-C
PS2
7-C
PS3
Paper empty sensor
7-C
PS4
Upper limit sensor
6-C
PS5
6-C
PS6
Tray set sensor
8-C
PS7
Lower limit over run sensor
5-G
PS8
Shft motor encoder sensor
5-G
PS9
Sub tray empty sensor
5-G
PS10
Paper lift motor encoder sensor
4-G
PS11
Shift position sensor
4-G
PS12
Shift home sensor
3-G
PS13
Lower limit sensor
3-G
PS14
Shift gate position sensor
6-G
RLB
Rely board
4-B
SD1
Tray lock solenoid
8-C
SW1
Tray release switch
3-G
bizhub 500 / 420
17.7 LU
A
Dehumidifier heater
OPTIONAL
HTR101
114-3 24V
J121-2
J121-1
114-2 P_GND
NC (2pin)
FT102 (4pin)
FT101 (1pin)
114-4 24V
114-1 T5M_24V
111- 1 24V
111- 2 PGND
J62- 1 24V
J62- 2 PGND
J62- 3 24V
J62- 4 RL_POWER
J63- 4 LUM_HL
J63- 3 T5_CLOSE
J63- 2 T5_UPM_ON
J63- 1 SGND
113- A1 24V
113- A2 T5SD_DRV
113- A3 S_GND
113- A4 LCT_JAM
113- A5 5V
113- A6 S_GND
113- A7 T5_FULL
113- A8 5V
113- A9 S_GND
113-A10 T5_ZERO
113-A11 5V
J82: 3J82: 2J82: 1-
3
4
5
127- 3
-2
-1
J83: 6J83: 5J83: 4-
1
2
3
J83: 3J83: 2J83: 1-
4
5
6
J84: 2 J84: 1 -
113- B4 S_GND
113- B5 T5_SET2
113- B6 5V
Symbol
1
2
PS155
LU exit sensor
125- 3
-2
-1
PS152
Upper limit sensor
124- 3
-2
-1
PS153
Paper empty sensor
126- 3
-2
-1
PS154
Remaining paper sensor/1
122- 3
-2
-1
PS151
Remaining paper sensor/2
PS156
LU set sensor
CL151
Feed clutch
J85: 2 J85: 1 -
113-B10 LUCL_DRV
113-B11 24V
SD151 Pick-up solenoid
129- 3
-2
-1
113- B7 S_GND
113- B8 LU_SET
113- B9 5V
Feed motor
1
2
Main body
M151 Paper lift motor
M150
J82: 5J82: 4-
113- B1 S_GND
113- B2 T5_SET1
113- B3 5V
Upper door interlock switch
C
120-11
-10
-9
-8
-7
-6
-5
-4
-3
-2
-1
112-4 24V
112-5 24V
112-6 P_GND
112-7 P_GND
112-8 LUM_HL
(LD)
112-9 LUM_FR
112-10 LUM_CLK
112-11 LUM_ON
112-12 SGND
112-13 5V
110- 1 SGND
110- 2 SGND
110- 3 5V2
110- 4 5V2
110- 5 LU_TYPE
110- 6 T5_SET_PS
110- 7 T5_SET2
110- 8 T5_SET1
110- 9 T5_ZERO_PS
110-10 T5_FULL_PS
110-11 LU_JAM_PS
110-12 LU_CL_ON
110-13 T5_SD_ON
110-14 LUM_ON
110-15 LUM_CLK
110-16 LUM_HL
110-17 T5_CLOSE
110-18 T5_UPM_ON
110-19 SGND
J63-19 SGND
J63-18 SGND
J63-17 5V2
J63-16 5V2
J63-15 LU_TYPE
J63-14 T5_SET_PS
J63-13 T5_SET2
J63-12 T5_SET1
J63-11 T5_ZERO_PS
J63-10 T5_FULL_PS
J63- 9 LU_JAM_PS
J63- 8 LU_CL_ON
J63- 7 T5_SD_ON
J63- 6 LUM_ON
J63- 5 LUM_CLK
121- 1
121- 2
112-1 T5M_24V
112-2 T5M_ON
112-3 P_GND
B
MS
151
1
2
LUDB
Faston
Connector
Crimp
Relay connector
I
1
I
4
bizhub 500 / 420
LU-201 location list

Symbol
CL151
Part name
Location
Feed clutch
7-H
HTR101
Dehumidifier heater
7-A
LUDB
LU drive board
4-A
M150
Feed motor
7-C
M151
Paper lift motor
7-C
MS151
Upper door interlock switch
7-B
PS151
Remaining paper sensor /2
7-G
PS152
Upper limit sensor
7-F
PS153
Paper empty sensor
7-F
PS154
Remaining paper sensor /1
7-G
PS155
LU exit sensor
7-E
PS156
LU set sensor
7-H
SD151
Pick-up solenoid
7-E
17.8.1
bizhub 500 / 420
17.8 FS
FS-510/PU-501
SW4 Guide plate switch
SD-502/MT-501
(Option)
PS5
PS12
Stacker paddle solenoid
M6
Exit roller release motor
CL1
Door switch
B
Entrance sensor
Registration clutch
M3
Entrance motor
SD2
Exit paddle solenoid
M2
Conveyance motor
SW1
FSCB
Punch Unit Setting 1st Detection
GND
Punch Unit Setting 2nd Detection
GND
Punch Unit Setting 3rd Detection
GND
SD1
PS4
Conveyance sensor
D
SD-502/MT-501
(Option)
PS11
PS10
Stapler home sensor
Staple Needle Empty Detect Sensor

Staple Selfpriming Detect Sensor
Staple Home Detect Sensor
Chopper Unit Setting Detection

GND
M1
Exit motor
M7
PU-501(Option)
Punch scraps full sensor
Punch position sensor 1
Punch position sensor 2
Encoder sensor
Punch motor
PS1
PS2
PS3
PS4
M1
PS8
Stacker sensor
PS7
Alignment sensor/Fr
PS6
Alignment sensor/Rr
M5
Alignment motor/Fr
M4
Alignment motor/Rr
M11
Tray lift motor
SW3
Tray overrun switch
M12
Shutter motor
SW2
Shutter switch
H
PS16
PS14
PS15
Symbol
Shutter home sensor

Lower limit sensor
Connector
Faston
Crimp
Relay connector
Upper limit sensor
TLB
PS3
bizhub 500 / 420
FS-510 location list

Symbol
CL1
PU-501 location list

Part name
Registration clutch
Location
7-B
Symbol
M1
Part name
Punch motor
Location
3-G
FSCB
FS control board
3-B
PS1
Punch scraps full sensor
3-E
M1
Exit motor
7-E
PS2
3-F
M2
Conveyance motor
7-C
PS3
3-F
M3
Entrance motor
7-C
PS4
Encoder sensor
3-F
M4
Alignment motor /Rr
7-G
M5
Alignment motor /Fr
7-F
M6
Exit roller release motor
7-B
M7
7-E
M11
Tray lift motor
7-G
M12
Shutter motor
7-G
PS3
7-I
PS4
Entrance sensor
7-B
PS5
Conveyance sensor
7-A
PS6
Alignment sensor /Rr
7-F
PS7
Alignment sensor /Fr
7-F
PS8
Stacker sensor
7-E
PS10
Stapler home sensor
7-D
PS11
7-C
PS12
7-A
PS14
Lower limit sensor
7-H
PS15
Upper limit sensor
7-I
PS16
Shutter home sensor
7-H
SD1
Stacker paddle solenoid
7-A
SD2
Exit paddle solenoid
7-C
SW1
Door switch
2-C
SW2
Shutter switch
7-H
SW3
Tray overrun switch
7-G
SW4
Guide plate switch
7-A
TLB
Tray lift board
5-H

FS-511
8
SW4
roller release motor
Paper exit motor
Stapler moving motor
M12
W
W
W
W
M6
CL1
M3
Conveyance motor/Lw
M2
Conveyance motor/Up
M4
PS15
Entrance conveyance
motor
PS1
Punch motor
M11
Sift motor
M8
Punch clutch
PS2
Only for inch

destination
Alignment motor
M5
M1
Hole punch
selector motor
Paddle motor/Lw
M9
Hole punch position switch

M14
bizhub 500 / 420
17.8.2
Path sensor (RU-502)
Door sensor (RU-502)
C
RU-502
M13
Tray lift motor
SD3 Paddle solenoid
M7
M15
Main tray lower limit switch
Paddle motor/Up
SW3
FSCB
SW2
SD1 Bypass gate solenoid
SD2 Main gate solenoid

PWB-E_GL
Interlock switch
SW1
PWB-E_GL
CN200C
LED19
PS18
RU-502
PS17
Main tray upper limit LED
Upper door sensor
Front door sensor
CN201B
PS6
PWD-F
PWD-F_GL
PS1
PS2
Sift encoder sensor
Sift home sensor
PS11
PS3
PS10
PS7
PS13
PS12
PS4
PS9
Symbol
PS19
Faston
Connector
Crimp
Relay connector
PWD-F_GL
PS5
PS14
I
PS8
PWD-F
Stapler home sensor
bizhub 500 / 420
FS-511 location list

Symbol
Part name
Location
CL1
Punch clutch
7-A
FSCB
FS control board
2-B
LED19
Main tray upper limit LED
7-E
M1
Entrance conveyance motor
4-B
M2
Conveyance motor /Lw
4-A
M3
Paper exit motor
2-A
M4
Conveyance motor /Up
4-B
M5
Alignment motor
5-B
M6
Stapler moving motor
4-A
M7
Tray lift motor
2-D
M8
Shift motor
2-C
M9
Paddle motor /Lw
5-A
M11
Punch motor
2-C
M12
Intermediate conveyance roller release motor
2-A
M13
8-D
M14
Hole punch selector motor (Inch area only)
7-A
M15
Paddle motor /Up
8-D
M16
Stapler motor /Rr
4-H
M17
Stapler motor /Fr
4-H
PS1
8-G
PS1
Door sensor (RU-502)
8-B
PS2
8-G
PS2
Path sensor (RU-502)
8-B
PS3
6-H
PS4
6-H
PS5
2-I
PS6
8-F
PS7
8-G
PS8
2-H
PS9
2-I
PS10
Shift home sensor
2-H
PS11
Shift encoder sensor
2-H
PS12
6-H
PS13
8-H
PS14
Stapler home sensor
6-I
PS15
7-B
PS17
Front door sensor
7-F
PS18
Upper door sensor
8-F
PS19
6-I
PS20
Staple empty sensor /Rr
4-H
PS21
Stapler ready sensor /Rr
4-H
PS22
4-H
PS23
Staple empty sensor /Fr
4-H
PS24
Stapler ready sensor /Fr
4-H
PS25
4-H
SD1
Bypass gate solenoid
8-E
SD2
Main gate solenoid
8-E
SD3
Paddle solenoid
8-D
SW1
Interlock switch
2-E
SW2
2-E
SW3
Main tray lower limit switch
2-D
SW4
Hole punch position switch (Inch area only)
7-A
1
2
3
H
E
17.9 SD
PS23
PS26
PS25
SW4
I
5
6
SDCB
M14
M9
M13
M8
PS22
M10
Symbol
Connector
Faston
Crimp
Relay connector
bizhub 500 / 420
PS20
Folding motor
PS18
Conveyance motor
PS21
Paper guide motor
Exit open/close motor
Exit motor encoder sensor
Staple guide motor
SD interlock switch
Staiple guide home senso
B
Exit sensor
2
Tray empty sensor

FS-510
F
F
G
G
bizhub 500 / 420
SD-502 location list

Symbol
M8
Part name
Location
Conveyance motor
6-G
M9
Exit open/close motor
6-G
M10
Folding motor
8-D
M13
Paper guide motor
6-G
M14
Staple guide motor
6-G
PS18
4-B
PS20
Exit sensor
4-B
PS21
Tray empty sensor
3-B
PS22
7-D
PS23
4-B
PS25
Exit motor encoder sensor
4-B
PS26
Staiple guide home sensor
4-B
SDCB
SD control board
3-C
SW4
SD interlock switch
5-G
1
2
3
4
SD2
SD1
Gate solenoid /1
Paper detection sensor/3
Conveyance sensor /Lw
Paper full sensor/1
Paper full sensor/3
Paper full sensor/4

B
Paper full sensor /2
Gate solenoid /2
Conveyance sensor /Up
Conveyance motor
Gate solenoid /3
17.10 MT
4
5
SD3
M1
PS9
PS6
PS3
PS1
PS10
PS5
PS2
PS7
PS4
PS8
PS11
FS-510
I
8
Symbol
Connector
Faston
Crimp
Relay connector
bizhub 500 / 420

C
C
D
D
E
E
MTCB
F
bizhub 500 / 420
MT-501 location list

Symbol
M1
Part name
Location
Conveyance motor
4-C
MTCB
MT control board
3-D
PS1
Paper detection sensor /1
5-C
PS2
6-C
PS3
5-C
PS4
6-C
PS5
5-C
PS6
4-C
PS7
6-C
PS8
6-C
PS9
Conveyance sensor /Up
4-C
PS10
Conveyance sensor /Lw
5-C
PS11
7-C
SD1
Gate solenoid /1
6-G
SD2
Gate solenoid /2
4-G
SD3
Gate solenoid /3
3-C
SERVICE MANUAL
Field Service
DF-607
2006.02
Ver. 1.0
Revision history
Revision mark:
NOTE
2006/02
1.0
Date
Service manual Ver.
Revision mark

Field Service Ver. 1.0 Feb. 2006
DF-607
CONTENTS
DF-607
OUTLINE
1.
PERIODIC CHECK..................................................................................................5
2.1
Maintenance procedure ........................................................................................5
2.1.1
Replacing the Pick-up Roller and Feed Roller...............................................5
2.1.2
Replacing the Separation Roller....................................................................6
2.1.3
Cleaning of the Pick-up Roller, Feed Roller and Separation Roller...............7
2.1.4
Cleaning of Miscellaneous Rolls ...................................................................8
2.1.5
Cleaning of Miscellaneous Rollers ................................................................9
2.1.6
Cleaning of the Scanning Guide..................................................................11
2.1.7
Cleaning of the Reflective Sensor Section ..................................................12
OTHER ..................................................................................................................13
3.1
Disassembly/Adjustment prohibited items ..........................................................13
3.2
Disassembling and assembling list .....................................................................14
3.3
Disassembling and assembling procedure .........................................................14
3.3.1
Cover /Fr, Cover /Rr and Original Feed Tray Cover /Lw ..............................14
3.3.2
DF Control Board (DFCB) ...........................................................................15
3.3.3
Original Size VR (VR1)................................................................................15
3.3.4
Complete Stamp Unit 2 ...............................................................................17
3.3.5
Replacing the Replace Stamp 2..................................................................18
ADJUSTMENT/SETTING
3.
MAINTENANCE
2.
OUTLINE
MAINTENANCE
ADJUSTMENT/SETTING
4.
4.1
MECHANICAL ADJUSTMENT..............................................................................19
Leading Edge Skew Adjustment .........................................................................19
MAINTENANCE
OUTLINE
DF-607
ADJUSTMENT/SETTING
Blank Page
ii
OUTLINE
DF-607
1.
A. Type
Reverse Automatic Document Feeder
Paper Feed
Paper Feed from top of stack
Type
Turnover
Switch back system
Paper Exit
Straight exit system
Installation
Screw cramp to the main unit
Document Alignment
Center
Document Loading
Left image side up
OUTLINE
Name
B. Functions
Modes
1-Sided Mode / 2-Sided Mode
C. Paper type
Standard Mode
Plain Paper
Type of Document
Mixed Original Detection

Mode
Plain Paper
FAX Mode
Plain Paper
1-Sided Mode
35 to 128 g/m2 (9.25 to 34 lbs)
2-Sided Mode
50 to 128 g/m2 (13.25 to 34 lbs)
1-Sided / 2-Sided Mode
50 to 128 g/m2 (13.25 to 34 lbs)
1-Sided Mode
35 to 128 g/m2 (9.25 to 34 lbs)
2-Sided Mode
50 to 128 g/m2 (13.25 to 34 lbs)
Inch area
A3, A4S, A4, B4, B5S, B5
Detectable Document
11 x 17, 81/2 x 14, 81/2 x 11S, 81/2 x 11, 81/2 x 51/2S, 81/2 x 51/2
Size*1
Metric area
A3, A4S, A4, A5S, A5, B4, B5S, B5, B6S
11 x 17, 81/2 x 11S, 81/2 x 11
Capacity
80 sheets (80 g/m2) or load height of 11 mm or less.
*1: For the Combined Original Detection Mode, Refer to the Mixed Original Detection Enabled
Size Combination Table.
DF-607
D. Paper feed prohibited originals

If fed, trouble occurrence will be highly possible.
Type of Original
Possible Trouble
Original that is stapled or clipped.

due to clip clogging
Book original
Original weighing less than 35g/m2 or 128g/m2

Feed failure
or more
OUTLINE
Torn original
Feed failure, damaged sheet
Highly curled original (15 mm or more)
Original misfeed due to dog-ear or skew
OHP transparencies
Feed failure
Label Sheet
Feed failure
Offset master
Feed failure
Sheets clipped or notched
Damaged sheet
Sheets patched
Patched part folded or torn sheet
E. Paper feed not guaranteed originals

If fed, paper feed will be possible to some extent but trouble occurrence will be possible.
Type of Original
Sheets lightly curled
(Curled amount: 10 - 15 mm)
Possible Trouble
Dog-eared, exit failure
Heat Sensitive Paper
Edge folded, exit failure, conveyance failure
Coated Paper (Ink Jet Paper)
Translucent paper
Paper immediately after paper exit from the

main unit
Paper with many punched holes (e.g., loose

Multi-page feed due to flashes from holes
leaf) limited to vertical feeding
Sheets with 2 to 4 holes
Conveyance failure
Sheets two-folded or Z-folded

(amount of non-flatness: 15 mm or less)
Take-up failure, conveyance failure, image deformation
Sheets folded
Image deformation, multi-page feed, take-up failure
DF-607
F. Mixed original feed chart

For Metric
Other
originals
A4
B4S
B5
A4S
A5
B5S
A5
A3
A4
B4S
B5
A4S
A5
B5S
A5S
OUTLINE

A3
For Inch
11 x 17
Other
originals
81/2 x 11
81/2 x 14
81/2 x 11S
51/2 x 81/2
51/2 x 81/2 S
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
G. Maintenance
Maintenance
H. Machine data
Power Requirements
24V DC 10% (supplied from the main body)
Max. Power
Consumption
48 W or less
Dimensions
582 (W) x 558 (D) x 145 mm (H)
Weight
Approx. 10 kg
I.
Temperature
10 to 30C
Humidity
10 to 80% RH (with no condensation)
NOTE
These specifications are subject to change without notice.
OUTLINE
DF-607
Blank Page
2. PERIODIC CHECK
MAINTENANCE
PERIODIC CHECK
2.1
DF-607
2.
Maintenance procedure
NOTE
The alcohol described in the cleaning procedure of Maintenance represents the isopropyl alcohol.
2.1.1
Replacing the Pick-up Roller and Feed Roller

Pick-up Roller: Every 500,000 prints (Actual replacement cycle: Every 200,000 faces)
B. Procedure
MAINTENANCE
1. Open the Open/Close Cover [1].
[1]
16eaf2c001na
2. Remove two screws [2], and remove the

cover [3].
[3]
[2]
16eaf2c002na
3. Remove two C-clips [4], and remove the

Pick-up Roller Assy [5].
[5]
[4]
16eaf2c003na
2. PERIODIC CHECK
DF-607
[13]
[12]
[7]
[13] [9]
[12]
[11]
[6]
[7]
[8]
[10]
4.
5.
6.
7.
8.
Remove two levers [6].

Remove five C-rings [7].
Remove the arm /Fr [8].
Remove the belt [9].
Remove the Pick-up Roller Shaft [11]
from the Arm /Rr [10].
9. Remove the 2 Spacers [12] from the
Pick-up Roller Shaft.
10. Remove two Pick-up Rollers [13].
NOTE
Be sure to take note of the direction of
the pick-up roller when installing it.
16eaf2c004na
11. Remove the C-ring [14], and remove the

gear [15] and the bushing [17].
12. Remove two pins [16].
13. Remove the Feed Roller [18].
NOTE
Use care not to lose the pin.
[14]
[17]
[15]
MAINTENANCE
[16]
[18]
2.1.2
16eaf2c005na
Replacing the Separation Roller

Separation Roller: Every 500,000 prints (Actual replacement cycle: Every 200,000 faces)
B. Procedure
[1]
16eaf2c006na
2. Hold the [2] sections in the figure, and

remove the cover [3].
[2]
[3]
[2]
16eaf2c007na
2. PERIODIC CHECK
[4]
3. Remove the Separation Roller Assy [4].

NOTE
Use care not to lose the spring at the
bottom side of the Separation Roller
Assy.
DF-607
16eaf2c008na
4. While opening up the holder [5], remove

the Separation Roller Shaft [6].
NOTE
Opening the holder too much can
break the holder.
[5]
[6]
MAINTENANCE
16eaf2c009na
5. Remove the Separation Roller [7] from

the Separation Roller Shaft.
[7]
16eaf2c010na
2.1.3
Cleaning of the Pick-up Roller, Feed Roller and Separation Roller
A. Periodic cleaning parts/cycle

Pick-up Roller: Every 250,000 prints (Actual replacement cycle: Every 50,000 faces)
Feed Roller: Every 250,000 prints (Actual replacement cycle: Every 50,000 faces)
Separation Roller: Every 250,000 prints (Actual replacement cycle: Every 50,000 faces)
B. Procedure
[1]
16eaf2c011na
2. PERIODIC CHECK
DF-607
2. Using a soft cloth dampened with alcohol, wipe the Pick-up Roller [2], Feed
Roller [3] and Separation Roller [4].
[3]
[4]
[2]
2.1.4
16eaf2c012na
Cleaning of Miscellaneous Rolls

Miscellaneous Rolls: Every 250,000 prints (Actual replacement cycle: Every 50,000 faces)
B. Procedure
2. Using a soft cloth dampened with alcohol, wipe the roll [2].
MAINTENANCE
[2]
16eaf2c013na
3. Lift up the Original Feed Tray [3].

[3]
[4]
16eaf2c014na
[5]
16eaf2c015na
5. Open the DF.

6. Remove the Platen Guide [5].
2. PERIODIC CHECK
DF-607
[6]
[6]
16eaf2c016na
2.1.5
Cleaning of Miscellaneous Rollers
B. Procedure
2. Using a soft cloth dampened with alcohol, wipe the roller [2].
[2]
[1]
16eaf2c017na
[3]
[4]
3. Lift up the Original Feed Tray [3].

16eaf2c018na
5. Remove the Cover /Fr and Cover /Rr.

(See P.14)
6. Disconnect eight connectors [5] on the
DF Control Board (DFCB).
[5]
[5]
[5]
16eaf2c019na
MAINTENANCE

Miscellaneous Rollers: Every 250,000 prints (Actual replacement cycle: Every 50,000 faces)
2. PERIODIC CHECK
DF-607
7. Remove the lever [6].

[6]
16eaf2c020na
MAINTENANCE
[7]
16eaf2c021na
10
9. Remove seven screws [8], and remove

the Paper Feed Unit [9].
[8]
DF-607
[8]
2. PERIODIC CHECK
16eaf2c022na
[10]
[10]
16eaf2c023na
2.1.6
Cleaning of the Scanning Guide
A. Periodic cleaning part/cycle

Scanning Guide: Every 250,000 prints (Actual replacement cycle: Every 50,000 faces)
B. Procedure
1. Open the DF.
2. Using a soft cloth dampened with alcohol, wipe the Scanning Guide [1].
[1]
16eaf2c024na
11
MAINTENANCE
[9]
2. PERIODIC CHECK
DF-607
2.1.7
Cleaning of the Reflective Sensor Section
A. Periodic cleaning part/cycle

Reflective Sensor: Every 250,000 prints (Actual replacement cycle: Every 50,000 faces)
B. Procedure
1. Clean the Original Size Sensor /2 (PS2)
[1] using a brush or other similar tools.
[1]
MAINTENANCE
16eaf2c025na
12
3.1
OTHER
Disassembly/Adjustment prohibited items
A. Screws to which blue paint or green paint is applied

Blue paint or green paint is applied to some screws to prevent them from coming
loose.
As a general rule, screws to which blue paint or green paint is applied should not be
removed or loosened.
DF-607
3.
3. OTHER
B. Red-painted screws
Do not remove or loosen any of the red-painted screws in the field. It should also be
noted that, when two or more screws are used for a single part, only one representative screw may be marked with the red paint.
NOTE
Do not turn the variable resistors on boards for which no adjusting instructions are
given in ADJUSTMENT/SETTING.
D. Removal of Boards
Caution
When removing a circuit board or other electrical component, refer to SAFETY AND
IMPORTANT WARNING ITEMS and follow the corresponding removal procedures.
The removal procedures given in the following omit the removal of connectors and
screws securing the circuit board support or circuit board.
When it is absolutely necessary to touch the ICs and other electrical components on
the board, be sure to ground your body.
13
MAINTENANCE
C. Variable Resistors on Board
3. OTHER
DF-607
3.2
Disassembling and assembling list
No.
Section
1
2
Ref.Page
P.14
Cover /Rr
P.14
Original Feed Tray Cover /Lw
P.14
DF Control Board (DFCB)
P.15
Original Size VR (VR1)
P.15
Complete Stamp Unit 2
P.17
Replace Stamp 2
P.18
6
7
8
3.3
Cover
Part name
Cover /Fr
Board and etc.
Others
Disassembling and assembling procedure
3.3.1
Cover /Fr, Cover /Rr and Original Feed Tray Cover /Lw
MAINTENANCE
[3]
[9]
[4]
[5]
[7]
[2]
[6]
[8]
[1]
16eaf2c026na
1. Remove two screws [1], and remove the Cover /Fr [2].
2. Remove the 2 Screws [3] and raise the Original Feed Tray. Open DF to release the Lock
Claws (at 2 places) and then remove the Cover /Rr [4].
3. Remove the screw [5] and the washer [6], and remove the stopper [7].
4. Lift up the Original Feed Tray.
5. Remove four screws [8], and remove the Original Feed Tray Cover /Lw [9].
14

DF Control Board (DFCB)
[1]
[1]
[2]
1. Turn OFF the Main Power Switch

(SW1).
2. Remove the Cover /Rr.
(See P.14)
3. Disconnect all the connectors on the DF
Control Board (DFCB).
4. Remove three screws [1], and then
remove the DFCB [2].
DF-607
3.3.2
3. OTHER
16eaf2c027na
NOTE
When DFCB is replaced, be sure to conduct the back-up data initialization, the original width detection adjustment and the rewrite of the firmware.
Original Size VR (VR1)
[1]
[2]
[3]
[2]
16eaf2c028na
A. Removal Procedure
1. Turn OFF the Main Power Switch
(SW1).
2. Remove the Original Feed Tray Cover
/Lw.
(See P.14)
3. Disconnect the connector [1].
4. Remove two screws [2] and the mounting plate [3].
5. Remove the gear [4].
[4]
16eaf2c029na
[5]
[6]
[7]
6. Remove the nut [5] and the washer [6],

and remove the Original Size VR (VR1)
[7].
16eaf2c030na
15
MAINTENANCE
3.3.3
3. OTHER
DF-607
[1]
16eaf2c031na
B. Reinstallation Procedure
1. Close the Side Edge Stop [1] of the
Original Feed Tray.
NOTE
Be sure to perform document width
detection adjustment after replacing
the Original Size VR (VR1).
(See P.212 "10.8 ADF" in Field Service
bizhub 500 / 420 main body.)
2. Use the nut [2] and the washer [3] to
install the VR1 [4].
NOTE
Align the protrusion of the VR1 and the
cutout of the mounting plate.
[2]
[3]
[4]
MAINTENANCE
16eaf2c032na
3. Turn the protrusion of the VR1 [5] counterclockwise until it stops.

[5]
16eaf2c033na
4. Reinstall the gear [6].

NOTE
Note the mounting position of the gear
and the VR1.
[6]
16eaf2c034na
[8]
[10]
5. Connect the connector [7].

6. Use two screws [8] to install the VR1 [9].
NOTE
Install the gear and rack gear by aligning the arrows [10] and [11].
[7]
[11]
[8]
[9]
16eaf2c035na
7. Install the Original Feed Tray Cover /Lw and turn ON the Main Power Switch (SW1).
16
3. OTHER
NOTE
When VR1 is replaced, be sure to conduct the back-up data initialization and the original width detection adjustment.
3.3.4
Complete Stamp Unit 2
DF-607

2. Open the Processing Guide [2].
[2]
[1]
16eaf2c036na
3. Remove the screw [3] and the cover [4].

[3]
MAINTENANCE
[4]
16eaf2c037na
4. Remove the screw [5] and disconnect

the connector [6], and remove the Complete Stamp Unit 2 [7].
[5]
[6]
[7]
16eaf2c038na
17
3. OTHER
3.3.5

Replacing the Replace Stamp 2
DF-607

2. Open the Processing Guide [2].
[2]
[1]
16eaf2c039na
[4]
[3]
MAINTENANCE
[5]
16eaf2c040na
18
3. Remove the stamp.

4. Reinstall the new Replace Stamp 2 [3].
NOTE
Align the protrusion [4] of the stamp to
the crevice [5] of the holder.
5. Close the Processing Guide.
6. Close the Open/Close Cover.
4.
MECHANICAL ADJUSTMENT
4.1
Leading Edge Skew Adjustment

[1]
DF-607
ADJUSTMENT/SETTING
1. Load the test chart [1] in the DF and

make one 1-sided copy five consecutive
times.
16eaf3c001na
2. Fold each of the sample copies as illustrated and check for any deviation.
Specifications: 0 3.0 mm
3. If the deviation does not fall within the
specified range, perform the following
adjustment procedure.
4. Open the DF.

5. Loosen the decorative screw [2] and the
nut [3] in the back to the right.
[2]
[3]
16eaf3c003na
6. If there is a deviation as shown on the

figure, turn the screw counterclockwise
to adjust it.
16eaf3c004na
19
ADJUSTMENT/SETTING
16eaf3c002na
DF-607
7. If there is a deviation as shown on the

figure, turn the screw clockwise to
adjust it.
8. After the adjustment procedure has
been completed, tighten the decorative
screw and the nut which has been loosened in step 5.
ADJUSTMENT/SETTING
16eaf3c005na
20
SERVICE MANUAL
Field Service
PC-202
(
500 / 420)
2006.02
Ver. 1.0
Revision history
Revision mark:
NOTE
2006/02
1.0
Date
Service manual Ver.
Revision mark

PC-202
CONTENTS
PC-202
OUTLINE
1.
2.
OUTLINE
MAINTENANCE
PERIODIC CHECK..................................................................................................3
2.1
2.1.1
Replacing the Separation Roller Assy...........................................................3
2.1.2
Replacing the Feed Roller.............................................................................4
2.1.3
Replacing the Pick-up Roller .........................................................................7
3.1
Disassembly/Adjustment prohibited items ............................................................9
3.2
Disassembling, assembling and cleaning list......................................................10
3.2.1
Disassembling and assembling list .............................................................10
3.2.2
Cleaning list.................................................................................................10
3.3
3.3.1
Right Door/Rear Right Cover/Lower Right Cover/Front Right Cover...........11
3.3.2
Rear Cover ..................................................................................................11
3.4
MAINTENANCE
OTHER ....................................................................................................................9
ADJUSTMENT/SETTING
3.
Cleaning procedure.............................................................................................12
3.4.1
Separation Roller.........................................................................................12
3.4.2
Feed Roller..................................................................................................13
3.4.3
Pick-up Roller ..............................................................................................13
3.4.4
Vertical Conveyance Roller .........................................................................13
ADJUSTMENT/SETTING
4.
4.1
Mis-centering adjustment of the Trays 3 and 4 ...................................................15
MAINTENANCE
OUTLINE
PC-202
ADJUSTMENT/SETTING
Blank Page
ii
OUTLINE
PC-202
1.
Name
2 way Paper Take-Up Cabinet
Type
Front loading type 2 way paper take-up device
Installation
Desk type
Document Alignment
Center
OUTLINE
A. Type
B. Paper type
56 to 90 g/m2
Paper Type
Plain paper
Paper Size
Metric: A3, B4, A4, A4S, B5, A5S, 11 17, 81/2 11, 81/2 11S, Foolscap
Inch: 11 17, 81/2 14, 81/2 11, 81/2 11S, 51/2 81/2S, A3, A4, A4S, Foolscap
Tray 3
Tray 4
Capacity
C. Maintenance
Maintenance
Power Requirements
Power Consumption
15 W or less
Dimensions
570 mm (W) 548 mm (D) 263 mm (H)
Weight
Approx. 26.0 kg
Temperature
Humidity
NOTE
OUTLINE
PC-202
Blank Page
2. PERIODIC CHECK
MAINTENANCE
PERIODIC CHECK
2.1
PC-202
2.
2.1.1
Replacing the Separation Roller Assy

Separation Roller Assy: Every 750,000 prints (Actual replacement cycle: Every 300,000
prints)
NOTE
Replace the Separation Roller Assy, Feed Roller and Pick-up Roller at the same time.
B. Procedure
[1]
1. Remove the Right Door.

(See P.11)
2. Remove two screws [1] and remove the
Jam Access Cover [2].
MAINTENANCE
[2]
4061f2c001na

Separation Roller Mounting Plate Assy
[4].
[4]
[3]
4061f2c002na
[7]
[5]
[6]
4. Remove two C-rings [5] and the shaft

[6], and remove the Separation Roller
Fixing Plate Assy [7].
NOTE
Be careful not to lose spring at this
time.
[5]
4061f2c003na
2. PERIODIC CHECK
[9]
PC-202
5. Remove the C-ring [8], the Guide [9],

and remove the Separation Roller Assy
[10].
6. Repeat steps 1 to 5 similarly for the Tray
4.
[10]
[8]
4061f2c004na
NOTE
When installing the Separation Roller
Mounting Plate Assy, be sure to fix the
holder with screws while holding it
down.
MAINTENANCE
4061f2c005na
2.1.2
Replacing the Feed Roller

Feed Roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints)
NOTE
B. Procedure
[2]
[1]
4061f2c006na
1. Remove the Rear Right Cover. (Remove

the Right Lower Cover for Tray 4.)
(See P.11)
2. Remove the Tray.
3. Remove the Separation Roller Mounting
Plate Assy.
(See P.3)
4. Disconnect the connector [1] (Tray 3),
two connectors [2] (Tray 4) and remove
the harness from two wire saddles.
NOTE
Be careful not to confuse the connector of the Tray 3 with the connectors of
the Tray 4.
2. PERIODIC CHECK
5. Remove four screws [3] and remove the
Paper Feed Unit [4].
PC-202
[4]
[3]
4061f2c007na
[5]

Mounting Frame [6] for the Separation
Roller Mounting Plate Assy.
[6]
4061f2c008na

Feed Roller Cover [8].
[8]
[7]
4061f2c009na
8. Remove the C-ring [9] and remove the

bearing [10].
[9]
[10]
4061f2c010na
MAINTENANCE
[3]
2. PERIODIC CHECK
PC-202
[11]
9. Shift the Shaft Assy [11] in the orientation as shown on the left, and remove
the C-ring [12] and the gear [13].
[13]
[12]
4061f2c011na
MAINTENANCE
10. Remove the C-ring [14], the bearing

[15], and remove the shaft Assy [16].
[16]
[15]
[14]
4061f2c012na
[17]
[19]
11. Remove two C-rings [17] and the bearing [18], and remove the Pick-up Roller
[17]
[18]
4061f2c013na
[20]
[21]
4061f2c014na

Feed Roller [21].
13. Repeat steps 1 to 12 similarly for the
Tray 4.

Replacing the Pick-up Roller

Pick-up Roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints)
NOTE
PC-202
2.1.3
2. PERIODIC CHECK
B. Procedure
4061f2c015na

[3]
[2]
[2]
4061f2c016na
[4]

[5] together with frame.
[5]
4061f2c017na
MAINTENANCE
1. Remove the Rear Right Cover. (Remove

the Right Lower Cover for Tray 4.)
(See P.11)
2. Remove the Tray.
Plate Assy.
(See P.3)
4. Disconnect the connector [1] and
remove the harness from two wire saddles.
[1]
2. PERIODIC CHECK
PC-202

[7]
[6]
4061f2c018na
8. Remove two C-rings [8], two bearings

[9], and remove the Pick-up Roller Assy
[10].
[8]
MAINTENANCE
[9]
[9]
[10]
4061f2c019na
[11]
[12]
4061f2c020na

Pick-up Roller [12].
10. Repeat steps 1 to 9 similarly for the tray
4.
3.1
OTHER

loose.
PC-202
3.
3. OTHER
NOTE
CAUTION
MAINTENANCE
3. OTHER
PC-202
3.2
3.2.1
Disassembling, assembling and cleaning list

No
Section
Rear Right Cover
See P.11
Lower Right Cover
See P.11
Front Right Cover
See P.11
Rear Cover
See P.11
3.2.2
No
Covers
Cleaning list
Section
1
2
3
MAINTENANCE
Ref. page
See P.11
10
Part name
Right Door
Paper feed section
Part name
Ref. page
Separation Roller
See P.12
Feed Roller
See P.13
Pick-up Roller
See P.13
Vertical Conveyance Roller
See P.13
3.3.1
Right Door/Rear Right Cover/Lower Right Cover/Front Right Cover

[1]
[3]
[2]
1. Open the Right Door [1].

2. Remove the Right Door [1].
Rear Right Cover [3].
Lower Right Cover [5].
Front Right Cover [7].
PC-202
3.3
3. OTHER
[4]
[5]
[7]
4061f2c021na
Rear Cover
Rear Cover [2].
[1]
[2]
[1]
4061f2c022na
11
MAINTENANCE
3.3.2
[6]
3. OTHER
PC-202
3.4
Cleaning procedure
NOTE
The alcohol described in the cleaning procedure represents the isopropyl alcohol.
3.4.1
Separation Roller
A. Periodically cleaning cycle

Separation Roller: Every 250,000 prints
B. Procedure
[2]
MAINTENANCE
[1]

(See P.11)
Jam Access Cover [2].
4061f2c023na
[4]

Paper Separation Roller Mounting Plate
Assy [4].
[3]
4061f2c024na
4. Using a soft cloth dampened with alcohol, wipe the Separation Roller [5].
4.
[5]
4061f2c025na
12

3.4.2
3. OTHER
Feed Roller
PC-202

Feed Roller: Every 250,000 prints
B. Procedure
1. Remove the Tray 3.
Plate Assy.
(See P.12)
3. Using a soft cloth dampened with alcohol, wipe the Feed Roller [1] clean of
dirt.
4.
[1]
4061f2c026na
Pick-up Roller

Pick-up Roller: Every 250,000 prints
B. Procedure
1. Remove the Tray 3.
Plate Assy.
(See P.12)
3. Using a soft cloth dampened with alcohol, wipe the Pick-up Roller [1].
4.
[1]
4061f2c027na
3.4.4

Vertical Conveyance Roller: Every 250,000 prints
B. Procedure
1. Open the Right Door.
2. Using a soft cloth dampened with alcohol, wipe the Vertical Conveyance Roller
[1].
[1]
4061f2c028na
13
MAINTENANCE
3.4.3
MAINTENANCE
PC-202
3. OTHER
Blank Page
14
ADJUSTMENT/SETTING
4.1
PC-202
4.
Mis-centering adjustment of the Trays 3 and 4
Conduct this adjustment when a mis-centering occurs that cannot be adjusted in the service
mode.
A. Procedure
1. Pull out the Tray [1].
2. If there remains any paper, remove it
thoroughly.
4. Move the Paper Guide [3] and adjust the
center position with the marking-off [4]
as a guide.
[2]
[1]
ADJUSTMENT/SETTING
[3] [4]
4061f3c001na
6. Set the Tray with paper put it in.

7. Conduct the copy/print operation and
check to see if the mis-centering
between the center [1] of the paper and
the center [2] of the copied image is
within a standard value ( 3 mm or less
[3]).
8. When the value is not within the standard value, repeat steps 1 to 7 until the
standard value can be obtained.
[2]
[3]
[1]
4061f3c002na
15
PC-202
ADJUSTMENT/SETTING
Blank Page
16
SERVICE MANUAL
Field Service
PC-402
(
500 / 420)
2006.02
Ver. 1.0
Revision history
Revision mark:
NOTE
2006/02
1.0
Date
Service manual Ver.
Revision mark

PC-402
CONTENTS
PC-402
OUTLINE
1.
PRODUCT SPECIFICATION...................................................................................1
2.
OUTLINE
MAINTENANCE
PERIODIC CHECK..................................................................................................3
2.1
2.1.1
Replacing the Separation Roller Assy...........................................................3
2.1.2
Replacing the Feed Roller.............................................................................4
2.1.3
Replacing the Pick-up Roller .........................................................................7
3.1
3.2
Disassembling, assembling and cleaning list......................................................10
3.2.1
Disassembling and assembling list .............................................................10
3.2.2
Cleaning list.................................................................................................10
3.3
3.3.1
Right Door/Rear Right Cover/Lower Right Cover/Front Right Cover...........11
3.3.2
Rear Cover ..................................................................................................11
3.3.3
Tray..............................................................................................................12
3.3.4
Wire .............................................................................................................13
3.4
MAINTENANCE
OTHER ....................................................................................................................9
ADJUSTMENT/SETTING
3.
Cleaning procedure.............................................................................................16
3.4.1
Separation Roller.........................................................................................16
3.4.2
Feed Roller..................................................................................................16
3.4.3
Pick-up Roller ..............................................................................................17
3.4.4
Vertical Conveyance Roller .........................................................................17
ADJUSTMENT/SETTING
4.
4.1
Mis-centering adjustment....................................................................................19
4.2
Shifter Movement Timing Belt Adjustment ..........................................................21
MAINTENANCE
OUTLINE
PC-402
ADJUSTMENT/SETTING
Blank Page
ii
OUTLINE
PRODUCT SPECIFICATION
PC-402
1.
Name
2500 sheets paper feed cabinet
Type
Front loading type LCC
Installation
Desk type
Document Alignment
Center
OUTLINE
A. Type
B. Paper type
Paper Type
Plain paper
Paper Size
Metric: A4
Inch: 81/2 11
Capacity
2500 sheets (80 g/m2)
56 to 90 g/m2
C. Maintenance
Maintenance
Power Requirements
Power Consumption
45 W or less
Dimensions
570 mm (W) 548 mm (D) 263 mm (H)
Weight
Approx. 26.0 kg
Temperature
Humidity
NOTE
OUTLINE
PC-402
Blank Page
2. PERIODIC CHECK
MAINTENANCE
PERIODIC CHECK
2.1
PC-402
2.
2.1.1
Replacing the Separation Roller Assy

Separation Roller Assy: Every 750,000 prints (Actual replacement cycle: Every 300,000
prints)
NOTE

(See P.11)
[2].
[2]
[1]
4061f2c201na
[5]
[4]
[3]
3. Remove two C-rings [3] and the shaft

[4], and remove the Separation Roller
NOTE
Be careful not to lose spring at this
time.
[3]
4061f2c202na
4. Remove the C-ring [6], the Guide [7],

and remove the Separation Roller Assy
[8].
[8]
[7]
[6]
4061f2c203na
MAINTENANCE
B. Procedure
2. PERIODIC CHECK
PC-402
NOTE
When installing the Separation Roller
Mounting Plate Assy, be sure to fix the
holder with screws while holding it
down.
4061f2c204na
2.1.2
Replacing the Feed Roller

Feed Roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints)
NOTE
MAINTENANCE
B. Procedure
1. Remove the Rear Cover and the Rear
Right Cover.
(See P.11)
2. Remove the Tray.
Plate Assy.
(See P.3)
4. Disconnect the connector [1] from the
PC Control Board (PCCB).
[1]
4061f2c205na

[3]
[2]
[2]
4061f2c206na
2. PERIODIC CHECK
[4]

Mounting Frame [5] for the Separation
Roller Mounting Plate Assy.
PC-402
[5]
4061f2c207na

[7]
4061f2c208na
8. Remove two C-rings [8] and remove the

bearing [9].
[8]
[9]
4061f2c209na
MAINTENANCE
[6]
2. PERIODIC CHECK
PC-402
[10]
9. Shift the Shaft Assy [10] in the orientation as shown on the left, and remove
the C-ring [11] and the gear [12].
10. Remove the Shaft Assy [10].
[12]
[11]
MAINTENANCE
4061f2c210na
[15]
11. Remove two C-rings [13] and the bearing [14], and remove the Pick-up Roller
[13]
[13]
[14]
4061f2c211na

Feed Roller [17].
[16]
[17]
4061f2c212na

Replacing the Pick-up Roller
A. Periodic replaced part/cycle

Pick-up Roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints)
NOTE
PC-402
2.1.3
2. PERIODIC CHECK
B. Procedure
MAINTENANCE
1. Remove the Rear Cover and the Rear

Right Cover.
(See P.11)
2. Remove the Tray.
Plate Assy.
(See P.3)
4. Disconnect the connector [1] from the
PC Control Board (PCCB).
[1]
4061f2c213na
5. Remove four screws [2] and the Paper

Feed Unit [3].
[3]
[2]
[2]
4061f2c214na
[4]

[5] together with frame.
[5]
4061f2c215na
2. PERIODIC CHECK
PC-402

Paper Feed Roller Cover [7].
[7]
[6]
4061f2c216na
[8]
8. Remove two C-rings [8], two bearings

[9], and the Pick-up Roller Assy [10].
[8]
[9]
MAINTENANCE
[9]
[10]
4061f2c217na
[11]
[12]
4061f2c218na

Pick-up Roller [12].
3.1
OTHER

loose.
PC-402
3.
3. OTHER
NOTE
CAUTION
MAINTENANCE
3. OTHER
PC-402
3.2
3.2.1
Disassembling, assembling and cleaning list

No
Section
Rear Right Cover
P.11
Lower Right Cover
P.11
Front Right Cover
P.11
Rear Cover
P.11
Tray
P.12
Wire
P.13
3.2.2
No
Cover
Tray section
Cleaning list
Section
MAINTENANCE
Ref. page
P.11
2
3
4
10
Part name
Right Door
Paper feed section
Part name
Ref. page
Separation Roller
P.16
Feed Roller
P.16
Pick-up Roller
P.17
P.17
3.3.1
Right Door/Rear Right Cover/Lower Right Cover/Front Right Cover

[1]
[3]
[2]
1. Open the Right Door [1].

2. Remove the Right Door [1].
Rear Right Cover [3].
Lower Right Cover [5].
Front Right Cover [7].
PC-402
3.3
3. OTHER
[4]
[5]
[7]
4061f2c219na
Rear Cover
Rear Cover [2].
[2]
[1]
4061f2c220na
11
MAINTENANCE
3.3.2
[6]
3. OTHER
Tray
PC-402
3.3.3
[3]
1. Press the Tray Release Key [1] and slide

out the Tray [2].
2. Remove the paper.
3. Remove four screws [3] and slide out
the Tray [2].
[2]
[3]
[1]
4061f2c221na
4. Remove two screws [4], the connector

[5], and remove the Relay Board (RLB)
[6].
5. Remove the Tray.
NOTE
When removing the RLB, take care not
to drop the Tray from the guide rail.
MAINTENANCE
[4]
[5]
[6]
4061f2c222na
CAUTION
To prevent injuries, press the guide rail
[7] inside the machine.
[7]
4061f2c223na
12

Wire
1. Remove the Tray.

(See P.12)
Front Cover Assy [2].
3. Unplug the connector [3].
[1]
[3]
PC-402
3.3.4
3. OTHER
[1]
[2]
4061f2c224na
MAINTENANCE
4. Remove two screws [4] and the Inner

Cover Assy [5].
NOTE
Do not peel off pulley protective mylar
sheet.
[4]
[5]
[4]
4061f2c225na

Driver Cover [7].
[7]
[6]
4061f2c226na
6. Remove three screws [8] and remove

the Driver Mounting Plate Assy [9].
[9]
[8]
4061f2c227na
13
3. OTHER
PC-402
NOTE
When assembling, be sure to engage
rib of gear 1 [10] with concave section
of gear 2 [11].
[10]
[11]
4061f2c228na
[13]

the Reinforcement Plate Assy [13].
[12]
MAINTENANCE
[12]
4061f2c229na
8. Remove two C-clips [14].

9. Remove four Pulley Covers [15].
10. Unhook four pulleys [16].
[15]
[16]
[15]
[15]
[16]
[14]
[15]
[14]
4061f2c230na
11. Remove the Ground Plate [17].

12. Remove four Cable Holders [18] and
remove the Main Tray [19].
NOTE
Take care not to bend the wires.
[18]
[18]
[19]
[18]
[18]
[17]
4061f2c231na
14
3. OTHER
PC-402
13. Remove four screws [20] and remove

the Side Guide Assy /Rr [21].
[21]
[20]
[20]
4061f2c232na
[22]
14. Remove four screws [22] and remove

the Side Guide Assy /Fr [23].
[22]
4061f2c233na
[24]
15. Remove three C-rings [24], the bearing

[25], and two gears [26].
16. Remove the Wire Pulley Assy [27].
[27]
[25]
[26]
[24]
4061f2c234na
[28]
[29]
[29]
[28]
17. Remove two C-rings [28] and the Wire

Pulley [29].
NOTE
Take care not to lose fixing pins.
When reinstalling the Wire Pulley,
check that the direction of the wire
coming from both wire pulleys are the
same.
Install so that cut parts [30] at both
ends of shaft face up.
[30]
4061f2c235na
15
MAINTENANCE
[23]
3. OTHER
PC-402
3.4
Cleaning procedure
NOTE
The alcohol described in the cleaning procedure represents the isopropyl alcohol.
3.4.1
Separation Roller

Separation Roller: Every 250,000 prints
B. Procedure
MAINTENANCE
[2]

(See P.11)
Paper Separation Roller Mounting Plate
Assy [2].
[1]
4061f2c236na
3. Using a soft cloth dampened with alcohol, wipe the Separation Roller [3].
[3]
4061f2c237na
3.4.2
Feed Roller

Feed Roller: Every 250,000 prints
B. Procedure
1. Remove the Tray.
Plate Assy.
(See P.16)
3. Using a soft cloth dampened with alcohol, wipe the Feed Roller [1].
[1]
4061f2c238na
16

3.4.3
3. OTHER
Pick-up Roller
PC-402

Pick-Up Roller: Every 250,000 prints
B. Procedure
1. Remove the Tray.
Plate Assy.
(See P.16)
3. Using a soft cloth dampened with alcohol, wipe the Pick-up Roller [1].
[1]
4061f2c239na

Vertical Conveyance Roller: Every 250,000 prints
B. Procedure
2. Using a soft cloth dampened with alcohol, wipe the Vertical Conveyance Roller
[1].
[1]
4061f2c240na
17
MAINTENANCE
3.4.4
MAINTENANCE
PC-402
3. OTHER
Blank Page
18
ADJUSTMENT/SETTING
4.1
PC-402
4.
Mis-centering adjustment
Conduct this adjustment when a mis-centering occurs that cannot be adjusted in the service
mode.
1. Press the Tray Release Key [1] and slide
out the Tray [2].
[2]
[1]
4061f3c201na
[3]
4061f3c202na
When moving the center of the paper to

the rear side, rotate the screw D counterclockwise.
4061f3c203na
When moving the center of the paper to

the front side, rotate the screw D clockwise.
4061f3c204na
19
ADJUSTMENT/SETTING

3. Loosen the adjustment screw [3] and
turn screw D [4].
NOTE
Do not damage the passage surface of
the Right Door.
[4]
PC-402
[2]
[3]
[1]
ADJUSTMENT/SETTING
4061f3c209na
20
4. Close the Right Door and set the Tray.

5. Conduct the copy/print operation and
check to see if the mis-centering
between the center [1] of the paper and
the center [2] of the copied image is
within a standard value ( 3 mm or less
[3]).
6. When the value is not within the standard value, repeat steps 1 to 5 until the
standard value can be obtained.
7. Slide out the Tray and tighten the adjustment screw.
Shifter Movement Timing Belt Adjustment

1. Slide out the Tray and remove it.
2. Lift the Main Tray [1], and remove two
screws [2] fixing the Shift Tray.
NOTE
When reinstalling, take care not to
unfasten the wire of the Main Tray.
[2]
[1]
PC-402
4.2
4061f3c205na

Shifter [4].
[4]
[3]
4. Push the tab [6] of the Shift Tray [5] as

shown on the left and release the lock.
5. Remove the Sub Tray [5].
[5]
[6]
4061f3c207na
6. Loosen the screw [7] as shown to the

left and move it in the direction of the
arrow.
7. After moving the Shifter, tighten the
screw [7].
[7]
4061f3c208na
21
ADJUSTMENT/SETTING
4061f3c206na
PC-402
ADJUSTMENT/SETTING
Blank Page
22
SERVICE MANUAL
Field Service
LU-201
2006.02
Ver. 1.0
Revision history
Revision mark:
NOTE
2006/02
1.0
Date
Service manual Ver.
Revision mark

CONTENTS
LU-201
CONTENTS
LU-201
OUTLINE
MAINTENANCE
2. PERIODIC CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1
Maintenance procedure of the paper feed section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1.1
Replacing the pick-up rubber and the feed rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.2
Replacing the separation roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1
3.2
Disassembling and assembling list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Disassembling and assembling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2.1
Removal and reinstallation of the right cover, the front cover and the rear cover. . . . . . . . . . . . 11
3.2.2
Replacing the wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ADJUSTMENT/SETTING
4. MECHANICAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1
Adjusting the tilt of the lift plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
LU-201
CONTENTS
Blank page
ii
LU-201
OUTLINE
A. Type
Type
Side mount type large volume paper feed tray
B. Functions
Maximum tray capacity
2,000 sheets (80 g/m2)
C. Type of paper
Paper type *1
Plain paper, recycled paper, high quality paper of 60 to 105 g/m2
Paper size
A4, 81/2 x 11
*1
Recommended paper
Plain paper
Inch:
Metric: Konica Profi (80 g/m2), Konica Minolta Original (80 g/m2)
Recycled paper Inch:
Weyehaeuser Recycled Laser Copy (20 lbs)

D. Maintenance
Maintenance
E. Machine data
Power source
Power consumption
30 W or less (internal heater is not used)
Dimensions
424 (W) x 515 (D) x 295 (H) mm
Weight
Approx. 16 kg
F.
Temperature
Humidity
Note
LU-201
Blank page
2. PERIODIC CHECK
LU-201
MAINTENANCE
2. PERIODIC CHECK
2.1
Maintenance procedure of the paper feed section
Caution
When connected to the main body, make sure that the power cord of the main body is unplugged
from the power outlet.
2.1.1
Replacing the pick-up rubber and the feed rubber
Pick-up rubber: Every 500,000 prints (Actual replacement cycle: Every 200,000 prints)
Feed rubber: Every 500,000 prints (Actual replacement cycle: Every 200,000 prints)
B. Procedure
1. Open the upper door [1].

2. Remove the C-clips [2], 1 each, and release the 2
[1]
bearings [3].
3. Remove the paper feed roller unit [4].
[2]
[3]
[4]
[3]
[2]
16aaf2c001na
2. PERIODIC CHECK

Note
LU-201
When installing the paper feed roller unit, be

sure to insert the shaft [1] into the ring of the
[3]
actuator [2].
[4]

sure to install it so that the hook [3] comes
above the lift-up shaft [4].
sure to insert the shaft [5] securely into the
coupling [6].
[2]
[6]
[1]
[5]
16aaf2c002na
2. PERIODIC CHECK
4. Remove the C-clip [1] and then remove the actuator [2].
5. Remove the C-clip [3] and then remove the bearing [4].
6. Pull out the shaft [5] in the arrow-marked direction

[6] and remove the feed roller [7].
[2]
[6]
[5]
[7]
[4]
[3]
[1]
16aaf2c003na
7. Remove the feed rubber [2] from the paper feed

[3]
roller [1].
Note
Be sure to install the feed rubber [2] so that
the paint mark [3] comes in the opposite
direction of the gear [4].
When setting the feed rubber, apply alcohol
on the inside of the feed rubber. By doing so,
the feed rubber can be set more easily.
[4]
[2]
[1]
16aaf2c004na
LU-201
[8]
2. PERIODIC CHECK
[4]
[5]
8. Remove the screw [1] and then remove the handle [3] from the roller mounting plate [2].
LU-201
9. Remove the screw [4] and then remove the bearing holder [5] from the roller mounting plate [2].
[2]
[3]
[3]
[1]
16aaf2c005na
10. Remove the bearing [1] and then remove the pick-
[1]
[2]
up roller [3] from the shaft [2].
16aaf2c006na
11. Remove the pick-up rubber [2] from the pick-up

roller [1].
Note
When setting the pick-up rubber, apply alcohol on the inside of the pick-up rubber. By
doing so, the pick-up rubber can be set more
easily.

steps in reverse.
[2]
[1]
16aaf2c007na

2.1.2
2. PERIODIC CHECK
Replacing the separation roller

Separation rubber: Every 500,000 prints (Actual replacement cycle: Every 200,000 prints)
LU-201
B. Procedure
1.
2.
3.
4.
[1]
Pull out LU from the main body.

Open the upper door [1].
Lift up the paper feed roller unit [2].
Remove the 2 screws [3] and then remove the
guide plate [4].
[2]
[4]
[3]
16aaf2c008na
5. Remove the 2 screws [1] and then remove the left
[1]
[2]
cover [2].
16aaf2c009na
2. PERIODIC CHECK

[1]
[3] [2]
LU-201
Note
When installing the separation roller assy, be
sure to set the upper section of the claw [2] at
the center of the marking-off [3] of the plate.
In this way, the separation roller assy can be
horizontally positioned.
16aaf2c010na
7. Release the lock lever [1] and remove the separa-
[1]
[2]
tion roller assy [2].
16aaf2c011na
2. PERIODIC CHECK
8. Pull out the shaft [2] while pressing the lever [1]
and remove the separation roller [3].
[2]
LU-201
[3]
[1]
16aaf2c012na
9. Remove the separation rubber [2] from the sepa[4]
[2]
[1]
ration roller [1].

Note
Be sure to install the separation rubber [2] so
that the paint mark [3] comes in the opposite
direction of the projection [4].
When setting the separation rubber, apply
alcohol on the inside of the separation rubber.
By doing so, the separation rubber can be set
more easily.

steps in reverse.
[3]
16aaf2c013na
3. OTHERS
3. OTHERS
LU-201
3.1
Note
This list shows the explanation of the disassembly and reassembly of the parts which are considered necessary to replace (other than periodically replaced parts). However, these parts except for
the covers are not required to be disassembled while in normal service operations.
For the method of replacing the periodically replaced parts, see "2.1 Maintenance procedure of
the paper feed section".
(See P.3)
No.
1
10
Section
Cover
Tray section
Part name
Page referred to
Right cover
P.11
Front cover
P.11
Rear cover
P.11
Wire A
P.14
Wire B
P.14
Wire C
P.14
Wire D
P.14
Caution
When connected to the main body, make sure that the power cord of the main body is unplugged
from the power outlet.
3.2.1
Removal and reinstallation of the right cover, the front cover and the rear cover
A. Procedure
[1]
[2]
1. Pull out LU from the main body side.

right cover [3].
Note
When installing the right cover [3], be sure to
take note of the direction of the 2 casters [4].
[3]
[4]
16aaf2c014na
11
LU-201
3.2
3. OTHERS
3. OTHERS

[1]
LU-201
front cover [3].
[3]
[2]
[3]
16aaf2c015na

7. Remove the screw [2] and then remove the auxil-
[1]
iary cover /Rr [3].
[2]
12
16aaf2c016na
3. OTHERS
[3]
rear cover [4].

steps in reverse.
[4]
[3]
[2]
[1]
16aaf2c017na
13
LU-201
cable cover [2].
3. OTHERS
3.2.2

Replacing the wires
The length of the wires
LU-201
Wire /A: 707.2 mm

Wire /B: 585.7 mm
Wire /C: 558.7 mm
Wire /D: 680.2 mm
Auxiliary wire: 706.3 mm
Detection wire: 609.6 mm
A. Removing the wire
1. Remove the right cover, the front cover and the

[6]
[5]
rear cover.
[3]
(See P.11)
2. Remove the connectors [1] and [2], and pull out

the wiring harness [4] from the hole [3].
[1]
[4]
[2]
16aaf2c018na
14
3. Remove the 2 connectors [5] and the connector

[6].
3. OTHERS
4. Remove the 5 connectors [2] from the LU drive

board (LUDB) [1].
LU-201
[2]
[2]
[1]
16aaf2c019na
5. Remove the 6 screws [1] and then remove the LU

drive board unit [2].
[1]
[1]
[2]
[1]
16aaf2c020na
15
3. OTHERS

Note
[1]
[2]
When removing the LU drive board unit, the
LU-201
bearings [1] and [2] may come off and fall. Be

careful that they do not get lost.
On the inside of the gear [3], the spacer [4] is
provided. Be careful that it does not get lost.
[4]
[3]
16aaf2c021na
[2]
paper lift motor (M151) [2].
[1]
16
16aaf2c022na
3. OTHERS

[1]
motor mounting plate [2].
LU-201
[2]
[1]
16aaf2c023na
8. Remove the E-ring [1], and remove the wire stop[6]
per [2].
[8]
9. Remove the assist wire [4] from the spring [3].
[7]
Note
Be careful that the lift plate [5] comes down
by its own weight.
10. Peel off the seal [7] from the detection reel [6].
11. Rotate the detection reel [6] clockwise as seen
from the rear side, and remove the detection wire
[8] from the reel.
C
D
B
A
[3]
[5]
[4]
[2]
[1]
16aaf2c024na
17
3. OTHERS
12. Remove the 2 E-rings [1] and the 2 wire stoppers

LU-201
[2]
[2].
[2]
13. Remove the 4 E-rings [4] and remove the 4 upper
[1]
[1]
pulleys [5].
C
D
B
A
[5]
[4]
[5]
[4]
16aaf2c025na
14. Remove the E-ring [1] and the drive pulley [2],
then remove the auxiliary wire [3], the wire A [4]
and the wire B [5].
15. Remove the E-ring [6] and the drive pulley [7],
C
then remove the detection wire [8], the wire D [9]

and the wire C [10].
D
B
A
[3]
[2]
[1]
[4] A
[5]
B
[10] D [9]
C
[8]
[7]
[6]
16aaf2c026na
18
3. OTHERS
B. Stringing wires
[14] [15]
C
D
[15]
D
and the wire D [4] through the lift plate [5].
2. Run the wire A [6] and the wire B [7] through the 2
upper pulleys [8] and the 2 lower pulleys [9], and
then through the adjustment part [10].
3. Tighten the 2 upper pulleys [8] with the 2 E-rings

[11] [8] [11] [8]
[16] [17] [16] [17]
[11].
4. Install the wire stopper [12] to each of the 2 lower

pulleys [9] in the direction as shown in the drawing. And then fasten it with the 2 E-Rings [13].
5. Run the wire C [14] and the wire D [15] through

[4]
C
[10]
the groove of the pulley [16].
6. Tighten the 2 pulleys [16] with each of the E-ring
D
[3]
[17].
B
A
[2]
[5]
[1]
[9]
[9]
[12]
[12]
[13]
[13]
16aaf2c027na
7. After putting the auxiliary wire [1], the wire A [2]

and the wire B [3] into the holes in the front section of the drive shaft [4], install the drive pulley [5]
and tighten it with the E-ring [6].
8. After putting the detection wire [7], the wire D [8]
and the wire C [9] into the holes in the rear section
of the drive shaft [4], install the drive pulley [10]
and tighten it with the E-ring [11].
[2] A
[1]
[5]
[3]
B
[9] D [8]
C
[7]
[10]
[6]
[11]
[4] [4]
16aaf2c028na
19
LU-201
1. Pass the wire A [1], the wire B [2], the wire C [3]
[7] [6]
B
A
A
[6]
3. OTHERS
9. Hold the drive pulley [1] and the drive pulley [2]
with both hands and rotate them counterclock-
[7]
wise as seen from the front side until there are no
LU-201
[9]
slacks found in the wires A, B, C, and D.
[10]
10. Rotate the coupling shaft [3] on the rear side to lift
[3]
the lift plate [4] to the upper limit.
[2]
Note
Be sure to wind the wires from the inside of
C
the LU to the outside.
[1]
At this time, the auxiliary wire [5] and the

detection wire [11] should not have been
wound around the drive pulleys [6] and [12].

A
[4]
[5] [8]
11. Wind the auxiliary wire [5] about half turn counterclockwise around the drive pulley [6].
12. Wind the auxiliary wire [5] about 1.5 turn clockwise around the pulley [7] and install it to the
spring [8].
13. Install the wire stopper [9] to the pulley [7] in the
[6]
[5]
[11]
[12]
16aaf2c029na
direction as shown in the drawing, and tighten it

with the E-ring [10].
14. With the lift plate [4] lifted fully up to the upper
limit, wind the detection wire [11] about half turn
clockwise around the drive pulley [12].
15. Set the wire attaching notch [2] at the right above
position with no tension applied on the detection
[2]
reel [1], and wind the detection wire [3] a full turn
counterclockwise around the detection reel [1]
starting at the top side.
Note
Be sure to wind the wire from the inside of the
LU to the outside.
[1]
[4]
[3]
16aaf2c030na
16. Rotate the detection reel [1] clockwise to apply

tension. After rotating about 3/4 turn, install the
detection wire [3].
17. Stick the seal [4] to the detection reel [1].

18. Follow Steps 1 to 10 in A. Removing the wire in
reverse order.
Note
After finishing wire replacement, move the lift
plate up and down to confirm that it moves
smoothly.
Make sure that the wires do not cross each
other, or a wire does not run on another wire.
After installing the wires, adjust the tilt of the
lift plate.
(See P.21)
20
LU-201
ADJUSTMENT/SETTING
4.1
Adjusting the tilt of the lift plate
When the lift plate is tilted, paper may not be fed correctly. Adjust the lift plate so that it becomes parallel to the
paper feed roller shaft. When replacing the wire, be sure to conduct this adjustment.
A. Procedure
1. Remove the right cover and the front cover.

(See P.11)
[1]
16aaf3c001na
21
[2]
[5]

4. Stand the scale [3] on the upper surface of the lift
LU-201
plate [2].
5. Move and adjust the wire adjusting member [6] so

that the distance from each of the upper surfaces
of the panels /Fr [4] and /Rr [5] to the upper surface of the lift plate become identical.
6. After completion of the adjustment, tighten up the

screw [7] securely.
[1]
[3]
[4] [7]
[6]
16aaf3c002na
22
SERVICE MANUAL
Field Service
FS-510/PU-501/
OT-601
2006.02
Ver. 1.0
Revision history
Revision mark:
NOTE
2006/02
1.0
Date
Service manual Ver.
Revision mark

FS-510/PU-501/OT-601
CONTENTS
FS-510/PU-501/OT-601
OUTLINE
1.1
FS-510 ..................................................................................................................1
1.2
PU-501..................................................................................................................3
1.3
OT-601 ..................................................................................................................4
OUTLINE
1.
MAINTENANCE
PERIODIC CHECK..................................................................................................5
2.1
2.1.1
Cleaning of the Roller and Roll......................................................................5
OTHER ....................................................................................................................7
3.1
3.2
Disassembling and assembling list .......................................................................8
3.3
Disassembling and assembling procedure ...........................................................9
3.3.1
Conveyance Front Cover /Up, /Rt, /Lw ..........................................................9
3.3.2
Conveyance Upper Cover .............................................................................9
3.3.3
Front Door ...................................................................................................10
3.3.4
Conveyance Front Cover /Lt ........................................................................10
3.3.5
Paper Exit Front Cover, Rear Cover, Connector Cover ...............................11
3.3.6
Tray /2..........................................................................................................12
3.3.7
OT ...............................................................................................................12
3.3.8
Tray /1..........................................................................................................12
3.3.9
Lift Tray ........................................................................................................13
3.3.10
Conveyance Unit .........................................................................................13
3.3.11
Stapler .........................................................................................................14
3.3.12
PU ...............................................................................................................15
3.3.13
Stacker Paddle Drive Clutch Assy ...............................................................16
3.3.14
Paper Holding Paddle Drive Clutch Assy ....................................................17
ADJUSTMENT/SETTING
3.
MAINTENANCE
2.
ADJUSTMENT/SETTING
4.
4.1
Staple Position Adjustment .................................................................................21
4.2
Adjustment of the Installation Position of the Shutter Drive Gear .......................22
4.3
Punch Mis-centering Adjustment (PU-501).........................................................23
ADJUSTMENT/SETTING
MAINTENANCE
OUTLINE
FS-510/PU-501/OT-601
Blank Page
ii
1.
FS-510/PU-501/OT-601
OUTLINE
1.1
FS-510
A. Type
Multi tray finisher built into the main body
Installation
Document Alignment
Center
Consumables
Staples (5,000 staples/cartridge)
OUTLINE
Name
B. Functions
Modes
Non sort, sort, group, sort staple, and punch (when PU-501 is mounted)
C. Paper type
(1) Non sort
Type
Size
Weight
Max. Capacity
Tray /1
Plain paper
Metric:
A3, B4, A4, A4S, B5,
B5S, A5, A5S, B6S
11 x 17, 81/2 x 11,
Translucent paper
Envelope
Label
Tray /2
B4, 81/2 x 14
or greater
500
sheets
91 to 210 g/m2
Thick paper
OHP transparencies
50 to 90 g/m2
200 sheets
A4S, 81/2 x 11S 1000
or less
sheets
Inch:
11 x 17, 81/2 x 14,
81/2 x 11, 81/2 x 11S,
51/2 x 81/2S
A3, A4, A4S, A5S,
Foolscap
Letterhead
20 sheets
(2) Sort/Group
Type
Size
Weight
Metric:
A3, B4, A4, A4S, B5,
B5S, A5
11 x 17, 81/2 x 11,
Plain paper
Inch:
11 x 17, 81/2 x 14,
81/2 x 11, 81/2 x 11S,
51/2 x 81/2S
A3, A4, A4S, A5S,
Foolscap
Max. Capacity
Tray /1
200 sheets
A4S, 81/2 x 11S 1000

or less
sheets
50 to 90 g/m2
Tray /2
B4, 81/2 x 14
or greater
500
sheets
FS-510/PU-501/OT-601
(3) Sort Staple

Type
Size
Weight
Inch:
11 x 17, 81/2 x 14,
81/2 x 11, 81/2 x 11S,
51/2 x 81/2S
A3, A4, A4S, A5S,
Foolscap
OUTLINE
200 sheets
A4S, 81/2 x 11S 1000

or less
sheets
50 to 90 g/m2
Plain paper
Max. Capacity
Tray /1
Metric:
A3, B4, A4, A4S, B5,
B5S, A5, A5S, B6S
11 x 17, 81/2 x 14,
81/2 x 11, 81/2 x 11S,
Foolscap
Tray /2
B4, 81/2 x 14
or greater
500
sheets
D. Stapling
Staple Filling Mode
Dedicated Staple Cartridge (5000 staples)
Staple Detection
Available (Nearly Empty: 20 remaining staples)

Front: Diagonal 45 1 point *1 A3, B4, A4, B5
Rear: Diagonal 45 1 point *1 11 x 17, 81/2 x 11
Stapling Position

Side: Parallel 2 point
A4S, B5S, A5
81/2 x 14, 81/2 x 11S, 51/2 x 81/2S
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 81/2S
*1: Diagonal 30 for B5 and B4

E. Maintenance
Maintenance
F. Machine specifications
Power Requirements
Power Consumption
66 W or less
Dimensions
319 (W) x 558 (D) x 573 mm (H)
Weight
Approx. 21.4 kg
G. Operating environment
Temperature
Humidity
1.2
FS-510/PU-501/OT-601
PU-501
A. Type
Type
Installation
FS built-in type punching operation device

Screwed to the FS
Paper Size
Inch:
2 holes: 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S
3 holes: 11 x 17, 81/2 x 11
A3, A4
Paper Type
Plain Paper (60 to 130 g/m2), Recycled Paper (60 to 130 g/m2)
Punch Hole
Metric: 4 holes, Swedish 4 holes ( 6.5 mm)

Inch: 2 and 3 holes (can be switched) ( 8 mm)
Number of Stored
Punch Wastes
Metric (4 holes): For 1,500 sheets of paper (80 g/m2)

Inch (2, 3 holes): For 1,000 sheets of paper (20 lbs)
Document Alignment
Center
OUTLINE
Metric:
A3, B4, A4, A4S, B5, B5S
11 x 17, 81/2 x 11, 81/2 x 11S, Foolscap
B. Maintenance
Maintenance
Power Requirements
24/5V DC (Supplied from FS)
Dimensions
114 (W) x 461 (D) x 136 mm (H)
Weight
Approx. 1.9 kg
Temperature
Humidity
FS-510/PU-501/OT-601
1.3
OT-601
A. Type
Type
Additional Tray to FS
Installation
Screwed to the FS
Mode
Non sort, sort, group, and sort staple
Number of Bins
1 bin
Document Alignment
Center
OUTLINE
B. Paper Type
Mode
Size
Metric:
A3, B4, A4, A4S, B5,
B5S, A5, A5S, B6S
11 x 17, 81/2 x 11,
Non sort
Inch:
11 x 17, 81/2 x 14,
81/2 x 11, 81/2 x 11S,
51/2 x 81/2S
A3, A4, A4S, A5S,
Foolscap
Sort / group
Metric:
A3, B4, A4, A4S, B5,
B5S, A5
11 x 17, 81/2 x 11,
Sort staple
Inch:
11 x 17, 81/2 x 14,
81/2 x 11, 81/2 x 11S,
51/2 x 81/2S
A3, A4, A4S, A5S,
Foolscap
Type
Plain Paper, Recycled Paper
(56 to 90 g/m2,15 to 24 lb)
Capacity
200 sheets
OHP transparencies
Thick paper
(91 to 210 g/m2)
Special
Envelope
20 sheets
Label paper
Letterhead
Translucent paper
200 sheets
Plain Paper, Recycled paper
(56 to 90 g/m2)
C. Maintenance
Maintenance
Dimensions
282 (W) x 368 (D) x 57 mm (H)
Weight
Approx. 0.7 kg
Temperature
Humidity
NOTE
2. PERIODIC CHECK
2.
FS-510/PU-501/OT-601
MAINTENANCE
PERIODIC CHECK
2.1
NOTE
2.1.1
Cleaning of the Roller and Roll
4. Using a soft cloth dampened with alcohol, wipe the roller and roll [1].
[1]
[1]
[1]
4349f2c001na
5. Lower Processing Guide FN1 [2].

[3]
[2]
4349f2c002na
7. Remove Punch Scraps Box FN3.1 [4].

(only when PU is installed)
[4]
4349f2c003na
MAINTENANCE
1. Remove the Lift Tray.

(See P.13)
2. Remove the Conveyance Unit.
(See P.13)
3. Remove the Conveyance Top Cover.
(See P.9)
FS-510/PU-501/OT-601
2. PERIODIC CHECK

8. Lower Processing Guide FN-3 [5].
[6]
[5]
4349f2c004na
10. Lower Processing Guide FN-4 [7].

[8]
[7]
MAINTENANCE
4349f2c005na
[10]
12. While turning Processing Knob FN-5

[9], wipe the roller [10] using a soft cloth
dampened with alcohol.
[9]
4349f2c006na
[11]
[11]
4349f2c007na
3.
3.1
3. OTHER
OTHER

loose.
FS-510/PU-501/OT-601
NOTE
Caution
MAINTENANCE
FS-510/PU-501/OT-601
3. OTHER
3.2
No.
MAINTENANCE
Part name
Ref.Page
Conveyance Front Cover /Up
P.9
Conveyance Upper Cover
P.9
Conveyance Front Cover /Rt
P.9
Front Door
P.10
Conveyance Front Cover /Lw
P.9
Conveyance Front Cover /Lt
P.10
Paper Exit Front Cover
P.11
Tray /2
P.12
OT (Option)
P.12
10
Tray /1
P.12
11
Connector Cover
P.11
12
Paper Exit Rear Cover
P.11
13
Lift Tray
P.13
14
Conveyance Unit
P.13
Stapler Unit
P.14
16
PU (Option)
P.15
17
Stacker Paddle Drive Clutch Assy
P.16
Paper Holding Paddle Drive Clutch Assy
P.17
15
18
Section
Cover
Unit
Others
3.3
3. OTHER
FS-510/PU-501/OT-601
3.3.1
Conveyance Front Cover /Up, /Rt, /Lw

1. Open the Front Door.
2. Unhook the tab, and remove the Conveyance Front Cover /Up [1].
[1]
4349f2c008na

Conveyance Front Cover /Rt [3].
[3]
4349f2c009na

Conveyance Front Cover /Lw [5].
[5]
NOTE
At reinstallation, first fit the claw [6]
into position.
[6]
[4]
3.3.2
4349f2c010na
Conveyance Upper Cover

1. Remove four screws [1], and remove the
Conveyance Upper Cover [2].
[1]
[2]
[1]
4349f2c011na
MAINTENANCE
[2]
3.3.3
Front Door
[5]
MAINTENANCE
FS-510/PU-501/OT-601
3. OTHER
[4]
[1]
[3]
[2]
1. Open the Front Door [1].

2. Remove the screw [2], and remove the
stopper [3].
3. Loosen two screws [4].
4. Slide up the Fulcrum /Up [5] and
remove the Front Door.
5. Reinstall the above parts following the
removal steps in reverse.
[3]
4349f2c036na
3.3.4
Conveyance Front Cover /Lt

1. Remove three screws [1], and remove
the Conveyance Front Cover /Lt [2].
[2]
[1]
4349f2c014na
10
Paper Exit Front Cover, Rear Cover, Connector Cover

1. Remove the Front Door.
(See P.10)
2. Remove the Conveyance Front Cover
/Lt.
(See P.10)
Paper Exit Front Cover [2].
[1]
[3]
[2]
4349f2c037na
[4]
[5]

Connector Cover [4].
the Paper Exit Rear Cover [6].
[6]
[5]
4349f2c038na
11
MAINTENANCE
3.3.5
3. OTHER
FS-510/PU-501/OT-601
FS-510/PU-501/OT-601
3. OTHER
3.3.6

Tray /2
Tray /2 [2].
[2]
[1]
3.3.7
4349f2c016na
OT
OT [2].
MAINTENANCE
[2]
[1]
3.3.8
4625f2c001na
Tray /1
Tray /1 [2].
[2]
[1]
12
4349f2c017na
Lift Tray
NOTE
When removing the Lift Tray, be sure to bring the Tray down to the bottom.
If the OT is installed, remove it in advance.
[1]
[1]
[2]
4349f2c019na
[4]
[3]
[3]

(See P.10)
/Lt.
(See P.10)
3. Disconnect three connectors [1].
ground wire.
5. Remove the Tray /1, Tray /2 and OT.
(See P.12)
6. Remove six screws [3], and lift the Lift
Tray [4] upward and off from the Conveyance Unit.
NOTE
The removal of the upper 2 screws [3]
is not available when the Lift Tray is
not brought down to the bottom.
4349f2c020na
3.3.10
[2]
Conveyance Unit
[1]

(See P.13)
(See P.10)
3. While holding down the lock release
button [1], remove the Conveyance Unit
[2].
4349f2c021na
13
FS-510/PU-501/OT-601
3.3.9
3. OTHER
MAINTENANCE
FS-510/PU-501/OT-601
3. OTHER
3.3.11

Stapler
[3]
[1]

2. Turn the knob [1], and move the stapler
forward.
3. Remove the Staple Cartridge.
cover [3].
[2]
4349f2c022na
5. Disconnect two connectors [4].
MAINTENANCE
[4]
4349f2c023na
[6]

Stapler Unit [6].
[5]
4349f2c024na

Stapler [8].
[8]
[7]
4349f2c025na
14
3.3.12
3. OTHER
PU
[1]
[2]
4512f2c001na

(See P.13)
(See P.13)
3. Remove the Conveyance Upper Cover.
(See P.9)
/Lw.
(See P.9)
Reinforcement Plate [2].
FS-510/PU-501/OT-601
6. Disconnect two connectors [3].
4512f2c002na
[6]
[7]

PU [7].
[6]
4512f2c003na
[8]
8. Remove nine screws [8], and the Punch

Unit [9].
[8]
[8]
[9]
[8]
4512f2c004na
15
MAINTENANCE
[3]
FS-510/PU-501/OT-601
3. OTHER
3.3.13

Stacker Paddle Drive Clutch Assy
(See P.13)
(See P.13)
(See P.9)
4. Remove the E-ring [1].
[1]
4349f2c026na
5. Loosen two hexagonal socket head

screws [2], and remove the Stacker
Paddle Drive Clutch Assy [3].
[3]
MAINTENANCE
[2]
4349f2c027na
[3]
[1]
[2]
[5]
[4]
[7]
[6]
16
4349f2c028na
1. Check that the 2-mm hole [2] of the
stacker paddle drive shaft [1] and the
cutout of the frame [3] are aligned and
install the Stacker Paddle Drive Clutch
Assy [4].
2. Refer to the figure and check the paddle
position [5].
3. Hook the Solenoid Flapper [7] to the
claw [6] of the Stacker Paddle Drive
Clutch Assy [4].
4. Attach the E-ring and reinstall the
Stacker Paddle Drive Clutch Assy.
5. Adjust the spacing between the E-ring
and the Stacker Paddle Drive Clutch
Assy to 0.2 mm and tighten two hexagonal socket head screws.
Paper Holding Paddle Drive Clutch Assy
[1]
[2]
4349f2c029na
[4]
[3]
(See P.13)
(See P.13)
(See P.9)
4. Remove the C-ring [1].
5. Remove the bearing [2].
6. Loosen two hexagonal socket head
screws [3], and remove the Paper Holding Paddle Drive Clutch Assy [4].
MAINTENANCE
3.3.14
3. OTHER
4349f2c030na
1. Reinstall the Paper Holding Paddle
Drive Clutch Assy [1].
[1]
FS-510/PU-501/OT-601
4349f2c031na
17
FS-510/PU-501/OT-601
3. OTHER
Precaution for Reinstallation

[3]
[4]
[5]
[2]
MAINTENANCE
[1]
4349f2c032na
[1] Solenoid Flapper
[4] Paper Holding Paddle Drive Clutch Assy
[2] 107 3mm
2. Install the bearing [2].
[2]
4349f2c033na
[3]
[4]
4349f2c034na
18
3. Hook the Solenoid Flapper [4] to the

claw [3] of the Paper Holding Paddle
Drive Clutch Assy.
NOTE
Install the Paper Holding Paddle Drive
Clutch Assy with the side having a
wider spacing between the claws facing upward.
4. Attach the C-ring and press the Paper

Holding Paddle Drive Clutch Assy [6] to
the bearing [5].
5. Adjust the spacing [7] between the
bushing [5] and the Paper Holding Paddle Drive Clutch Assy [6] to 0.2 mm and
tighten two hexagonal socket head
screws.
[6]
[7]
4349f2c035na
MAINTENANCE
[5]
3. OTHER
FS-510/PU-501/OT-601
19
MAINTENANCE
FS-510/PU-501/OT-601
3. OTHER
Blank Page
20
ADJUSTMENT/SETTING
4.1
Staple Position Adjustment
B
1. Set the staple and make a print.

2. Check the staple position of the paper.
Slant one point Staple [1]
(Paper Width: 216 to 297 mm)
279 to 297 mm: 45,
B5, B4: 30
[1]
A
C
D
Measurement
position
Specification
Adjustment
range
A, C
4.4 mm
B, D
12.1 mm
+1 to 2mm
[2]
Parallel one point Staple [2]

(Paper Width: 182 to 216 mm)
Measurement
position
Specification
Adjustment
range
4.5 mm
6 mm
+1 to 2mm
Parallel two points Staple [3]

C
[3]
D
E
4349f3c001na
Measurement
position
Specification
Adjustment
range
C, F
6 mm
+1 to 2mm
ADJUSTMENT/SETTING
4.
FS-510/PU-501/OT-601
Y = (paper widthX11) / 2
X = A3, A4: 137 mm
B4, B5: 114 mm
A4S: 190 mm
B5S: 162 mm
11 x 17, 81/2 x 11: 119.4 mm
81/2 x 11S: 196 mm
Substitute above into the equation.
3. If the staple position is misaligned,
adjust with the following procedure.
21
FS-510/PU-501/OT-601
[3]

5. Turn the knob [1], and move the stapler
forward.
6. Loosen the screw [2], and remove the
cover [3].
[1]
[2]
4349f3c002na
7. Loosen two adjustment screws [2] and

move the Stapler Unit [3] in the direction
of the arrow to make the adjustment.
8. Make another print and check the staple
position.
[5]
[4]
4349f3c003na
4.2
Adjustment of the Installation Position of the Shutter Drive Gear

[2]
ADJUSTMENT/SETTING
[1]
[1]
4349f3c004na
22
1. Set three gears.

NOTE
Set the gears so that the marks on
Gears 1 and 3 [1] are aligned with the
rib of Gear 2 [2] as shown on the right.
Punch Mis-centering Adjustment (PU-501)
4512f3c001na
[2]
[1]
1. Set the copier into the Punch mode and

make a 1-sided print from a 1-sided
original.
2. Fold the output paper in half and check
whether the punch hole positions are
aligned.
Specification: 0 2 mm
3. If the punch hole position is misaligned,
adjust with the following procedure.
/Lw.
(See P.9)
5. Loosen the adjustment screw [1], and
move the Punch Unit [2] forward or
backward to make the adjustment.
6. Make another print and check the punch
displacement.
4512f3c002na
ADJUSTMENT/SETTING
4.3
FS-510/PU-501/OT-601
23
FS-510/PU-501/OT-601
ADJUSTMENT/SETTING
Blank Page
24
SERVICE MANUAL
Field Service
FS-511/RU-502
2006.02
Ver. 1.0
Revision history
Revision mark:
NOTE
2006/02
1.0
Date
Service manual Ver.
Revision mark

CONTENTS
FS-511/RU-502
CONTENTS
FS-511/RU-502
OUTLINE
1.1
FS-511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2
RU-502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MAINTENANCE
2. OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1
2.2
Disassembling and assembling list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Disassembling and assembling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2.1
Removal/reinstallation of the upper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2.2
Removal/reinstallation of the front cover /Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2.3
Removal/reinstallation of the front cover /Lw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2.4
Removal/reinstallation of the rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.5
Removal/reinstallation of the punch unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2.6
Replacing the stapler unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ADJUSTMENT/SETTING
3. MECHANICAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1
3.2
3.3
3.4
Output check mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.1.1
Switches provided inside the board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1.2
Output check mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Adjusting the punch hole position in the vertical direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Adjusting the solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3.1
Adjustment of the bypass gate solenoid (SD1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3.2
Adjustment of the main gate solenoid (SD2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Adjusting the belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.4.1
Adjustment of the timing belt of the conveyance motor /Up (M4) . . . . . . . . . . . . . . . . . . . . . . . 28
3.4.2
Adjustment of the timing belt of the conveyance motor /Lw (M2) . . . . . . . . . . . . . . . . . . . . . . . 29
3.4.3
Adjustment of the timing belt of the paper exit motor (M3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.5
Adjusting the tray upper surface detection position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.6
Adjusting the tray overload detection level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
FS-511/RU-502
CONTENTS
Blank page
ii
FS-511/RU-502
OUTLINE
1.1
FS-511
A. Type
Type
Multi staple finisher
Installation
Floor-mounted type
Document alignment
Center
Consumables
Staples
B. Functions
Mode
Normal
Non-sort, sort, group, sort-staple
Punch
Non-sort-punch, sort-punch, group-punch,

sort-staple-punch
C. Type of paper
Maximum load capacity: (80 g/m2) when loaded with paper of the same size.
(1) Straight
Type of paper
Size of paper
Weight
Max. capacity
Exit tray
60 to 90 g/m2
250 sheets
Sub tray
91 to 130 g/m2
20 sheets
Max. number of
sheets stapled
Plain paper
A3, B4, A4, A4S, B5,
Recycled paper B5S, A5S, and B6S

51/2 x 81/2S, 81/2 x 11,
Thick paper
Thin paper
OHP
81/2 x 11S, 81/2 x 14,
11 x 17
50 to 59 g/m2
transparencies
Label
Envelope
Label sheet
Letterhead
FS-511/RU-502
(2) Non-sort, sort, group

Type of paper
Size of paper
Weight
Max. capacity
Exit tray
Max. number of
50 to 130 g/m2
3000 sheets
Main tray
Max. number of
sheets stapled
Plain paper
A3, B4, A4, A4S, B5,
Recycled paper B5S

81/2 x 11, 81/2 x 11S,
Thick paper
Thin paper
(A4S or smaller)
1500 sheets
(B4 or larger)
81/2 x 14, 11 x 17
(3) Sort-staple, group-staple

Type of paper
Size of paper
Weight
Max. capacity
Exit tray
60 to 90 g/m2
3000 sheets
Main tray
50 sheets
Max. number of
sheets stapled
Plain paper
A3, B4, A4, A4S, B5,
Recycled paper B5S

81/2 x 11, 81/2 x 11S,
(A4S or smaller)
1500 sheets
(B4 or larger)
81/2 x 14, 11 x 17
(4) Punch
a.
Metric/Swedish
Type of paper
Size of paper
Weight
Max. capacity
Exit tray
60 to 90 g/m2
Main tray
sheets stapled
Plain paper
A3, B4, A4, A4S, B5,
Recycled paper B5S

b.
Sub tray
Inch 2 holes
Type of paper
Size of paper
Weight
Max. capacity
Exit tray
60 to 90 g/m2
Main tray
Max. number of
sheets stapled
Plain paper
81/2 x 11S, 81/2 x 14
c.
Sub tray
Recycled paper
Inch 3 holes
Type of paper
Size of paper
Weight
Max. capacity
Exit tray
60 to 90 g/m2
Main tray
Max. number of
sheets stapled
Plain paper
Recycled paper
81/2 x 11S, 11 x 17
Sub tray
Staple filling method
Dedicated staple cartridge (5000 staples)
Staple detection
Available (near empty: 20 remaining staples)
Staple position *1
Metric: A3, B4, A4, B5
Inch: 81/2 x 11, 11 x 17
Metric: B4, B5
Inch:
Metric: A4S, B5S
Inch: 81/2 x 11S, 81/2 x 14
Side: 2 points
FS-511/RU-502
D. Stapling
A4, A4S, A3, B5, B5S, B4, 81/2 x 11, 81/2 x 11S,
81/2 x 14, 11 x 17
Manual staple
*1
None
In case of the 1-staple mode, conduct a parallel and a skew adjustment according to the length in the
main scan direction.
Parallel: main scan direction 182 to 216 mm
Diagonal: main scan direction 216 to 297 mm
E. Punch
No. of holes
Inch:
2 holes, 3 holes
Metric: 4 holes
Punch scraps full detection
F.
None
Maintenance
Maintenance
G. Machine data
Power source
Power consumption
64 W or less
Dimensions
538 (W) x 637 (D) x 978 (H) mm
Weight
39.2 kg
H. Operating environment
Temperature
10 to 30 C
Humidity
Note
FS-511/RU-502
1.2
RU-502
A. Type
Type
Roller method relay conveyance unit
B. Functions
Conveyance
Paper conveyance from the main body to FS
C. Type of paper
Paper size
Paper type
Amount of curling
b = 10 mm or less
(5 sheets)
16fat1c001na
D. Maintenance
Maintenance
E. Machine data
Power source
5.1V DC 5 % (supplied from FS)
Dimensions
474.5 (W) x 469.5 (D) x 254.4 (H) mm
Weight
Approx. 4.5 kg
F.
Temperature
10 to 30 C
Humidity
Note
2. OTHERS
FS-511/RU-502
MAINTENANCE
2. OTHERS
2.1
No.
1
Section
Cover
Part name
Page referred to
Upper cover
P.6
Front cover /Up
P.8
Front cover /Lw
P.9
Rear cover
P.10
Punch section
Punch unit
P.11
Staple section
Stapler unit
P.13
2. OTHERS
FS-511/RU-502
2.2
2.2.1

Removal/reinstallation of the upper cover
A. Procedure
1. Remove the sub tray [1].
[1]
4521f2c004na
2. OTHERS
Open the upper door [2].
Remove the screw [3].
Loosen 2 screws [4].
Loosen the screw [5] and remove the upper cover
[6].

steps in reverse.
[3]
[4]
[2]
[6]
[5]
4521f2c005na
FS-511/RU-502
2.
3.
4.
5.
2. OTHERS
2.2.2

Removal/reinstallation of the front cover /Up
FS-511/RU-502
A. Procedure
[1]
1. Loosen 2 screws [1].

2. Loosen 2 screws [2] and remove the front cover
/Up [3].

steps in reverse.
[2]
[3]
4521f2c006na

Removal/reinstallation of the front cover /Lw
A. Procedure
1. Loosen 2 screws [1] and remove the front cover

[1]
/Lw [2].

steps in reverse.
[2]
4521f2c007na
FS-511/RU-502
2.2.3
2. OTHERS
2. OTHERS
2.2.4

Removal/reinstallation of the rear cover
FS-511/RU-502
A. Procedure
1. Remove the screw [1] and loosen the screw [2].

2. Loosen 2 screws [3] and remove the rear cover
[1]
[4].

steps in reverse.
[2]
[4]
10
[3]
4521f2c008na

Removal/reinstallation of the punch unit
A. Installation of the Swedish punch kit G

When installing the Swedish punch kit G, be sure to remove the existing punch unit and follow the procedure
given below.
B. Procedure
1. Remove the upper cover.

(See P.6)

3. Remove the screws [2] and [3]. After sliding the
punch unit [4] in the arrow-marked direction [5],
remove it in the arrow-marked direction [6].
Note
The screw [2] is provided with the spacer [7]
and the washer [8]. Be careful that they do not
get lost.
[6]
[1]
[5]
[3]
[2][7][8]
[4]
4521f2c009na
11
FS-511/RU-502
2.2.5
2. OTHERS
2. OTHERS
FS-511/RU-502
[9]
Note
[13] [14]
When installing the punch unit, be sure to set

the gear [9] of the main body to the gear [10]
of the punch unit, and then insert the shaft
[11] into the hole [12] of FS.
When engaging the gears, be sure to engage
them so that the gear flange [13] of the main
body comes inside the gear flange [14] of the
punch unit.

steps in reverse.
[10]
12
[12] [11]
4521f2c010na

2.2.6
2. OTHERS
Replacing the stapler unit
FS-511/RU-502
A. Procedure
1. Open the punch scraps box holder [1].

[1]
4521f2c001na
2. Rotate the dial [1] in the arrow-marked direction
[5]
[2] to expand the intervals of the stapler units /Fr

[3] and /Rr [4].
Note
After replacing the stapler units /Fr and /Rr,
be sure to return these intervals to their original widths.
3. While pressing both sides [6] of each of the stapler unit covers [5], remove 2 stapler unit covers.
Note
For each FS unit, 2 stapler units are provided.
[6]
When replacing these 2 stapler units, they are

replaced at the same time. So, be sure to
remove both the covers.
[3]
[1]
[2]
[4]
4521f2c002na
13
2. OTHERS
FS-511/RU-502
[10]
4. Remove 2 connectors [6].

[6]
6. Remove the screw [9] and then remove the stapler unit /Rr [10].
7. Remove 2 connectors [11].

9. Remove the screw [14] and then remove the stapler unit /Fr [15].
[7][8]
[9]
[15]
[14]
14
[12][13]
[11]
4521f2c003na
2. OTHERS
[17], 1 each, from each of the stapler units.
[17]

steps in reverse.
4521f2c029na
15
FS-511/RU-502
10. Remove 2 screws [16] and then remove the plate

[16]
FS-511/RU-502
2. OTHERS
Blank page
16
FS-511/RU-502
ADJUSTMENT/SETTING
3.1
3.1.1
Output check mode

Switches provided inside the board
Test switch [1]
Dipswitch used for the mode setting of the output check mode. (All settings
are off in the initial condition.)
Output check switch /1 [2]
Used to execute the output check mode.
Output check switch /2 [3]

LED1 to 4 [4]
Display the conditions while in the output check mode.
[1]
[3]
[2]
[4]
4521f3c001na
17
3.1.2
Output check mode
FS-511/RU-502
A. Setting of the output check mode.

(1) Procedure for setting
Note
Before executing the output check mode, be sure to remove the upper cover, the front cover /Up
and the rear cover of FS in advance.
(See P.6, P.8, P.10)
When removing the covers of FS, be sure to block the light that strikes on the front door sensor
(PS17) and the upper door sensor (PS18).
1. Turn OFF the power switch (SW2) of the main

body.
2. Switch the test switch [1] to the output check

mode.
(See P.19)
3. Turn ON SW2.
4. The output check mode is set.
[1]
18
4521f3c002na
1. Turn OFF the power switch (SW2) of the main

body.
2. Set the test switch [1] to the initial condition (all

OFF).
3. Turn ON SW2.
[1]
4521f3c003na
B. Types of the output check modes

Output check mode
Test switch
LED1 to 4
Sub tray paper exit mode
ON
OFF
OFF
OFF
Main tray paper exit mode
OFF
ON
OFF
OFF
ON
ON
OFF
OFF
Shift operation mode
ON
OFF
ON
OFF
z
z
z
z
Alignment tray paper exit mode
Alignment plate operation mode
OFF
ON
ON
OFF
Stapler unit CD movement mode
ON
ON
ON
OFF
z
z
z
z
z
Paper exit roller release mode
OFF
OFF
OFF
ON
ON
OFF
OFF
ON
z
z
Main tray operation mode
OFF
ON
OFF
ON
ON
ON
OFF
ON
z
z
Punch hole operation mode

Sensor output check mode
ON
OFF
ON
ON
{
{
release mode
{
z
z
The sensor conditions are displayed.
z : Blink { : Off
19
FS-511/RU-502
(2) Method for release
C. Operation of each of the output check modes
FS-511/RU-502
(1) Sub tray paper exit mode
Output check switch /1 : ON
The motor and the solenoid turn ON.

The motor and the solenoid turn OFF.

(2) Main tray paper exit mode
The motor turns ON.

Shift motor (M8)
The motor turns OFF.

Shift motor (M8)
(3) Alignment tray paper exit mode
20
The motor and the solenoid turn ON.

The motor and the solenoid turn OFF.

FS-511/RU-502
(4) Shift operation mode

The main tray shifts to the front side.
The shift motor (M8) turns ON.

The main tray shifts to the rear side.
The shift motor (M8) turns ON.
(5) Alignment plate operation mode

The alignment plate moves to the home position for
the 1st time.

The alignment plate moves to the A4 alignment position for the 2nd time.

The alignment plate moves to the 81/2 x 11 alignment
position for the 3rd time.

The alignment plate moves to the A4S alignment
position for the 4th time.

The alignment plate moves to the 81/2 x 11S alignment
position for the 5th time.
(6) Stapler unit CD moving mode

The stapler unit moves to the home position for the
1st time.

The stapler unit moves to the A4 corner for the 2nd
time.
21
FS-511/RU-502
(7) Paper exit roller release mode

The paper exit roller is in the pressure/release operation
(8) Intermediate conveyance roller release mode

The intermediate conveyance roller is pressured.

The intermediate conveyance roller is released.
(9) Main tray operation mode

The main tray goes up until the light of the main tray
upper limit LED (LED19) is blocked.

The main tray goes down until the main tray upper
limit sensor (PS19) receives the light.
(10) Punch hole operation mode

The punch motor (M11) drives.

The punch clutch (CL1) turns ON.

The punch motor (M11) stops.
22
Sensor
Status
LED
1
Light pass through
Light blocked
Light blocked
Light blocked
z : On { : Off
23
FS-511/RU-502
(11) Sensor output check mode
FS-511/RU-502
3.2
Adjusting the punch hole position in the vertical direction
A. Procedure
1. Set the punch hole mode, and make a copy in the

single sided original -> single sided print mode.
2. Fold the copy exited into two and check the position of the punch holes to see if the discrepancy
"A" [1] is 2 mm or less.
3. When "A" is in excess of 2 mm, adjust the punch

hole position in the vertical direction.
[1]
4521f3c004na
24
[6]
[5]
[2]

5. Loosen the screw [3] and move the handle [4] in
the arrow-marked direction [5] to adjust the position of the punch unit [6].
6. Repeat steps 1 and 2 and check the punch holes

to see if the discrepancy "A" is 2 mm or less.
7. When "A" is in excess of 2 mm, repeat steps 3 to

6 until "A" gets inside 2 mm.
[4]
[3]
4521f3c005na
25
FS-511/RU-502
FS-511/RU-502
3.3
3.3.1
Adjusting the solenoid

Adjustment of the bypass gate solenoid (SD1)
A. Procedure

(See P.6)
2. Remove the rear cover.

(See P.10)

4. Move the bypass gate solenoid (SD1) [2] in the
arrow-marked direction [3] and tighten the screw
[1] when the length of "A" [4] comes to the specified value.
Specified value "A" = 4.4 mm
[1]
[2]
[3]
[4]
4521f3c006na
26

3.3.2
Adjustment of the main gate solenoid (SD2)
FS-511/RU-502
A. Procedure

[1]
(See P.6)
[2]
2. Remove the front cover /Up.

(See P.8)

4. Move the main gate solenoid (SD2) [2] and tighten
the 2 screws [1] when the length of "A" [3] comes
to the specified value.
Note
With the plunger of SD2 pressed in the arrow-
[4]
marked direction [4] in advance, be sure to
[3]
adjust the clearance with no play.

Specified value "A" = 3.6 mm
4521f3c007na
27
FS-511/RU-502
3.4
3.4.1
Adjusting the belt tension

Adjustment of the timing belt of the conveyance motor /Up (M4)
A. Procedure

[2]
[4]
(See P.6)
2. Remove the rear cover.

(See P.10)

4. Press the timing belt at the center section [2] with
a spring balance [3] from above. And when the
amount of the deflection [4] comes to 4 mm,
[3]
tighten 2 screws [1] at the position in which the

scale of the spring balance points to the specified
value "A."
Specified value "A" = 200 100 gf
[1]
4521f3c008na
28

3.4.2
Adjustment of the timing belt of the conveyance motor /Lw (M2)
FS-511/RU-502
A. Procedure

[2]
[4]
[3]
(See P.6)
2. Remove the rear cover /Up.

(See P.10)

4. Pull the square hole [3] provided on the conveyance motor /Lw mounting plate [2] with the spring
balance [4] and tighten 2 screws [1] at the position
in which the scale of the spring balance points to
the specified value "A."
Specified value "A" = 800 50 gf
[1]
4521f3c009na
29
3.4.3
Adjustment of the timing belt of the paper exit motor (M3)
FS-511/RU-502
A. Procedure
[2]
[3]
1. Loosen the screw [1] and 2 screws [2].

2. Tighten the screw [1] and 2 screws [2] at the posi-
[1]
tion [5] in which the external form of the screw [1]
[5]
and that of the oblong hole [4] provided on the

paper exit motor mounting plate [3] coincide each
other.
[4]
[1]
4521f3c010na
30
Adjusting the tray upper surface detection position
This adjustment is made when replacing the FS control board (FSCB), or the main tray upper limit LED (LED19)
or the main tray upper limit sensor (PS19).
A. Procedure
1. Set the output check mode "Sensor output check

mode."
(See P.17)
2. Rotate VR1 [1] provided on the FS control board

(FSCB) up to the limit counterclockwise.
[1]
4521f3c011na
3. Place the paper [3] on the main tray [2] to block

[4]
[3]
the light of the main tray upper limit LED (LED19)

[4].
[2]
4521f3c012na
31
FS-511/RU-502
3.5
4. Check to see if LED4 [5] on FSCB turns OFF from

FS-511/RU-502
ON. If it is left ON, rotate VR1 [1] slowly clockwise

and stop the rotation of VR1 at the position in
which LED4 turns OFF.
[5]
[1]
32
4521f3c013na
Adjusting the tray overload detection level
This adjustment is made when replacing the FS control board (FSCB) or replacing the tray lift motor (M7).
A. Procedure
1. Set the output check mode "Main tray operation
[1]
mode."
(See P.17)
2. Rotate VR2 [1] on the FS control board (FSCB)

counterclockwise up to the limit.
4521f3c014na
33
FS-511/RU-502
3.6
3. Place the paper [3] to block the light of the main

FS-511/RU-502
[2]
[3]
tray upper limit LED (LED19) [2].
4521f3c015na
4. Press the output check switch /2 [4] to bring

down the main tray.
[4]
34
4521f3c016na
main tray.
6. Remove the paper that was put in step 3 to block

the light and let the light of LED19 pass through.
Note
When letting the light of LED19 pass through,
the main tray starts to go up. Be sure to conduct the following steps 7 and 8 while in the
up drive of the main tray.
7. While in the up drive of the main tray, rotate VR2

[1] on FSCB clockwise.
LED3 [5] on FSCB turns ON.
[5]
4521f3c017na
35
FS-511/RU-502
5. Load 1500 sheets of A3 paper (80 g/m2) on the

[1]
8. When LED3 [5] on FSCB turns ON, rotate VR2 [1]

FS-511/RU-502
[1]
counterclockwise, and stop VR2 at the position in

which LED3 changes to OFF from ON.
[5]
36
4521f3c018na
SERVICE MANUAL
Field Service
SD-502
(
500 / 420)
2006.02
Ver. 1.0
Revision history
Revision mark:
NOTE
2006/02
1.0
Date
Service manual Ver.
Revision mark

SD-502
CONTENTS
SD-502
OUTLINE
1.
2.
OUTLINE
MAINTENANCE
PERIODIC CHECK..................................................................................................3
2.1
2.1.1
Cleaning of the Rollers and Rolls ..................................................................3
3.1
3.2
3.3
3.3.1
Paper Output Tray/Front Cover......................................................................5
3.3.2
Rear Cover ....................................................................................................6
3.3.3
Upper Cover ..................................................................................................6
3.3.4
Saddle Unit....................................................................................................7
3.3.5
Folding Unit ...................................................................................................8
3.3.6
Stapler Unit....................................................................................................9
3.3.7
Paper Guide Motor (M13)............................................................................14
3.3.8
Folding Roller ..............................................................................................16
MAINTENANCE
OTHER ....................................................................................................................4
ADJUSTMENT/SETTING
3.
ADJUSTMENT/SETTING
4.
4.1
Fold Skew Adjustment ........................................................................................23
4.2
Center Staple Skew Adjustment .........................................................................24
MAINTENANCE
OUTLINE
SD-502
ADJUSTMENT/SETTING
Blank Page
ii
OUTLINE
SD-502
1.
A. Type
FS built-in saddle-stitching device
Installation
Screwed to the FS
Document Alignment
Center
Stapling Function
Center parallel two points

No. of sheets to be stapled together: 2 to 15
Consumables
Staples (2000 staples/cartridge)
OUTLINE
Type
B. Paper type
Type
Plain Paper
Size
Metric: A3, B4, A4S, B5S

Inch: 11 x 17, 81/2 11S
Capacity
56 to 90 g/m2
C. Maintenance
Maintenance
Power Requirements
24/5V DC (supplied from FS)
Power Consumption
9.5 W or less
Dimensions
445 (W) x 203 (D) x 478 mm (H)
Weight
Approx. 9.3 kg
Temperature
Humidity
NOTE
OUTLINE
SD-502
Blank Page
2. PERIODIC CHECK
MAINTENANCE
2.1
PERIODIC CHECK
SD-502
2.
NOTE
2.1.1
Cleaning of the Rollers and Rolls

Various Rollers: Every 250,000 prints
Various Rolls: Every 250,000 prints
[2]
1. Using a soft cloth dampened with alcohol, wipe the roller [1] and roll [2].
MAINTENANCE
[1]
[2]
4511f2c001na
2. Remove the Folding Unit.

(See P.8)
[4]
3. Using a soft cloth dampened with alcohol, wipe the roller [3] and roll [4].
[3]
4511f2c002na
3. OTHER
3.
SD-502
3.1
OTHER

loose.
MAINTENANCE
NOTE
Caution
No.
Section
Paper Output Tray
Part name
Ref.Page
Paper Output Tray
P.5
Front Cover
P.5
Upper Cover
P.6
Rear Cover
P.6
Saddle Unit
P.7
Folding Unit
P.8
Stapler Unit
P.9
Paper Guide Motor (M13)
P.14
Folding Roller
P.16
2
3
3.3
3.3.1
Cover
Unit
Others

Paper Output Tray/Front Cover
MAINTENANCE
SD-502
3.2
3. OTHER
[3]
[1]
[2]
4511f2c004na
1. Align the cutout and remove the Paper Output Tray [1].
2. Remove two screws [2], and remove the Front Cover [3].
3. OTHER
Rear Cover
SD-502
3.3.2
[2]
[1]
MAINTENANCE
4511f2c005na
1. Remove two screws [1], and remove the Rear Cover [2].
3.3.3
Upper Cover
1. Remove the Front Cover.

(See P.5)
2. Remove the Rear Cover.
(See P.6)
[1]
[1]
[2]
4511f2c006na

Upper Cover [2].

Saddle Unit

Connector Cover [2].
SD-502
3.3.4
3. OTHER
[1]
[2]
4511f2c007na
[5]
4511f2c008na

Front Cover /Lw [7].
[7]
[6]
4511f2c009na
[8]
5. Pull the lock release lever [8], and open

the Saddle Unit.
[9]
4511f2c010na
MAINTENANCE

3. Unplug two connectors [5].
[4]
[3]
3. OTHER

7. Remove two screws [10], and remove
the Saddle Unit [11].
SD-502
[11]
[10]
3.3.5
4511f2c011na
Folding Unit
MAINTENANCE
1. Remove the Saddle Unit.

(See P.7)
(See P.13 in "Field Service FS-510/PU-501/OT-601")
3. Remove the Horizontal Conveyance Unit.
(See P.13 in "Field Service FS-510/PU-501/OT-601")
Horizontal Conveyance Upper Cover [2].
[1]
[2]
[1]
4511f2c012na

Reinforcement Plate [4].
[3]
[4]
4511f2c013na
[6]
[7]
[5]
4511f2c014na

Horizontal Conveyance Front Cover /Lw
[6].
NOTE
At reinstallation, first fit the claw [7]
into position.
3. OTHER
7. Unplug the connector [8].
SD-502
[8]
4511f2c015na
[9]
[10]

Folding Unit [10].
[9]
3.3.6
MAINTENANCE
4511f2c016na
Stapler Unit

(See P.7)
2. Remove the Paper Output Tray.
(See P.5)
(See P.5)
(See P.6)
5. Remove the Upper Cover.
(See P.6)
holder [4].
[4]
[3]
[3]
[1]
[2]
4511f2c017na
8. Release the lock release lever [5], and

slide the Saddle Unit Mounting Plate [6].
9. Remove the screw [7] and the washer
[8], and remove the Saddle Unit Mounting Plate [6].
[6]
[7]
[5]
[8]
4511f2c018na
3. OTHER
SD-502
10. Remove the harness clamp [6] from the

Metal Plate.
11. Remove the wiring harness from the
harness clamp [6].
[6]
4511f2c019na
[7]
12. Unplug four connectors [7].

13. Remove the C-ring [8], and remove the
bearing [9].
14. Remove five screws [10], and remove
the Drive Unit [11].
[11] [10]
MAINTENANCE
[7]
[10] [9]
[8]
[10]
4511f2c020na
15. Remove the harness clamp [12], and

unplug the connector [13].
[13]
[12]
4511f2c021na
16. Remove two screws [14] and two

screws [15].
[15]
[14]
4511f2c022na
10
3. OTHER
SD-502
17. Remove the Tray [16].
[16]
4511f2c023na
[17]
4511f2c024na

lock release lever [19].
[19]
[18]
4511f2c025na
21. Remove eight screws [20], and remove

the Lower Cover [21].
[20]
[20]
[21]
[20]
[20]
4511f2c026na
11
MAINTENANCE
18. Unplug all the connectors on the SD

Control Board (SDCB) [17].
19. Remove the Board support, and then
remove the SDCB.
3. OTHER

22. Remove the harness clamp and unplug
the connector.
23. Remove three screws [22], and remove
the Clincher /1 [23].
SD-502
[22]
[23]
4511f2c027na
24. Remove the Staple Cartridge /1 [24].
MAINTENANCE
[24]
4511f2c028na
[26]
[25]
25. Remove four screws [25], unplug the

connector, and remove the Stapler /1
[26].
NOTE
To replace Clincher /2 and Stapler /2,
repeat steps 22 to 25.
4511f2c029na
Precaution for Clincher Reinstallation

When the Clincher is installed, the position of the Stapler and the Clincher will be
misaligned. Be sure to perform the following adjustment.
1. Use three screws [1] to temporary fix
the Clincher [2].
2. Install the Staple Cartridge.
[1]
[2]
12
4511f2c030na
3. OTHER
3. Loosen three screws [3] of the stopper.
4. Loosen three screws [4] of the Clincher.
SD-502
[3]
[4]
[3]
4511f2c031na
[6]
[6]
5. Aligning the protrusions of the jig [6]

with the recesses in the Staple Cartridge [5], fit the jig to the Stapler.
NOTE
Make sure that the protrusions of the
jig properly rest in the recesses.
[7]
6. Turn the gear [7] of the Clincher and

then slide the Clincher so that the protrusion of the Clincher [9] fits into the
recess in the jig [8].
[9]
[8]
4511f2c033na
7. Tighten six screws [10].

NOTE
Turn the gear again and check to see
that the protrusion of the Clincher
smoothly fits into the recess in the jig.
8. Turn the gear and remove the jig.
[10]
[10]
4511f2c034na
13
MAINTENANCE
[5]
4511f2c032na
3. OTHER
SD-502
3.3.7

Paper Guide Motor (M13)

(See P.7)
2. Remove the Paper Output Tray.
(See P.5)
(See P.5)
(See P.6)
5. Remove the Upper Cover.
(See P.6)
holder [4].
[4]
MAINTENANCE
[3]
[1]
[3]
[2]
4511f2c035na
8. Release the lock release lever [5], and

slide the Saddle Unit Mounting Plate [6].
9. Remove the screw [7] and the washer
[8], and remove the Saddle Unit Mounting Plate [6].
[6]
[7]
[5]
[8]
4511f2c036na

lock release lever [10].
[10]
[9]
4511f2c037na
14
3. OTHER
11. Remove eight screws [11], and remove
the Lower Cover [12].
SD-502
[11]
[11]
[12]
[11]
[11]
4511f2c038na
12. Remove the wire saddle [13], and

unplug two connectors [14].
[14]
4511f2c039na

Paper Guide Motor Assy [16].
[16]
[15]
4511f2c040na
14. Remove two C-rings [17].

15. Remove two bearings [18], and remove
the Clutch Gear Assy [19].
[17]
[18]
[19]
[17]
4511f2c041na
[20]
[20]

M13 [21].
[21]
4511f2c042na
15
MAINTENANCE
[13]
3. OTHER
SD-502
Precaution for M13 Reinstallation
[2]
[1]
[4]
[3]
MAINTENANCE
4511f2c043na
1. Press the two Paper Guides [1] in and check that they touch the stopper [2] simultaneously.
2. Check that pins [4] can be inserted through the positioning holes [3] (3 holes) of the Paper
Guide Sensor Assy.
3. Use two screws to secure M13.
3.3.8
Folding Roller
1. Remove the Folding Unit.

(See P.8)
[1]
2. Remove four screws [1] and two

springs, and remove the Upper Plate
[2].
[2]
[1]
4511f2c044na

guide plate [4].
[4]
[3]
4511f2c045na
16
3. OTHER
Folding Blade Assy [6].
SD-502
[6]
[5]
4511f2c046na
[A]
4511f2c047na
5. Remove three C-rings [7], and remove

three gears [8].
[7]
[8]
4511f2c048na
NOTE
Install the gears so that the mark [9]
are aligned to the position shown in
the left figure.
[9]
4511f2c049na
17
MAINTENANCE
[B]
NOTE
Install the Folding Blade Assy in the
direction shown in the left figure.
[A] Front
[B] Rear
3. OTHER
[11]
SD-502
[10]
6. Remove three C-rings [10], and remove

two bearings [11].
7. Remove the bearing [12].
[12]
4511f2c050na

the Rear Holder [14].
MAINTENANCE
[14]
[13]
4511f2c051na
9. Remove the gear [15] of Folding Roller

/Rt, and remove the Lower Guide Plate
[16].
[16]
[15]
4511f2c052na
[19]
[17]
[18]
4511f2c053na
18
NOTE
When installing the gear [17] to the
Lower Guide Plate [18], insert the gear
[17] at an angle and take care not to
break the claws [19].
Install the Lower Guide Plate as shown
on the left.
[21]
3. OTHER
[20]
[22]

11. Remove two C-rings [21], and remove
the Folding Roller A [22], B [23] and C
[24].
SD-502
[24]
[23]
4511f2c054na
MAINTENANCE
12. Remove the gear [25] of Folding Roller

/Lt, and remove the Lower Guide Plate
[26].
[26]
[25]
4511f2c055na
[29]
[28]
[27]
NOTE
When installing the gear [27] to the
Lower Guide Plate [28], insert the gear
[27] at an angle and take care not to
break the claws [29].
Install the Lower Guide Plate as shown
on the left.
4511f2c056na
[31]
[30]
[32]

14. Remove two C-rings [31], and remove
the Folding Roller A [32], B [33] and C
[34].
[34]
[33]
4511f2c057na
19
3. OTHER

NOTE
When installing the Folding Rollers A,
B and C, be sure to align the direction
of the mark [35] of the gear with the
direction in which the screw [36] is
tightened.
MAINTENANCE
SD-502
[36]
[35]
4511f2c059na
20

NOTE
When installing the Folding Rollers /Rt
and /Lt, be sure to install them so that
the mark [37] of the Roller Gear /Rt
provided on the front of the Folding
Unit comes one tooth above the mark
[38] of the Roller Gear /Lt.
When installing the Folding rollers /Rt
the gear of the Guide Gear /Lt [40]
comes one tooth above the gear of the
Guide Gear /Rt [41] as seen from the
direction of the arrow mark [39].
When installing the Folding Rollers /Rt
the mark [43] of the Guide Gear /Rt and
the mark [44] of the Sector Gear get
aligned with each other as seen from
the direction of the arrow mark [42].
[37]
[39]
[42]
[41]
[40]
[43]
[44]
4511f2c060na
21
SD-502
[38]
3. OTHER
MAINTENANCE
MAINTENANCE
SD-502
3. OTHER
Blank Page
22
ADJUSTMENT/SETTING
4.1
SD-502
4.
Fold Skew Adjustment
NOTE
Make this adjustment after any of the following procedures has been performed.
When the Folding Unit has been replaced.
When skew occurs in the crease.
1. Enter the Half-fold mode and make a copy. (A3 or 11 x 17 Size)
2. Fold the output paper along the crease
[2].
3. Fold the output paper and measure the
width A of the paper.
Specification: 0 1.5 mm
4. If the fold position is skewed as shown
on the left, make the following adjustment.
A
[1]
[2]
[3]
[4]
[1] Center
[2] Crease
[3] Exit direction
5. Open the Front Door, loosen the adjustment screw [4], and move the Folding
Unit to the left to make the adjustment.
Graduated in 1 mm divisions
If the fold position is skewed opposite to
the figure of step 4, move the Folding Unit
to the right to make the adjustment.
6. Make another copy and check the fold
position.
4511f3c002na
23
ADJUSTMENT/SETTING
4511f3c001na
SD-502
4.2
Center Staple Skew Adjustment
NOTE
Make this adjustment after any of the following procedures has been performed.
When Staple Unit 1 or 2 has been replaced.
When skew occurs in the position of the center staple.
1. Set to Fold & Staple mode and make a
copy. Measure the width A of the paper.
Specification: 0 1.5 mm
2. If the staple position is skewed as
shown on the left, make the following
adjustment.
[1] Exit direction
[1]
4511f3c003na
3. Release the lock release lever [2] of the

Saddle Unit.
4. Loosen the adjustment screw [3] and
move the lock member [4] to the left to
make the adjustment.
If the staple position is skewed opposite
to the figure of step 2, move the lock
member to the right to make the adjustment.
5. Make another copy and check the staple
position.
[4]
ADJUSTMENT/SETTING
[3]
[2]
24
4511f3c004na
SERVICE MANUAL
Field Service
MT-501
(
500 / 420)
2006.02
Ver. 1.0
Revision history
Revision mark:
NOTE
2006/02
1.0
Date
Service manual Ver.
Revision mark

MT-501
CONTENTS
MT-501
OUTLINE
1.
2.
OUTLINE
MAINTENANCE
PERIODIC CHECK..................................................................................................3
2.1
2.1.1
Cleaning of the Roller and Roll......................................................................3
OTHER ....................................................................................................................4
3.1
3.2
3.3
3.3.1
Rear Cover/Right Door ..................................................................................5
3.3.2
Front Cover/Upper Cover/Paper Output Tray.................................................5
MAINTENANCE
3.
MAINTENANCE
OUTLINE
MT-501
Blank Page
ii
OUTLINE
MT-501
1.
A. Type
4 bins Mailbin (available only for printing from PC)
Installation
Screwed to the FS
Number of Bins
4 bins
Number of Sheets
Stored per Bin
Storable Paper
Storable Paper Size
Metric: A4, B5, 81/2 x 11

Inch: 81/2 x 11, 51/2 x 81/2S
OUTLINE
Type
B. Maintenance
Maintenance
Power Requirements
24V DC (supplied from FS)
Dimensions
624 (W) x 503 (D) x 390 mm (H)
Weight
Approx. 8 kg
Temperature
Humidity
NOTE
OUTLINE
MT-501
Blank Page
2. PERIODIC CHECK
MAINTENANCE
2.1
PERIODIC CHECK
MT-501
2.
NOTE
2.1.1
Cleaning of the Roller and Roll

Various Rollers: Every 250,000 prints
Various Rolls: Every 250,000 prints
B. Procedure
MAINTENANCE

2. Using a soft cloth dampened with alcohol, wipe the rollers [1] and rolls [2].
[1]
[1]
[1]
[2]
[2]
4510f2c001na
3. OTHER
3.
MT-501
3.1
OTHER

loose.
MAINTENANCE
NOTE
NOTE
No.
Section
Part name
1
2
3
Cover
4
5
3.3
Paper Output Tray
MT-501
3.2
3. OTHER
Ref. page
Rear Cover
P.5
Front Cover
P.5
Upper Cover
P.5
Right Door
P.5
Paper Output Tray
P.5
3.3.1
Rear Cover/Right Door

1. Remove the screw [1] and remove the
Rear Cover [2].
2. Remove the screw [3], the stopper [4],
and remove the Right Door [5].
[2]
MAINTENANCE
[5]
[3]
3.3.2
[4]
[1]
4510f2c002na
Front Cover/Upper Cover/Paper Output Tray

[3]
[4]
[2]
[1]
1. Remove the screw [1] and remove the

Front Cover [2].
(See P.5)
3. Remove the Upper Cover [3].
4. Remove the Paper Output Trays [4].
4510f2c003na
MAINTENANCE
MT-501
3. OTHER
Blank Page
SERVICE MANUAL
Field Service
JS-502
(
500 / 420)
2006.02
Ver. 1.0
Revision history
Revision mark:
NOTE
2006/02
1.0
Date
Service manual Ver.
Revision mark

JS-502
CONTENTS
JS-502
OUTLINE
1.
OTHER ....................................................................................................................3
2.1
2.2
2.3
2.3.1
Upper Cover ..................................................................................................4

MAINTENANCE
2.
OUTLINE
MAINTENANCE
MAINTENANCE
OUTLINE
JS-502
Blank Page
ii
OUTLINE
JS-502
1.
Name
Job Separator
Type
Expansion tray
Installation
Document Alignment
Center
OUTLINE
A. Type
B. Paper type
Exit Tray
Size
Inch:
Tray 1
(Main
Body
Tray)
11 x 17, 81/2 x 14,

81/2 x 11, 81/2 x 11S,
51/2 x 81/2S
A3, A4, A4S, A5S,
8 x 13
B5S, A5S
11 x 17, 81/2 x 11,
81/2 x 11S, 8 x 13
11 x 17, 81/2 x 14,

81/2 x 11, 81/2 x 11S,
Tray 2
51/2 x 81/2S
(Job Tray)
B5S, A5S
Type
Plain Paper (56 to 90
g/m2)
Capacity
250 sheets
OHP transparencies
Thick paper (91 to 210g/m2)
Envelope
Special
Label
20 sheets
Letterhead
Inch:
100 sheets
C. Maintenance
Maintenance
None
Power Requirements
Power Consumption
0.2 W or less
Dimensions
450 (W) x 443 (D) x 75 mm (H)
Weight
Approx. 1.7 kg
Temperature
Humidity
NOTE
OUTLINE
JS-502
Blank Page
2. OTHER
MAINTENANCE
2.1
OTHER
JS-502
2.

loose.
NOTE
Caution
MAINTENANCE
2. OTHER
JS-502
2.2
No.
1
2.3
2.3.1
Section
Cover
Part name
Ref.Page
Upper Cover
See P.4

Upper Cover
[1]
MAINTENANCE
[2]
4347f2c001na
1. Remove two screws [1], and remove the Upper Cover [2].
SERVICE MANUAL
Field Service
IC-204
2006.02
Ver. 1.0
Revision history
Revision mark:
page.
NOTE
2006/02
1.0
Date
Service manual Ver.
Revision mark

Field Service Ver1.0 February.2006
CONTENTS
IC-204
CONTENTS
IC-204
OUTLINE
MAINTENANCE
2. FIRMWARE VERSION UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. DISASSEMBLY / REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2
Removal / Installation of Printer key control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ADJUSTMENT / SETTING
4. SERVICE MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5. Starting and Finishing the Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TROUBLESHOOTING
6. TROUBLESHOOTING THE PRINTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.1
Troubleshooting of the print controller and copier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7. Data Capture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
IC-204
CONTENTS
Blank Page
ii
IC-204
OUTLINE
A. Type
Type:
Built-in box type for the KONICA MINOLTA Printer/Copier
B. Functions
Resolution
600 x 600 dpi
Gradation
binary
Blank area
PCL6: 4.23mm (left, right, top and bottom without variation)

PCL5e: 4.23mm (left, right, top and bottom without variation)
PS: 4.23mm (left, right, top and bottom without variation)
Printable Area
292.77 x 427.57mm (The maximum paper size)
No. of Print
1 to 999
Continuous Print Speed
bizhub 500: 50 ppm (A4, 8.5 x 11) / (600 x 600 dpi)

bizhub 420: 42 ppm (A4, 8.5 x 11) / (600 x 600 dpi)
Printer Description Language
PCL5e/PCL6/PostScript3 (compatible)
Compliant OS
Windows 98SE/Me
Windows NT 4.0 (Service Pack 6a or more)
Windows 2000 (Service Pack 4 or more)
Windows XP (Service Pack 1 or more)
Windows XP x64 Edition
Windows Server 2003
Windows Server 2003 x64 Editions
Mac OS 9.x
Mac OS X v10.2/v10.3/v10.4
Printer Driver
PCL printer driver for Windows 98SE/Me/NT 4.0/2000/XP/Server

2003 (XP/Server 2003 includes the x64 Edition (PS).)
PS printer driver for Windows
PS printer driver for Windows/Macintosh
No driver for PCL5e
Network Functions
Printing Method
SMB (Windows), Pserver (IPX/SPX), lpd/lpr (TCP/IP for Windows NT

4.0/2000), lpd/lpr (TCP/IP for UNIX), IPP (TCP/IP), AppleTalk (EtherTalk), NPrinter/RPrinter (IPX/SPX), RAW (Port 9100; extensible up to 6
ports)
Dedicated Utilities
EMS Plug-in
NDPS Gateway
Direct Print
C. Paper
Paper Size
Same as copier
Paper Type
Same as copier
Paper Weight
Same as copier
IC-204
D. Maintenance and Life

Maintenance
Same as copier
Machine Service Life
Same as copier
E. Machine Data
System Memory
Same as copier
Host Interface
Ethernet, Serial (RS-232C/USB), Parallel (IEEE1284)
Hard Disk Drive
40 GB (supporting HD-505)
Power
Same as copier
Network Function
Network Interface
Ethernet (100 Base-TX/10-Base-T)
Frame Type
IEEE 802.2/802.3/Ethernet II/IEEE802.3 SNMP
Ethernet Connection
100 Base-TX/10-Base-T
Network Connector
RJ-45
LED
Green LED 2
F.
Operating Environment
Temperature
Same as copier
Humidity
Same as copier
IC-204
MAINTENANCE
Firmware for IC-204 is contained in the copier firmware (MFP Controller).
With the updating of MFP controller version, the version of the IC-204 firmware is also updated.
Firmwares version is upgraded by ISW.
See 5. FIRMWARE VERSION UP in the Field Service for the main body.
3. DISASSEMBLY / REASSEMBLY
IC-204
Caution
Assembly should be made in reverse order of disassembly unless otherwise noted.
Precautions against static electricity.
Keep the image controller in an antistatic bag while transporting it or storing it.
When working in places where static electricity tends to accumulate, such as on a carpet, discharge electricity from your body by touching any metallic portion before handling the image controller.
Do not touch the contacts on the image controller with your hands, as that may result in poor conductivity.
Do not physically damage the image controller by dropping it, bending it, etc.
3.1
Tools Required
Standard screwdriver
Caution
Be sure to unplug the power cable, not only to turn the copier off, before attempting to make servicing.
Caution
Before engaging in Disassembly/Reassembly, check to make sure that all the cables are
unplugged from the copier.
There may be occasions when boards are damaged if no appropriate grounding measures are
taken. Wear a wrist strap or others during servicing.
Disassembly/Reassembly should be made on cushioning materials.
Removal / Installation of Printer key control board

1.
Turn the Sub and Main power switches OFF of

the main body, and unplug the power cord from
the outlet.
2.
Remove the back cover(6 screws).
3.
Remove the board cover(4 screws).
4.
Remove the image controller in the location with
Back cover
Board cover
the IC204 mark on the system control board.

NOTE
You should be careful not to damage the
board.
Align concave
areas
Remove the image controller pulling it perpendicularly to the system control board.
Align the concave area on the left side of the
Image controller
image controller and the concave area on left

side of the slot in the system control board
when installing.
Assembly should be made in reverse order
from disassembly.
IC-204
3.2
IC-204
Blank Page
4. SERVICE MODE
IC-204
ADJUSTMENT / SETTING
4. SERVICE MODE
In the service mode, various adjustments / settings are available.
See 10. SERVICE MODE in Field Service for the main body.
5. Starting and Finishing the Service Mode

1.
2.
Confirm that the normal Copy Mode screen is on the display.

Press the [Utility/Counter] button.
[MetaCount/Utility] screen appears.
3.
Press the [Details] key.

[MetaCount] screen appears.
4.
Press the keypad in the following order.

Stop -> 0 -> 0 -> Stop -> 0 -> 1
[Service Mode menu] screen appears.
NOTE
If the CE password has been provided, you should enter the password to enter the service mode.
5.
Press the key of items to be set.

Setting screen of each item appears.
6.
Set items as required and press the [OK] key after completion.
Setting is accepted and the [Service Mode menu] screen returns.
7.
Press the [Exit] key.

Normal Copy Mode screen returns.
IC-204
5. Starting and Finishing the Service Mode
Blank Page
6. TROUBLESHOOTING THE PRINTING SYSTEM
IC-204
TROUBLESHOOTING
6. TROUBLESHOOTING THE PRINTING SYSTEM
This table lists information about the symptoms, possible causes, and remedies for problems that may occur
with the printing system (combination of the print controller and copier). It is intended to help engineers find
information as quickly as possible, and provide basic solutions.
Caution
See the Copier Service Manual for information about Error Cord List.
6.1
Troubleshooting of the print controller and copier
Symptoms
Causes
Actions
Warming up does not disappear.
Copier is in trouble.
Locate the cause of trouble of the

copier.
Printout is defective, or nothing can be

printed.
The system board or some Put the copier in service mode and perboards of the copier are
form test. If it operates properly, system
defective.
board may be failure.
Print controller does not start.
The printer key control

board is inactive.
Or printer key control
board is not installed.
Check the connector of the controller

board. Replace the system board as
necessary.
Software of the print con- Reinstall the software of the print controller is defective.
troller.
Test print can be produced but not from
the parallel port, USB port.
The parallel port, USB port

has something wrong or
the cable is wrong or, the
problem is on the computer side.
Test print can be produced and all ports Some software error has
are good, but user jobs cannot be printed. happened.
Check the cables (internal/external).

Perform test using a data generator or
a well-proven PC/I/O cable. Replace
the system board as necessary.
Print controllers software or application
program has something wrong. Save
the file, which failed to be printed, in the
disk and analyze the problem by suitable means.
7. Data Capture
7. Data Capture
IC-204
If any fault is caused in relation with the printer, acquire the print job data for the fault analysis.
Capture data of up to 5 jobs can be saved. When new data is saved, oldest one is deleted.
Caution
To enable this function, following conditions should be met.
Hard disk should have been installed in the main body printer (copier).
[Administrator Setting] - [Security Setting] - [Security Details] - [Print Data Capture] should be set
to [Allow].
[Administrator Setting] - [Network Setting] - [FTP Setting] - [FTP Server] should be set to [ON].
1.
Activate the service mode.

(Refer to the steps 1 through 7 of "ADJUSTMENT
/ SETTING, 5. Starting and Finishing the Service
Mode".)
2.
Press [System2] - [Data Capture] and select

[ON]. Selecting [ON] saves the job data transmitted from PC in the copier hard disk.
3.
4.
Confirm the IP address of the copier.

Connect the Windows PC and copier with the
Ethernet cable.
5.
Activate the command prompt, specify the IP

address of the copier and activate the FTP.
6.
Enter User and Password.
User: capture
Password: sysadm
7.
Display the list of files which can be captured

with the [ls] or [dir] command.
10
7. Data Capture
8.
Set the file transfer mode to binary transfer with
IC-204
the [binary] command.
9.
Transfer the data to be captured to PC with the

[get] or [mget] command.
10. Exit from the command prompt.

NOTE
If you set [Administrator Setting] - [Security
Setting] - [Security Details] - [Print Data Capture] to [Restrict] after acquiring the capture
data, the job data saved in the hard disk will
be deleted.
11
IC-204
7. Data Capture
Blank Page
12
2006 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.

Use of this manual should be strictly supervised to avoid
disclosure of confidential information.
Printed in Japan
NN50GAPE1-0900

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Bizhub 500 420 Service Manual Main Body Options PDF

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SERVICE MANUAL

THEORY OF OPERATION TOTAL CONTENTS

bizhub 500 / 420 Main Body

SAFETY AND IMPORTANT WARNING ITEMS

SAFETY AND IMPORTANT WARNING ITEMS

DESCRIPTION ITEMS FOR DANGER,

:Precaution when using the

SAFETY AND IMPORTANT WARNING ITEMS

Using any fuse or thermostat not specified by KMBT.

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

SAFETY AND IMPORTANT WARNING ITEMS

[2] POWER PLUG SELECTION

Power Cord Set or Power Plug

- the plug has pin/terminal(s) for grounding, and

Use of inadequate cord set leads to fire or electric shock.

White or Light Blue:

Wrong connection may cancel safeguards within the

SAFETY AND IMPORTANT WARNING ITEMS

[3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE

Connection to Power Supply

Connect power plug directly into wall outlet having same

SAFETY AND IMPORTANT WARNING ITEMS

Connection to Power Supply

Power Plug and Cord

Check whether the power cord is damaged. Check

SAFETY AND IMPORTANT WARNING ITEMS

Power Plug and Cord

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

SAFETY AND IMPORTANT WARNING ITEMS

Prohibited Installation Places

When not Using the Product for a long time

SAFETY AND IMPORTANT WARNING ITEMS

Inspection before Servicing

Work Performed with the Product Powered On

SAFETY AND IMPORTANT WARNING ITEMS

Check electrode units such as a charging corona unit for

SAFETY AND IMPORTANT WARNING ITEMS

SAFETY AND IMPORTANT WARNING ITEMS

Handling of Service Materials

Do not replace the cover or turn the product ON before

INDICATION OF WARNING ON THE MACHINE

MEASURES TO TAKE IN CASE OF AN ACCIDENT

MEASURES TO TAKE IN CASE OF

MEASURES TO TAKE IN CASE OF AN ACCIDENT

Composition of the service manual

System configuration, product specifications,

COMPOSITION/OPERATION: Configuration of each unit, explanation of the operating

System configuration, and product specifications

Service schedule *, maintenance steps,

Utility mode *, service mode *, security and mechanical

List of jam codes, their causes, operation when a jam

Parts layout drawings, connector layout drawings, timing

Notation of the service manual

(2) bizhub 500 / 420:

(3) Microsoft Windows 95:

Microsoft Windows 98:

Microsoft Windows Me:

Microsoft Windows NT 4.0:

Windows NT 4.0 or Windows NT

Microsoft Windows 2000:

Microsoft Windows XP:

When the description is made in combination of the OS's mentioned above:

C. Electrical parts and signals

Utility mode , service mode , security and mechanical