bizhubPROC6501 C6501P C65hc C5501E SM v3

Ⅰ 調整
Ⅱ サービスツール
SERVICE MANUAL Theory of Operation
Ⅲ サービス
C6501/C6501P/
C65hc/C5501
Ⅳ ジャムコード
Ⅴ 異常コード
2009.07
Ver. 3.0
THEORY OF OPERATION TOTAL CONTENTS
SAFETY AND IMPORTANT WARNING ITEMS ..............................................................S-1

IMPORTANT NOTICE ................................................................................................S-1
DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION .........................S-1
SAFETY WARNINGS .................................................................................................S-2
SAFETY INFORMATION ...............................................................................................S-13
IMPORTANT NOTICE ..............................................................................................S-13
INDICATION OF WARNING ON THE MACHINE .....................................................S-14
MEASURES TO TAKE IN CASE OF AN ACCIDENT ....................................................S-19
Legal restrictions on copying .......................................................................................... C-1
Composition of the service manual ................................................................................. C-2
Notation of the service manual ....................................................................................... C-3
bizhub PRO C6501/C6501P/C65hc/C5501

OUTLINE ........................................................................................................................ 1
CONFIGURATION/OPERATION.................................................................................. 15
MAINTENANCE.......................................................................................................... 137
* For particulars, see the contents of the main body.
DF-609
OUTLINE ........................................................................................................................ 1
CONFIGURATION/OPERATION.................................................................................... 7
MAINTENANCE............................................................................................................ 31
* For particulars, see the contents of DF-609.
PF-602/HT-504
OUTLINE ........................................................................................................................ 1
MAINTENANCE............................................................................................................ 31
* For particulars, see the contents of PF-602/HT-504.
LU-202/HT-503
OUTLINE ........................................................................................................................ 1
MAINTENANCE............................................................................................................ 27
* For particulars, see the contents of LU-202/HT-503.
i
RU-504
OUTLINE ........................................................................................................................ 1
CONFIGURATION/OPERATION ................................................................................... 7
MAINTENANCE ........................................................................................................... 17
* For particulars, see the contents of RU-504.
RU-506
OUTLINE ........................................................................................................................ 1
MAINTENANCE ........................................................................................................... 23
* For particulars, see the contents of RU-506.
FD-503
OUTLINE ........................................................................................................................ 1
CONFIGURATION/OPERATION ................................................................................. 15
MAINTENANCE ........................................................................................................... 59
* For particulars, see the contents of FD-503.
LS-505
OUTLINE ........................................................................................................................ 1
MAINTENANCE ........................................................................................................... 31
* For particulars, see the contents of LS-505.
FS-521
OUTLINE ........................................................................................................................ 1
MAINTENANCE ........................................................................................................... 55
* For particulars, see the contents of FS-521.
FS-520/607
OUTLINE ........................................................................................................................ 1
CONFIGRATION/OPERATION .................................................................................... 13
MAINTENANCE ........................................................................................................... 73
* For particulars, see the contents of FS-520/607.
ii
PI-502
OUTLINE ........................................................................................................................ 1
COMPOSITION/OPERATION ........................................................................................ 5
MAINTENANCE............................................................................................................ 13
* For particulars, see the contents of PI-502.
PK-512/513
OUTLINE ........................................................................................................................ 1
COMPOSITION/OPERATION ........................................................................................ 5
MAINTENANCE............................................................................................................ 17
* For particulars, see the contents of PK-512/513.
SD-506
OUTLINE ........................................................................................................................ 1
MAINTENANCE.......................................................................................................... 119
* For particulars, see the contents of SD-506.
PB-501/502
OUTLINE ........................................................................................................................ 1
MAINTENANCE.......................................................................................................... 137
* For particulars, see the contents of PB-501/502.
GP-501
OUTLINE ........................................................................................................................ 1
MAINTENANCE............................................................................................................ 19
* For particulars, see the contents of GP-501.
iii
Blank Page
iv
SAFETY AND IMPORTANT WARNING ITEMS

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

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

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

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

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

copier. General Unplug Ground/Earth
instruction
S-1
SAFETY WARNINGS
[1] MODIFICATIONS NOT AUTHORIZED BY KONICA MINOLTA
BUSINESS TECHNOLOGIES, INC.
Konica Minolta brand products are renowned for their high reliability. This reliability is
achieved through high-quality design and a solid service network.
Product design is a highly complicated and delicate process where numerous mechanical,
physical, and electrical aspects have to be taken into consideration, with the aim of arriving
at proper tolerances and safety factors. For this reason, unauthorized modifications involve
a high risk of degradation in performance and safety. Such modifications are therefore
strictly prohibited. The points listed below are not exhaustive, but they illustrate the reason-
ing behind this policy.
Prohibited Actions
DANGER
• Using any cables or power cord not specified by KMBT.
• Using any fuse or thermostat not specified by KMBT.

Safety will not be assured, leading to a risk of fire and
injury.
• Disabling fuse functions or bridging fuse terminals with

wire, metal clips, solder or similar object.
• Disabling relay functions (such as wedging paper between

relay contacts)
• Disabling safety functions (interlocks, safety circuits, etc.)

injury.
• Making any modification to the product unless instructed

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

In some countries or areas, the power plug provided with the product may not fit wall outlet
used in the area. In that case, it is obligation of customer engineer (hereafter called the CE)
to attach appropriate power plug or power cord set in order to connect the product to the
supply.
Power Cord Set or Power Plug
WARNING
• Use power supply cord set which meets the following
criteria:
AC230V
- provided with a plug having configuration intended for
the connection to wall outlet appropriate for the prod-
uct's rated voltage and current, and
- the plug has pin/terminal(s) for grounding, and
- provided with three-conductor cable having enough cur-
rent capacity, and
AC208V 240V
- the cord set meets regulatory requirements for the area.
Use of inadequate cord set leads to fire or electric shock.
• Attach power plug which meets the following criteria:
- having configuration intended for the connection to wall
outlet appropriate for the product's rated voltage and
current, and
- meets regulatory requirements for the area.
Use of inadequate cord set leads to the product connect-
ing to inadequate power supply (voltage, current capac-
ity, grounding), and may result in fire or electric shock.
• Conductors in the power cable must be connected to ter-

minals of the plug according to the following order:
•Black or Brown:L (line)
•White or Light Blue:N (neutral)
•Green/Yellow:PE (earth)
Wrong connection may cancel safeguards within the
product, and results in fire or electric shock.
S-3
[3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE

Konica Minolta brand products are extensively tested before shipping, to ensure that all
applicable safety standards are met, in order to protect the customer and CE from the risk
of injury. However, in daily use, any electrical equipment may be subject to parts wear and
eventual failure. In order to maintain safety and reliability, the CE must perform regular
safety checks.
1. Power Supply
Connection to Power Supply
WARNING
• Check that mains voltage is as specified.
Connection to wrong voltage supply may result in fire or
electric shock. ?V
• Connect power plug directly into wall outlet having same

configuration as the plug.
Use of an adapter leads to the product connecting to kw
inadequate power supply (voltage, current capacity,
grounding), and may result in fire or electric shock.
If proper wall outlet is not available, advice the customer
to contact qualified electrician for the installation.
• Plug the power cord into the dedicated wall outlet with a
capacity greater than the maximum power consumption.
If excessive current flows in the wall outlet, fire may
result.
• If two or more power cords can be plugged into the wall

outlet, the total load must not exceed the rating of the wall
outlet.
result.
• Make sure the power cord is plugged in the wall outlet

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

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

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

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

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

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

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

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

detached.
High-voltage exists around the drum unit. A risk of elec-
tric shock exists.
S-8
Safety Checkpoints
WARNING
• When taking a report of problems from a user, check each
part and repair properly.
A risk of product trouble, injury, and fire exists.
• Check the exterior and frame for edges, burrs, and other
damages.
The user or CE may be injured.
• Do not allow any metal parts such as clips, staples, and
screws to fall into the product.
They can short internal circuits and cause electric shock
or fire.
• Check wiring for squeezing and any other damage.

Current can leak, leading to a risk of electric shock or
fire.
• Carefully remove all toner remnants and dust from electri-

cal parts and electrode units such as a charging corona
unit.
Current can leak, leading to a risk of product trouble or
fire.
• Check high-voltage cables and sheaths for any damage.

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

deterioration and sign of leakage.
Current can leak, leading to a risk of trouble or fire.
• Before disassembling or adjusting the write unit (P/H unit)

incorporating a laser, make sure that the power cord has
been disconnected.
The laser light can enter your eye, leading to a risk of
loss of eyesight.
S-9
Safety Checkpoints
WARNING
• Do not remove the cover of the write unit. Do not supply
power with the write unit shifted from the specified mount-
ing position.
loss of eyesight.
• When replacing a lithium battery, replace it with a new lith-

ium battery specified in the Parts Guide Manual. Dispose
of the used lithium battery using the method specified by
local authority.
Improper replacement can cause explosion.
• After replacing a part to which AC voltage is applied (e.g.,
optical lamp and fixing lamp), be sure to check the instal-
lation state.
• Check the interlock switch and actuator for loosening and

check whether the interlock functions properly.
If the interlock does not function, you may receive an
electric shock or be injured when you insert your hand in
the product (e.g., for clearing paper jam).
• Make sure the wiring cannot come into contact with sharp
edges, burrs, or other pointed parts.
fire.
• Make sure that all screws, components, wiring, connec-

tors, etc. that were removed for safety check and mainte-
nance have been reinstalled in the original location. (Pay
special attention to forgotten connectors, pinched cables,
forgotten screws, etc.)
A risk of product trouble, electric shock, and fire exists.
S-10
Handling of Consumables
WARNING
• Toner and developer are not harmful substances, but care
must be taken not to breathe excessive amounts or let the
substances come into contact with eyes, etc. It may be
stimulative.
If the substances get in the eye, rinse with plenty of water
immediately. When symptoms are noticeable, consult a
physician.
• Never throw the used cartridge and toner into fire.

You may be burned due to dust explosion.
Handling of Service Materials
CAUTION
• Unplug the power cord from the wall outlet.
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
4. Fuse
Fuse
CAUTION
• CAUTION
Double pole / neutral fusing
• ATTENTION
Double pôle / Fusible sur le neutre
5. Used Batteries Precautions

Handling of batteries
CAUTION
• ALL Areas
CAUTION
Danger of explosion if battery is incorrectly replaced.
Replace only with the same or equivalent type recommended by the manufacturer.
Dispose of used batteries according to the manufacturer’s instructions.
• Germany
VORSICHT!
Explosionsgefahr bei unsachgemäßem Austausch der Batterie.
Ersatz nur durch denselben oder einen vom Hersteller empfohlenen gleichwertigen Typ.
Entsorgung gebrauchter Batterien nach Angaben des Herstellers.
• France
ATTENTION
Il y a danger d’explosion s’il y a remplacement incorrect de la batterie.
Remplacer uniquement avec une batterie du même type ou d’un type équivalent recom-
mandé par le constructeur.
Mettre au rebut les batteries usagées conformément aux instructions du fabricant.
• Denmark
ADVARSEL!
Lithiumbatteri - Eksplosionsfare ved fejlagtig håndtering.
Udskiftning må kun ske med batteri af samme fabrikat og type.
Levér det brugte batteri tilbage til leverandøren.
• Finland, Sweden
VAROlTUS
Paristo voi räjähtää, jos se on virheellisesti asennettu.
Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin.
Hävitä käytetty paristo valmistajan ohjeiden mukaisesti.
VARNING
Explosionsfara vid felaktigt batteribyte.
Använd samma batterityp eller en ekvivalent typ som rekommenderas av apparat-
tillverkaren.
Kassera använt batteri enligt fabrikantens instruktion.
• Norway
ADVARSEL
Eksplosjonsfare ved feilaktig skifte av batteri.
Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten.
Brukte batterier kasseres i henhold til fabrikantens instruksjoner.
S-12
SAFETY INFORMATION
SAFETY INFORMATION
IMPORTANT NOTICE
The Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Admin-
istration implemented regulations for laser products manufactured since August 1, 1976.
Compliance is mandatory for products marketed in the United States.
This copier is certified as a "Class 1" laser product under the U.S.
Department of Health and Human Services (DHHS) Radiation Performance Standard
according to the Radiation Control for Health and Safety Act of 1968. Since radiation emit-
ted inside this copier is completely confined within protective housings and external covers,
the laser beam cannot escape during any phase of normal user operation.
S-13
SAFETY INFORMATION
INDICATION OF WARNING ON THE MACHINE

Caution labels shown below are attached in some areas on/in the machine.
When accessing these areas for maintenance, repair, or adjustment, special care should
be taken to avoid burns and electric shock.
a03up0e001ca
S-14
SAFETY INFORMATION
a03up0e002ca
S-15
SAFETY INFORMATION
CAUTION
The paste tank
unit is very hot.
To avoid getting
burned DO NOT
TOUCH.
a03up0e003ca
S-16
SAFETY INFORMATION
(Large Capacity Unit LU-202)
CAUTION
To avoid any unexpected
injury, DO NOT put your hand
into the holes (3 places) on
the bottom plate of the LU.
(Finisher FS-520/FS-607)
CAUTION
To avoid injury, DO NOT
put your hand on top of
the printed sheets.
Be sure to hold both
sides of the printed
sheets when removing
them, and DO NOT leave
your hand on the printed
sheets while the primary
(main) tray goes up.
a03up0e004ca
S-17
SAFETY INFORMATION
WARNING
This safety message you could
get an electrical shock because
disconnecting power from this
section does not cut off power
from adjacent sections of the
machine.
WARNING
This safety message means
that you might get seriously
hurt or killed if you open the
product and expose yourself to
hazardous voltage. NEVER
remove the screwed on covers.
ALWAYS refer service
requirements to qualified
service personnel.
a0g6m0e004ca
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-18
MEASURES TO TAKE IN CASE OF AN ACCIDENT
MEASURES TO TAKE IN CASE OF

AN ACCIDENT
1. If an accident has occurred, the distributor who has been notified first must immediately
take emergency measures to provide relief to affected persons and to prevent further
damage.
2. If a report of a serious accident has been received from a customer, an on-site evalua-
tion must be carried out quickly and KMBT must be notified.
3. To determine the cause of the accident, conditions and materials must be recorded
through direct on-site checks, in accordance with instructions issued by KMBT.
4. For reports and measures concerning serious accidents, follow the regulations speci-
fied by every distributor.
S-19
Blank page
S-20
Legal restrictions on copying
Certain types of originals must never be copied with the purpose or intent to pass copies of
such originals off as the originals.
The following is not a complete list, but is meant to be used as a guide to responsible copy-
ing.
<Financial Instruments>
• Personal checks
• Traveler’s checks
• Money orders
• Certificates of deposit
• Bonds or other certificates of indebtedness
• Stock certificates
<Legal Originals>
• Food stamps
• Postage stamps (canceled or uncanceled)
• Checks or drafts drawn by government agencies
• Internal revenue stamps (canceled or uncanceled)
• Passports
• Immigration papers
• Motor vehicle licenses and titles
• House and property titles and deeds
<General>
• Identification cards, badges, or insignias
• Copyrighted works without permission of the copyright owner
In addition, it is prohibited under any circumstances to copy domestic or foreign currencies,

or works of art without permission of the copyright owner.
When in doubt about the nature of an original, consult with legal counsel.
Detail
In order to prohibit the illegal reproduction of certain originals, such as paper currency, this
machine is equipped with a counterfeit prevention feature.
Due to the counterfeit prevention feature that this machine is equipped with, images may
be distorted.
C-1
Composition of the service manual
This service manual consists of the following sections and chapters:
<Theory of Operation section>
OUTLINE: System configuration, product specifications,

unit configuration, and paper path
COMPOSITION/OPERATION: Configuration of each unit, explanation of the operating
system and explanation of the control system
MAINTENANCE: Maintenance steps,
removal/reinstallation methods of major parts
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. This section
also explains the procedure of maintenance.
<Field service section>
OUTLINE: System configuration, and product specifications

MAINTENANCE: Service schedule,
list of service tools and directions for use,
and firmware version up method
ADJUSTMENT/SETTING: Utility menu mode, Service mode, security and mechanical
adjustment
TROUBLESHOOTING: List of jam codes, their causes, operation when a jam
occurs and its release method, and list of error codes,
their causes, operation when a warning is issued and esti-
mated abnormal parts.
APPENDIX: Parts layout drawings, connector layout drawings, timing
chart, overall layout drawing
This section gives, as information required by the CE at the site (or at the customer's
premise), a rough outline of the service schedule and its details, the object and role of each
adjustment, error codes and supplementary information.
C-2
Notation of the service manual
A. Product name
In this manual, each of the products is described as follows:
(1) bizhub PRO C6501/C6501P/C65hc/C5501: Main body

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

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

IN
PS
Sensor PS Door PS1 Sensor detection signal
SIG
102 PS
24V Power to drive the solenoid
Solenoid SD DRV
Drive signal
SOL
24V Power to drive the clutch
Clutch CL DRV
Drive signal
SOL
C-3
24V Power to drive the motor
CONT Drive signal
DRV1
Motor M
DRV2
Drive signals of two kinds
D1
D2
_U
_V
_W
Drive signals (control signals) of three kinds
DRV1
DRV2
DRV3
D1
D2
D3
D4
DRV A
DRV A
DRV B Drive signals (control signals) of four kinds
DRV B Motor, phases A and B control signals
A
Motor M /A
B
/B
AB
BB
CLK, PLL PLL control signal
LCK, Lock, LD PLL lock signal
FR Forward/reverse rotation signal
EM, Lock, LCK, LD Motor lock abnormality
BLK Drive brake signal
P/S Power/stop
S/S
Operating load start/stop signal
SS
CW/CCW, F/R Rotational direction switching signal
ENB Effective signal
TEMP_ER Motor temperature abnormality detection signal
24V Power to drive the fan motor
CONT, DRIVE Drive signal
Fan FM
HL Speed control signal (2 speeds)
EM, Lock, LCK, FEM Detection signal
Others TH1.S, ANG Analog signal
C-4
SG, S.GND, S_GND Signal ground
Ground
PG, P.GND Power ground
DCD Data carrier detection
SIN Serial input
SOUT Serial output
DTR Data terminal operation available
GND Signal ground (earth)
Serial com-
DSR, DSET Data set ready
munication
RTS Transmission request signal
CTS Consent transmission signal
RI Ring indicator
TXD Serial transmission data
RXD Serial reception data
D. Paper feed direction

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

Transverse feed A4
A4
Longitudinal feed A4S
A3 Longitudinal feed A3
C-5
Blank Page
C-6
C6501/C6501P/
C65hc/C5501
Main body
2009.07
Ver. 3.0
Revision history
After publication of this service manual, the parts and mechanism may be subject to change for
improvement of their performance.
Therefore, the descriptions given in this service manual may not coincide with the actual machine.
When any change has been made to the descriptions in the service manual, a revised version will be
issued with a revision mark added as required.
Revision mark:
• To indicate clearly a section revised, 1 is shown at the left margin of the revised section.
The number inside 1 represents the number of times the revision has been made.
• To indicate clearly a page that contains the revision, 1 is shown near the page number of the
corresponding page.
NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
• When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
• When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.
2009/07 3.0 2 Revision in relation to launching of GP-501 and RU-506.

2009/03 2.0 1 Revision in relation to launching of bizhub PRO C65hc.
2008/07 1.0 — Issue of the first edition
Date Service manual Ver. Revision mark Descriptions of revision
Theory of Operation Ver.3.0 Jul. 2009 CONTENTS
CONTENTS
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bizhub PRO C6501
OUTLINE
1. SYSTEM CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. PRODUCT SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. UNIT CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CONFIGURATION/OPERATION
5. CONTROL BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6. IMAGE CREATING PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.1 Flow and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2 Charging process (Step 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.3 Laser exposure process (Step 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.4 Image development process (Step 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.5 First transfer process (Step 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.6 Second transfer process (Step 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.7 Separation process (Step 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.8 Drum cleaning (Sub step 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.9 Exposure before charging (Sub step 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.10 Transfer belt cleaning (Sub step 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.11 Second transfer roller/Lw cleaning (Sub step 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.12 Toner collection (Sub step 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.13 Process speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7. SCANNER SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.3.1 Scanner/Exposure lamp control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.3.2 Original size detection control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.3.3 Original reading area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.3.4 AE/ACS control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.3.5 Image processing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8. WRITE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.2.1 Laser beam path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.2.2 Write unit control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.2.3 Color registration control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.2.4 Front/back sides skew correction in main scan direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.2.5 Back side magnification adjustment in sub scan direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.2.6 Image stabilization control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9. PHOTOCONDUCTOR SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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CONTENTS Theory of Operation Ver.3.0 Jul. 2009
9.3.1 Image creation control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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9.3.2 Erase lamp (EL) control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

bizhub PRO C6501

10. CHARGING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10.1 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.2.1 Charging control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
11. INTERMIDIATE TRANSFER SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
11.1 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
11.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
11.2.1 Transfer belt conveyance/pressure drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
11.2.2 Second transfer pressure/release drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
11.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
11.3.1 First transfer roller pressure/release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
11.3.2 First transfer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
11.3.3 Second transfer mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
11.3.4 Second transfer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
11.3.5 Image correction unit shutter mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
11.3.6 Control of flip prevention for the belt cleaning blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

11.3.7 Control against belt filming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
12. DEVELOPING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
12.1 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
12.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
12.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
12.3.1 Developer conveyance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
12.3.2 Developing bias control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
12.3.3 Developing suction control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
13. TONER SUPPLY SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
13.1 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
13.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
13.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
13.3.1 Toner conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
13.3.2 Remaining toner detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
13.3.3 Stop control for print operation with no toner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
14. TONER COLLECTION SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
14.1 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
14.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
14.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
14.3.1 Toner collection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
14.3.2 Toner collection box control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
14.3.3 Box full control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
15. PAPER FEED SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
15.1 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
15.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
15.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
15.3.1 Plate up/down control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
15.3.2 Paper size detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
15.3.3 Paper feed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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15.3.4 Remaining paper detection control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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16. BYPASS FEED TRAY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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16.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
16.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
16.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
16.3.3 Paper feed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
16.3.4 Paper empty detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
17. VERTICAL CONVEYANCE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
17.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
17.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
17.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
17.3.1 Vertical conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
18. REGISTRATION SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
18.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
18.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
18.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
18.3.1 Loop control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
18.3.2 Registration operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
18.3.3 Paper leading edge timing correction control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
18.3.4 Registration speed correction control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
19. ADU SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
19.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
19.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
19.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
19.3.1 Paper reverse control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
19.3.2 ADU conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
19.3.3 Back side centering correction control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
20. REVERSE/PAPER EXIT SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
20.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
20.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
20.2.1 Reverse/paper exit drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
20.2.2 Paper exit drive/OT-502 drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
20.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
20.3.1 Conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
20.3.2 Reverse/paper exit timing control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
20.3.3 Paper exit decurler roller pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
20.3.4 Reverse decurler roller rotation control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
20.3.5 Paper exit full detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
21. FUSING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
21.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
21.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
21.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
21.3.1 Fusing roller drive control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
21.3.2 Pressure/release control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
21.3.3 Fusing temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
21.3.4 Protection against abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
21.3.5 Fusing roller/Lw cooling control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
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22. INTERFACE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

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22.1 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

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22.2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

23. IMAGE STABILIZATION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
23.1 Outline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
23.2 Operation flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
23.2.1 Image stabilizing controls when the sub power switch (SW2) is ON,
during printing, and during idling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
23.2.2 Image stabilizing controls when selecting the “Stability“ in expert settings. . . . . . . . . . . . . . . . 119
23.2.3 Other Image stabilizing controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
24. IMAGE PROCESSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
24.1 Operation flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
24.2 Image type classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
25. OTHER CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
25.1 Power On control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
25.1.1 Parts that operate when the main power switch (SW1) is turned on . . . . . . . . . . . . . . . . . . . . 124
25.1.2 Parts that operate when the sub power switch (SW2) is turned on . . . . . . . . . . . . . . . . . . . . . 125
25.2 Fan control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
25.2.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

25.2.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
25.3 Counter control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
25.3.1 Structure of counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
25.3.2 Counter operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
25.4 Dehumidifier heater control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
25.5 ACS control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
25.5.1 Switching from the color mode to the black-and-white mode . . . . . . . . . . . . . . . . . . . . . . . . . 135
25.5.2 Count when using ACS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
MAINTENANCE
26. MAINTENANCE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
26.1 Housing section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
26.1.1 Replacing the Dust-proof filter /1 assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
26.1.2 Replacing dust-proof filter /2 assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
26.2 Photoconductor section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
26.2.1 Process unit disassembly flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
26.2.2 Opening/closing toner supply section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
26.2.3 Pulling out the process unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
26.2.4 Removing drum cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
26.3 Charging section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
26.3.1 Replacing the charging corona . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
26.3.2 Replacing the charging dust-proof filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
26.4 Intermediate transfer section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
26.4.1 Removing/installing the transfer belt unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
26.4.2 Replacing the belt cleaning blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
26.4.3 Replacing 1st transfer roller /Y, /M, /C, /K and Transfer roller bearing . . . . . . . . . . . . . . . . . . . 151
26.4.4 Replacing the transfer belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
26.4.5 Replacing the 2nd transfer roller /Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
26.4.6 Replacing the separation claw assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
26.4.7 Replacing the belt cleaner unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
26.4.8 Replacing the toner collection sheet /1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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26.4.9 Replacing the 2nd transfer roller /Lw and the transfer earth plate assy . . . . . . . . . . . . . . . . . . 159
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26.4.10 Replacing the belt separation claw solenoid (SD1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
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26.4.11 Replacing the separation discharging assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
26.5 Developing section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
26.5.1 Replacing the developer /Y, /M, /C, /K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
26.5.2 Replacing the developing unit /C, /M, /Y, /K. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
26.6 Toner collection box assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
26.6.1 Replacing the toner collection box assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
26.7 Paper feeding section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
26.7.1 Replacing the pick-up roller/paper feed roller rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
26.7.2 Replacing the separation roller rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
26.7.3 Replacing the paper feed clutch/pre-registration clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
26.8 Bypass feed tray section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
26.8.1 Replacing the pick-up roller/paper feed roller rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
26.8.2 Replacing the separation roller rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
26.8.3 Replacing the paper feed clutch/BP (MC6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
26.9 Vertical conveyance section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
26.9.1 Replacing the intermediate conveyance clutch /1 (MC13). . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
26.10 Registration section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
26.10.1 Replacing the cleaning stay assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
26.10.2 Replacing the registration roller assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
26.11 ADU section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
26.11.1 Replacing the intermediate conveyance clutch/2 (MC4) and /3 (MC5) . . . . . . . . . . . . . . . . . . 184
26.11.2 Replacing the ADU conveyance clutch/1 (MC1), /2 (MC2), /3 (MC3),
and the ADU pre-registration clutch (MC18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
26.12 Reverse/paper exit section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
26.12.1 Replacing Reverse decurler roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
26.12.2 Replacing the paper exit decurler roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
26.13 Fusing section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
26.13.1 Removing/installing the fusing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
26.13.2 Replacing the fusing drive gear /B and the fusing duct 2 assy . . . . . . . . . . . . . . . . . . . . . . . . 196
26.13.3 Replacing the fusing drive gear /M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
26.13.4 Replacing the fusing lamp /Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
26.13.5 Replacing the fusing roller /2, fusing bearing, and fusing drive gear /O . . . . . . . . . . . . . . . . . . 202
26.13.6 Replacing the fusing belt, fusing roller /1, insulating sleeve /Up,
fusing bearing /Up, and belt regulation sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
26.13.7 Replacing the fusing heater lamp /4 (L5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
26.13.8 Replacing the fusing roller /Lw, fusing bearing /Lw, and insulating sleeve /Lw . . . . . . . . . . . . 209
26.13.9 Replacing the sensor mounting plate A assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
26.13.10Replacing the sensor stay B assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
26.13.11Replacing the fusing paper exit roller /Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
26.13.12Replacing the fusing regulation gear /A and the fusing limiter . . . . . . . . . . . . . . . . . . . . . . . . 217
26.14 OT-502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
26.14.1 Replacing the paper retainer roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
26.14.2 Replacing the paper exit roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
26.14.3 Replacing the paper exit driven roller/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
27. OTHER PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
27.1 Items not allowed to be disassembled and adjusted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
27.1.1 Scanner section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
27.1.2 Write section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
27.1.3 Photoconductor section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
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27.1.4 Charging section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

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27.1.5 Intermediate transfer section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

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27.1.6 Fusing unit section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

27.2 Disassembly/reassembly parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
27.3 Disassembly/reassembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
27.3.1 Removing/reinstalling rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
27.3.2 Removing/reinstalling left cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
27.3.3 Removing/installing right cover/Up1, /Up2, /Up3, /Lw1 and /Lw2. . . . . . . . . . . . . . . . . . . . . . 234
27.3.4 Removing/reinstalling original glass assy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
27.3.5 Removing/reinstalling upper cover/Fr, /Rt, and Lt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
27.3.6 Removing/reinstalling upper cover /Rr1 and /Rr2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
27.3.7 Removing/installing main board unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
27.3.8 Removing/installing CCD unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
27.3.9 Removing/installing exposure unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
27.3.10 Removing/installing exposure lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
27.3.11 Removing scanner wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
27.3.12 Reinstalling the scanner wire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
27.3.13 Removing/installing write unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
27.3.14 Removing/installing process unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

27.3.15 Removing/reinstalling image correction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
27.3.16 Removing/installing belt collectin pipe, vertical conveyance pipe
and horizontal conveyance pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
27.3.17 Removing/reinstalling ADU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
27.3.18 Replaceing the lock lever/1, /2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
27.3.19 Removing/reinstalling paper feed tray /1, /2 and /3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
27.3.20 Removing/reinstalling tray up/down wire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
27.3.21 Removing/installing temperature sensor /1 (TEMS/1), thermostat /1 (TS1) and /2 (TS2) . . . . . 275
27.3.22 Removing/installing temperature sensor /2 (TEMS/2) and thermostat /3 (TS3) . . . . . . . . . . . . 278
27.3.23 Removing/reinstalling OT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
27.4 Commercially available parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
27.4.1 Installing the status indicator light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
27.4.2 Installing the key counter (KCT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
vi
Theory of Operation Ver.3.0 Jul. 2009 1. SYSTEM CONFIGURATION
OUTLINE
/C6501P/C65hc/C5501
bizhub PRO C6501
1. SYSTEM CONFIGURATION
A. System configuration (PRO C6501/C6501P/C65hc)
[24]
[23]
[2]
[19] [9]
[3]
[20] [21] [10]
[25] [4]
[18] [1]
[5]
[22]
[8]
[13]
[6]
[17] [7]
[12]
[11]
[16] [13]
[15]
[12]
[14]
a0u0t1e001ca
1 2
/C6501P/C65hc/C5501 1. SYSTEM CONFIGURATION Theory of Operation Ver.3.0 Jul. 2009
[1] Main body [14] Flat stitching staple finisher (FS-520)

bizhub PRO C6501
[2] Dehumidifier fan heater (HT-503) [15] Simplified perfect binding machine (PB-501/502)
[3] Large capacity paper feed tray (LU-202) [16] Saddle stitching unit (SD-506)
[4] Large capacity paper feed tray (PF-602) [17] Large capacity stacker (LS-505)
[5] Dehumidifier fan heater (HT-504) [18] Punch and folding unit (FD-503)
[6] Built-in type image controller (IC-408) *1 [19] Staple finisher (FS-521)
[7] Server type image controller (IC-304/305) [20] Relay unit RU-506
[8] Hard disk (HD-506) *1 [21] Multi punch unit GP-501
[9] Output tray (OT-502) [22] Die set (DS-5##) *3
[10] Conveyance cooling unit (RU-504) [23] Original cover (OC-506) *1
[11] Saddle stitching staple finisher (FS-607) [24] Auto double sided original feeder (DF-609) *2
[12] Punch kit (PK-512/513) [25] Key counter
[13] Post inserter (PI-502)
*1 PRO C6501 only.

*2 In the case of PRO C6501P/C65hc, no scanner/DF function is provided.
*3 Selectable arbitrarily in accordance with the number and shape of pins.
Model Paper size The number Shape of pin Model Paper size The number Shape of pin
of pins of pins
DS-501 81/2 x 11 3 Round DS-510 A4 34 Round
DS-502 81/2 x 11 19 Rectangle DS-511 A4 23 Round
DS-503 81/2 x 11 32 Square DS-512 A4 47 Round
DS-505 81/2 x 11 44 Round DS-514 To be determined
DS-507 To be determined DS-516 A4 20 Rectangle
DS-508 A4 4 Round DS-517 A4 23 Square
DS-509 A4 21 Rectangle DS-518 A4 34 Square
2 2
B. Configuration for optional device connection (PRO C6501/C6501P/C65hc)
/C6501P/C65hc/C5501
bizhub PRO C6501
Note
• Any combination other than those listed below is not available.
• IC-304/305 is available with all combinations.
• IC-408 is available with combination No.3, 9, 10 or 19.
• IC-408 is for C6501 only.
No. Paper feed option Combinations for finishing AC power to be connected

1 RU-504 FS-521 External (RU-504)
2 RU-504 FD-503 External (RU-504/FD-503)
3 RU-504 SD-506 External (RU-504)
4 RU-504 LS-505 External (RU-504/LS-505)
5 RU-504 FD-503 FS-521 External (RU-504/FD-503)
6 RU-504 LS-505 FS-521 External (RU-504/LS-505)
7 RU-504 LS-505 SD-506 External (RU-504/LS-505)
8 RU-504 FD-503 LS-505 External (RU-504/FD-503)
9 FS-607*3 —
10 OT-502 —
11 RU-504 PB-501/502 External (RU-504/PB-501/502)
12 RU-504 FD-503 PB-501/502 External (RU-504/FD-503/PB-501/
502)
13 PF-602*1/ RU-504 SD-506 PB-501/502 External (RU-504/PB-501/502)
14 LU-202*2 RU-504 FD-503 SD-506 PB-501/ External (RU-504/FD-503/PB-501/
502 502)
15 RU-504 LS-505 PB-501/502 External (RU-504/LS-505/PB-501/
502)
16 RU-504 FD-503 SD-506 External (RU-504/FD-503)
17 RU-504 SD-506 FS-521 External (RU-504)
18 RU-504 FD-503 SD-506 FS-521 External (RU-504/FD-503)
19 FS-520*3 —
20 RU-504 GP-501 RU-506 FS-521 External (RU-504/GP-501)
21 RU-504 GP-501 RU-506 FD-503 FS-521 External (RU-504/GP-501/FD-503)
22 RU-504 GP-501 RU-506 SD-506 FS-521 External (RU-504/GP-501)
23 RU-504 GP-501 RU-506 LS-505 FS-521 External (RU-504/GP-501/LS-505)
24 RU-504 GP-501 RU-506 LS-505 PB-501/ External (RU-504/GP-501/LS-505/
502 PB-501/502)
*1 HT-504 can be connected to PF-602 arbitrarily.

*2 HT-503 can be connected to LU-202 arbitrarily.
*3 PK-512, PK-513 or PI-502 can be connected to FS-520/607 arbitrarily.
*4 Metric destination : External (RU-504/FD-503)
Inch destination : External (RU-504)
3 2
1. SYSTEM CONFIGURATION Theory of Operation Ver.3.0 Jul. 2009
C. System configuration (PRO C5501)

/C6501P/C65hc/C5501
bizhub PRO C6501
[10]
[13]
[12]
[9] [2]
[7]
[3]
[11]
[14]
[1]
[10]
[9]
[6]
[4]
[8] [5]
a03ut1c005cc
[1] Main body [8] Saddle stitching staple finisher (FS-607)

[2] Dehumidifier fan heater (HT-503) [9] Punch kit (PK-512/513)
[3] Large capacity paper feed tray (LU-202) [10] Post inserter (PI-502)
[4] Built-in type image controller (IC-408) [11] Staple finisher (FS-520)
[5] Server type image controller (IC-304/305) [12] Original cover (OC-506)
[6] Hard disk (HD-506) [13] Auto double sided original feeder (DF-609)
[7] Output tray (OT-502) [14] Key counter
4
D. Configuration for optional device connection (PRO C5501)
/C6501P/C65hc/C5501
bizhub PRO C6501
Note
No. Paper feeding option Combinations for finishing AC power to be connected to
1 LU-202 *1 FS-607 *2 —
2 LU-202 *1 FS-520 *2 —
3 LU-202 *1 OT-502 —

*2 PK-512/513 or PI-502 can be connected to FS-520/607 arbitrarily.
5
2. PRODUCT SPECIFICATIONS Theory of Operation Ver.3.0 Jul. 2009
2. PRODUCT SPECIFICATIONS
/C6501P/C65hc/C5501
bizhub PRO C6501
A. Type
Type Console type (floor-mounted type)

Copying method Four-drum tandem laser electrostatic method
Original stand Fixed
Original alignment Left rear standard
Photo conductor OPC
Writing method Two-beam laser scanning method
Paper capacity Three trays (500 sheets x 3, 80g/m2)
Multi bypass (250 sheets, 80g/m2)
PF-602 (3000 sheets x 2, 80g/m2)*1 *2
LU-202 (2500 sheets, 80g/m2)*1
*1 PF-602 and LU-202 are optional.

*2 PRO C6501/C6501P/C65hc only.
B. Functions
Original Sheet, book, solid object

Max. original size A3, or 11 x 17 (Custom paper is Max.303 x 438mm)
Copy size Tray1, 2, 3 SRA3, A3, B4, SRA4, A4, SRA4S, A4, A4S, B5, B5S, A5S
13 x 19, 12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S,
51/2 x 81/2S
81/2 x 13, 81/4 x 13, 8 1/8 x 131/4, 8 x 13
8K, 16K, 16KS
Tab paper (A4, 81/2 x 11)
Custom paper (Max. 330 x 487 mm, Min. 140 x 182 mm)
Bypass feed SRA3, A3, B4, SRA4, SRA4S, A4, A4S, B5, B5S, A5, A5S,
B6S, A6S,
13 x 19, 12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11,
81/2 x 11S, 51/2 x 81/2S
81/2 x 13, 81/2 x 13, 81/8 x 131/4, 8 x 13
8K, 16K, 16KS
ADU SRA3, A3, B4, SRA4, SRA4S, A4, A4S, B5, B5S, A5, A5S
13 x 19, 12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11,
81/2 x 11S, 51/2 x 81/2S
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
8K, 16K, 16KS
1 6
Theory of Operation Ver.3.0 Jul. 2009 2. PRODUCT SPECIFICATIONS
/C6501P/C65hc/C5501
Magnification Fixed magnifi- Inch: x 1.000, x 2.000, x 1.545, x 1.294, x 1.214,
cation x 0.785, x 0.772, x 0.647, x 0.500
bizhub PRO C6501

Metric: x 1.000, x 2.000, x 1.414, x 1.224, x 1.154,
x 0.866, x 0.816, x 0.707, x 0.500
Zoom magnifi- x 0.25 to x 4.00 (at the step of 0.001 step)
cation
Warm-up time Inch: 390 seconds or less
Metric: 420 seconds or less
First copy out time Full color 6.5 seconds or less (A4 / 81/2 x 11)
Monochrome 6.5 seconds or less (A4 / 81/2 x 11)
Black-and-white 5.0 seconds or less (A4 / 81/2 x 11)
Continuous copy speed Full color 65 copies /min. (A4 / 81/2 x 11)*3
55 copies /min. (A4 / 81/2 x 11)*4
Monochrome 65 copies /min. (A4 / 81/2 x 11)*3
55 copies /min. (A4 / 81/2 x 11)*4
Black-and-white 65 copies /min. (A4 / 81/2 x 11)*3
55 copies /min. (A4 / 81/2 x 11)*4
Continuous copy count Up to 9,999 sheets
Resolution Scan Main scanning : 600 dpi Sub-scanning : 600 dpi
Write Main scanning : 600 dpi Sub-scanning : 600 dpi (1800 dpi *1)
Standard memory 256 MB for each color (Y, M, C, K)
Expansion memory 30 GB for each color (Y, M, C, K)
(HD-506)*5
No. of originals in memory Full color Line1/Line2/Dot1/Dot2: 23 sheets [5461 sheets*2]
(Reference value)*5 Priority in high compression: 110 sheets [16384 sheets *2]
Conditions Original: KM #101/A3 (color)
Density: Standard
Mode: Text/Photo, printed original, life size
Memory capacity: Standard 256 MB
Black-and- Line1/Line2/Dot1/Dot2: 126 sheets or more [16384 sheets *2]
white/mono- Priority in high compression: 271 sheets or more [16384
chrome sheets *2]
Conditions Original: FAX test chart #4 /A4
Density: Standard
Interface section RJ45 Ethernet, Serial port (RS232-C), Service port, Serial port (USB
TypeB),Connector for printer controller
*1 When "smoothing" is selected at the printer driver.

*2 When HD-506 is installed.
*3 PRO C6501/C6501P/C65hc
*4 PRO C5501
*5 C6501/C5501 only.
7 1
C. Available types of paper and ranges of paper weight

/C6501P/C65hc/C5501
bizhub PRO C6501
Type of paper Tray1, 2, 3 Bypass feed

Plain paper { {
A4 or 81/2 x 11 or larger : 64 to 256 g/m2 64 to 300g/m2
A4 or smaller than 81/2 x 11 : 64 to 209 g/m2
High Quality paper { {
2
A4 or smaller than 8 /2 x 11 : 64 to 209 g/m
1
Color Specific paper { {

Coated_GL, ML, GO , MO U U
paper A4 or 81/2 x 11 or larger : 81 to 256 g/m2 64 to 300g/m2
Label paper*1 — {
OHP film*1 *2 { {
Index paper*1 *3 { {
{:Available U: Available only one sheet at a time —: Not available
*1 Paper type of the label paper can be Plain, High Quality, Color Specific, or Coated_GL, ML, GO, MO
paper. Available ranges of paper weight (thickness) of the label paper are the same with those of the corre-
sponding paper type.
*2 Print quality not guaranteed.
*3 Paper loading direction predetermined, single-sided printing only.
8
D. Materials
/C6501P/C65hc/C5501
bizhub PRO C6501
Parts name Useful life Type name
26,000 prints*1 TN612Y*5
Toner bottle /Y
25,000 prints*3 TN614Y*6
26,000 prints*1 TN612M*5
Toner bottle /M
25,000 prints*3 TN614M*6
26,000 prints*1 TN612C*5
Toner bottle /C
25,000 prints*3 TN614C*6
38,500 prints*1 TN612K*5
Toner bottle /K
37,400 prints*3 TN614K*6
200,000 prints *2
Drum cartridge DU-102C
150,000 prints *4
200,000 prints *2
Developer /Y DV610Y
150,000 prints *4
200,000 prints *2 DV610M*5
Developer /M
150,000 prints *4 DV611M*5
200,000 prints *2 DV610C*5
Developer /C
150,000 prints *4 DV611C*5
200,000 prints *2
Developer /K DV610K
150,000 prints *4
*1 PRO C6501/C6501P/C65hc (A4 original at 5% coverage for each color.)

*2 PRO C6501/C6501P/C65hc (The end of actual useful life is reached when the number of sheets is
printed, or when the total drive distance reaches a certain level, whichever comes first.)
*3 PRO C5501 (A4 original at 5% coverage for each color.)
*4 PRO C5501 (The end of actual useful life is reached when the number of sheets is printed, or when the
total drive distance reaches a certain level, whichever comes first.)
*5 PRO 6501/C6501P/C5501
*6 PRO 65hc
9 2
E. Maintenance
/C6501P/C65hc/C5501
bizhub PRO C6501
Every 200,000 prints*3

Maintenance cycle
Ave. number of prints*1 35,000 to 75,000 per month
Max. number of prints*1 Q zone*2 : 300,000 per month*3, 250,000 per month*4, 10,000 per day
B,C zone*2 : 150,000 per month, 8,500 per day
A zone*2 : 100,000 per month, 5,000 per day*3, 4,200 per day*4
*1 The number of prints include all monochrome, solid color, and full color printings.
*2 The zone mean a temp&humidity range indicated in the graph below.
*3 PRO C6501/C6501P/C65hc
*4 PRO C5501
80
70
A
Humidity (%RH)
60
B Q
40
30
20 C
10
10 18 20 23 30
Temperature (°C)
a03ut1c004ca
1 10
F. Machine data
/C6501P/C65hc/C5501
bizhub PRO C6501
Power source Inch: AC208 to 240V 16A, 60Hz
Metric: AC230V 15A, 50Hz
Maximum power consump- Inch: 5,100W or less : PRO C6501 (B. When the type of the optional unit
tion connection configuration (P3) is No. 14)
3,800W or less : PRO C5501
3,950W or less (B. When the type of the optional unit connection
configuration (P3) is No. 9)
Metric: 4,800W or less : PRO C6501 (B. When the type of the optional unit
connection configuration (P3) is No. 14)
Dimensions Main body + OC-506 786 (W) x 992 (D) x 1,056 (H)*1 mm
Main body (PRO C6501) 3,852 (W) x 992 (D) x 1,414 (H)*2 mm
+ DF-609 + RU-504 + LS-505
+ SD-506
+ DF-609 + LU-202 + FS-607
Weight Approx. 360kg(PRO C6501/C5501)
Approx. 323kg (PRO C6501P/C65hc)
*1 Exclude the operation panel.

*2 Include the operation panel.
G. 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.
11 1
3. UNIT CONFIGURATION Theory of Operation Ver.3.0 Jul. 2009
3. UNIT CONFIGURATION
/C6501P/C65hc/C5501
bizhub PRO C6501
DF-609 (option) Operation panel
Fusing section
OT-502 (option) Scanner section
Toner supply
section
Developing
section
Write section
Reverse/exit
section
Bypass feed tray

section
ADU section
Vertical convey-
ance section
Paper feed section

Toner collection
Photo conductor section Registration Charging section section
section a03ut1c002ca
12
Theory of Operation Ver.3.0 Jul. 2009 4. PAPER PATH
4. PAPER PATH
/C6501P/C65hc/C5501
bizhub PRO C6501
Straight paper exit
Paper exit (common) Transfer/Fusing

conveyance
Paper feed
(common)
Reversed paper Bypass tray

exit paper feed
Reverse
conveyance
ADU conveyance
PF paper feed,
LU paper feed
Tray /1 paper feed
Vertical
conveyance
Tray /2 paper feed
Tray /3 paper feed

a03ut1c003ca
13
/C6501P/C65hc/C5501 4. PAPER PATH Theory of Operation Ver.3.0 Jul. 2009
bizhub PRO C6501
Blank page
14
Theory of Operation Ver.3.0 Jul. 2009 5. CONTROL BLOCK DIAGRAM
/C6501P/C65hc/C5501
bizhub PRO C6501
5. CONTROL BLOCK DIAGRAM
USB RS232C LAN Parallel

OB NRB
I/F I/F I/F I/F
CCD IC HDD OACB
IPB IMCB FS FS FD LS SD PB PF LU DF
Write
IFB RU
Section
PRCB
Fusing
ACDB CDB SCDB DCPS HV TDB
Unit
M M MC SD PS M PS M MC M MC SD PS
Image bus Clock SYN UART bus Other buses Individual signal IDE
line
a03ut2c001cd
Board name Functions ISW

Overall control board (OACB) Performs overall control of the MFP. Yes
Image memory control board Controls image memory (DRAM + HDD Option). No
(IMCB)
Image processing board (IPB) Controls various image processing. No
Printer control board (PRCB) Controls printer mechanism load applied to the components Yes
such as motors, fans, solenoids and sensors.
NVRAM board (NRB) Performs various adjustments/stores setting data. No
15 1
6. IMAGE CREATING PROCESS Theory of Operation Ver.3.0 Jul. 2009
6. IMAGE CREATING PROCESS

/C6501P/C65hc/C5501
bizhub PRO C6501
6.1 Flow and functions

Steps Processes Functions
Step 1 Charging process Distributes electrostatic charges uniformly over the surface of the 4
photoconductor drums.
Step 2 Laser exposure process Forms an electrostatic latent image on each photoconductor drum.
Step 3 Image development process Develops the electrostatic latent image with toner on each photoconductor drum.
Step 4 First transfer process Transfers the 4 toner images (YMCK) created on each photocon-
ductor drum to the transfer belt one by one to create a complete
toner image on the belt.
Step 5 Second transfer process Transfers the toner image on the transfer belt to paper.
Step 6 Separation process Separates the toner-transferred paper from the transfer belt.
Sub step 1 Drum cleaning Removes the remaining toner on the surface of the photoconductor
drums after the first transfer.
Sub step 2 Exposure before charging Discharges the surface of the photoconductor drums after the drum cleaning.
Sub step 3 Transfer belt cleaning Removes the remaining toner on the transfer belt surface after the second transfer.
Sub step 4 Second transfer roller /Lw Removes the remaining toner on the second transfer roller/Lw sur-
cleaning face after the second transfer.
Sub step 5 Toner collection Collects the toner removed at sub step 1 and 3. (This step is not
illustrated in the figure below.)
[11] [1]
Step 3
Sub step 3 [2]
[12] [4] [3]
Step 2
Step 4
Step 1
Sub step 1
[10]
Sub step 2
[9]
[8]
Step 6 [5]
[6]
[7] Step 5 / Sub step 4 a03ut2c002ca
[1] Developing unit [7] Discharging section for separation

[2] Write unit [8] Second transfer roller /Up
[3] Charging corona [9] Transfer belt
[4] Erase lamp (EL) [10] Blade (for drum cleaning)
[5] Paper [11] Blade (for transfer belt cleaning)
[6] Second transfer roller /Lw [12] Drum
16
Theory of Operation Ver.3.0 Jul. 2009 6. IMAGE CREATING PROCESS
6.2 Charging process (Step 1)
/C6501P/C65hc/C5501
bizhub PRO C6501
A negative high DC voltage is applied to the gold-plate tungsten wire of the charging corona which is provided
for each Y, M, C, and K photoconductor drums. Then the wire discharges toward the drum in order to charge
the entire drum surface with the negative electrostatic charge. The charge on the drum is uniformly distributed
on the drum surface with the charging control plate.
[1]
[2]
[4] [3]
a03ut2c003ca
[1] Drum [3] Charging corona

[2] Negative electrostatic charge [4] Charging control plate
6.3 Laser exposure process (Step 2)

The material used for the drum surface has a characteristic that holds electrostatic charges in darkness and dis-
charges under light. This enables creating a electrostatic latent image on the drum with laser beam. The laser
beam draws the image shining on certain points on the drum where the text or image presents according to
color separation data (Y, M, C, K data) created on the image processing section.
[4]
[3]
[1]
[2]
a03ut2c004ca
[1] Write unit [3] Discharged points

[2] Laser beam [4] Negative electrostatic charge
17
6.4 Image development process (Step 3)

/C6501P/C65hc/C5501
bizhub PRO C6501
The non-image points of the electrostatic latent image on the photoconductor drum is charged negatively while
the image points are neutralized. As the toner is negatively charged, it is attracted to the image points on the
drum and as a result, a visible toner image is created on the drum. This operation is referred to as "develop-
ment."
[4]
[3]
[2]
[1]
a03ut2c005ca
[1] Drum [3] Negatively charged toner

[2] Negative electrostatic charge [4] Developing roller
18
6.5 First transfer process (Step 4)
/C6501P/C65hc/C5501
bizhub PRO C6501
The toner images created on each of the Y, M, C, and K photoconductor drums are transferred to the transfer
belt one by one in the order of Y, M, C, and K. As a result, the 4 toner images are overlaid and a complete toner
image is formed on the belt. This is called as "first transfer."
In order to carry out the first transfer, a positive high DC voltage bias is applied to the first transfer roller provided
on the back surface of the transfer belt. This makes the transfer belt surface have a positive potential higher than
that of the each drum surface so that the toner on the drums are attracted to the transfer belt.
[3] [4] [5]
[2]
[1]
[8] [5]
[7]
[6]
a03ut2c006ca
[1] Drum /Y [5] Negative electric charges

[2] First transfer roller /Y [6] Drum /M
[3] Transfer belt [7] First transfer roller /M
[4] Toner /Y [8] Toner /M
19
6.6 Second transfer process (Step 5)

/C6501P/C65hc/C5501
bizhub PRO C6501
Transferring the complete toner image formed on the transfer belt to paper is called as "second transfer." For the
second transfer, the second transfer roller/Lw located at the back side of the transfer belt rotates to transport
paper applying a pressure on the belt, while a high negative DC bias is applied to the second transfer roller/Up
inside the belt.
Because of a potential difference between the 2 rollers, the toner image can be transferred to the paper from the
belt.
[1]
[4]
[2]
[3]
a03ut2c007ca
[1] Transfer belt [3] Second transfer roller /Lw

[2] Paper [4] Second transfer roller /Up
20
6.7 Separation process (Step 6)
/C6501P/C65hc/C5501
bizhub PRO C6501
For the second transfer, the paper is negatively charged by the second transfer roller/Up so that the paper
makes intimate contact with the transfer belt. Once the toner is transferred to the paper, the paper must be sep-
arated from the belt. The separating operation is called as "separation."
In order to achieve the separation, a high AC or DC bias is applied to the discharging section to attract the paper
separating it from the transfer belt.
[1]
[2]
[4] [3]
a03ut2c008ca
[1] Transfer belt [3] Second transfer roller /Lw

[2] Paper [4] Discharging section for separation
21
6.8 Drum cleaning (Sub step 1)

/C6501P/C65hc/C5501
bizhub PRO C6501
The toner remains slightly on the drum after the first transfer. The process that cleans the remaining toner off is
called "drum cleaning."
The cleaning is made by the cleaning blade provided for each drum. Its edge made of urethane rubber scrapes
the toner off the drum surface.
[3] [1]
[2] a03ut2c009ca
[1] Drum [3] Remaining toner

[2] Cleaning blade
6.9 Exposure before charging (Sub step 2)

After the drum cleaning, electric potential slightly remains on the drum surface while the toner is completely
removed.
Since charging the drum for the next copying or printing cannot be normally performed with the remaining
potential, the potential on the drum surface is completely neutralized by means of erase lamp (EL). This process
is called "Exposure before charging."
[1]
[3]
[2] a03ut2c010ca
[1] Drum [3] Remained electric charge

[2] Erase lamp (EL)
22
6.10 Transfer belt cleaning (Sub step 3)
/C6501P/C65hc/C5501
bizhub PRO C6501
The toner remains slightly on the transfer belt after the second transfer. The process that cleans the remaining
toner off is called "Transfer belt cleaning".
The transfer belt cleaning is made by the cleaning blade. Its edge made of urethane rubber scrapes the toner off
the belt surface.
[3] [1]
[2]
a03ut2c011ca
[1] Transfer belt [3] Cleaning blade

[2] Remaining toner
23
6.11 Second transfer roller/Lw cleaning (Sub step 4)

/C6501P/C65hc/C5501
bizhub PRO C6501
Since the second transfer roller/Lw directly contacts with the toner on the transfer belt, the roller is contaminated
with the toner.
To clean the roller, a negative and positive high DC bias is applied to the second transfer roller/Up alternately so
that the toner on the second transfer roller/Lw is attracted to the transfer belt. The toner transferred to the belt
surface is removed by the transfer belt cleaning described in the previous section.
[1]
[3]
[2]
[5] [4]
a03ut2c012ca
[1] Transfer belt [4] When a positive DC bias is applied

[2] Second transfer roller /Lw [5] When a negative DC bias is applied
[3] Second transfer roller /Up
24
6.12 Toner collection (Sub step 5)
/C6501P/C65hc/C5501
bizhub PRO C6501
The toner removed from the drums and the transfer belt is collected to the toner collection box through the toner
collection screw.
[3]
[2]
[4]
[5]
[6]
[1]
a03ut2c013ca
[1] Toner collection box [4] Toner collecting port (Drum /M)
[2] Toner collecting port (Transfer belt) [5] Toner collecting port (Drum /C)
[3] Toner collecting port (Drum /Y) [6] Toner collecting port (Drum /K)
25
6.13 Process speed

/C6501P/C65hc/C5501
bizhub PRO C6501
The printer has 3 process speed settings to accommodate with various types of paper. One of the 3 settings is
used according to the paper thickness/weight and whether the paper is coated or not.
Paper weight Plain paper Glossy photo paper

64 to 135 g/m2 300 mm/s (1/1 speed) —
106 to 135 g/m2 — 207.7 mm/s (2/3 speed)
136 to 209 g/m2 207.7 mm/s (2/3 speed) 150 mm/s (1/2 speed)
210 to 300 g/m2 150 mm/s (1/2 speed) —
26
Theory of Operation Ver.3.0 Jul. 2009 7. SCANNER SECTION
7. SCANNER SECTION
/C6501P/C65hc/C5501
bizhub PRO C6501
7.1 Configuration
Exposure unit CCD board
Shading correc-
tion plate
CCD unit
Mirror unit
a03ut2c014ca
7.2 Drive
[5]
[4] [1]
FRONT
[3] [2] a03ut2c015ca
[1] Exposure unit [4] Scanner wire /Rr

[2] Scanner wire /Fr [5] Scanner motor (M1)
[3] V mirror unit
27
7. SCANNER SECTION Theory of Operation Ver.3.0 Jul. 2009
7.3 Operation
/C6501P/C65hc/C5501
bizhub PRO C6501
7.3.1 Scanner/Exposure lamp control

A. Home position search of the exposure unit
• When the sub power switch (SW2) is turned on, the exposure unit starts to search the home position after
the specified time passed.
[1] [2] [3]
a03ut2c016ca
[1] Home position [3] Platen APS position

[2] Scanner home sensor (PS1)
B. Shading correction
• After searching the home position, the exposure unit performs shading correction.
• The white standard board attached to the rear side of the platen glass is used for the shading correction.
• There are 2 types of shading correction: white correction (2 times) and black correction (one time).
• The white correction is performed by reading the white standard board (L1) with the exposure lamp turned on.
• The black correction is performed by reading the brightness with the L1 turned off.
• To acquire the white correction data, the brightness of each pixel is compared between the first time cor-
rection and the second time correction, and the brighter one is used as a white correction data.
• The shading correction reading operation differs between when the sub power switch (SW2) ON and when
the start button ON.
(1) The reading operation when the SW2 ON
[1] [2] [3]
[4]
[5]
[6]
*1 *2
[7] a03ut2c017ca
[1] Home position [5] White correction (Second time)

[2] Scanner home sensor (PS1) [6] Black correction
[3] Platen APS position [7] Returning the amount moved
[4] White correction (First time)
*1 Platen cover or DF is closed: The exposure unit stops at the home position.
*2 Platen cover or DF is opened: The exposure unit stops at the platen APS position.
28
(2) The reading operation when the start button is turned on
/C6501P/C65hc/C5501
• After finishing the movement for the shading correction, the exposure unit shifts to scanning operation auto-
bizhub PRO C6501

matically.
• The other movements of the exposure unit are the same as when the SW2 is turned on.
C. Original reading mode

• There are 2 original reading modes; platen mode and DF mode.
• Whether the density setting is set to manual or AE, the 2 modes differ in movement of the exposure unit.
(1) When selecting the manual density setting
[1] [2] [3]
[4]
[5]
[6]
[7]
a03ut2c018ca

[2] Scanner home sensor (PS1) [6] Exposure scan
[3] Platen APS position [7] Home position search
29
(2) When selecting the AE density setting

/C6501P/C65hc/C5501
bizhub PRO C6501
[1] [2] [3]
[4]
[5]
[6]
[7]
[8] a03ut2c019ca

[2] Scanner home sensor (PS1) [6] AE scan
[3] Platen APS position [7] Exposure scan
[4] White correction (First time) [8] Home position search
D. Original reading control

• The light reflected off the original goes to the CCD sensor through the lens.
• The CCD sensor outputs an electric signal (analog) corresponding to the amount of light.
• The CCD sensor includes 3 separate photo receivers corresponding to each color R, G and B.
• The R, G and B analog signals are individually converted to a digital signal (A/D convert) in the CCD board
(CCDB).
• The A/D convert is controlled by the image processing board (IPB).
30
E. Original reading timing
/C6501P/C65hc/C5501
• When AE/ACS is not set, the exposure unit movement is the same in the platen mode and the DF.
bizhub PRO C6501

• When AE/ACS is set, the exposure unit movement differs between the platen mode and the DF mode.
(1) When AE/ACS is not set
[1] [2] [3]
[4]
[5]
[6]
[7] a03ut2c020ca

[2] Scanner home sensor (PS1) [6] Exposure scan (270 mm/s)
[3] Platen APS position [7] Home position search
(2) When AE/ACE is set (Platen mode)
[1] [2] [3]
[4]
[5]
[6]
[7]
[8] a03ut2c021ca

[2] Scanner home sensor (PS1) [6] AE/ACS scan (409 mm/s)
[3] Platen APS position [7] Exposure scan (270 mm/s)
[4] White correction (First time) [8] Home position search
31
(3) When AE/ACS is set (DF mode)

/C6501P/C65hc/C5501
bizhub PRO C6501
[1] [2] [3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[13]
[14] a03ut2c022ca
[1] Home position [9] AE/ACS scan for the second page
[2] Scanner home sensor (PS1) (409 mm/s)
[3] Platen APS position [10] Exposure scan for the second page
[4] White correction (First time) (270 mm/s)
[5] White correction (Second time) [11] Timing of the original replacement
[6] AE/ACS scan for the first page (409 mm/s) [12] AE/ACS scan for the last page (409 mm/s)
[7] Exposure scan for the first page (270 mm/s) [13] Exposure scan for the last page (270 mm/s)
[8] Timing of the original replacement [14] Home position search
32
7.3.2 Original size detection control
/C6501P/C65hc/C5501
A. Detection method
bizhub PRO C6501

• The detection method differs between in the platen mode and in the DF mode.
(1) DF mode
• Refer to DF-609.
(2) Platen mode

• Main scanning direction: CCD sensor
• Sub-scanning direction: Turning on/ off of the APS sensors/1 (PS3) and /2 (PS4)
Original size CCD sensor PS3 PS4

(Length of detection: mm) (ON/OFF) (ON/OFF)
Smallest 102 OFF OFF
B5S 182 ON OFF
B5 257 OFF OFF
B4 257 ON ON
A4S 210 ON OFF
A4 297 OFF OFF
A3 297 ON ON
81/2 x 11S 215.9 ON OFF
81/2 x 11 279.4 OFF OFF
81/2 x 14 215.9 ON ON
11 x 17 279.4 ON ON
B. Detection timing
(1) DF mode
• Refer to DF-609.
(2) Platen mode

• The original size in the main scanning direction is detected twice and the larger one is regarded as the orig-
inal size.
[1] [2]
APS sensor /1 (PS3)
APS sensor /2 (PS4)
Exposure lamp (L1)
APS timing sensor /1 (PS2)
Read switch (RS)

a03ut2c023ca
[1] First Original size detection [2] Second original size detection (main scan-
(Main scanning/Sub-scanning direction ning direction)
detection)
33
7.3.3 Original reading area

/C6501P/C65hc/C5501
• The original reading area for both in platen mode and DF mode is determined as described below.
bizhub PRO C6501
A. When the automatic "Erase outside of original" is turned ON

Out of original auto-reading area equals to the max. original size.
B. When the automatic "Erase outside of original" is turned OFF

The scanning size specified in the user setting menu "Erase outside of original" equals to the original reading
area.
Setting for Erase outside of original Mode Scanning size

Erase outside of original All Original size
Auto-size/Auto magnification only Auto-size/Auto magnifi- Original size
cation
Manual Paper size
Except original Glass (1:1) Equal magnification to Paper size
platen
Other than equal magni- Original size

fication to platen
7.3.4 AE/ACS control

• When AE/ACS is selected, the density of the original is detected, and the print density is automatically
adjusted.
• When ACS is selected, the color of the original is detected, and color or black-and-white print is selected
automatically.
A. AE/ACS sampling area

• The original density sampling area for both in platen mode and DF mode is same as the original reading
area.
7.3.5 Image processing

For the image processing, the following items are provided: Refer to"24. IMAGE PROCESSING " for details.
(Refer to P.121)
• AOC (automatic offset control)
• AGC (automatic gain control)
• Shading correction
• AE processing
• ACS processing
• Brightness/Density conversion
• Filter/scaling
• Half tone processing (Error diffusion)
• Compression
• Image data storage
• Screen processing
34
Theory of Operation Ver.3.0 Jul. 2009 8. WRITE SECTION
8. WRITE SECTION
/C6501P/C65hc/C5501
bizhub PRO C6501
8.1 Configuration
Write unit /Y
Write unit /M
Write unit /C
Write unit /K
CY2 lens fθ lens Index mirror
Dust-proof glass
Laser correction
motor Laser drive board
(LASDB)
Index board
(INDEXB)
Collimator lens
unit
Index lens
CY1 lens
Temperature sensor
board (TEMSB) *1
Laser correction home sensor Polygon mirror
a03ut3c025ca
*1 Write unit /K only.
35
8. WRITE SECTION Theory of Operation Ver.3.0 Jul. 2009
8.2 Operation
/C6501P/C65hc/C5501
bizhub PRO C6501
8.2.1 Laser beam path
[1]
[2]
[3]
[10]
[4]
[5]
[9]
[8] [1] [6]
[7]
a03ut2c026ca
[1] Laser diode [6] Index lens

[2] Collimator lens [7] Index board (INDEXB)
[3] CY1 lens [8] Drum
[4] Polygon mirror [9] Dust-proof glass
[5] fθ lens [10] CY2 lens
36
8.2.2 Write unit control
/C6501P/C65hc/C5501
• The read data converted into digital data in the CCD board is sent to the image process board (IPB).
bizhub PRO C6501

• The RGB signals are converted to the YMCK signals in the IPB.
• The converted YMCK signals are distributed to the corresponding laser drive board; /Y (LASDB/Y), /M
(LASDB/M), /C (LASDB/C), /K (LASDB/K) in the IPB.
• The laser drive boards emit laser beam to create an electrostatic latent image on the corresponding drums.
• Each laser drive board emits 2 beams per 1 laser diode, and writes 2 lines per 1 scanning.
• The write start position is determined according to the INDEX signals detected by the Index boards/Y
(INDEXB/Y), /M (INDEXB/M), /C (INDEXB/C) and /K (INDEXB/K) to prevent the misalignment of scanned
image in main scanning direction.
[1] [2]
[3]
a03ut2c027ca
[1] Laser beam [3] Drum

[2] Polygon mirror
37
8.2.3 Color registration control

/C6501P/C65hc/C5501
In a black-and-white copier, a toner image formed on its drum can be directly transferred onto paper. In a color
bizhub PRO C6501
copier, the process is much complicated. This machine uses 4 photoconductor drums correspond to yellow,
magenta, cyan, and black colors. In order to create a complete toner image, the 4 separated single-color toner
images formed on the drums must be overlaid on the transfer belt without misalignment. The control to prevent
the misalignment is referred to as "color registration control."
A. Types of the color registration control

There are following 5 color registration controls and the 5 controls are carried out for each color correcting yel-
low (Y), magenta (M), and cyan (C) with reference to black (K).
The color registration control in the "Partial horizontal magnification" is made by adjusting the write units
mechanically. The other 4 color registration controls are performed electrically.
Correction type Correction method

Drift in the main scan- Adjusts the write start timing in the main
ning direction scan direction
Drift in the sub-scanning Adjusts the write start timing in the sub-scan
direction direction
Entire horizontal magni- Adjusts the clock frequency for the wire
fication units
Inclination Adjusts the angle of the CY2 lens 2 (CY2

lens is driven by the laser correction motor)
Partial horizontal magni- Adjusts the position of the write unit (paral-
fication lelism against the drum)
See adjusting the timing for the image
adjustment in service mode.
*1 To show the symptoms plainly, the sample figures in the table indicate the positions of only 2 colors.
*2 The gap between the upper and lower lines in the sample figures for "Drift in the main scanning direction",
"Entire horizontal magnification" and "Partial horizontal magnification" is not a misalignment. Just for show-
ing the symptoms clearly.
38
B. Overview of the color registration control
/C6501P/C65hc/C5501
In the color registration control, the color registration marks of each color are formed on the transfer belt (outside
bizhub PRO C6501

of the largest paper area). The color registration sensors; /Fr (PS8) and /Rr (PS9) detect the marks to know how
much they are shifted from each other. If the shift amount falls outside the prescribed range, the image write tim-
ing, the clock frequency and the angle of the CY2 lens 2 for the corresponding color are adjusted as necessary.
[13]
[1]
[2]
[12] [3]
[4]
[11]
[5]
[6]
[7]
[10]
[8]
[9]
a03ut2c108ca
[1] Drum /Y [8] Write unit /K

[2] Write unit /Y [9] Transfer belt
[3] Drum /M [10] Transferring direction
[4] Write unit /M [11] Color registration sensor /Fr (PS8)
[5] Drum /C [12] Color registration sensor /Rr (PS9)
[6] Write unit /C [13] Data processing
[7] Drum /K
39
C. Procedure for the color registration control operation

/C6501P/C65hc/C5501
1. Transferring the color registration mark

bizhub PRO C6501
The color registration mark " " of each black, cyan, magenta, and yellow colors are transferred on the transfer
belt in that order forming 2 marks per line, one each on the left and right sides on the belt. The left and right
positions of the marks on the belt correspond to the positions of the color registration sensors; /Rr (PS9) and /Fr
(PS8).
[7]
[1]
[2]
[3]
[4]
[6] [5] a03ut2c109ca
[1] Color registration mark /K [5] Color registration sensor /Fr (PS8)
[2] Color registration mark /C [6] Color registration sensor /Rr (PS9)
[3] Color registration mark /M [7] Transferring direction
[4] Color registration mark /Y
40
2. Detecting the color registration marks
/C6501P/C65hc/C5501
The PS8 and PS9 detect the edges of the color registration mark " " of each color and convert the detected
bizhub PRO C6501

result into digital signals. The edge detection is performed at 4 points (edges) per mark.
[4] [5]
[1]
[3]
[2] a03ut2c110ca
[1] Detecting direction (transferring direction) [4] Color registration sensor /Fr and /Rr (PS8
[2] Binarized digital signals and PS9)
[3] Detection signal of the color registration [5] Color registration mark
sensors /Fr and /Rr (PS8 and PS9) (analog
signal)
41
3. Calculating and correcting the color drift amount

/C6501P/C65hc/C5501
The interval between the detection of 1 edge of the registration mark and the next edge with the PS8 and PS9
bizhub PRO C6501
sensors are recorded. As shown below, each time interval between the edge detections is determined with the
counts of clock signal, and the counts with the PS8 and those with the PS9 are recorded separately.
[1]
[5]
0 1 2 3 4 5 6 7 8 [2]
[4]
150 300
[3]
180 330 a03ut2c111ca
[1] Detecting direction (transferring direction) [4] Clock signal

[2] Address number of the detected edge [5] Binarized digital signals
[3] Counts of clock signal corresponding to the
address for each detected edge
The recorded time intervals for cyan, magenta, yellow colors are compared with those for black color, and the
differences are determined as color drift amounts. In addition to that, the difference between the PS8 and PS9
time intervals of black color is compared with those of the other colors in order to determine color drift amounts
caused by tilt of write units. According to the obtained drift amounts, the registration control is performed.
42
D. Operation condition of the color registration control
/C6501P/C65hc/C5501
The color registration control is performed when:
bizhub PRO C6501

• Operation condition 1
The color registration automatic correction is executed in the service mode.
Be sure to perform the above operation when replacing components listed in "8. ADJUSTMENT LIST" in
Field Service manual.
During warm-up. However, it is not performed if 70 degrees C or higher of fusing temperature is detected
when starting the warm-up.
The prescribed number of pages are copied/printed.
A copy/print job is received after the specified time passed.
Changes in temperature detected by the temperature sensor board (TMSB) fall outside the prescribed
range. The control is performed when a copy/print job is received first time after the status occurs.
NOTE
• In the case of the Operation condition 3, the registration control is performed interrupting the
copy/print job. This can be changed with DIPSW in service mode to carry out the control after fin-
ishing a copy/print job.
• In the case of the Operation condition 4 and 5, the color registration correction control is per-
formed at the beginning of the first copy/print after unity of the operating condition.
8.2.4 Front/back sides skew correction in main scan direction

• If a black image written by the write unit /K is skewed in the main scan direction when performing duplex
printing, black images finally printed on front and back sides of paper will be skewed in opposite way.
• The inclination of the CY2 lens2 of the write unit /K should be adjusted in order to correct the skew.
• The adjustment can be made manually using the following menus.
User's mode: chart adjustment
Service mode: CD skew adjustment
8.2.5 Back side magnification adjustment in sub scan direction

• When the back side mag. adjustment is enabled with the utility, the adjustment is carried out by changing
the number of revolutions of the polygon motor.
• In order to reduce magnification rate in sub scan direction, the number of revolutions of the polygon motor
increases lowering the clock rate.
• The magnification reduction rate can be set manually using the following menus.
User's mode: chart adjustment
Service mode: FD mag. adjustment
43
8.2.6 Image stabilization control

/C6501P/C65hc/C5501
To achieve stable image quality, the following controls are provided. Refer to "23. IMAGE STABILIZATION CON-
bizhub PRO C6501
TROL" for details.

(Refer to P.114)
• MPC (maximum power control)
• APC (automatic power control)
• Vm adjustment control
• Color registration control
44
Theory of Operation Ver.3.0 Jul. 2009 9. PHOTOCONDUCTOR SECTION
9. PHOTOCONDUCTOR SECTION
/C6501P/C65hc/C5501
bizhub PRO C6501
9.1 Configuration
Drum /Y
Drum /M
Drum /C
Drum /K
Transfer belt unit Drum
Developing unit
Lubricant applying roller
Erase lamp
Lubrication
Cleaning blade
Toner collection screw
a03ut2c028ca
45
9. PHOTOCONDUCTOR SECTION Theory of Operation Ver.3.0 Jul. 2009
9.2 Drive
/C6501P/C65hc/C5501
bizhub PRO C6501
[2]
[1] a03ut2c026ca
[1] Drum motor /Y (M14), /M (M15), /C (M16) [2] Drum

and /K (M17)
46
9.3 Operation
/C6501P/C65hc/C5501
bizhub PRO C6501
9.3.1 Image creation control
• The image creation process starts when the drum motor /K (M17) turns on [1], though transferring each
color toner image to the transfer belt is made in the order of yellow, magenta, cyan, and black.
• After M17 turns on, the other drum motors are turned on in the order of motor /Y (M14) [2], /M (M15) [3]
and /C (M16) [4].
• The erase lamp, charging corona and developing bias of each color turns on when the corresponding drum
motor starts to rotate.
• The developing motor starts to rotate [5] after the specified time passed from the start of the writing opera-
tion [6].
• The on [6] and off [8] of writing operation corresponds to the on and off of the developing bias (AC) and the
first transfer.
• The developing motor and the toner supply motor stop and the writing operation is finished [11].
• The charging corona is deenergized and the first transfer is finished. [12].
• When the turning corona turns off [15], the DC bias supply, the erase lamp and the drum motor are
stopped. This is the end of Y toner image creating process.
• Creating toner images of the other colors is performed subsequently.
• The first transfer pressure/release motor (M119) and the second transfer pressure/release motor (M34) turn
on while creating the toner images on each drum.
• When the transfer belt is moved to the first transfer position by the M19, the V_TOP signal which triggers
the second transfer is output [7].
• The toner images on each drum are transferred to the transfer belt one by one (first transfer).
• The separation (HV/2) turns on [9] after the specified time passed from when the V_TOP signal is output.
• After the specified time passed from when the separation (HV/2) turns on, the second transfer (HV/2) turns
on [10] to transfer the complete toner image on the belt to paper (second transfer). The bias supply is
stopped [10] and second transfer cleaning is canceled.
• The second transfer operation is terminated after the specified time passed from when supplying the devel-
oping AC bias for black is stopped [13].
• After the specified time passed from when M19 stops applying pressure [14] against the transfer belt, the
bias is applied [16] and second transfer cleaning is performed.
47
/C6501P/C65hc/C5501 9. PHOTOCONDUCTOR SECTION Theory of Operation Ver.3.0 Jul. 2009
bizhub PRO C6501
[1][2] [3] [4] [5] [6] [8] [11] [12] [15]

Drum motor /Y (M14)
Developing motor /Y (M20)
Toner supply motor /Y (M49)
Erase lamp /Y (EL/Y)
Charging corona /Y (HV/1)

Laser drive board /Y (LASDB/Y)
Developing bias /Y (DC) (HV/1)
Developing bias /Y (AC) (HV/1)
1st transfer /Y (HV/2)
Drum motor /M (M15)

Developing motor /M (M21)
Toner supply motor /M (M50)
Erase lamp /M (EL/M)
Charging corona /M (HV/1)

Laser drive board /M (LASDB/M)
Developing bias /M (DC) (HV/1)
Developing bias /M (AC) (HV/1)
1st transfer /M (HV/2)
Drum motor /C (M16)

Developing motor /C (M22)
Toner supply motor /C (M51)
Erase lamp /C (EL/C)
Charging corona /C (HV/1)

Laser drive board /C (LASDB/C)
Developing bias /C (DC) (HV/1)
Developing bias /C (AC) (HV/1)
1st transfer /C (HV/2)
Drum motor /K (M17)

Developing motor /K (M23)
Toner supply motor /K (M52)
Erase lamp /K (EL/K)
Charging corona /K (HV/1)

Laser drive board /K (LASDB/K)
Developing bias /K (DC) (HV/1)
Developing bias /K (AC) (HV/1)
1st transfer /K (HV/2)
Transfer belt motor (M18)
1st transfer pressure/release motor (M19)
2nd transfer pressure/release motor (M34)
2nd transfer CONT

Bias (HV/2)
2nd transfer (HV/2)
Separation (HV/2)
[7] [9] [10] [13] [14] [16]

a03ut2c030ca
[1] M17 ON [9] Separation ON

[2] M14 ON [10] Start of second transfer
[3] M15 ON [11] Finish of writing (The last toner image)
[4] M16 ON [12] Finish of first transfer /Y
[5] M20 ON [13] Developing bias /K (AC) OFF (End of writing)
[6] Start of writing (First toner image) [14] Start of transfer belt release
[7] V_TOP signal generation [15] Charging corona /Y OFF
[8] Finish of writing (First toner image) [16] Start of second transfer cleaning
48
9.3.2 Erase lamp (EL) control
/C6501P/C65hc/C5501
A. Purposes
bizhub PRO C6501

• To eliminate remained electric potential on the drum surface
• To distribute the electric potential uniformly on the drum surface
• To light when the drum is in the position before charging
B. Execution timing
• Turns on/off synchronously with each drum motor.

TROL" for details. (Refer to P.114)
• Drum rotation control
• Vm adjustment control
49
10. CHARGING SECTION Theory of Operation Ver.3.0 Jul. 2009
10. CHARGING SECTION

/C6501P/C65hc/C5501
bizhub PRO C6501
10.1 Configuration
Charging wire Charging plate
Charging
corona /Y
Charging
corona /M
Charging
corona /C
Charging
corona /K
a03ut2c031ca
50
Theory of Operation Ver.3.0 Jul. 2009 10. CHARGING SECTION
10.2 Operation
/C6501P/C65hc/C5501
bizhub PRO C6501
10.2.1 Charging control
A. Charging wire
• The high voltage unit /1 (HV/1) boosts 24 VDC and apply a negative DC voltage to the charging wire. The
wire discharges the negative voltage.
• Charging output range: -450 to -1,100 µA
B. Charging grid
• To let the charging wire discharge stably, a negative high voltage is applied to the charging grid from the
high voltage unit /1 (HV/1).
• Charging grid output range: -250 to -1,000V
51
11. INTERMIDIATE TRANSFER SECTION Theory of Operation Ver.3.0 Jul. 2009
11. INTERMIDIATE TRANSFER SECTION

/C6501P/C65hc/C5501
bizhub PRO C6501
11.1 Configuration
Color registration sensor shutter /Fr

Color registration sensor shutter /Rr Belt cleaning blade
Toner guide roller

Toner collection screw First transfer roller /Y
First transfer roller /M

PGC sensor shutter
Second transfer roller /Lw

Image correction unit
First transfer roller /C
First transfer roller /K
Second transfer roller /Up
Transfer belt
Separation claw unit
a03ut2c032ca
52
Theory of Operation Ver.3.0 Jul. 2009 11. INTERMIDIATE TRANSFER SECTION
11.2 Drive
/C6501P/C65hc/C5501
bizhub PRO C6501
11.2.1 Transfer belt conveyance/pressure drive
[9]
[8]
[1]
A
[2]
[3]
[7]
[4]
[6]
[15] [16]
[14]
[13]
[5] [12] [11] [10]
a03ut2c033ca
[1] First transfer roller /Y [9] Belt driving roller

[2] Drum [10] Standby (all released)
[3] First transfer roller /M [11] Black-and-white mode (Only first transfer
rollers /K is pressed)
[4] First transfer roller /C [12] Full color mode (all pressed)
[5] First transfer roller /K [13] First transfer roller /K pressure release arm
[6] First transfer pressure/release motor (M19) [14] Drive coupling
[7] Transfer belt [15] First transfer roller /K pressure release cam
[8] Transfer belt motor (M18) [16] First transfer rollers /Y /M /C pressure
release cam
53
11.2.2 Second transfer pressure/release drive

/C6501P/C65hc/C5501
bizhub PRO C6501
[4]
[3]
[2]
A
[1] a03ut2c026ca
[1] Second transfer pressure/release motor [3] Second transfer roller /Lw
(M34)
[2] Pressure arm [4] Transfer belt
54
11.3 Operation
/C6501P/C65hc/C5501
bizhub PRO C6501
11.3.1 First transfer roller pressure/release mechanism
• During first transfer, the transfer belt [9] is pressed against and released from the drums /Y [8], /M [10], /C
[11] and /K [12].
• The three first transfer rollers /Y [18], /M [17] and /C [14] are included in the color first transfer roller assy [16]
and driven simultaneously.
• The color first transfer roller assy drives the first transfer pressure/release motor (M19) [15] via the first trans-
fer roller /C pressure release cam [7].
• The first transfer roller /K [13] drives the M19 via the first transfer roller /K pressure release arm [4] and the
first transfer roller /K pressure release cam [6].
• The 2 cams rotate synchronously. The difference in shape between the 2 cams enables to move the color
first transfer roller assy between the 3 positions according to the print mode.
• In full color mode, the both color first transfer roller assy and the first transfer roller /K are pressed [3].
• In black-and-white mode, only the first transfer roller /K is pressed.
• The rotating position of the cam is detected by the first transfer HP sensor (PS15).
• The rotation amount of the cam is controlled by the drive force of the M19 that starts to rotate when the
PS15 turns off.
[18] [8]
[9]
[10]
[17]
[16]
[15]
[11]
[6] [7]
[14]
[5]
[12] [4]
[3] [2] [1]

[13]
a03ut2c035ca
[1] In standby mode [10] Drum /M

[2] In black-and-white mode [11] Drum /C
[3] In full color mode [12] Drum /K
[4] First transfer roller /K pressure release arm [13] First transfer roller /K
[5] Drive coupling [14] First transfer roller /C
[6] First transfer roller /K pressure release arm [15] First transfer pressure/release motor (M19)
[7] First transfer roller /C pressure release cam [16] Color First transfer roller assy
[8] Drum /Y [17] First transfer roller /M
[9] Transfer belt [18] First transfer roller /Y
55
11.3.2 First transfer control

/C6501P/C65hc/C5501
A. First transfer operation

bizhub PRO C6501
• Toner on the drum is transferred onto the transfer belt by a DC bias applied to the first transfer roller that
presses the transfer belt from its inside.
B. First transfer roller DC bias

The DC bias for the first transfer roller changes depending on the following conditions:
• Process speed
• Black-and-white mode or color mode
• Humidity
• Count of uses of the first transfer roller
• Count of uses of the developer
C. Operation timing
Refer to "9.3.1 Image creation control"
(Refer to P.47)
56
11.3.3 Second transfer mechanism
/C6501P/C65hc/C5501
• The cam [5] is rotated by the second transfer pressure/release motor (M34).
bizhub PRO C6501

• When the cam pushes the pressure arm [6], the second transfer roller /Lw [7] is pushed up and pressed to
the transfer belt unit [4].
• Pressure can be selected from "Normal [2]" or "Low [3]". (If the image failure (transfer failure) occurs when
printing onto thick papers, select "Low".)
• Pressure can also be selected from the paper setting in the basic screen by setting "1" for DipSW1-0.
• When the cam further rotates, the pressure to the pressure arm is released and the second transfer roller /
Lw comes down to be released from the transfer belt unit [1].
[7] [4]
[5]
[6]
[1] [2] [3]

a03ut2c036ca
[1] Released [5] Cam

[2] Pressed (Normal) [6] Pressure arm
[3] Pressed (Low) [7] Second transfer roller /Lw
[4] Transfer belt unit
11.3.4 Second transfer control

A. Second transfer operation
• The toner on the transfer belt is transferred onto paper when the paper is conveyed in between the transfer
belt and the second transfer roller /Lw.
B. Second transfer roller /Up DC bias

The DC bias for the second transfer roller changes depending on the following conditions:
• Process speed
• Black-and-white mode or color mode
• Humidity
• Type of paper
• Front side or back side of paper
C. Operation timing
Refer to "9.3.1 Image creation control".
(Refer to P.47)
57
11.3.5 Image correction unit shutter mechanism

/C6501P/C65hc/C5501
• The image correction unit is provided with a shutter mechanism that covers the sensors while they are not
bizhub PRO C6501
used to prevent them from contamination.

• The color registration sensor shutter /Fr [6] and /Rr [7] are driven by the color registration shutter solenoid
(SD2) [2] in order to protect the color registration sensor /Fr (PS8) [5] and /Rr (PS9) [8].
• The PGC sensor shutter [3] that protects the PGC sensor [4] is driven by the PGC shutter solenoid (SD3)
[1].
[5] [6] [7] [8]
[4] [3] [2] [1] a03ut2c037ca
[1] PGC shutter solenoid (SD3) [5] Color registration sensor /Fr (PS8)
[2] Color registration shutter solenoid (SD2) [6] Color registration sensor shutter /Fr
[3] PGC sensor shutter [7] Color registration sensor shutter /Rr
[4] PGC sensor [8] Color registration sensor /Rr (PS9)
11.3.6 Control of flip prevention for the belt cleaning blade

• As countermeasures against the flip of the belt cleaning blade and the occurrence of white bands on
images, a toner band is periodically created on the transfer belt.
• Creating the toner band can be enabled/disabled with DipSW20-4.
11.3.7 Control against belt filming

• Lubricant contained in the toner adheres to the transfer belt, and can cause white bands on images.
• Therefore, toner is stored between the belt cleaning blade and the toner guide roller to scrape the lubricant
off the belt surface with the toner at regular intervals.

TROL" for details.
(Refer to P.114)
• Color registration control
58
Theory of Operation Ver.3.0 Jul. 2009 12. DEVELOPING SECTION
12. DEVELOPING SECTION
/C6501P/C65hc/C5501
bizhub PRO C6501
12.1 Configuration
Developing unit /Y
Developing unit /M
Developing unit /C
Developing unit /K
Developer conveyance guide
Feed magnet
Developing roller roller
Conveyance screw
TCR sensor /Y (TCRS/Y) Agitator screw

TCR sensor /M (TCRS/M)
TCR sensor /C (TCRS/C)
TCR sensor /K (TCRS/K) a03ut2c038ca
59
12. DEVELOPING SECTION Theory of Operation Ver.3.0 Jul. 2009
12.2 Drive
/C6501P/C65hc/C5501
bizhub PRO C6501
[6] [7]
[1]
[5]
[4]
[3] [2]
a03ut2c102ca
[1] Agitator screw [4] Conveyance screw

[2] Developing coupling /2 [5] Developing coupling /1
[3] Developing motor /Y (M20), /M (M21), /C [6] Developing roller
(M22), /K (M23) [7] Feed roller
60
Theory of Operation Ver.3.0 Jul. 2009 12. DEVELOPING SECTION
12.3 Operation
/C6501P/C65hc/C5501
bizhub PRO C6501
12.3.1 Developer conveyance
• The developer in the developing unit is agitated by the agitator screw [1] and conveyed to the conveyance
screw [2].
• The developer around the conveyance screw is conveyed to the developing roller [4] by the feed roller [7]
and the developer conveyance guide [6].
• The developer on the developing roller is spread uniformly by the developing regulation plate [5].
• After transfering the developer onto the drum [3], the remained developer on the developing roller is sent
back to the conveyance screw and the agitator screw.
[5] [6] [7]

[4]
[3]
[1]
[2]
a03ut2c039ca
[1] Agitator screw [5] Developing regulation plate

[2] Conveyance screw [6] Developer conveyance guide
[3] Drum [7] Feed roller
[4] Developing roller
12.3.2 Developing bias control

A. Purpose
• The developing bias is applied to the developing roller in order to attract toner to the drum surface.
B. Timing
• Refer to "9.3.1 Image creation control".
(Refer to P.47)
61
12. DEVELOPING SECTION Theory of Operation Ver.3.0 Jul. 2009
12.3.3 Developing suction control

/C6501P/C65hc/C5501
• The machine intakes the external air to effectively cool down the heat around the developing unit.
bizhub PRO C6501
• The developing fans /1 (M45) [1] and /2 (M46) [2] are provided to cool down the rear of the developing unit.
The fresh-air brought by the M45 and M46 is sent to the rear of the developing unit via the duct [4].
• The developing fan /3 (M64) [3] is provided to cool down the heat around the front side of the developing
unit. The fresh-air brought by the M64 is sent to the front of the developing unit via the duct [5].
[5] [1]
[2]
[4] [3]
a03ut2c040ca
[1] Developing fan /1 (M45) [4] Duct

[2] Developing fan /2 (M46) [5] Duct
[3] Developing fan /3 (M64)

TROL" for details.
(Refer to P.114)
• Toner density control
62
Theory of Operation Ver.3.0 Jul. 2009 13. TONER SUPPLY SECTION
13. TONER SUPPLY SECTION
/C6501P/C65hc/C5501
bizhub PRO C6501
13.1 Configuration
Toner supply door open/

close sensor (PS54)
Interlock switch /2 (MS2)
Piezoelectric sensor /Y (PZS/Y)
Piezoelectric sensor /M (PZS/M)
Toner bottle clutch /Y (MC14)
Toner supply motor /Y (M49)
Toner bottle clutch /M (MC15)

Toner supply motor /M (M50)
Toner bottle motor (M53)
Toner bottle clutch /C (MC16)

Toner supply motor /C (M51)
Toner bottle clutch /K (MC17)
Piezoelectric sensor /C (PZS/C) Piezoelectric sensor /K Toner supply motor /K (M52)

(PZS/K) a03ut2c041ca
63
13. TONER SUPPLY SECTION Theory of Operation Ver.3.0 Jul. 2009
13.2 Drive
/C6501P/C65hc/C5501
bizhub PRO C6501
[1]
[11]
[2]
[12]
[10]
[3] C
[9]
[8]
[7] [4]
[5]
D
B
[6]
[13]
a03ut2c042ca
[1] Toner supply gear /A (same shaft as C) [8] Toner supply motor /C (M51)
[2] Toner bottle clutch /Y (MC14) [9] Toner bottle motor (M53)
[3] Toner bottle clutch /M (MC15) [10] Toner supply motor /M (M50)
[4] Toner bottle clutch /C (MC16) [11] Toner supply motor /Y (M49)
[5] Toner supply gear /A (same shaft as D) [12] Toner bottle drive gear
[6] Toner bottle clutch /K (MC17) [13] Toner conveyance screw
[7] Toner supply motor /K (M52) [14] Toner supply screw
64
Theory of Operation Ver.3.0 Jul. 2009 13. TONER SUPPLY SECTION
13.3 Operation
/C6501P/C65hc/C5501
bizhub PRO C6501
13.3.1 Toner conveyance control
A. Toner supply control to the toner hopper
• When toner level in the toner hopper becomes about 50g, the bottle motor (M53) and the toner bottle
clutch /Y (MC14), /M (MC15), /C (MC16) and /K (M52) are turned on. Then the toner bottle rotates to supply
new toner.
B. Toner supply control to the developing unit

(1) When the power is turned on
• Each of the TCR sensors /Y (TCRS/Y), /M (TCRS/M), /C (TCRS/C) and /K (TCRS/K) detects the toner den-
sity in each developing unit after the specified time passed from when the sub power switch (SW2) turns
on.
• When the detected density is below the reference toner density that is stored in the CPU on the printer con-
trol board (PRCB), the toner supply motors /Y (M49), /M (M50), /C (M51) and /K (M52) are turned on to
supply toner up to the specified density.
(2) While in printing
• While in the print operation, each of the TCRS /Y, /M, /C and /K monitors the toner density.
• When output voltage of the TCRS /Y, /M, /C and /K is below the reference value, the toner supply motors
are turned on to supply toner up to the specified density.
13.3.2 Remaining toner detection control

A. Remaining toner detection control
• Toner levels in each toner hopper are detected by the piezoelectric sensors /Y (PZS/Y), /M (PZS/M), /C
(PZS/C) and /K (PZS/K).
B. Detection timing
• During printing (always on)
C. No-toner display on the operation panel

• When the value output from the piezoelectric sensor still indicates the "no-toner" status even after the toner
is supplied to the toner hopper, it is judged that the toner bottle has run out of toner and the message
"Please replace toner bottle" is displayed on the touch panel.
13.3.3 Stop control for print operation with no toner

• After the message "Please replace toner bottle" is displayed on the touch panel, the consumption of the
remaining toner (about 50g) in the toner hopper is detected by the driving time of the toner supply motors /
Y (M49), /M (M50), /C (M51) and /K (M52).
• When it is detected that the remaining toner has been consumed, the print operation is stopped by the set-
tings of DIPSW1-2 and 1-3.
• When toner density in the developing unit becomes below the reference value while in the printing stop
operation described above, print operation is immediately stopped after exiting the paper in progress.
65
14. TONER COLLECTION SECTION Theory of Operation Ver.3.0 Jul. 2009
14. TONER COLLECTION SECTION

/C6501P/C65hc/C5501
bizhub PRO C6501
14.1 Configuration
Belt waste toner socket
Drum /Y waste toner socket
Belt collection pipe

Drum /M waste toner socket
Drum /C waste toner socket
Vertical conveyance pipe

Drum /K waste toner socket

Waste toner door sensor (PS60)
Horizontal con- Waste toner outlet

veyance pipe
Toner collection box

Waste toner full sensor (PS52)
a03ut2c043ca
66
Theory of Operation Ver.3.0 Jul. 2009 14. TONER COLLECTION SECTION
14.2 Drive
/C6501P/C65hc/C5501
bizhub PRO C6501
[7]
[8]
[6]
[1]
[2] [3]
[5]
[4]
a03ut2c044ca
[1] Drum waste toner inlet [5] Vertical conveyance pipe

[2] Horizontal conveyance screw [6] Belt collection screw
[3] Horizontal conveyance pipe [7] Transfer belt motor (M18)
[4] Paper feed motor (M41) [8] Belt collection cam
67
14. TONER COLLECTION SECTION Theory of Operation Ver.3.0 Jul. 2009
14.3 Operation
/C6501P/C65hc/C5501
bizhub PRO C6501
14.3.1 Toner collection control

• Toner collection section is driven by the transfer belt motor (M18) and the paper feed motor (M41).
• Collecting toner is performed by the M18 that drives the transfer belt and the paper feed operation driven
by the M41.
14.3.2 Toner collection box control

• The presence of toner collection box is detected by on/off of the waste toner door sensor (PS60).
14.3.3 Box full control

• When the waste toner full sensor (PS52) is turned on, a warning message is displayed on the touch panel.
• There is a box full counter in the NVRAM board (NRB). After the PS52 is turned on, the counter starts
counting.
• For operation details, refer to the table blow.
PS60 PS52 Box full counter Operation

ON OFF — Print available

ON ON Less than 2500 • Warning message is displayed on the touch panel when
the PS52 turns on.
• After the PS52 turns on, printing is available unless the
count exceeds 2500.
ON ON 2500 or more • Rejects incoming new jobs
• Job in progress is continued 3000 is counted.
• Print stopped at 3000 counts
68
Theory of Operation Ver.3.0 Jul. 2009 15. PAPER FEED SECTION
15. PAPER FEED SECTION
/C6501P/C65hc/C5501
bizhub PRO C6501
15.1 Configuration
Pre-registration roller Paper feed

roller
Pick-up roller Separation roller
Lift plate
Tray /2
Tray /1
Tray /3
a03ut2c045ca
69
15. PAPER FEED SECTION Theory of Operation Ver.3.0 Jul. 2009
15.2 Drive
/C6501P/C65hc/C5501
bizhub PRO C6501
[17] [19][18] [27] [21][20]
[15] [16] [23] [24] [26]

[22] [25]
[3] [1]
[6] [4] [2]
[14] [13] [12][11] [9] [10] [8] [7] [5]
a03ut2c046ca
[1] Pre-registration roller /3 [15] Lift wire

[2] Pre-registration clutch /3 (MC12) [16] Paper lift motor /1 (M38)
[3] Drive coupling /3 [17] Pick-up roller /1
[4] Paper feed motor (M41) [18] Paper feed roller /1
[5] Separation roller /3 [19] Paper feed clutch /1 (MC7)
[6] Paper feed roller /3 [20] Pre-registration roller /1
[7] Paper feed clutch /3 (MC11) [21] Pre-registration clutch /1 (MC8)
[8] Pick-up roller [22] Paper feed roller /2
[9] Separation roller /2 [23] Paper feed clutch /2 (MC9)
[10] Paper lift motor /3 (M40) [24] Drive coupling /2
[11] Pick-up roller /2 [25] Pre-registration roller /2
[12] Paper lift motor /2 (M39) [26] Pre-registration clutch /2 (MC10)
[13] Separation roller /1 [27] Drive coupling /1
[14] Lift plate
70
15.3 Operation
/C6501P/C65hc/C5501
bizhub PRO C6501
15.3.1 Plate up/down control
A. Plate-up operation
• The lift plate [7] lies on the both left and right shaft [6].
• The lift wires [8] are connected to each shaft and the plate is kept in a horizontal position by the drive pulley
[4], one for each of the lift drive shaft [5] via each pulley [9].
• When the each lift drive shaft of the trays are rotated by the paper lift motors /1 (M38) [1], /2 (M39) [2] and /
3 (M40) [3], the each drive pulley winds up the wire and then the lift plate goes up.
[9]
[1]
[2]
[8]
[3]
[5] [4]
[7] [6]
a03ut2c047ca
[1] Paper lift motor /1 (M38) [6] Shaft

[2] Paper lift motor /2 (M39) [7] Lift plate
[3] Paper lift motor /3 (M40) [8] Lift wires
[4] Drive pulley [9] Pulleys
[5] Lift drive shaft
71
B. Plate-down operation
/C6501P/C65hc/C5501
• When each tray is pulled out, the each lift drive shaft is disengaged from the couplings of the lift motors /1
bizhub PRO C6501
(M38), /2 (M39), /3 (M40).

• The disengagement cuts off the drive force from the M38, M39 and M40 to the lift plate, and the plate goes
down by its own weight.
C. Operation timing
• When the tray is set, the paper lift motors /1 (M38), /2 (M39), and /3 (M40) start to rotate and the lift plate
goes up.
• When the upper limit sensors /1 (PS30), /2 (PS36) and /3 (PS42) are turned on by the top sheet, the M38,
M39 and the M40 stop.
• When the PS30, PS36 and PS42 are turned off by paper feeding, the M38, M39 and M40 rotate again, to
lift the lift plate until each upper limit sensor turns on.
15.3.2 Paper size detection control

A. Detection in main scanning direction
• Paper size in main scanning direction is detected by the resistance value of the paper size VR/1 (VR1), /2
(VR2) and /3 (VR3).
• The resistance value of the VR1, VR2, and VR3 varies depending on the position of the guide plate.
B. Detection in sub-scanning direction

• Paper size in sub-scanning direction is detected by on/off status of the paper size sensors /Fr1 (PS33) and
/Rr (PS34), /Fr2 (PS39) and /Rr2 (PS40), and /Fr3 (PS45) and /Rr3 (PS46).
Paper size Paper size sensors /Fr1 Paper size sensors /Rr1 Paper size VR/1 (VR1), /2
(PS33), /Fr2 (PS39), /Fr3 (PS34), /Rr2 (PS40), /Rr3 (VR2), /3 (VR3) *1
(PS45) (PS46)
13 x 19 ON ON 333.2
SRA3 ON ON 317.0
SRA4 OFF OFF 317.0
12 x 18 ON ON 292.8
A3 ON OFF 280.4
A4 OFF OFF 280.4
11 x 17 ON OFF 252.4
81/2 x 11 OFF OFF 252.4
8K ON OFF 237.4
16K OFF OFF 237.4
B4 ON OFF 216.7
B5 OFF OFF 216.7
81/2 x14 ON OFF 151.3
81/2 x11S OFF OFF 151.3
A4S OFF OFF 141.9
81/2 x13 ON OFF 151.3
B5S OFF OFF 97.3
A5S OFF OFF 43.2
81/2 x 51/2S OFF OFF 30.0
*1 VR angles
72
15.3.3 Paper feed control
/C6501P/C65hc/C5501
A. Pick-up control
bizhub PRO C6501

• The paper feed motor (M41) starts to rotate upon receiving a print start signal [1].
• After the specified time passed from when the start signal is received [1], the pick-up solenoids /1 (SD7), /2
(SD8) and /3 (SD9) and the paper feed clutches /1 (MC7), /2 (MC9) and /3 (MC11) are turned on.
• When the SD7, SD8 and SD9 turn on, the pick-up roller descends and presses the paper by its own
weight.
• The pick-up roller rotates to feed the top sheet to the paper feed roller by means of the M41 drive force
transmitted via the MC7, MC9, and MC11.
• The subsequent feeding by the pick-up roller is made when the paper feed sensors /1 (PS29), /2 (PS35),
and /3 (PS41) detect the rear end of the previous paper [3].
[1] [2] [3]

Paper feed motor (M41)
Pick-up solenoid /1 (SD7), /2 (SD8), /3 (SD9)
Paper feed clutch /1 (MC7), /2 (MC9), /3 (MC11)
Paper feed sensor /1 (PS29), /2 (PS35), /3 (PS41)
a03ut2c048ca
[1] Print start signal [3] Second pick-up

[2] First pick-up
73
B. Separation mechanism
/C6501P/C65hc/C5501
• The separation roller [4] is driven in the opposite direction [2] to the paper feed direction [10] via the torque
bizhub PRO C6501
limiter [1].
• The separation roller is pressed against the paper feed roller [8] by means of the spring [3] force [9] and the
pressure applied from the torque limiter.
• The friction force between the separation roller and the paper feed roller is limited by the torque limiter in
order to prevent multi-feed.
• When no paper exists between the separation roller and the paper feed roller or when the only 1 sheet of
paper is present, the separation roller is driven by the paper feed roller in the direction of arrow [5] since the
torque is over the limit.
• When multiple sheets of paper are fed, the separation roller reverses the direction of rotation [2] (opposite to
the paper feed roller)
• the separation roller the direction of rotation [2] (opposite to the paper feed roller) feeds the lower paper [7]
that contacts with the separation roller back to the tray [6]. The drop in frictional force between the 2 rollers
due to the multiple sheets causes the counter rotating of the separation roller.
[8] [9] [10]

[7] [6] [5]
[4]
[3] [2] [1] a03ut2c049ca
[1] Torque limiter [6] To the tray

[2] Rotation toward the separation [7] Second sheet of paper
[3] Spring [8] Paper feed roller
[4] Separation roller [9] Pressing force
[5] Driven rotation [10] Paper feed direction
74
C. Loop formation mechanism
/C6501P/C65hc/C5501
• The paper passed between the paper feed roller [5] and the separation roller [3] is conveyed to the pre-reg-
bizhub PRO C6501

istration roller [7].
• The paper pushes the actuator [1] and the actuator turns on the paper feed sensors /1 (PS29), /2 (PS35)
and /3 (PS41).
• In order to correct skew of the paper, the leading edge of the paper is pressed against the pre-registration
roller that is not moving until the paper forms a small loop [2]. This is made by stopping the paper feed roller
after the specified time passed from when the PS29, PS35, and PS41 turn on.
[4] [5] [6] [7]
[1]
[3] [2] a03ut2c050ca
[1] Actuator [5] Paper feed roller
[2] Loop [6] Paper feed sensors /1 (PS29), /2 (PS35) and
[3] Separation roller /3 (PS41)
[4] Pick-up roller [7] Pre-registration roller
75
D. Pre-registration control
/C6501P/C65hc/C5501
• The pre-registration roller is driven by the paper feed motor (M41) via the pre-registration clutch /1 (MC8), /
bizhub PRO C6501
2 (MC10) and /3 (MC12).

• When paper feeding is started with the pick-up roller, the MC8, MC10 and MC12 do not transmit the drive
force from the motor to the pre-registration roller so as not to rotate the roller.
• The fed paper is pressed against the pre-registration roller, and since the roller is stopping, the pressure
causes the paper to form a small loop [2] in order to correct skew of the paper.
• The MC8, MC10, and MC12 start to transmit [3] the drive force to the pre-registration roller to rotate it after
the specified time passed form when the paper feed sensors; /1 (PS29), /2 (PS35), /3 (PS41) turn on.
• The paper feed clutches; /1(MC7), /2 (MC9), and /3 (MC11) continue to transmit the drive force to the paper
feed roller to assist the paper feed until the pre-registration roller grips the paper.
• The pre-registration operation for the second and subsequent papers [5] is performed turning off [6] the
MC8, MC10, and MC12 after the specified time passed from when the PS29, PS35, and PS41 turn on so
that the operation does not interrupt feeding of the previous paper.
• When the intermediate sensor /1 (PS27) turns on upon detection of the front edge of the previous paper,
the MC8, MC10 and MC12 turns on again [7] and restart the pre-registration.
[1] [2] [4][6] [7]

Pick-up solenoid/1 (SD7), /2 (SD8), /3 (SD9)
Paper feed clutch/1 (MC7), /2 (MC9), /3 (MC11)
Pre-registration clutch/1 (MC8), /2 (MC10), /3 (MC12)
Paper feed sensor/1 (PS29), /2 (PS35), /3 (PS41)
Intermediate conveyance sensor/1 (PS27)
[3] [5] a03ut2c051ca
[1] Print start signal [5] Second sheet pre-registration

[2] First sheet loop formation [6] A pause of second sheet pre-registration
[3] First sheet pre-registration [7] Restart of second sheet pre-registration
[4] Second sheet loop formation
76
15.3.4 Remaining paper detection control
/C6501P/C65hc/C5501
• Remaining amount of papers in the tray is detected by the paper near empty sensor /1 (PS32), /2 (PS38), /
bizhub PRO C6501

3 (PS44) [2].
• As the papers get lower, the actuator [6] on the front side of the tray is gradually rotated.
• The PS32, PS38 and PS44 turn on and off each time the slits [3], [4] and [5] of the actuator passes through.
• The main body control section counts the number of on/off's of the PS32, PS38 and PS44 to detect the
amount of remaining paper in 4 levels.
Slit count Remaining amount of paper Remaining amount Indication on

the touch panel
0 100 to 75% 4 lit
1 75 to 50% 3 lit
2 50 to 25% 2 lit
3 25 to 0% 1 lit
[2] [1]
[3]
[6] [5] [4]
a03ut2c052ca
[1] Rotation direction when lift plate goes up [4] Slit

[2] Paper near empty sensor /1 (PS32), /2 [5] Slit
(PS38) and /3 (PS44) [6] Actuator
[3] Slit
77
16. BYPASS FEED TRAY SECTION Theory of Operation Ver.3.0 Jul. 2009
16. BYPASS FEED TRAY SECTION

/C6501P/C65hc/C5501
bizhub PRO C6501
16.1 Configuration
Paper feed roller Pick-up roller
Lift plate
Separation roller
Paper size sensor /BP1 (PS48) Paper size sensor /BP2 (PS49)
Paper empty sensor /BP (PS47)
a03ut2c053ca
78
Theory of Operation Ver.3.0 Jul. 2009 16. BYPASS FEED TRAY SECTION
16.2 Drive
/C6501P/C65hc/C5501
bizhub PRO C6501
[6] [7] [2] [8]
[1]
[5] [3]
[4]
a03ut2c054ca
[1] Lift gear [5] Drive coupling

[2] Pick-up roller [6] Paper feed roller
[3] Separation roller [7] Paper feed clutch /BP (MC6)
[4] Paper feed motor (M41) [8] Paper lift motor /BP (M35)
79
16.3 Operation
/C6501P/C65hc/C5501
bizhub PRO C6501

A. Plate-up operation
• The paper lift motor /BP (M35) drives the lift gear to lift the lift plate.
B. Plate-down operation
• The paper lift motor /BP (M35) drives the lift gear to lower the lift plate.
C. Operation timing
(1) Plate-up operation
• When the tray is set, paper lift motor /BP (M35) rotates in forward and the lift plate goes up.
• The lift plate elevation makes the top sheet turns on the upper limit sensor /BP (PS25). This deactivates the
M35 to stop the plate.
• When the PS25 are turned off by paper feeding, the M35 starts to rotate again to lift the lift plate. Then the
PS25 is turned on again by the top sheet the and makes the M35 stop to stop lifting the lift plate.
(2) Plate-down operation

• The paper empty sensor /BP (PS47) turns off when the bypass feed tray runs out of paper. This makes the
M35 rotate in reverse to lower the lift plate.
• The lift plate goes down when the paper is removed from the tray.
• When the paper supply door of LU is opened, the lift plate goes down.
• The M35 stops reverse rotation after the specified time passed to stop lowering the lift plate.

A. Detection in main scanning direction
• Paper size in main scanning direction is detected by the resistance value of the paper size VR/BP (VR4).
• The resistance value of the VR4 varies depending on the position of the guide plate.
B. Detection in sub-scanning direction

• Paper size in sub-scanning direction is detected by ON/OFF statuses of the paper size sensors /BP1
(PS48) and /BP2 (PS49).
80
Theory of Operation Ver.3.0 Jul. 2009 16. BYPASS FEED TRAY SECTION
/C6501P/C65hc/C5501
A. Pick-up control
bizhub PRO C6501

• The paper feed motor (M41) starts to rotate upon receiving a print start signal [1].
• After the specified time passed from when the start signal is received [1], the pick-up solenoid /BP (SD5)
and the paper feed clutch /BP (MC6) are turned on [2].
• When the SD5 turns on, the pick-up roller descends and presses the paper by its own weight.
• The pick-up roller rotates to feed the top sheet to the paper feed roller by means of the M41 drive force
transmitted via the MC6.
• The subsequent feeding by the pick-up roller is made when the paper feed sensor /BP (PS26) detects the
rear end of the previous paper [3].
[1] [2] [3]
Pick-up solenoid /BP (SD5)
Paper feed clutch /BP (MC6)
Paper feed sensor /BP (PS26)
a03ut2c055ca
[1] Print start signal [3] Second pick-up

[2] First pick-up
81
/C6501P/C65hc/C5501
• The separation roller [4] is driven in the opposite [1] to the paper feed direction [8] via the torque limiter [6].
bizhub PRO C6501
• The separation roller is pressed against the paper feed roller [10] by means of the spring [5] force [9] and the
pressure applied from the torque limiter.
• When no paper exists between the separation roller and the paper feed roller or when the only 1 sheet of
• When multiple sheets of paper are fed, the separation roller reverses the direction of rotation [7] (opposite to
the paper feed roller) and feeds the lower paper [2] that contacts with the separation roller back to the tray
[1]. The drop in frictional force between the 2 rollers due to the multiple sheets causes the counter rotating
of the separation roller.
[10]
[9]
[8]
[4] [3] [2] [1]
[7] [5]
[6]
a03ut2c092ca
[1] To the tray [6] Torque limiter

[2] Second sheet of paper [7] Rotation toward the separation
[3] Driven rotation [8] Paper feed direction
[4] Separation roller [9] Spring force
[5] Spring [10] Paper feed roller
16.3.4 Paper empty detection control

• No paper status of the tray is detected by the paper empty sensor /BP (PS47).

• When the paper empty sensor /BP (PS47) turns off, a message saying that the bypass feed tray is empty
appears on the touch panel.
82
Theory of Operation Ver.3.0 Jul. 2009 17. VERTICAL CONVEYANCE SECTION
17. VERTICAL CONVEYANCE SECTION
/C6501P/C65hc/C5501
bizhub PRO C6501
17.1 Configuration
Intermediate conveyance roller /1

Intermediate conveyance
roller /1
Vertical conveyance
sensor (PS50)
Vertical conveyance
door sensor (PS51)
Vertical conveyance door
a03ut2c056ca
83
17. VERTICAL CONVEYANCE SECTION Theory of Operation Ver.3.0 Jul. 2009
17.2 Drive
/C6501P/C65hc/C5501
bizhub PRO C6501
[4]
[1]
[3]
[2]
a03ut2c057ca
[1] Intermediate conveyance clutch /1 (MC13) [3] Drive coupling

[2] Paper feed motor (M41) [4] Intermediate conveyance roller /1
84
Theory of Operation Ver.3.0 Jul. 2009 17. VERTICAL CONVEYANCE SECTION
17.3 Operation
/C6501P/C65hc/C5501
bizhub PRO C6501
17.3.1 Vertical conveyance control
• Paper that is fed from trays /1, /2 and /3 is conveyed to the intermediate conveyance section of ADU.
• Paper that is fed from the tray /1 is conveyed to the intermediate conveyance roller /2 of the intermediate
conveyance section (ADU) by the pre-registration roller.
• The intermediate conveyance roller /1 assists to convey the paper that is fed from the trays /2 and /3
because the conveyance distance to the intermediate conveyance roller /2 is rather long.
• The paper feed motor (M41) drives the intermediate conveyance roller /1 via the intermediate conveyance
clutch /1 (MC13).
• The MC13 turns ON at the same time as the paper feed clutches /1 (MC7), /2 (MC9) and /3 (MC11) turn on.
• The MC13 turns OFF after the specified time passed from when the intermediate conveyance sensor /1
(PS27) turns on.
85
18. REGISTRATION SECTION Theory of Operation Ver.3.0 Jul. 2009
18. REGISTRATION SECTION

/C6501P/C65hc/C5501
bizhub PRO C6501
18.1 Configuration
Registration tempera-
Leading edge sensor ture sensor (TEMS1)
(PS63)
Registration driven roller
Leading edge
sensor (PS63) Registration
sensor (PS22)
Registration roller Registration

Loop roller Loop roller
driven roller
Registration temperature sensor (TEMS1) Registration sensor (PS22)
a03ut2c058ca
86
Theory of Operation Ver.3.0 Jul. 2009 18. REGISTRATION SECTION
18.2 Drive
/C6501P/C65hc/C5501
bizhub PRO C6501
[4] [1]
[3] [2]
a03ut2c059ca
[1] Loop motor (M31) [3] Registration roller
[2] Loop roller [4] Registration motor (M30)
87
18. REGISTRATION SECTION Theory of Operation Ver.3.0 Jul. 2009
18.3 Operation
/C6501P/C65hc/C5501
bizhub PRO C6501
18.3.1 Loop control

• All papers are passed through the loop roller and conveyed to the registration roller.
• Loop motor (M31) that drives the loop roller stops after specified time passed from when the registration
sensor (PS22) turns ON upon detecting the leading edge of paper.
• Because the registration motor (M30) is stopping, the leading edge of paper is pressed against the registra-
tion roller that is not moving. The paper forms a small loop before the M31 stops.
• Making paper form a loop enables to correct skew of the paper.
[6] [7] [8] [9]

[5] [4] [3] [2] [1]

a03ut2c060ca
[1] Intermediate conveyance roller /2 [6] Transfer belt unit

[2] Loop roller [7] Leading edge sensor (PS63)
[3] Registration loop [8] Registration sensor (PS22)
[4] Registration roller [9] Intermediate conveyance sensor /2 (PS28)
[5] Second transfer roller /Lw
88
Theory of Operation Ver.3.0 Jul. 2009 18. REGISTRATION SECTION
18.3.2 Registration operation
/C6501P/C65hc/C5501
• After the specified time passed from when the print start signal is received [1], the loop motor (M31) starts
bizhub PRO C6501

to turn to rotate the loop roller.
• The paper conveyed from the intermediate conveyance section or the ADU is conveyed to the registration
roller by the loop roller.
• When the registration sensor (PS22) detects the paper front-end, M31 turns OFF after the specified time
passed.
• At this point, because the registration motor (M30) is stopping, the paper is pressed against the registration
roller and forms a small loop [2] before the M31 stops.
• Making paper from a small loop enables to correct skew of the paper.
• The V_TOP signal is generated when the transfer belt becomes ready for the first transfer.
• After the specified time passed from when the V_TOP signal is received, the M30 and M31 stop and carry
out registration.
[1]
Registration motor (M30)
Loop motor (M31)
Intermediate conveyance sensor /2 (PS28)
Registration sensor (PS22)
V TOP
[2] [3]
a03ut2c093ca
[1] Print start signal is received [3] Second sheet registration loop
[2] First sheet registration loop
18.3.3 Paper leading edge timing correction control

• The time period from when the registration motor (M30) starts to rotate until the leading edge sensor (PS63)
detects the leading edge of paper is counted.
• Based on the counted time, the time when the paper gets to the second transfer section is estimated.
• If the estimated arrival time is earlier/later than the proper arrival time, the deceleration timing of the registra-
tion roller and the loop roller line speed is adjusted to meet the arrival timing.
• The timing correction control is carried out for every sheet of paper.
18.3.4 Registration speed correction control

• When restarting registration, the registration roller and loop roller conveyance speed are adjusted according
to the ambient temperature detected by the registration temperature sensor (TEMS1).
• The TEMS1 measures the temperature at regular intervals.
• The speed of the registration speed correction control is the same as normal line speed when TEMS1
detection temperature is 25 °C.
89
19. ADU SECTION Theory of Operation Ver.3.0 Jul. 2009
19. ADU SECTION

/C6501P/C65hc/C5501
bizhub PRO C6501
19.1 Configuration
ADU conveyance ADU pre-registration roller Intermediate conveyance roller /2

ADU conveyance roller /2
roller /1
Intermediate
ADU conveyance ADU conveyance roller /3 Intermediate conveyance conveyance sensor /1
sensor (PS61) sensor /2 (PS28) (PS27)
ADU pre-registration sensor (PS23)

ADU stop sensor
(PS20) ADU gate ADU loop roller
ADU reverse sensor (PS21)

Intermediate conveyance
ADU centering sensor ADU reverse roller roller /2
(PS65) a03ut2c061ca
90
Theory of Operation Ver.3.0 Jul. 2009 19. ADU SECTION
19.2 Drive
/C6501P/C65hc/C5501
bizhub PRO C6501
[14] [15] [16][17] [18] [19][20] [21]
[1][2]
[13] [12] [11] [10] [9] [8] [7] [6] [5] [4]
[3] a03ut5c062ca
[1] Intermediate conveyance roller /2 [12] ADU loop motor (M57)

[2] Intermediate conveyance clutch /2 (MC4) [13] ADU reverse motor (M32)
[3] Paper feed motor (M41) [14] ADU conveyance roller /1
[4] ADU pre-registration roller [15] ADU conveyance clutch /1 (MC1)
[5] ADU pre-registration clutch (MC18) [16] ADU conveyance roller /2
[6] ADU conveyance roller /3 [17] ADU conveyance clutch /2 (MC2)
[7] ADU conveyance clutch /3 (MC3) [18] Belt
[8] ADU loop roller [19] Intermediate conveyance roller /3
[9] Belt [20] Intermediate conveyance clutch /3 (MC5)
[10] ADU reverse roller [21] Drive coupling
[11] Belt
91
19.3 Operation
/C6501P/C65hc/C5501
bizhub PRO C6501
19.3.1 Paper reverse control

A. Paper conveyance
• During paper conveyance, the ADU gate [1] is open.
• Paper conveyed from the reverse roller /Lw [2] is conveyed to the ADU reverse roller [3] through the ADU
gate.
• Paper conveyed to the ADU reverse roller is then conveyed to the ADU loop roller [4].
[2] [3] [4]

[1] a03ut2c063ca
[1] ADU gate [3] ADU reverse roller

[2] Reverse roller /Lw [4] ADU loop roller
92
B. Loop formation
/C6501P/C65hc/C5501
• When the ADU stop sensor (PS20) [3] detects the rear end of paper and turns OFF, ADU loop roller [5]
bizhub PRO C6501

stops after the specified time passed.
• While the paper is stopped with its leading edge nipped by the ADU loop roller, the ADU reverse roller [4]
continues to rotate.
• The ADU reverse roller stops after the rear end of the paper passed through. (after the specified time
passed from when the ADU loop roller stops.)
• The above 2 rollers’ operation make the paper form a loop [1] between the 2 rollers.
• When the paper is forming the loop, its rear edge is pressed against the ADU reverse roller. This enables to
correct skew of the paper before starting the reverse paper conveyance.
[3] [4] [5]
[2] [1] a03ut2c064ca
[1] Loop [4] ADU reverse roller

[2] ADU gate [5] ADU loop roller
[3] ADU stop sensor (PS20)
93
C. Paper reverse
/C6501P/C65hc/C5501
• When the ADU reverse roller [6] stops, the ADU gate [4] closes.
bizhub PRO C6501
• After the specified time passed from when the ADU reverse roller stops, the ADU loop roller [8] and ADU
reverse roller rotate reversely at the same time.
• Paper is conveyed in the reverse direction keeping the loop [3], and because the ADU gate is closed, it is
conveyed to the ADU conveyance roller /1 [5].
• By means of the above operations, the paper is turned upside down.
• Then the paper is conveyed to the ADU conveyance roller /2 [7], /3 [3], ADU pre-registration roller [1] and
loop roller [9] for back side printing.
[5] [6] [7] [8] [9]

[4] [3] [2] [1]

a03ut2c065ca
[1] ADU pre-registration roller [6] ADU reverse roller

[2] ADU conveyance roller /3 [7] ADU conveyance roller /2
[3] Loop [8] ADU loop roller
[4] ADU gate [9] Loop roller
[5] ADU conveyance roller /1
94
19.3.2 ADU conveyance control
/C6501P/C65hc/C5501
• When the front side of the first sheet is fixed [2], after receiving a print start signal [1], the ADU loop motor
bizhub PRO C6501

(M57) and the ADU reverse motor (M32) start to rotate in the normal direction.
• When the ADU stop sensor (PS20) detects the rear end [3] of the first sheet while the paper is conveyed to
the reverse paper exit section, the M57 stops to stop the ADU loop roller.
• The M32 stops after the M57stops. This makes the paper form a loop [4] between the ADU loop roller and
the ADU reverse roller.
• After the specified time passed from when the PS20 turns off [3], the ADU gate solenoid (SD10) turns on [5]
and closes the ADU gate. At the same time, the M57 and M32 start to rotate in reverse direction to convey
the paper reversely.
• When the ADU conveyance sensor (PS61) provided on the ADU conveyance section detects the rear end
of the paper [6], the rotation direction of the M57 and M32 is switched to normal. The SD10 turns off and
opens the ADU gate again for the next paper.
[1] [2] [3] [6] [9]

V TOP
Fusing paper exit sensor (PS17)
Reverse paper exit sensor (PS17)
ADU stop sensor (PS20)
ADU reverse sensor (PS21)
ADU conveyance sensor (PS61)
ADU loop motor (M57) Forward
Reverse
ADU reverse motor Forward
(M32) Reverse
ADU gate solenoid (SD10)
ADU conveyance clutch/1 (MC1)
ADU conveyance clutch/2 (MC2)
[4][5] [7][8] a03ut2c066ca
[1] Print start signal is received [6] Second sheet paper rear end detection
[2] First sheet front side fusing complete [7] Second sheet loop formation
[3] First sheet paper back end detection [8] ADU gate close
[4] First sheet loop formation [9] First sheet back side fusing complete
[5] ADU gate close
19.3.3 Back side centering correction control

• The ADU centering sensor (PS65) detects the paper edges of the paper that has been reverse conveyed
from the ADU reverse roller for back side printing.
• Depending on the detected value, the distance from the center to the edge of paper is calculated, and the
laser writing position is adjusted so that the image is precisely centered on the printed page.
95
20. REVERSE/PAPER EXIT SECTION Theory of Operation Ver.3.0 Jul. 2009
20. REVERSE/PAPER EXIT SECTION

/C6501P/C65hc/C5501
bizhub PRO C6501
20.1 Configuration
Reverse gate Reverse gate

Decurler sensor
(PS62)
Reverse
decurler roller
Reverse paper
exit sensor
(PS19)
Small size
roller
Reverse decurler roller

Reverse roller/Lw Paper exit decurler roller
Paper exit
roller
Paper exit Paper exit sensor

decurler roller (PS13)
Paper exit
roller
a03ut2c069ca
96
Theory of Operation Ver.3.0 Jul. 2009 20. REVERSE/PAPER EXIT SECTION
20.2 Drive
/C6501P/C65hc/C5501
bizhub PRO C6501
20.2.1 Reverse/paper exit drive
[7]
[1]
[2]
[6]
[3]
[4]
[5]
a03ut2c070ca
[1] Decurler motor (M55) [5] Reverse paper exit motor (M33)
[2] Reverse decurler roller [6] Paper exit solenoid (SD4)
[3] Small size roller [7] Reverse gate
[4] Reverse roller /Lw
97
20.2.2 Paper exit drive/OT-502 drive

/C6501P/C65hc/C5501
bizhub PRO C6501
[6]
[5] [1]
[2]
[4]
[3]
a03ut2c071ca
[1] Paper exit motor (M54) [4] OT-502

[2] Paper exit decurler roller [5] OT paper exit roller
[3] Cam [6] Paper exit roller
98
20.3 Operation
/C6501P/C65hc/C5501
bizhub PRO C6501
20.3.1 Conveyance control
A. Reverse/paper exit switch control
• The paper exit path for paper conveyed from the fusing section is switched by the paper exit gate.
• The paper exit gate is driven by the paper exit solenoid (SD4).
• Switching the paper exit path with the gate is made according to the print mode and the paper exit type.
B. Conveyance path
(1) Straight paper exit
• Paper is exited face-up after printed on the one side or printed on the both sides.
[6]
[5]
[7]
[1]
[4]
[3]
[2]
a03ut2c072ca
[1] Fusing section [5] OT-502 (Option)

[2] Fusing paper exit sensor (PS17) [6] Paper exit roller
[3] Reverse gate [7] Paper exit sensor (PS13)
[4] Paper exit decurler roller
99
(2) ADU conveyance path

/C6501P/C65hc/C5501
• This paper path is used to exit paper face down after printing the one side for one-side printing or double-
bizhub PRO C6501
side printing.
[5] [6] [1]
[2]
[3]
[4]
a03ut2c073ca
[1] Fusing section [4] Reverse paper exit sensor (PS19)

[2] Reverse decurler roller [5] OT-502 (Option)
[3] Fusing paper exit sensor (PS17) [6] Reverse gate
100
C. Reverse/paper exit
/C6501P/C65hc/C5501
• This paper path is used to exit paper face down after printing on the backside in one-side printing or dou-
bizhub PRO C6501

ble-side printing.
[10] [11] [12]
[13]
[1]
[2]
[9] [8]
[7]
[3]
[4]
[5]
[6]
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[1] Fusing section [8] Paper exit pressure sensor (PS10)

[2] Reverse decurler roller [9] Paper exit decurler roller
[3] Fusing paper exit sensor (PS17) [10] OT-502 (Option)
[4] Reverse paper exit sensor (PS19) [11] Paper exit roller
[5] Small size roller [12] Paper exit sensor (PS13)
[6] Reverse roller /Lw [13] Reverse gate
[7] Decurler sensor (PS62)
101
20.3.2 Reverse/paper exit timing control

/C6501P/C65hc/C5501
• In face down paper exit, paper conveyed from the fusing section to the reverse decurler roller passing under
bizhub PRO C6501
the reverse gate.

• The reverse decurler roller conveys the paper to the small size roller by the normal rotation of the decurler
motor (M55).
• The small size roller and the reverse roller /Lw convey the paper to the ADU reverse section by the reverse
paper exit motor (M33).
• When the decurler sensor (PS62) detects the rear end of paper and turns off [2], the M55 and M33 switch
to reverse rotation.
• The rollers rotate in reverse and convey the paper in reverse direction, but due to the guide on the convey-
ance path, the paper is conveyed to the paper exit roller, not to the reverse gate side.
• By means of the above operations, paper is exited with its upside down.
• When the paper exit sensor (PS13) detects the rear end of the paper and turns off [3], the M55 and M33
starts the normal rotation again and the next paper is reversed/exited.
[1]
Registration motor (M30)

Paper exit solenoid (SD4)
Decurler motor Forward

(M55)
Reverse
Forward
Reverse paper
exit motor (M33) Reverse
Paper exit motor (M54)
Decurler sensor (PS62)
Reverse paper exit sensor (PS19)
Paper exit sensor (PS13)
[2] [3] [4] [5]

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[1] Print start signal is received [4] Second sheet reverse conveyance
[2] First sheet reverse conveyance [5] Second sheet exit
[3] First sheet exit
102
20.3.3 Paper exit decurler roller pressure control
/C6501P/C65hc/C5501
A. Paper exit decurler roller pressure mechanism
bizhub PRO C6501

• The paper exit decurler roller [1] that faces to the paper exit roller is pressed by the rotation of the cam [2].
• The cam is driven by the paper exit motor (M54).
• Forward rotation of the M54 causes paper exit operation, and its reverse rotation moves the cam to apply
pressure to the paper exit decurler roller.
• The cam and the encoder [3] are located on the same shaft. Paper exit pressure sensor (PS10) [4] detects
the slits on the encoder in order to determine the home position of the decurler roller.
• The pressure applied to the paper exit decurler roller is changed by the cam position in 4 levels; release [8],
low pressure [7], middle pressure [6], and high pressure [5]. The pressure level is controlled according to the
time period of the M54 rotation from when the PS10 turns off.
[1]
[2]
[3]
[4]
[8] [7] [6] [5]
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[1] Paper exit decurler roller [5] High pressure

[2] Cam [6] Middle pressure
[3] Encoder [7] Low pressure
[4] Paper exit pressure sensor (PS10) [8] Release
B. Print mode and paper exit decurler roller pressure level

• The pressure level applied to the paper exit decurler roller changes according to print mode.
Print mode Pressure amount

Standby, jam processing Release
Straight paper exit mode Low pressure
Double-sided mode Low pressure, Middle pressure*
Reverse paper exit mode High pressure
* In the double-sided mode, the pressure level can be changed (Low/Middle) with DIPSW.
103
20.3.4 Reverse decurler roller rotation control

/C6501P/C65hc/C5501
A. Purpose
bizhub PRO C6501
• To prevent the reverse decurler roller from deformation when the roller has not been used for certain period
of time.
• To minimize unevenness in temperature on the decurler roller surface, which can cause unevenness in color
of printed images, after a continuous printing is carried out.
B. Operation timing
• The decurler motor (M55) operates under the following conditions to rotate the reverse decurler motor.
Device status Remaining paper Rotation speed Rotational direction

Standby Executing image stabilization 1/1 speed (high) Reverse
operation
After finishing printing 5 minutes 1/1 speed (high) Reverse
NOTE
• When a new print job is received, the after-printing operation is canceled to accept the job.
• The after-printing operation can be enabled/disabled with software DipSW.
• This control is not carried out by default.
20.3.5 Paper exit full detection control

• When the OT-502 (option) is installed in the paper exit section, paper exit full detection control is performed.
• The OT-502 paper exit full sensor (PS12) is kept on while the OT-502 tray is used. If the prescribed number
of sheets are exit, or if the "on" status of the sensor is kept for a certain time period, it is detected as a full
status of the OT-502 tray and a message notifying the status appears on the touch panel.
104
Theory of Operation Ver.3.0 Jul. 2009 21. FUSING SECTION
21. FUSING SECTION
/C6501P/C65hc/C5501
bizhub PRO C6501
21.1 Configuration
Fusing belt Fusing lamp /Up (L2, L3, L4)
Fusing roller /1
Fusing paper exit
roller /Up
Fusing roller /2 Fusing roller /Lw Fusing heater lamp /4 (L5)

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105
21. FUSING SECTION Theory of Operation Ver.3.0 Jul. 2009
21.2 Drive
/C6501P/C65hc/C5501
bizhub PRO C6501
[5]
[1]
[4] [6]
[7]
[8]
[2]
[3]
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[1] Fusing motor (M29) [5] Fusing roller /1

[2] Cam (fusing roller /Lw for applying pressure) [6] Fusing belt
[3] Same gear [7] Fusing roller /2
[4] Fusing exit roller /Lw [8] Fusing roller /Lw
106
21.3 Operation
/C6501P/C65hc/C5501
bizhub PRO C6501
21.3.1 Fusing roller drive control
A. Fusing process speed table
• There are 3 types of fusing process speed 1/1 speed (300mm/s), 2/3 speed (207mm/s), 1/2 speed
(150mm/s).
• The fusing process speed is selected according to the paper weight (thickness) and whether the glossy
mode or not as shown in the table below.
Paper weight Paper type *1

A B C D E
Normal Glossy Normal Glossy Normal Glossy Normal Glossy Normal Glossy
64 to High speed 1/1 1/1 — — — — — — — —
74g/m2 Middle speed 2/3 1/1 — — — — — — — —
75 to High speed 1/1 1/1 — — — — — — — —
80g/m2 Middle speed 2/3 1/1 — — — — — — — —
81 to High speed 1/1 1/1 1/1 1/1 1/1 1/1 1/1 1/1 1/1 1/1
105g/m2 Middle speed 2/3 1/1 2/3 1/1 2/3 1/1 2/3 1/1 2/3 1/1
106 to High speed 1/1 2/3 1/1 2/3 1/1 2/3 1/1 2/3 1/1 2/3
135g/m2 Middle speed 2/3 2/3 2/3 2/3 2/3 2/3 2/3 2/3 2/3 2/3
Low speed 1/2 2/3 1/2 2/3 1/2 2/3 1/2 2/3 1/2 2/3
136 to Middle speed 2/3 1/2 2/3 1/2 2/3 2/3 2/3 1/2 2/3 2/3
162g/m2 Low speed 1/2 1/2 1/2 1/2 1/2 2/3 1/2 1/2 1/2 2/3
163 to Middle speed 2/3 1/2 2/3 1/2 2/3 2/3 2/3 1/2 2/3 2/3
209g/m2 Low speed 1/2 1/2 1/2 1/2 1/2 2/3 1/2 1/2 1/2 2/3
210 to 256g/m2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2
257 to 300g/m2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2
*1 Paper select mode and paper type
Paper select mode Paper type

Plain paper A
Color specific A
Colored paper A
High quality paper A
Coated paper GL B
Coated paper ML C
Coated paper GO D
Coated paper MO E
107
B. Fusing process speed correction control

/C6501P/C65hc/C5501
• This control is carried out to avoid improper slack in paper when the paper comes to the fusing section
bizhub PRO C6501
from the second transfer section.

• If the fusing process speed differs from the process speed of the second transfer section (difference in
speed between the fusing roller /Lw [8] and the second transfer roller /Lw [4]) when the leading edge of the
paper is nipped [1] by the fusing roller /Lw, the paper loop amount becomes increase.
• The fusing loop sensor (PS64) [5], located between the second transfer roller /Lw and the fusing roller /Lw,
detects the paper loop.
• When the paper loop is detected by the PS64, the fusing process speed is corrected so that it becomes
faster than the preset speed.
• The fusing process speed correction control is applied to all the 1/1 speed, 2/3 speed and 1/2 speed.
[10]
[1]
[9]
[2]
[8] [3]
[7]
[6] [5] [4]
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[1] Proper paper loop [6] Actuator

[2] Transfer belt [7] Improper paper loop
[3] Second transfer roller /Up [8] Fusing roller /Lw
[4] Second transfer roller /Lw [9] Fusing roller /2
[5] Fusing loop sensor (PS64) [10] Fusing belt
108
21.3.2 Pressure/release control
/C6501P/C65hc/C5501
• The fusing roller /Lw is pressed against the fusing belt during performing a print job.
bizhub PRO C6501

• When the fusing paper exit sensor (PS17) detects paper (the last page of the job) after completion of fusing,
the fusing roller /Lw moves to stop pressing the fusing belt.
• The fusing roller drive assy which includes the fusing roller /Lw moves up/down to press/release the fusing
belt with the roller.
• The up/down movements of the fusing roller drive assy are made by the cam which is driven by the fusing
motor (M29).
• The home position of the cam is determined by the fusing release home sensor (PS16). The sensor detects
the cam position with the actuator attached to the cam shaft.
• A one-way clutch is provided on the M29 drive transmission path toward the drive gear so that the M29
drive force is transmitted only to the cam when the M29 is rotating in reverse direction.
[5]
[6] [1]
[4]
[3] [2]
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[1] Release [4] Fusing roller /Lw

[2] Pressure/release driver gear [5] Fusing roller /Lw driver gear
[3] Cam [6] Pressure
109
21.3.3 Fusing temperature control

/C6501P/C65hc/C5501
A. Fusing temperature detection

bizhub PRO C6501
• The fusing roller /1 is heated by the fusing heater lamp /1 (L2), /2 (L3), /3 (L4).
• The fusing belt is heated by the heated fusing roller /1.
• The fusing roller /Lw is heated by the fusing heater lamp /4 (L5).
• The surface temperature of the fusing belt is detected by the temperature sensor /1 (TEMS/1), /3 (TEMS/3).
• The surface temperature of the fusing roller /Lw is detected by the temperature sensor /2 (TEMS/2), /4
(TEMS/4).
• Each temperature sensor monitors the surface temperature of the fusing belt and fusing roller /Lw at speci-
fied time intervals, and the AC drive board (ACDB) turns the lamps; L2, L3, L4, L5 ON/OFF according to the
detected temperatures.
[3] [4]
[2] [1]
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[1] Temperature sensor /4 (TEMS/4) [3] Temperature sensor /3 (TEMS/3)

[2] Temperature sensor /2 (TEMS/2) [4] Temperature sensor /1 (TEMS/1)
B. Fusing heater control

• The ON/OFF statuses of the 4 fusing heater lamps /1 (L2), /2 (L3), /3 (L4), /4 (L5) are predetermined for
each mode as shown below.
Mode L2 L3 L4 L5
Warm-up ON ON OFF ON
Standby OFF OFF ON ON
Charging mode ON ON OFF ON
Printing ON *1 OFF ON
Low power mode OFF OFF ON ON
Returned from low power mode ON ON OFF ON
Shut off mode OFF OFF OFF OFF
*1 During printing, the L3 is turned on/off according to the temperature detected by the temperature sensor /
3 (TEMS/3) and the paper size in the main scan direction.
110
21.3.4 Protection against abnormality
/C6501P/C65hc/C5501
• When the temperature sensor /1 (TEMS/1), /2 (TEMS/2), /3(TEMS/3), /4 (TEMS/4) is over the prescribed
bizhub PRO C6501

temperature for a specified time period, it is judged as a high temperature error and the main relay (RY1) is
turned off, then the product is stopped after the first transfer, second transfer and fusing pressure are
stopped/released.
• When the temperature sensor /1 (TEMS/1), /2 (TEMS/2), /3 (TEMS3), /4 (TEMS/4) detect a temperature
of under -50 °C continuously for a specified time period, it is judged as a low temperature error and the
main relay (RY1) is turned off, then the product is stopped after the first transfer, second transfer and fix-
ing pressure are stopped/released.
• The thermostat /1 (TS1), /2 (TS2) shut down the power line to the fusing heater lamp /1 (L2), /2 (L3), /3 (L4)
at 190 ± 7 °C.
• The thermostat /3 (TS3) shuts down the power line to the fusing heater lamp /4 (L5) at 160 ± 7 °C.
• When the fusing temperature abnormality occurs, the relay-off status is maintained by latch (SC latch) and
an error message appears on the touch panel.
• After troubleshooting the cause of the error, the SC latch must be released by the software DipSW3-1.
CBR/1 RY/1
NF
L2
CBR/2 TS1 TS2
AC L3
drive
RY section L4
drive
TS3
section
L5
ACDB
PRCB
Control section
TEMS/1
TEMS/2
TEMS/3
TEMS/4
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111
21.3.5 Fusing roller/Lw cooling control

/C6501P/C65hc/C5501
• When the temperature of the fusing roller /Lw [2] detected by the temperature sensor /2 (TEMS/2) rises
bizhub PRO C6501
higher than a specified temperature, and the difference between the detected and the specified tempera-
tures exceeds a predetermined level, the fusing fan /Lw (M65) [4] turns on and cools down the fusing roller
/Lw.
• While the M65 is operating, the fusing heater lamp /4 is kept off.
• The fusing fan /Lw (M65) takes in air from the front side, through the duct [3] to cool the fusing roller /Lw.
• Air that passed through the fusing roller /Lw is exhausted to the rear side through the duct [1].
[1]
[4]
[3] [2]
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[1] Duct [3] Duct

[2] Fusing roller /Lw [4] Fusing fan /Lw (M65)
112
Theory of Operation Ver.3.0 Jul. 2009 22. INTERFACE SECTION
22. INTERFACE SECTION
/C6501P/C65hc/C5501
bizhub PRO C6501
22.1 Configuration
CN493 CN495
CN1000
USB port (USB
TypeB)
Connector for printer controller
Serial port RJ45 Ethernet connector

(RS-232C)
Service port
Parallel port
(IEEE1284 com-
pliant)
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22.2 Application
Type Application
Connector for printer controller For IC-304 /305 /408
RJ45 Ethernet connector For network
Service port For mouse, keyboard/for USB memory ISW
USB port (USB TypeB) For ISW of copier/printer
Serial port (RS-232C) For CS Remote care
Parallel port For ISW of copier/printer
CN1000 (Overall control board (OACB)) For consolidation vendor connection
CN493 For key counter (KCT) connection
CN495 For status indicator light
113 1
23. IMAGE STABILIZATION CONTROL Theory of Operation Ver.3.0 Jul. 2009
23. IMAGE STABILIZATION CONTROL

/C6501P/C65hc/C5501
bizhub PRO C6501
23.1 Outline
• This unit carries out various image stabilizing controls in order to achieve stable high print quality.
• The image stabilizing controls carried out during printing are different from those carried out when the sub
power switch (SW2) is turned on.
23.2 Operation flow

23.2.1 Image stabilizing controls when the sub power switch (SW2) is ON, during printing, and dur-
ing idling
An operation flow when the sub power switch (SW2) is ON, during printing, and during idling is described in the
figure below.
When the sub power switch (SW2) is turned ON: Carries out the controls from A to H.
During printing and idling: Carries out the controls from D to H.
A. Drum rotation control B. Environmental decision control
MPC/APC
C. Color registration adjustment
D. PGC sensor baseline correction control 1
E. Maximum density correction
F. V0 correction
G. Vm correction
D. PGC sensor baseline correction control 2
H. Gamma correction
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114
Theory of Operation Ver.3.0 Jul. 2009 23. IMAGE STABILIZATION CONTROL
A. Drum rotation control
/C6501P/C65hc/C5501
(1) Purpose
bizhub PRO C6501

• To prevent uneven electrostatic charges on the drum, which causes improper images under high humidity
conditions.
• To prevent unevenness in density caused by the difference in sensitivity between the part that the cleaner or
the developer is applied to and other parts when leaving them in low/normal humidity conditions.
(2) Operation
• Rotates the drum for approx. 4 min and 30 sec during warm-up if the fusing temperature is 50 degrees C or
less when the sub power switch (SW2) is turned ON .
• Performs the following operations based on the environmental decision if the fusing temperature is more
than 50 degrees C when the SW2 is turned ON.
If the product is not ready to print 1 minute after turning the SW2 on under high humidity conditions, the
drum is rotated for 4 min and 30 sec. On the other hand, if the fusing warm-up is completed within 1 minute
after turning the SW2 on, the drum is not rotated. Under low/normal humidity conditions, the drum is
rotated slightly at constant intervals based on the humidity and the period of time that the product is left to
stand.
B. Environmental decision control
(1) Purpose
• To achieve high print quality, the temperature/humidity sensor detects the environmental temperature and
humidity and feed back the findings to the various types of controls to maintain the image at a fixed quality.
(2) Execution timing

• The ambient status is judged using the measurement result of the sensor under the following conditions.
More than 8 hours have passed since turning the sub power switch (SW2) off previous time when turning
the SW2 on, and that the fusing temperature is 50 degrees C or below.
115
C. Color registration adjustment

/C6501P/C65hc/C5501
(1) Purpose
bizhub PRO C6501
• Performed in order to correct the misalignment in main or sub scanning direction, entire horizontal magnifi-
cation, and skew.
(2) Operation
• The color registration sensors /Fr and /Rr reads a patch image created on the transfer belt.
• The correction is carried out by calculating the amount of the misalignment from the read value.

• When adjusting in service mode.
• When the sub power switch (SW2) is turned on with the fusing temperature is 50 °C or less.
• Every 1,000 prints.
• When printing is not performed for a predetermined period of time.When the temperature in the write sec-
tion has changed 10 °C.
• When printing is not performed for 1 hour after the correction is finished.
D. PGC sensor baseline correction control 1, 2

(1) Purpose
• This correction is necessary to be executed in advance to carry out the maximum density control and the
gamma correction control.
(2) Operation
• To carry out the maximum density control, reference values for the PGC sensor (PS11) are determined by
measuring the density of the transfer drum surface when no toner is attached on the belt.

• When printing has not been performed for 6 hours or longer.
• When a change in humidity exceeds 20% from the last time the control is performed.
• When turning on the sub power switch (SW2) after replacing the materials.
116
E. Maximum density correction control
/C6501P/C65hc/C5501
(1) Purpose
bizhub PRO C6501

• To keep the maximum density constant regardless of the ambient condition and the number of printed
pages.
(2) Operation
• The maximum density correction method differs in each color of Y, M, C, and K.
• The correction of Y, M, and C.
The target value of each toner adhesion stored in the NVRAM board (NRB) is used for the correction.
A patch image is created on the transfer belt using the maximum exposure level, to be read by the PGC
sensor (PS11).
According to the detected density, a target range of developing bias is calculated and determined for devel-
opment.
• The correction of K.
A gradation patch image is created on the transfer belt using the intermediate exposure level, to be read by
the PS11.
According to the detected density, a target range of developing bias is calculated and determined for devel-
opment.
• Every 1,000 prints
F. V0 adjustment
(1) Purpose
• To charge the drums appropriately compensating for deterioration of related parts, and the effects of ambi-
ent conditions.
(2) Operation
• A voltage applied to the grid is adjusted so that a target electric potential is obtained. The target potential is
determined according to the developing bias calculated at the maximum density correction control.
• The electric potential on the drums are detected by the drum potential sensors; /Y (DPRS/Y), /M (DPRS/M),
/C (DPRS/C), and /K (DPRS/K).

• When a change in humidity exceeds 20% from the last time the adjustment is performed.
117
G. Vm adjustment
/C6501P/C65hc/C5501
(1) Purpose
bizhub PRO C6501
• To achieve stabilized intermediate exposure potential regardless of a drop in sensitivity of photosensitive

materials or the stain of the writing system.
(2) Operation
• While the drums are irradiated with a PWM128 intensity laser beam, the electric potential on the drums are
detected by the drum potential sensor /Y (DPRS/Y), /M (DPRS/M), /C (DPRS/C), and /K (DPRS/K). Accord-
ing to the detected results, the laser MPC value is corrected.

• When a change in humidity exceeds 20% from the last time the adjustment is performed.
H. Gamma correction control

(1) Purpose
• In order to correct print density with respect to the original density according to gamma characteristic of
toner images formed on each drum and the transfer belt in relation to the exposure level.
(2) Operation
• Patch images are created on the transfer belt, and read by the PGC sensor (PS11).
• The PS11 output level is checked against a predetermined output level with respect to print density, and the
gamma is corrected according to the result.

• Every 1,000 prints
118
23.2.2 Image stabilizing controls when selecting the “Stability“ in expert settings
/C6501P/C65hc/C5501
The image stabilizing controls described below is only executed when "Stability" is selected in "Expert adjust-
bizhub PRO C6501

ment" → "Quality adjustment" → "Image Quality stability".
A. Simple - Maximum density correction
B. Simple - Gamma correction

a03ut2c112ca
A. Simple-maximum density correction

(1) Purpose
• To keep the maximum density constant regardless of the ambient condition and the number of printed
sheets.
(2) Operation
• Patch images are created on the transfer belt, and read by the PGC sensor (PS11). The PS11 output level
is checked against a predetermined output level with respect to print density. The result is reflected to the
developing DC bias and the Grid voltage.

• The correction setting is enabled in "Utility" → "Machine Admin. setting" → "System settings" → "Expert
adjustment" → "Quality adjustment" → "Image Quality stability".
When the print/copy job reaches the number of pages that correspond to a level of density selected on the
operation panel.
Operation panel setting -2 -1 normal +1 +2

Number of print pages 200 100 50 30 10
B. Simple-gamma correction
(1) Purpose
• To correct print density according to gamma characteristic of toner images formed on each drum and the
transfer belt in relation to the exposure level.
(2) Operation
• Patch images are created on the transfer belt with the settings selected in the "Menu" → "Qualty adjust-
ment" → " Screen" and read by the PGC sensor (PS11).

• The correction setting is enabled in the "Utility" → "Machine Admin. setting" → "System settings" → "Expert
adjustment" → "Quality adjustment" → "Image Quality stability".
When the value of simple maximum density correction reaches the value that correspond to a level of
gamma correction selected on the operation panel.
Operation panel setting -2 -1 normal +1 +2

Simple-maximum density correction value 15 10 8 5 3
119
23.2.3 Other Image stabilizing controls

/C6501P/C65hc/C5501
The image stabilizing controls described below is only executed when selecting "Stability" on the "Expert adjust-
bizhub PRO C6501
ment" → "Quality adjustment" → "Image Quality stability" screen.
A. Toner refresh mode control

a03ut2c113ca
A. Toner refresh mode control

(1) Purpose
• Printing low coverage images makes the developer (toner) become deteriorated due to agitation with little
consumption of developer, and as the result, print quality becomes degraded. To prevent this, the
deteriorated toner in the developer is ejected and replaced with new toner.
(2) Operation
a. Manual toner refresh mode
• Develops the amount of toner that equals the consumption for printing 8 papers (A3 size) for each color to
eject the deteriorated toner.
b. Automatic toner refresh mode

• Checks the average of print coverage for each color with each specific drive distance of the developing
roller /K and consumes a certain amount of toner for the color that the density is lower than 5% converted
in A4 size after completion of printing.
Execution frequency Refresh quantity

Small Continuously printing approx. 1,000 Approx. 3 solid sheets
sheets in A4 size in A3 size
Medium Continuously printing approx. 500 Approx. 5 solid sheets
Large Continuously printing approx. 330 Approx. 8 solid sheets
• The execution frequency varies depending on the environmental temperature and print mode.

a. Manual toner refresh mode
• When selecting the execution of toner refresh mode on the operation panel and returning to the normal screen or
when turning on/off the sub power switch (SW2).
b. Automatic toner refresh mode
• When "Execution existence" is set to [ON], this mode works according to the combination of "Execution fre-
quency" and "Refresh quantity".
120
Theory of Operation Ver.3.0 Jul. 2009 24. IMAGE PROCESSING
24. IMAGE PROCESSING
/C6501P/C65hc/C5501
bizhub PRO C6501
24.1 Operation flow
3 line CCD sensor / A/D convert
R G B K
• Shading correction • Shading

• RGB gap correction correction
• Brightness/Density conversion • Image

• Scanner gamma correction distinction
• 10/8bit convert • ACS
Image distinction signal
• Scaling (main scan)
• Spatial filter
• AE
• Background adjustment
3D look up table Brightness conversion

(Color mode) (black-and-white mode)
C M Y K
• Error diffusion
• Data compression/expansion
Screen process
Write/C Write/M Write/Y Write/K

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121
24. IMAGE PROCESSING Theory of Operation Ver.3.0 Jul. 2009
24.2 Image type classification

/C6501P/C65hc/C5501
bizhub PRO C6501
A. OUTLINE
• A scanned image type is classified as text, dots, solid or chroma.
• After the classification, gamma curve used for writing the image is changed to the appropriate one for the
image type.
• The image classification function works "Text/Photo", "Text", or "Map" is selected in the original setting
menu.
• The function does not work when "Photo" is selected.
Image data
Text Dots Solid Chroma

(Characters) (Dot pattern for offset (silver-halide (Chromatic or achromatic
printing) photo) color)
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122
Theory of Operation Ver.3.0 Jul. 2009 24. IMAGE PROCESSING
B. Writing bit and resolution
/C6501P/C65hc/C5501
Relations between number of write bit and the resolution by the combination of the display and the image quality
bizhub PRO C6501

is shown in the figure below.
Display of operation panel Enhance Mode Writing bit and resolution

Line1 Text/Photo Text: 8bit 600dpi / Other: Approx. 200lpi screen
Photo Approx. 200lpi screen
Text 1bit ED 600dpi
Map 1bit ED 600dpi
Line2/ Type1 Text/Photo Text: 8bit 600dpi / Other: Approx. 180lpi screen
Text 1bit ED 600dpi
Map 1bit ED 600dpi
Line2/ Type2 Text/Photo Text: 8bit 600dpi / Other: Approx. 135lpi screen
Text 1bit ED 600dpi
Map 1bit ED 600dpi
Dot1 Text/Photo Text: 8bit 600dpi / Other: Approx. 190lpi screen
Text 1bit ED 600dpi
Map 1bit ED 600dpi
Dot2/ Type1 Text/Photo Text: 8bit 600dpi / Other: Approx. 200lpi screen
Text 1bit ED 600dpi
Map 1bit ED 600dpi
Dot2/ Type2 Text/Photo Text: 8bit 600dpi / Other: Approx. 140lpi screen
Text 1bit ED 600dpi
Map 1bit ED 600dpi
Compression Gives priority Text/Photo 1bit ED 600dpi
to lessening Photo
color scanned Text
data
Map
123
25. OTHER CONTROLS Theory of Operation Ver.3.0 Jul. 2009
25. OTHER CONTROLS

/C6501P/C65hc/C5501
bizhub PRO C6501
25.1 Power On control

25.1.1 Parts that operate when the main power switch (SW1) is turned on
A. Configuration
SW2
SW1
CBR/1
NF 5VDC IFB IMCB OACB

CBR/2 DCPS/1
DCPS/2
SW3 RY/2
HTR
LU/PF(OPTION)
HTR1 HTR2
ACDB
a03ut2c091ca
B. Operation
• When the main power switch (SW1) turns ON, AC power is supplied to the DC power unit /1 (DCPS1), /2
(DCPS/2).
• Then, 5VDC is distributed to the overall control board (OACB) through the I/F board (IFB) and the image
memory control board (IMCB).
124
Theory of Operation Ver.3.0 Jul. 2009 25. OTHER CONTROLS
25.1.2 Parts that operate when the sub power switch (SW2) is turned on
/C6501P/C65hc/C5501
A. Configuration
bizhub PRO C6501

SW2
SW1
CBR/1 5VDC
OACB
NF 3.3VDC IFB IMCB
DCPS/1 24VDC 12VDC HD
CBR/2
24VDC
12VDC
PRCB
5VDC
PK
DCPS/2 24VDC
24VDC 24VDC 24VDC 24VDC 24VDC 24VDC
DF PF LU FS RU PI
AC drive
L2,L3,L4,L5
RY/1 section
SW3
HTR
RY/2
LU/PF(OPTION)
HTR1 HTR2
ACDB
a03ut2c094ca
B. Operation
• When the sub power switch (SW2) turns ON, the overall control board (OACB) sends a control signal to the
DC power unit /1 (DCPS/1) via the image memory control board (IMCB) and the I/F board (IFB).
• DCPS /1 generates voltages of 3.3VDC, 5VDC, 12VDC, 24VDC, and distributes them to the printer control
board (PRCB) and other control boards.
• Then, the PRCB sends a control signal to the DC power unit /2 (DCPS/2) in order to make the unit generate
24 VDC is supplied to the all driver boards and option units.
• Main relay (RY/1) turns ON to supply AC power to the fusing heater lamp /1 (L2), /2 (L3), /3 (L4) and /4(L5),
and the initial operation is performed.
• The sub relay (RY/2) turns OFF to shut off the AC power to the dehumidifier heater (HTR), the dehumidifier
heater /1 inside the PF/LU (HTR1), and the dehumidifier heater /2 (HTR2) (PF only).
125
25.2 Fan control

/C6501P/C65hc/C5501
bizhub PRO C6501
25.2.1 Configuration
[16] [17] [18] [19] [20] [21] [22] [23] [24] [25] [26]
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[15] [14] [13] [12] [11] [10] [9]

a03ut2c095ca
[1] Main unit fan (M47) [14] ADU fan /2 (M67)

[2] Developing fan /1 (M45) [15] ADU fan /1 (M66)
[3] Developing fan /2 (M46) [16] Fusing fan /Lw (M65)
[4] Writing suction fan /1 (M43) [17] Paper exit fan /1 (M61)
[5] IPB fan /2 (M25) [18] Transfer belt fan (M11)
[6] IPB fan /1 (M24) [19] Paper exit fan /2 (M62)
[7] Developing fan /3 (M64) [20] Paper exit fan /3 (M63)
[8] Writing suction fan /2 (M44) [21] Fusing belt ventilation fan (M10)
[9] Power supply fan (M42) [22] Deodorization fan (M36)
[10] Charging air suction fan (M48) [23] Fusing ventilation fan (M37)
[11] Tucking fan /1 (M26) [24] Drum fan /1 (M12)
[12] Tucking fan /2 (M27) [25] Drum fan /2 (M13)
[13] Tucking fan /3 (M28) [26] Scanner fan (M2)
126
25.2.2 Operation
/C6501P/C65hc/C5501
A. Scanner fan (M2) control
bizhub PRO C6501

(1) Purpose
• To cool the scanner section.
(2) ON timing
• Starts to operate upon starting of scanning.
During DF scan, however, the fan keeps operating.
(3) OFF timing

• Stops to operate upon completion of scanning.
B. Fusing belt ventilation fan (M10) control

(1) Purpose
• To cool around the fusing section near the paper exit.
(2) Low/high speed switch timing

• Rotates at low speed during standby.
• Switches to high speed upon starting of printing.
• Switches to low speed for a predetermine time period after printing is finished.
C. Transfer belt fan (M11) control

(1) Purpose
• To cool around the transfer belt.
(2) ON timing
• Starts to operate upon starting of printing.
(3) OFF timing

• Stops a predetermined time period after printing is finished.
D. Drum fan /1 (M12), /2 (M13) control

(1) Purpose
• Exhaust the heat around the drum motor/developing motor.
(2) ON timing
(3) OFF timing

127
E. IPB fan /1 (M24), /2 (M25) control

/C6501P/C65hc/C5501
(1) Purpose
bizhub PRO C6501
• To cool around the image processing board (IPB).
(2) ON timing
• Starts to operate upon starting of scanning.
• Starts to operate upon starting of HDD operation.
(3) OFF timing

• Starts to operate upon completion of printing.
• Starts to operate upon completion of scanning.
• Starts to operate upon completion of HDD operation.
F. Tucking fan/1 (M26), /2 (M27), /3 (M28) control

(1) Purpose
• To cool around the reverse paper exit section and the paper.
(2) ON timing
• Stops during printing front side of double side print.
• Starts to operate upon starting of printing back side of double print or single print.
(3) OFF timing

• Stops when the single print counter reaches a predetermined level.
G. Deodorization fan (M36) control

(1) Purpose
• To cool around the fusing section.
(2) Low/high speed switching timing

• Switches to low speed a predetermine time period after printing is finished.
H. Fusing ventilation fan (M37) control

(1) Purpose
• To cool around the fusing section.
(2) Low speed/fast switch timing

128
I. Power supply fan (M42) control
/C6501P/C65hc/C5501
(1) Purpose
bizhub PRO C6501

• To cool the DC power unit /1 (DCPS/1), /2 (DCPS/2).
(2) Low/high speed switching timing

J. Writing suction fan /1 (M43), /2 (M44) control

(1) Purpose
• To cool the polygon motor and the writing optical parts.
(2) ON timing
• Rotates at high speed during standby and printing.
• The number of revolutions during standby can be set using software DIPSW.
K. Developing fan /1 (M45), /2 (M46), /3 (M64) control
(1) Purpose
• To cool around the developing section.
(2) ON timing
• Starts to operate upon starting of the developing motor /Y (M14), developing motor /M (M15), developing
motor /C (M16) and developing motor /K (M17).
(3) OFF timing

• The predetermined time period differs depending on the ambient humidity. (5 minutes 30 seconds at max.)
L. Main unit fan (M47) control

(1) Purpose
• To cool around the drum section.
(2) ON timing
• Starts to operate upon starting of the developing motor /Y (M14), developing motor /M (M15), developing
motor /C (M16) and developing motor /K (M17).
(3) OFF timing

• The predetermined time period differs depending on the ambient humidity. (5 minutes 30 seconds at max.)
129
M. Charging air suction fan (M48) control

/C6501P/C65hc/C5501
(1) Purpose
bizhub PRO C6501
• To cool around the charging coronas.
(2) ON timing
• Starts to operate upon starting of charging.
• Starts to operate upon starting of image stabilization control.
(3) OFF timing

• Stops a predetermined time period after finishing the image stabilization control.
N. Paper exit fan /1 (M61), /2 (M62), /3 (M63) control

(1) Purpose
• To cool the exited paper to prevent unevenness of wax on the paper surface.
(2) ON timing
(3) OFF timing

• FS connected : Stops a predetermined time period after the FS paper exit sensor turns off.
• FS disconnected: Stops a predetermined time period after the main unit paper exit sensor (PS13) turns off.
O. Fusing fan/Lw (M65) control

(1) Purpose
• To cool the fusing roller /Lw.
(2) ON timing
• Starts to operate when the temperature of the fusing roller /Lw rises higher than a prescribed level exceed-
ing the allowable range.
• The M65 and the fusing heater lamp /4 (L5) do not turn ON at the same time.
(3) OFF timing

• Stops when the temperature of the fusing roller /Lw drops to a prescribed level.
P. ADU fan /1 (M66) control

(1) Purpose
• To cool around the ADU.
(2) ON timing
• Starts to operate upon starting of printing in double side or reverse paper exit mode.
(3) OFF timing

130
Q. ADU fan /2 (M67) control
/C6501P/C65hc/C5501
(1) Purpose
bizhub PRO C6501

• To cool the ADU loop motor (M57) and the ADU reverse motor (M32).
(2) ON timing
• Starts to operate upon starting of printing in double side or reverse paper exit mode.
(3) OFF timing

131
25.3 Counter control

/C6501P/C65hc/C5501
bizhub PRO C6501
25.3.1 Structure of counter
TCT/1
PRCB TCT/2
KCT
LCD
IFB IMCB OACB
OB/3
a03ut2c096ca
132
25.3.2 Counter operation
/C6501P/C65hc/C5501
bizhub PRO C6501
Item Specification/mechanism
Total counter /1 (TCT/1) • Display the total number of printed sheets in all print modes.
• Mechanical counter driven by electrical signals.
• Counts up by paper exit signal.
Total counter /2 (TCT/2) • Display the total number of printed sheets in black-and-white print
modes.
• Counts up by paper exit signal.
Electrical counter • Display the total number of printed sheets on the LCD board (LCDB).
• Data collection *1
• Counts up by paper exit signal, and stores the data in NVRAM board
(NRB).
For key counter (KCT) • Counter to disable copy operation when count up to the set print
Option number. (removable)
*1 Refer to "9.6 Counter/data" in the field service manual for information on the collected data. (Refer to
P.239)
[3] [2] [1]

a03ut2c097ca
[1] Total counter /1 (TCT/1) [3] Key counter (KCT)

[2] Total counter /2 (TCT/2)
133
25.4 Dehumidifier heater control

/C6501P/C65hc/C5501
bizhub PRO C6501
A. Configuration
SW1
CBR/1
NF
CBR/2
SW3 RY/2
HTR
LU/PF(OPTION)
HTR1 HTR2
ACDB
a03ut2c098ca
B. Operation
• The dehumidifier heater switch (SW3) supplies AC power to the sub relay (RY/2) inside the AC drive board
(ACDB).
• When the main power switch (SW1) is OFF, the RY /2 can transmit the AC power to the dehumidifier heater
(HTR) and the dehumidifier heater /1 (HTR1), dehumidifier heater /2 (HTR2) (PF only) inside the LU (option).
• Then, if SW3 is turned ON when SW1 is turned off, AC power can be supplied to HTR or HTR1/HTR2.
• When the SW1 and the sub power switch (SW2) are turned on, 24VDC is supplied to the ACDB and the
RY/2 is disconnected. Since the AC power line to the HTR and the HTR1/HTR2 is shut off with the RY /2,
the power is not supplied to the heaters even when the SW3 is turned on.
134
25.5 ACS control
/C6501P/C65hc/C5501
bizhub PRO C6501
25.5.1 Switching from the color mode to the black-and-white mode
A. OUTLINE
• If more than 5 black-and-white sheets are fed consecutively from the DF in which both the color sheets and
the black-and-white sheets are stored, the pressure on the first transfer rollers /Y/M/C are released and it
shifts to the black-and-white mode.
• At this time, the switch is performed during the job, so there is a time lag between the color print and the
black-and-white print.
B. Switching sequence from the color mode to the black-and-white mode

1. The second transfer for the previous print sheet (color) is complete.
2. A pressure is applied only to the first transfer roller /K (the first transfer rollers /Y/M/C are in release state).
3. Writing/K is started.
4. The operation of the drum unit /Y/M/C, the developing unit /Y/M/C, and the toner supply unit /Y/M/C are
canceled.
C. Switching sequence from the black-and-white mode to the color mode
1. A color print job is detected.
2. The second transfer for the previous print sheet (black-and-white) is complete.
3. The operation of the drum unit /Y/M/C, the developing unit /Y/M/C, and the toner supply unit /Y/M/C are
started.
4. MPC or APC is executed for the write unit /Y/M/C.
5. A pressure is applied to the first transfer roller /Y/M/C/K.
6. Writing /Y is started.
25.5.2 Count when using ACS

• There are 2 kinds of print count when using ACS.
A. The black-and-white mode (the first transfer roller /Y/M/C is in the release state)
Black-and-white original
Total count Counts as black-and-white
Developer counter Counts as black-and-white
B. The color mode (the first transfer roller /Y/M/C/K is in the pressure state)
Color original Black-and-white original

Total count Counts as color Counts as black-and-white
Developer counter Counts as color Color count *1
*1 When the original is black-and-white, the output will be black-and-white; however, the developer counter
counts it as color print and the total counter counts it as black-and-white print.
135
/C6501P/C65hc/C5501 25. OTHER CONTROLS Theory of Operation Ver.3.0 Jul. 2009
bizhub PRO C6501
Blank page
136
Theory of Operation Ver.3.0 Jul. 2009 26. MAINTENANCE PROCEDURE
MAINTENANCE
/C6501P/C65hc/C5501
bizhub PRO C6501
26. MAINTENANCE PROCEDURE
26.1 Housing section
26.1.1 Replacing the Dust-proof filter /1 assy
A. Periodically replaced parts/cycle
• Dust-proof filter /1 assy : Every 200,000 prints (actual replacement cycle: Varies depending on the cover-
age,the developing roller drive distance and temp/humidity) *1
: Every 150,000 prints (actual replacement cycle: Varies depending on the cover-
age,the developing roller drive distance and temp/humidity) *2
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
1. Remove the screw [1], and remove the filter cover
[1] [2]
[2].
a03uf2c001ca
2. Remove the Dust-proof filter /1 assy [1].

3. Reinstall the above parts following the removal
steps in reverse.
[1] a03uf2c002ca
137 1
26. MAINTENANCE PROCEDURE Theory of Operation Ver.3.0 Jul. 2009
26.1.2 Replacing dust-proof filter /2 assy

/C6501P/C65hc/C5501

bizhub PRO C6501
• Dust-proof filter /2 assy : Every 200,000 prints *1

: Every 150,000 prints *2
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
1. Loosen the 2 screws [1] and remove the filter
[1]
cover [2].
[2] a03uf2c003ca
2. Pull out the dust-proof filter /2 assy [2] from the fil-
[2] [1]
ter cover [1].
steps in reverse.
a03uf2c004ca
1 138
26.2 Photoconductor section
/C6501P/C65hc/C5501
bizhub PRO C6501
26.2.1 Process unit disassembly flowchart
Open the toner supply section.
Open the fan cover /Fr.
Pull out the process unit. Removing charging corona unit
Remove the transfer belt unit.
Removing drum cartridge Removing developing unit
Removing process unit
Removing image correction unit
139
26.2.2 Opening/closing toner supply section

/C6501P/C65hc/C5501
A. Procedure
bizhub PRO C6501
1. Open the front door [1].

2. Loosen the screws [2] and [3], and open the toner
supply section [4].
Note
• Do not exert force on the toner supply section
when it is opened. Otherwise the hinge of the
toner supply section may be deformed.
• When closing the toner supply section, be
sure to tighten the screw 2 turns with your fin-
gers before using a screwdriver so as not to
[2] [3] strip the thread.
[1] [4]
a03uf2c037ca
140
3. Remove the door lock [2] on the inside of the
/C6501P/C65hc/C5501
toner supply section [1], and attach the lock as a
bizhub PRO C6501

stopper as shown in the figure.
4. When closing the toner supply section, follow the
removal steps in reverse.
Note
• When the toner supply section is opened, be
sure to use the door lock as a stopper so as
not to hit the toner supply section with the
process unit upon removal.
[2] [1]
[2] [1]
a03uf2c038ca
141
26.2.3 Pulling out the process unit

/C6501P/C65hc/C5501
bizhub PRO C6501
Note
• In order to prevent rollover accidents, safety feature of the product does not allow the process unit
and the ADU to be pulled out at the same time.
• Be sure to put the ADU in the main body before pulling out the process unit.
• If you cannot pull out the process unit, check the lock lever/1 and /2 for deformation and replace
them as necessary. (Refer to P.269)
1. Open the toner supply section.

(Refer to P.140)
2. Loosen the screw [1] and open the fan cover/Fr
[2].
[1] [2] a03uf2c039ca
3. Push the mount handle /Lt [1] and the process

[3]
mount handle /Rt [2] inward together to unlock
the process unit [3], and pull out the process unit
[3] by holding the handles.
[1] [2] a03uf2c040ca
142
26.2.4 Removing drum cartridge
/C6501P/C65hc/C5501
bizhub PRO C6501

• Drum cartridge : Every 200,000 prints (actual replacement cycle: 106 km of drum drive distance, or 130 km
of roller drive distance after lubrication, whichever comes first) *1
: Every 150,000 prints (actual replacement cycle: 106 km of drum drive distance,or 130 km
of roller drive distance after lubrication, whichever comes first) *2
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
Note
• The product installs 4 drum cartridges 1 each for yellow, magenta, cyan, and black. Yellow,
magenta, and cyan are common parts, and black is exclusive part. Do not use a once-used drum
cartridge for another color even they are common parts, or the old remaining toner and the new
toner mix up and the print quality degrade.
1. Pull out the process unit.

(Refer to P.142)
2. Remove the transfer belt unit.
(Refer to P.147)
3. Lift up the both ends [2] of the drum stay/Up [1],
grab the ends, and remove the drum cartridge/Y
[3].
[2]
4. Remove the drum cartridge/M [4], /C [5], and /K
[8] [1] [7]
[6] in the same manner as step 3.
Note
• When installing drum cartridges, confirm that
the both ends of the cartridges are fitted in
the groove of the drum attachment block/Fr
[7] and /Rr [8]. (Drum attachment block/Fr [7]
and /Rr [8] shown on the left is the 1 for yel-
low drum cartridge. Install magenta, cyan,
and black drum cartridges in the same man-
ner.)
• When installing the drum cartridge/K [6], be
careful not to entangle the sheet [9].
[5] [6] [9] [4] [3] • Do not damage or touch the drum photocon-
a03uf2c005ca ductor area with bare hands.
• When leaving drum cartridges, be sure to
spread a sheet over the cartridges to protect
from light, and put them in a dark place.
143 1
5. Apply setting powder uniformly to both sides of

/C6501P/C65hc/C5501
[1] [2]
the drum [1], and turn around both ends of the
bizhub PRO C6501
drum with fingers in the arrow-marked direction

[2] until no more setting power is visible.
Note
• Be sure to turn around the drum with the
flanges on the outer side of the edges [3]. Do
not touch the image area.
• Be sure to turn around in forward direction
[2]. Be careful not to turn around in the
reverse direction, otherwise the blade gets
damaged.

steps in reverse.
[3] [4] a0u0t3c001ca
144
26.3 Charging section
/C6501P/C65hc/C5501
bizhub PRO C6501
26.3.1 Replacing the charging corona
• Charging corona : Every 100,000 prints *1
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
Note
• The product installs 4 charging coronas 1 each for yellow, magenta, cyan, and black, and they are
common parts. However, do not use a once-used charging corona for another color, or the old
remaining toner and the new toner will mix up and the print quality will degrade.

(Refer to P.140)
2. Place the lever [2] of the charging corona [1] in its
lower right position, then pull the lever toward you
[3] to remove the charging corona.
[1]
Note
• Push the charging corona gently in the direc-
tion to the upper left [4] after installing the
charging corona [1]. This operation makes
[4] the distance appropriate between the drum
[2] cartridge and the charging corona. Be careful
not to push hard, otherwise the charging
corona becomes deformed.
[3]
steps in reverse.
a0u0t3c002ca
145 1
26.3.2 Replacing the charging dust-proof filter

/C6501P/C65hc/C5501

bizhub PRO C6501
• Charging dust-proof filter : Every 600,000 prints *1

*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
[3] [1]
(Refer to P.140)
2. Remove the charging dust-proof filter [3] from the
charging suction assy [2] installed inside the toner
supply section [1].
steps in reverse.
[2] 8050ma3074
1 146
26.4 Intermediate transfer section
/C6501P/C65hc/C5501
bizhub PRO C6501
26.4.1 Removing/installing the transfer belt unit
A. Procedure
[3] [2] [1] [3] [2] [1]
(Refer to P.142)
2. Remove the screws [1], 1 each.
3. Loosen the 2 screws [2].
4. Turn the belt positioning shaft [3] counterclock-
wise, and remove the shaft.
a03uf2c041ca
5. Remove the supporting shaft [3] from the charging

[3] [1]
suction assy [2] installed inside of the toner supply
unit [1].
Note
• Supporting shaft is an assist device to let the
transfer belt unit stand by itself and the sup-
porting shaft should be made ready before-
hand when removing the transfer belt unit.
[2]
8050ma3044
147
6. Lift up the handles [1] and remove the transfer belt

/C6501P/C65hc/C5501
[1] [2]
unit [2].
bizhub PRO C6501
Note
• Do not damage or touch the transfer belt [3]
with bare hands.
• When removing the transfer belt unit, be sure
to hold the handles on both ends.
[3] a03uf2c042ca
7. Attach the supporting shaft [2] to the transfer belt

unit [1] and let the unit stand by itself.
steps in reverse.
Note
• Do not rotate the transfer belt when the trans-
fer belt unit is standing alone.
[2] [1] 8050ma3046
148
/C6501P/C65hc/C5501
Note
[1]
bizhub PRO C6501

• Before installing the transfer belt unit [1],
rotate the cam [3] clockwise as far as it will
go.
• When installing the transfer belt unit, align the
[2] guide pins [2] on the front and the rear of the
[2] unit with 2 notches of the transfer block/Fr [4]
and 2 notches of the transfer block/Rr [5].
Be careful not to hit the drum with the belt.
[3]
[5] [4] a03uf2c043ca
149
26.4.2 Replacing the belt cleaning blade

/C6501P/C65hc/C5501

bizhub PRO C6501
• Belt Cleaning blade : Every 200,000 prints *1

*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
[4] [3]
1. Remove the belt cleaner unit.
(Refer to P.157)
2. Remove the 2 springs [1].
3. Remove the C-clip [2], pull out the blade support
shaft [3], and remove the belt Cleaning blade [4].
Note
• When installing the belt cleaner unit, apply
setting powder to entire surface of the trans-
fer belt to which the belt cleaner unit is
attached. After applying setting powder,
[3]
[1] rotate the transfer belt tobrush all setting
powder off.
• Take extra care not to touch or damage the
blade of the belt Cleaning blade [4].
[2]
8050ma3049
steps in reverse.
1 150
26.4.3 Replacing 1st transfer roller /Y, /M, /C, /K and Transfer roller bearing
/C6501P/C65hc/C5501
bizhub PRO C6501

• Transfer roller /Y, /M, /C : Every 200,000 prints *1
• Transfer roller /K : Every 200,000 prints *1
• Transfer roller bearing : Every 3,000,000 prints
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
1. Remove the transfer belt.
[5]
(Refer to P.153)
2. Place the transfer belt unit as shown in the figure
on the left.
3. Remove the C-clip [1].
4. Remove the bearing [2] and slide the stopper/4 [3]
to release the tip of the transfer release arm [4].
5. Slide and remove the 1st transfer roller/K [6].
6. Remove the 1st transfer roller/Y, /M, /C [5],1 each.
Note
[4] [3] [3] [4] • Do not touch the roller surface of the 1st
[6] transfer roller. When handling the 1st transfer
roller, always grasp it by its metal shaft.
• Install the 1st transfer roller so that the shaft
surface with grooves faces toward you.
• When installing the 1st transfer roller, confirm
that the cables are securely fastened and the
plastic films on the cables are not twisted. If
the cables are not fastened, correct by press-
[1] [2] a0u0t3c003ca ing the cables against the metal frame side. If
the plastic films are twisted, move the films to
the center of the cables.
151 1
7. Remove 2 claws [7] each, and remove 8 transfer

/C6501P/C65hc/C5501
[8]
roller bearings [8].
bizhub PRO C6501
Note
• Be careful not to lose the springs [9] when
removing the transfer roller bearings [8].
• Be careful not to breake the claw [7].
[7] 8. Reinstall the above parts following the removal

steps in reverse.
[9] [8]
[8]
a0u0t3c004ca
152
26.4.4 Replacing the transfer belt
/C6501P/C65hc/C5501
bizhub PRO C6501

• Transfer belt : Every 200,000 prints *1
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
[1] [1]
(Refer to P.147)
(Refer to P.157)
3. Remove the separation claw assy.
(Refer to P.156)
8050ma3053
153 1
5. Have the transfer belt unit [1] stand with its front
/C6501P/C65hc/C5501
[2] [3] [6]

side facing down.
bizhub PRO C6501
6. Remove the screw [2] and release the handle [3].

7. Remove the 2 screws [4] and remove the shaft
[7] stopper [5].
8. Remove the screw [6] and remove the tension
plate /Rr [7].
[4] [5] 9. Remove the 2 screws [8] and remove the high
voltage power supply collar/Rr [9].
10. Remove the C-clip [10] and remove the bearing
[11].
11. Remove the transfer belt [12] by pulling it straight
up.
steps in reverse.
[1]
[11] [8]
[10] [9] 8050ma3054
Note
• When installing the tension plate/Rr, be sure
to push the projection of the plate as far as it
will go as shown in the figure on the left. Do
not pinch the black sheet when tightening the
screw.
8050ma3152 • When installing the C-clip, lift up the shaft so
that the C-clip is securely fitted in the groove
of the shaft.
• Install the transfer belt with the UP SIDE mark
facing up.
• Hold the transfer belt by its both ends within
10 mm from the edge, and do not touch other
areas.
• Do not damage or touch the transfer belt with
bare hands.
• When installing the transfer belt cleaner unit,
apply setting powder to the entire surface of
the transfer belt to which the belt cleaner unit
is attached. After applying setting powder,
rotate the transfer belt to brush all setting
powder off.
154
26.4.5 Replacing the 2nd transfer roller /Up
/C6501P/C65hc/C5501
bizhub PRO C6501

• 2nd transfer roller /Up : Every 200,000 prints *1
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
1. Remove the transfer belt.
[2]
(Refer to P.153)
2. Lift the 2nd transfer roller /Up [1] upward tempo-
rarily, and remove the roller obliquely downward.
Note
• the 2nd transfer roller /Up has been released
since the high voltage power supply collar /Rr
is removed.
[1] • Do not touch the roller surface of the 2nd
transfer roller /Up. When handling the 2nd
transfer roller /Up, hold it by its metal shaft.
• Install the transfer roller/Lw with the concave
1
shaft end facing down.
3. Remove the 2 bearings [2] from the 2nd transfer

2
roller /Up [1].
steps in reverse.
[2] [1] 8050ma3056
155 1
26.4.6 Replacing the separation claw assy

/C6501P/C65hc/C5501

bizhub PRO C6501
• Separation claw assy : Every 600,000 prints
B. Procedure
[3]
(Refer to P.147)
2. Remove the screw [1] and remove the separation
claw unit [2].
[4] Note
• Do not damage or touch the transfer belt [3]
with bare hands.
• Before installing the separation claw unit,
apply setting powder to half the area [4] of the
transfer belt [3]. After applying setting pow-
[2] der, rotate thetransfer belt to brush all setting
powder off.
[2]
[1]
8050ma3050
3. Remove the three screws [1], and remove the

three separation claw assys [2].
steps in reverse.
[1]
[2]
8050ma3051
156
26.4.7 Replacing the belt cleaner unit
/C6501P/C65hc/C5501
bizhub PRO C6501

• Belt cleaner unit : Every 600,000 prints (actual replacement cycle: 130km of belt Cleaning blade drive dis-
tance)
B. Procedure
[2] [2]
(Refer to P.147)
2. Holding the belt cleaner unit [1], remove the 2
screws [2], and remove the belt cleaner unit.
Note
• Handle the belt cleaner unit gently when
removing the unit, or the toner accumulated
in between the toner guide roller and the belt
[1]
cleaning belt may spill. It is normal if the toner
is accumulated because the toner is used to
grind the belt surface. If the toner is spilled
over the separation tab unit, remove and
clean the unit.
• The belt cleaner unit consists of the belt
[3] cleaning roller unit and the following compo-
nents: Belt cleaning blade: 1
Spring: 2
8050ma3048 C-clip: 2
Blade support shaft: 1
Toner collection sheet /1: 1
Toner collection sheet /2: 1
Screw: 3
• Before installing the belt cleaner unit, apply
setting powder to the part [3] on the transfer
belt. After applying setting powder, rotate the
transfer belt tobrush all setting powder off.
• When installing the belt cleaner unit, insert
the tow guides at the both bottom ends of the
belt cleaner unit over the pins of the transfer
belt unit and tighten the screws.

steps in reverse.
157
26.4.8 Replacing the toner collection sheet /1

/C6501P/C65hc/C5501

bizhub PRO C6501
• Toner collection Sheet /1 : Every 200,000 prints *1

*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
(Refer to P.157)
2. Remove the three screws [1], toner collection
sheet /2 [2], and the toner collection sheet /1 [3].
Note
• Do not bend or damage the PET sheet of the
toner collection sheet /1.

steps in reverse.
[1]
[2] [3] 8050ma3159
1 158
26.4.9 Replacing the 2nd transfer roller /Lw and the transfer earth plate assy
/C6501P/C65hc/C5501
bizhub PRO C6501

• 2nd transfer roller /Lw : Every 200,000 prints *1
• 2nd transfer earth plate assy : Every 1,000,000 prints *1
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
1. Remove the separation discharging assy [1].
(Refer to P.161)
[4] 2. Remove the screw [2] and remove the 2nd trans-
fer earth plate assy [3].
3. Remove the 2 C-clips [5].
4. Slide the 2 bearings [6] outward, and remove the
2nd transfer roller /Lw [4].
5. Remove the 2 bearings [6] from the 2nd transfer
roller /Lw[4].
[1] [6]
Note
• Do not touch the roller surface of the 2nd
transfer roller /Lw [4] with bare hands. Always
hold the 2nd transfer roller/Lw by its shaft.
• When installing the 2nd transfer roller /Lw,
make sure that the shaft surface with a con-
cave portion is facing the rear side of the
[6] [5] device. (The concave portion should not face
[2] [3] [5] 8050ma3089 to the 2nd transfer earth plate assy.)

steps in reverse.
159 1
26.4.10 Replacing the belt separation claw solenoid (SD1)

/C6501P/C65hc/C5501

bizhub PRO C6501
• Belt separation claw solenoid (SD1) : Every 1,400,000 prints *1

: Every 1,350,000 prints *2
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
(Refer to P.147)
Disconnect the connector [1].
2. Remove the screw [2] and release the cable [4]
from the cable clamp [3].
3. Remove the 2 screws [5] and remove the belt
separation claw solenoid (SD1) [6].
Note
• After installing the solenoid lever, check if the
shaft of SD1 slides smoothly.
[6]
steps in reverse.
[5]
[2] [3] [4] [1] 8050ma3069
1 160
26.4.11 Replacing the separation discharging assy
/C6501P/C65hc/C5501
bizhub PRO C6501

• Separation discharging assy : Every 200,000 prints *1
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
(Refer to P.140)
2. Pull out the ADU.
(Refer to P.184)
3. Remove the fusing unit.
(Refer to P.194)
4. Remove the screw [1], and remove the terminal
cover [2].
Note
• When installing the terminal cover, match the
[2] [1] projection [3] with the positioning hole [4].
[3][4]
a03uf2c045ca
5. Remove the 2 separation installation screws [1].

[2] [3]
6. Lift up the separation discharging assy [2], remove
the faston [3], and remove the separation dis-
charging assy [2].
Note
• When removing the faston from the separa-
tion discharging assy, pull out the cover sec-
tion of the faston straight.
• When installing the separation discharging
assy, tighten the separation installation screw
on the front side first positioning the assy
properly. Then tighten the other separation
[1] 8050ma3088
installation screw.
steps in reverse.
161 1
26.5 Developing section

/C6501P/C65hc/C5501
bizhub PRO C6501
26.5.1 Replacing the developer /Y, /M, /C, /K

• Developer /Y, /M, /C, /K : Every 200,000 prints (actual replacement cycle: 130km of the developing
roller drive distance) *1
: Every 150,000 prints (actual replacement cycle: 130km of the developing
roller drive distance) *2
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
1. Remove the developing unit.
[4] [2] [1] [3] (Refer to P.164)
2. Remove the fixing screw [2] on the plate [1], turn
the plate 90 degrees counterclockwise, and rotate
the upper side of the developing unit to eject the
developer. After that, repeat steps 3 and 4 to eject
all the developer.
Note
• Do not remove the cover [4] of the developing
unit or the developer charging funnel [3] when
8050ma3149
ejecting developer.
• After ejecting developer, be sure to put the
platel [1] back to its original position, and
secure the plate with a screw.
3. Attach the rotating jig [1] installed inside the toner

[1] [2]
supply unit to the coupling [2] on the agitator
screw side, and turn the jig in the direction of the
arrow.
Note
• Do not turn the coupling against the direction
of the arrow.
8050ma3150
1 162
4. Attach the rotating jig to the coupling [1] on the
/C6501P/C65hc/C5501
[1]
developing roller side, and turn the jig in the direc-
bizhub PRO C6501

tion of the arrow.
Note
• Do not turn the coupling against the direction
of the arrow.
• After replacing the developing unit, be sure to
perform the “Toner Density Sensor Initial
Auto. adjustment.” in service mode.
(Refer to Field Service P.210)
8050ma3151
163
26.5.2 Replacing the developing unit /C, /M, /Y, /K

/C6501P/C65hc/C5501
bizhub PRO C6501

• Developing unit /C : Every 600,000 prints
• Developing unit /M : Every 600,000 prints
• Developing unit /Y : Every 600,000 prints
• Developing unit /K : Every 600,000 prints
B. Procedure
Note
• Do not bend the teflon coated sheet attached to the developing roller side of the upper cover of
the developing unit.
• Always use a hydro wipe authorized as a CE tool to clean the developing unit. Use of paper or
cloth other than the specified cloth (hydro wipe) will contaminate the developing control plate
inside the developing unit with paper dust or lint and may cause white bands on images.
• The product installs 4 developing units 1 each for yellow, magenta, cyan, and black, and they are
common parts. However, do not use a once-used developing unit for another color, or the old
remaining toner and the new toner will mix up and the print quality will degrade.

[2]
[3] (Refer to P.140)
2. Remove the 2 screws [1] and remove the 4 devel-
oping support plate [3] installed inside the toner
supply section [2].
Note
• When having the developing unit stand alone,
insert a developing support plate into the
[3] body of the developing unit and use the plate
[1] as a base so as to protect the bristle section
of the toner from contacting other parts.

(Refer to P.142)
8050ma3062
164
4. Remove the screws [1], three each, and remove
/C6501P/C65hc/C5501
the upper side of the developing holding frames
bizhub PRO C6501

[2] in the direction of the arrow.
[1] [2] [1] [2] a03uf2c050ca
5. Disconnect the 4 connectors [1] and remove the

three developing units /C, /M, /Y [2] and the
developing unit /K [3].
steps in reverse.
Note
• Before installing developing units without
black, attach labels included in each of the 4
unit packages.
[1] [3] [2]

8050ma3064
165
26.6 Toner collection box assy

/C6501P/C65hc/C5501
bizhub PRO C6501
26.6.1 Replacing the toner collection box assy

• Toner collection box assy : Every 50,000 prints
B. Procedure
1. Open the toner collection door [1], and pull out the
[1]
toner collection box assy [2].
[2] a03uf2c051ca
2. Peel off the label [2] on the toner collection box

assy [1] and close the opening [3] of the toner col-
lection box assy [1] with the label.
steps in reverse.
[3]
[2]
[2]
[1] 8050ma3008
166
26.7 Paper feeding section
/C6501P/C65hc/C5501
bizhub PRO C6501
26.7.1 Replacing the pick-up roller/paper feed roller rubber
• Pick-up roller : Every 2,400,000 prints (actual replacement cycle: every 800,000 feed)
(PRO C6501/C5501)
• Paper feed roller rubber : Every 400,000 prints (actual replacement cycle: every 125,000 feed) *1
: Every 300,000 prints (actual replacement cycle: every 125,000 feed) *2
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
Note
• The tray /1 was used to illustrate the replacement procedure below. The procedure is the same for
the tray /2 and tray/3.
1. Pull out the paper feed tray /1 [1].

2. Remove the 4 screws [2] and remove the paper
feed unit cover [3].
[2] [3] [2] [3] [3]
[1] a03uf2c052ca
167 1
3. Disconnect the connector [1].

/C6501P/C65hc/C5501
[5] [3] [2] [1]

4. Remove the screw [2] and loosen the fixing shaft
bizhub PRO C6501
screw [3].
5. Slide the paper feed unit [4] in the direction of the
arrow, and lift the unit to remove it disconnecting
the connector [5].
[4]
a03uf2c053ca
6. Remove the 2 C-clips [1], slide the 2 bearings [2]

[1]
outward, and remove the paper feed roller assy
[3].
Note
• Before installing the paper feed roller assy,
make sure the rollers are free of grease or
dust.
[2] [3] a03uf2c054ca
168
7. Remove the bearing [1].
/C6501P/C65hc/C5501
[3] [2] [6] [5] [1]
8. Remove the C-clip [2] and remove the pick-up
bizhub PRO C6501

roller [3].
Note
• When installing the pick-up roller, be sure that
the arrow mark [4] is facing toward the C-clip
[2].
9. Remove the C-clip [5] and remove the paper feed

roller [6].
[4] [7] Note

• When installing the paper feed roller, be sure
that the arrow mark [7] is facing toward the
C-clip [5].
10. Remove the paper feed roller rubber [8] from the
[9] [8] paper feed roller.
a03uf2c055ca
Note
• When installing the paper feed roller rubber,
be sure that the painted mark [9] is facing
toward the arrow mark [7].

steps in reverse.
169
26.7.2 Replacing the separation roller rubber

/C6501P/C65hc/C5501

bizhub PRO C6501
• Separation roller rubber : Every 400,000 prints (actual replacement cycle: every 125,000 feed) *1
: Every 300,000 prints (actual replacement cycle: every 125,000 feed )*2
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
Note
the tray /2 and tray /3.
1. Remove the paper feed roller assy

[2] [1]
(Refer to P.167)
2. Remove the C-clip [1] and remove the separation
roller [2].
Note
• Before installing the separation roller, make
sure the roller is free of grease or dust.
3. Remove the separation roller rubber [3] from the

separation roller [2].
[3] [4] [2] Note

• When installing the separation roller rubber,
toward the c-clip [1].

steps in reverse.
a03uf2c056ca
1 170
26.7.3 Replacing the paper feed clutch/pre-registration clutch
/C6501P/C65hc/C5501
bizhub PRO C6501

• Paper feed clutch /1 - /3 (MC7, MC9, MC11) : Every 4,000,000 prints
(actual replacement cycle: every 2,000,000 feed)
• Pre-registration clutch /1 - /3 (MC8, MC10, MC12) : Every 4,000,000 prints
(actual replacement cycle: every 2,000,000 feed)
B. Procedure
Note
the tray /2 and tray /3.
1. Pull out the paper feed tray /1.

[9] [10] [4] [3] [1]
2. Remove the paper feed unit.
(Refer to P.167)
clutch /1 (MC7) [3].
Note
• When installing MC7, match the stopper [4]
with the guide [5].

[8] [7] [6] [5] [2] a03uf2c057ca
6. Remove the C-clip [7] and remove the pre-regis-
tration clutch (MC8) [8].
Note
with the guide [10].

steps in reverse.
171
26.8 Bypass feed tray section

/C6501P/C65hc/C5501
bizhub PRO C6501
26.8.1 Replacing the pick-up roller/paper feed roller rubber

• Paper feed roller rubber : Every 1,400,000 prints (actual replacement cycle: every 125,000 feed) *1
: Every 1,350,000 prints (actual replacement cycle: every 125,000 feed) *2
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
[1]
(Refer to P.184)
feed solenoid cover [2].
[2] [1] a03uf2c058ca

[2] [1]
4. Remove the bearing [2] and remove the paper
feed roller unit [3].
[3] 8050ma3076
1 172
/C6501P/C65hc/C5501
Note
[4] [3] [2]
bizhub PRO C6501

• When installing the paper feed roller unit [1],
be sure to fit the actuator [2] in the detection
section of the paper empty sensor/BP (PS47)
[3].
• When installing the paper feed roller unit [1],
bring the tip of the paper feed lift-up lever [4]
into contact with the undersurface of the
plate of the paper feed roller unit [1].
[1] 8050ma3079
5. Remove the C-clip [1], pull out the shaft [2], and
[2] [3]
remove the pick-up roller assy [3].
6. Remove the pick-up roller [4] from the pick-up
roller assy [3].
[4] [1] 8050ma3077
7. Remove the paper feed roller assy [2] from the

[4]
shaft [1].
8. Remove the paper feed roller rubber [3] from the
paper feed roller assy [2].
Note
• When installing the paper feed roller rubber,
toward the gear [5].

steps in reverse.
[2] [3] [5] [1] a03uf2c059ca
173
26.8.2 Replacing the separation roller rubber

/C6501P/C65hc/C5501

bizhub PRO C6501
• Separation roller rubber : Every 400,000 prints (actual replacement cycle: every 125,000 feed) *1
: Every 300,000 prints (actual replacement cycle: every 125,000 feed) *2
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
1. Remove the pick-up roller and the paper feed
[6]
roller assy.
(Refer to P.172)
remove the separation roller assy [4].
[5] separation roller assy.
Note
• When installing the separation roller rubber,
toward the gear [7].

steps in reverse.
[3] [2] [4] [1] [7] a03uf2c060ca
1 174
26.8.3 Replacing the paper feed clutch/BP (MC6)
/C6501P/C65hc/C5501
bizhub PRO C6501

• Paper feed clutch/BP (MC6) : Every 4,000,000 prints (actual replacement cycle: every 2,000,000 feed)
B. Procedure
[3]
(Refer to P.140)
(Refer to P.184)
(Refer to P.194)
4. Remove the 4 screws [1]. (1 screw is located at
[2] [1] the bottom of the ADU cover /Rt [2].)
5. Pull out the ADU cover /Rt [2] halfway, disconnect
the 2 connectors [3], and remove the ADU cover /
Rt [2].
7. Remove the screw [5] and remove the ADU
release lever [6].
8. Remove the 2 screws [7] and remove the ADU
cover /Lt [8].
[1] [2]
[8] [4] [5]
[7] [6] a03uf2c061ca
175

/C6501P/C65hc/C5501
[3] [2]
bizhub PRO C6501
clutch/BP (MC6) [3].
[1] 8050ma3082
Note
[3] [1]
• When installing MC6 [1], match the stopper
[2] with the guide [3].

steps in reverse.
[2] a03uf2c062ca
176
26.9 Vertical conveyance section
/C6501P/C65hc/C5501
bizhub PRO C6501
26.9.1 Replacing the intermediate conveyance clutch /1 (MC13)
• Intermediate conveyance clutch /1 (MC13) : Every 2,000,000 prints *1
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
1. Remove the right cover /Lw1 and /Lw2.
[5] [4]
(Refer to P.234)
2. Pull out the paper feed tray /1 [1], /2 [2], and /3
[3].
3. Remove the three screws [4] and remove the right
cover /Lw3 [5].
Note
• Remove the right cover/Up1 before installing
the LU-202.
(Refer to P.234)
[1] [2] [3] a03uf2c063ca
177 1
4. Push up the 2 tabs [2] and separate the vertical

/C6501P/C65hc/C5501
conveyance section [3] from the bypass up/down

bizhub PRO C6501
cover [2].
[1] [2] [2] [1]
[2] [3] a03uf2c064ca
5. Remove the 7 screws [1].

[1]
6. Pull out the vertical conveyance section [2], dis-
connect the connector [3], and remove the verti-
cal conveyance section [2].
Note
• Always close the vertical conveyance door
and tighten the screws when installing the
vertical conveyance section.
[10] [2] [3] a03uf2c065ca

[7] [6] [4] [3] [2]
8. Remove the E-ring [2], spacer [3], and the gear
[4].
9. Remove the C-clip [5] and remove the intermedi-
ate conveyance clutch /1 (MC13) [6].
Note
with the guide [8].

steps in reverse.
[8] [5] [1]
a03uf2c066ca
178
26.10 Registration section
/C6501P/C65hc/C5501
bizhub PRO C6501
26.10.1 Replacing the cleaning stay assy
• Cleaning stay assy : Every 600,000 prints
B. Procedure
[1] [2]
(Refer to P.140)
(Refer to P.184)
3. Remove the three screws [1] and remove the
cover [2].
4. Remove the 2 screws [3] and remove the cleaning
stay assy [4].
steps in reverse.
[3] [4] [3] a03uf2c067ca
179
26.10.2 Replacing the registration roller assy

/C6501P/C65hc/C5501

bizhub PRO C6501
• Registration roller assy : Every 1,400,000 prints *1

*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
1. Remove the cleaning stay assy.
(Refer to P.179)
[5]
2. Remove the ADU cover /Rt, ADU release lever,
and ADU cover /Lt.
[7] [6] 3. Remove the terminal cover. (Refer to P.161)
4. Remove the 2 screws [1] and remove the gear
cover [2].
5. Disconnect the connector [3] and remove the wire
from the 2 clamps.
6. Remove the C-clips [4] and remove the bearings
[5] at the both and rear sides on the registration
assy.
7. Remove the 2 screws [6] and remove the registra-
tion unit [7].
Note
• Before removing the registration unit [7],
[6] [1] [2] [8] open the conveyance guide plate/Up [8],
move the registration unit toward the rear
side of the ADU, and pull the shaft on the front
side out of the ADU panel.
• When installing the registration unit, be care-
ful not to scratch the surface of the guide
plate where contacts with paper.
[3] [5] [4]

8050ma3208
1 180
8. Remove the E-ring [1], registration gear [2], and
/C6501P/C65hc/C5501
[5]
the pin [3].
bizhub PRO C6501

Note
• When installing the registration gear [2], make
sure you install the pin [3].

10. Remove the 2 E-rings [5] and the 2 bearings [6].
[6] [4]
[1] [3] [2]
[5] [4] [6] 8050ma3209
181
11. Disengage the hooked end [2] of the spring [1],

/C6501P/C65hc/C5501
and remove the registration roller assy [3].

bizhub PRO C6501
Note
• Make sure to attach the spring [1] as shown
in the figure on the left.
[3]
[1] [2] 8050ma3210
182
12. Remove the E-ring [1], and remove the spacer/1
/C6501P/C65hc/C5501
[3], /2 [4], registration regulating plate [5] (together
bizhub PRO C6501

[2]
with the spring [6]), torque limiter [7], and pin/A [8]
from the registration roller assy [2].
Note
• When installing the registration regulating
plate, insert the 2 indentations [9] over the 2
projections [10] on the torque limiter.
[1]
steps in reverse.
[10] [5] [4]

[3]
[7]
[6]
[9]
[8] 8050ma3211
183
26.11 ADU section

/C6501P/C65hc/C5501
bizhub PRO C6501
26.11.1 Replacing the intermediate conveyance clutch/2 (MC4) and /3 (MC5)

• Intermediate conveyance clutch/2 (MC4) : Every 2,000,000 prints *1
• Intermediate conveyance clutch/3 (MC5) : Every 2,000,000 prints *1
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
(Refer to P.140)
2. While releasing the lock [2] of the ADU release
lever [1], turn the lever counterclockwise, and pull
out the ADU [3].
Note
• In order to prevent rollover accidents, safety
feature of the product does not allow the pro-
cess unit and the ADU to be pulled out at the
same time.
• Be sure to put the process unit in the main
[3]
body before pulling out the ADU.
• If you cannot pull out the ADU, check the lock
lever/1 and /2 for deformation and replace
them as necessary.
(Refer to P.267)
[1] [2]
a03uf2c068ca
1 184
/C6501P/C65hc/C5501
3. Remove the ADU cover/Rt.
[10] [9] [7] [5] [4]
bizhub PRO C6501

(Refer to P.175)
ate conveyance clutch/2 (MC4) [3].
Note
with the guide [5].

[8] [6] [1] [3] [2] ate conveyance clutch/3 (MC5) [8].
a03uf2c069ca
Note
with the guide [10].

steps in reverse.
185
26.11.2 Replacing the ADU conveyance clutch/1 (MC1), /2 (MC2), /3 (MC3), and the ADU pre-regis-
/C6501P/C65hc/C5501
tration clutch (MC18)

bizhub PRO C6501
A. Spot replacement parts/cycle

• ADU conveyance clutch/1 (MC1) : 3,600,000 prints
• ADU pre-registration clutch (MC18) : 3,600,000 prints
B. Procedure
[4] [3] [2] [1] [4] [3] [2] [1]
(Refer to P.140)
(Refer to P.184)
(Refer to P.194)
4. Remove the ADU cover/Rt.
(Refer to P.175)
5. Remove the ADU cover/Lt.
(Refer to P.175)
7. Remove the C-clip [2], and remove the MC1 and
the MC2 [3].
Note
• When installing the MC1 and the MC2, align
a03uf2c138ca the stopper [4] with the guide.

steps in reverse.
186
/C6501P/C65hc/C5501
[1]
ADU lock solenoid unit [2].
bizhub PRO C6501

11. Remove the 2 C-clips [4], the ADU conveyance
clutch/3 (MC3) [5], and the ADU pre-registration
clutch (MC18) [7].
[2]
Note
• When installing the MC3 and the MC18, align
the stopper [6] with the guide [8].

steps in reverse.
[5] [7] [8]
[6] [4]
[3]
a03uf2c139ca
187
26.12 Reverse/paper exit section

/C6501P/C65hc/C5501
bizhub PRO C6501
26.12.1 Replacing Reverse decurler roller

• Reverse decurler roller : Every 400,000 prints *1
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
(Refer to P.184)
(Refer to P.194)
4. Release the hook [3] of the spring from the screw
[2], and remove the 2 screws [2], [4].
5. Remove the paper eject guide plate /4 assy [5].
[5]
[1]
[2] [3] [4]

8050ma3096
1 188
6. Remove the screw [1], and remove the knob [2].
/C6501P/C65hc/C5501
[11] [10] [9] [13] [12] 7. Remove the paper exit mounting plate/Fr [3] and
bizhub PRO C6501

the spring [4].
8. Remove the 2 screws [5] and remove the bearing
[6].
9. Remove the E-ring [7], spacer [8], bearing [9], and
paper exit mounting plate/Rr [10].
10. Remove the spring [11] and the spacer [12].
11. Remove the bearing [13] and the reverse decurler
[8] [7] roller [14].
steps in reverse.
[6] [14]
[5]
[4] [3] [2] [1]

8050ma3097
189
26.12.2 Replacing the paper exit decurler roller

/C6501P/C65hc/C5501

bizhub PRO C6501
• paper exit decurler roller : Every 1,000,000 prints *1

*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
1. Remove the left cover.
[2]
(Refer to P.233)
(Refer to P.184)
3. Disconnect the 2 connectors [1].
[1] a03uf2c070ca
1 190
5. Lower the front upper portion [2] of the paper exit
/C6501P/C65hc/C5501
unit [1], and remove the paper exit unit taking care
bizhub PRO C6501

not to hit the frame [4] with the pin [3].
Note
• When installing the paper exit unit, insert the
tab [5] into the slot on the frame first.
[5] [2] [4]
[1]
[3]
a03uf2c071ca
6. Remove the 4 screws [1] and remove the

strengthening plate/Lt [2].
[1] [2] [1]
a03uf2c072ca
191
7. Remove the E-ring [1] and the gear [2].

/C6501P/C65hc/C5501
[8] [3]
bizhub PRO C6501
Note
• When installing the gear [2], be sure that the
arrow mark [3] is facing toward the E-ring [1].

Note
• When installing the gear [7], be sure that the
[7] [4] [5] [6] [2] [1]
a03uf2c073ca
192
10. Remove the E-ring [1] and the bearing [2].
/C6501P/C65hc/C5501
[5]
bizhub PRO C6501

12. Remove the paper exit decurler roller [5].
[1] [2] [3] [4]

a03uf2c074ca
13. Remove the 2 E-rings [1], and remove the 2 bear-

ings [2].
steps in reverse.
[1] [2] [2] [1]
a03uf2c075ca
193
26.13 Fusing section

/C6501P/C65hc/C5501
bizhub PRO C6501
26.13.1 Removing/installing the fusing unit
Caution:
• Immediately after turning off the main power switch (SW1) or the power switch (SW2), the fusing
section is very hot and you may get burnt. Be sure to start operations when the temperature cools
down sufficiently.
A. Procedure
1. Open the front door and the toner supply section.
[1] [2]
(Refer to P.140)
(Refer to P.184)
3. Remove the screw [1], and remove the connector
cover [2].
[3]
a03uf2c006ca
194
/C6501P/C65hc/C5501
[1] [2]
6. Remove the 2 screws [3] and remove the fusing
bizhub PRO C6501

cover /Fr [4].
[3] [4]
a03uf2c007ca

[2] [4]
8. Open the reverse/exit section [2].
9. Remove the screw [3] and remove the fusing unit
[4].
Note
• When installing/removing the fusing unit, be
sure to hold both ends of the unit and slide it
toward you in the direction of the arrow
before lifting up the unit.

steps in reverse.
[3] [1]
a03uf2c008ca
195
26.13.2 Replacing the fusing drive gear /B and the fusing duct 2 assy
/C6501P/C65hc/C5501

bizhub PRO C6501
• Fusing drive gear /B : Every 400,000 prints *1

• Fusing duct 2 assy : Every 600,000 prints
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
cover/Rr [2].
[1]
a03uf2c009ca
1 196
/C6501P/C65hc/C5501
4. Remove the screw [2] and release the fusing duct
bizhub PRO C6501

2 assy [3].
5. Remove the screw [4] and remove the sensor
positioning plate assy [5].
Note
• Make sure that the fusing duct /2 assy is
released before removing the fusing drive
assy. If you attept to remove the fusing drive
assy with the fusing duct /2 assy secured,
fusing heater lamp /4 (L5) may be broken.
[7] [3] [2] [1] [6]
drive assy [7].
[4] [5] [6]

a03uf2c010ca
7. Remove the fusing drive gear /B [1].

[1]
Note
• When installing new fusing drive gear /B, be
sure to apply multemp FF-RM to its gear sec-
tion.
• When installing the fusing drive gear /B,
attach it so that the end surface with three
indentations [2] faces toward you.
[2]
a03uf2c011ca
197
/C6501P/C65hc/C5501 26. MAINTENANCE PROCEDURE Theory of Operation Ver.3.0 Jul. 2009
8. Pull out and remove the fusing duct/2 assy [1].

bizhub PRO C6501

steps in reverse.
[1]
a03uf2c046ca
198
26.13.3 Replacing the fusing drive gear /M
/C6501P/C65hc/C5501
bizhub PRO C6501

• Fusing drive gear /M : Every 1,000,000 prints *1
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
[3] [2] [1] [4]
(Refer to P.194)
2. Remove the fusing drive assy.
(Refer to P.196)
3. Remove the E-ring [1], spacer [2], and the fusing
drive gear/M [3].
Note
• When installing the fusing drive gear /M,
attach it so that the arrow mark [4] indicated
as shown in the figure.
• Before installing the fusing drive gear /M, be
sure to apply multemp FF-RM to the gear.

steps in reverse.
a03uf2c012ca
199 1
26.13.4 Replacing the fusing lamp /Up

/C6501P/C65hc/C5501

bizhub PRO C6501
• Fusing lamp /Up : Every 2,400,000 prints
Note
• The fusing lamp /Up consists of the fusing heater lamp /1 (L2), /2 (L3), and /3 (L4).
B. Procedure
(Refer to P.194)
(Refer to P.196)
3. Remove the screw [1] and remove the fusing duct
/5 assy [2].
Note
• When installing the fusing duct/5 assy, make
sure that the tip of the duct is placed under
the retention plate /2, or the fusing heater
[1] [2] lamp may be broken.
a03uf2c013ca

[3] [2] [1] 5. Remove the three screws [2] and remove the fus-
ing power supply plate/Up assy [3].
Note
• The cables [4] should remain attached to the
fusing power supply plate/Up assy.
[4] [2] a03uf2c014ca
200
6. Remove the screw [1] and remove the heater sup-
/C6501P/C65hc/C5501
[5] [3] [4]
porting plate /Rr [2].
bizhub PRO C6501

Note
• When installing the heater supporting plate /
Rr, fit the projection [5] of the fusing lamp /Up
[4] in the slit [3].
[2] [1]
a03uf2c015ca

8. Remove the screw [2] and remove the heater sup-
porting plate /Fr [3].
[2] [3] [1]

a03uf2c016ca
9. Remove the fusing lamp/Up [1].
Note
• Make sure to remove the fusing lamp /Up in
the direction of the arrow.
• Do not touch the lamp of the fusing lamp /Up
with bare hands.
steps in reverse.
[1] a03uf2c017ca
201
26.13.5 Replacing the fusing roller /2, fusing bearing, and fusing drive gear /O
/C6501P/C65hc/C5501

bizhub PRO C6501
• Fusing roller /2 : Every 400,000 prints *1

• Fusing bearing : Every 400,000 prints *1
• Fusing drive gear /O : Every 400,000 prints *1
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
(Refer to P.194)
(Refer to P.196)
3. Remove the fusing lamp/Up.
(Refer to P.200)
cover/Up assy [2].
[1] [2] [1]

a03uf2c018ca
5. Locate the removed fusing drive assy [1].

[2] [4] 6. Remove the 2 screws [2] and remove the 2 fusing
jigs [3].
Note
• When installing the fusing jigs, be sure not to
obstruct the screw holes [4].
[3] [1] a03uf2c019ca
1 202
7. Insert the 2 fusing jigs [2], 1 each into the 2 slits
/C6501P/C65hc/C5501
[1], and loosen the pressure of the fusing belt [3].
bizhub PRO C6501

8. Remove the three screws [4] and remove the roller
mounting plate [5].
9. Remove the fusing bearing [6].
[1] [2] [2] [1]

[3]
[4]
[5] [6] a03uf2c020ca
203
10. Spread a hydro wipe [2] over the fusing belt [1].
/C6501P/C65hc/C5501
[2] [1]
bizhub PRO C6501
Note
• Do not touch the fusing belt with bare hands.
11. Insert a screwdriver [4] into the fusing roller /2

assy [3], and remove the fusing roller /2 assy while
holding the fusing belt.
Note
• When removing the fusing roller /2 assy,
through the hole [5] on the frame, be careful
[5] not to let the assy contact with the hole edge.
[3] [4] a03uf2c021ca
12. Remove the E-ring [1] and the fusing drive gear /O
[3]
[2].
Note
• When installing the fusing drive gear /O, be
sure that the arrow mark [3] is facing toward
the fusing bearing [4].
[1] [2] [4] • Before installing the fusing drive gear /O, be
sure to apply multemp FF-RM to the gear.
13. Remove the fusing bearing [4] from the fusing

roller /2 assy [5].
steps in reverse.
[5]
a03uf2c022ca
204
26.13.6 Replacing the fusing belt, fusing roller /1, insulating sleeve /Up, fusing bearing /Up, and belt
/C6501P/C65hc/C5501
regulation sleeve
bizhub PRO C6501

• Fusing belt : Every 400,000 prints *1
• Fusing roller/1 : Every 400,000 prints *1
• Insulating sleeve/Up : Every 400,000 prints *1
• Fusing bearing/Up : Every 400,000 prints *1
• Belt regulation sleeve : Every 400,000 prints *1
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
[2]
[3] [1]
(Refer to P.194)
(Refer to P.196)
3. Remove the fusing lamp /Up.
(Refer to P.200)
4. Remove the fusing roller /2 assy.
(Refer to P.202)
5. Remove the 2 O-rings [1].
6. Remove the 2 insulating sleeve /Up [2] and the 2
fusing bearing/Up [3].
Note
[4] [5]
• When installing the insulating sleeve /Up,
apply multemp FF-RM to the contact surface
with the fusing bearing /Up and the fusing
roller /1 assy [4].
7. Remove the fusing roller /1 assy [4] and the fusing

belt [5].
Note
• Do not touch the roller of the fusing roller /1
assy, nor the area other than the both ends of
[3] [2] [1]
the fusing belt.
a03uf2c023ca
205 1
8. Remove the fusing belt [2] from the fusing roller /1

/C6501P/C65hc/C5501
[3]
assy [1].
bizhub PRO C6501
Note
• Install the fusing belt with the lot number [3]
facing to the far side.
[1]
• Be careful not to let the carriers adhere to the
inside of the fusing belt or the surface of the
fusing roller /1 assy. If the developer adheres,
image failures may occur.
[2]
a03uf2c024ca
[1] [2] [2] [1] 9. Remove the 2 O-rings [1] and the 2 belt regulation
sleeve [2].
Note
• Do not touch the roller of the fusing roller /1
[3].
• When laying the fusing roller /1 on the ground,
spread a hydro wipe [4] under it in order not
to let the developer adhere to the roller.

steps in reverse.
[4] [3]
a03uf2c025ca
206
26.13.7 Replacing the fusing heater lamp /4 (L5)
/C6501P/C65hc/C5501
bizhub PRO C6501

• Fusing heater lamp /4 (L5) : Every 2,400,000 prints
B. Procedure
[2]
(Refer to P.194)
(Refer to P.196)
3. Remove the fusing lamp /Up.
(Refer to P.200)
4. Remove the fusing roller /2 assy.
(Refer to P.202)
5. Remove the fusing belt.
(Refer to P.205)
6. Remove the 2 screws [1], and remove the fusing
access guide plate [2].
[1] a03uf2c026ca
[2] 7. Remove the 2 screws [1] and open the fusing

main unit/Up assy [2].
[1] [1]
a03uf2c027ca
207

/C6501P/C65hc/C5501
9. Remove the screw [2], and remove the fusing

bizhub PRO C6501
duct/3 assy [3] and the fusing duct/4 assy [4].
[1] [2]
[4] [3]
a03uf2c028ca
10. Disconnect the connector [1] and remove the fus-

ing heater lamp/4 (L5) [2].
Note
• Do not touch the lamp of L5 with bare hands.
• When installing the L5, be sure to route the
white wire to the rear as shown in the figure.
• When installing the fusing ducts /3 assy and /
4 assy, make sure that the tip of the duct is
placed under the retention plate/1, or the fus-
ing heater lamp may be broken.
[2] [1] a03uf2c029ca
steps in reverse.
208
26.13.8 Replacing the fusing roller /Lw, fusing bearing /Lw, and insulating sleeve /Lw
/C6501P/C65hc/C5501
bizhub PRO C6501

• Fusing roller/Lw : Every 200,000 prints *1
• Fusing bearing/Lw : Every 600,000 prints *1
• Insulating sleeve/Lw : Every 600,000 prints *1
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
(Refer to P.194)
(Refer to P.196)
3. Remove the fusing lamp/Up.
(Refer to P.200)
4. Remove the fusing roller/2 assy.
(Refer to P.202)
5. Remove the fusing belt.
(Refer to P.205)
6. Remove the fusing heater lamp/4 (L5).
[1] [2]
a03uf2c030ca (Refer to P.207)
7. Remove the 2 screws [1] and remove the reten-
tion block/Rr assy [2].
209 1
8. Loosen the screw [1] once and tighten it again at

/C6501P/C65hc/C5501
[2] [1]
the position where the fusing separation plate
bizhub PRO C6501
assy [2] is opened so that the plate works as a

stopper.
9. Remove the C-ring [3], insulating sleeve/Lw [4],
and fusing bearing/Lw [5].
[2]
Note
• When installing the insulating sleeve, apply
multemp FF-RM to the contact surface with
the fusing roller/Lw.
10. Remove the screw [6] and remove the retention

plate/1 [7].
11. Remove the fusing roller/Lw assy [8].
[8]
[6] [7] [5] [4] [3]

a03uf2c031ca
12. Remove the C-ring [1] and the gear [2].
[1] [2]
a03uf2c032ca
210
13. Remove the C-ring [1], insulating sleeve/Lw [2],
/C6501P/C65hc/C5501
and fusing bearing/Lw [3].
bizhub PRO C6501

Note
• When installing the fusing roller/Lw [4] and
the insulating sleeve, apply multemp FF-RM
to each contact surface.

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

a03uf2c033ca
211
26.13.9 Replacing the sensor mounting plate A assy

/C6501P/C65hc/C5501

bizhub PRO C6501
• Sensor mounting plate A assy : Every 2,400,000 prints
B. Procedure
(Refer to P.194)
2. Remove the fusing access guide plate.
(Refer to P.207)
mounting plate A assy [3].
steps in reverse.
[1] [3] [2]

a03uf2c034ca
212
26.13.10Replacing the sensor stay B assy
/C6501P/C65hc/C5501
bizhub PRO C6501

• Sensor stay B assy : Every 2,400,000 prints
B. Procedure
(Refer to P.194)
2. Remove the fusing cover /Up assy.
(Refer to P.202)
3. Remove the fusing cover /Rr.
(Refer to P.196)
4. After removing the screw [1], loosen the screw [2]
[1] [2]
and remove the cover [3].
Note
• Make sure that the screw [2] comes free from
the cover [3] as the screw [2] cannot be taken
out.
[3]
a03uf2c035ca
213
5. Remove the 2 screws [1] and the 2 cable clamps

/C6501P/C65hc/C5501
[1] [2].
bizhub PRO C6501

7. Remove the screw [4] and remove the sensor stay
B assy [5].
steps in reverse.
[2] [3]
[4] [5]
a03uf2c036ca
214
26.13.11Replacing the fusing paper exit roller /Up
/C6501P/C65hc/C5501
bizhub PRO C6501

• Fusing paper exit roller /Up : Every 200,000 prints *1
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
(Refer to P.194)
2. Open the fusing paper exit plate assy [1], and
keep it opened with a screwdriver [2] as shown in
the figure.
[1]
[2]
a03uf2c047ca
215 1
3. Remove the 2 E-rings [1].

/C6501P/C65hc/C5501
[3] [2]
4. Slide the shaft [2] in the direction of the arrow [3],
bizhub PRO C6501
and remove the 2 fusing paper exit rollers /Up [4].
[4] [1] [1] [4]

a03uf2c048ca
[1] 5. Remove the 2 bearings [2] from each fusing paper

exit roller /Up [1].
steps in reverse.
[2] a03uf2c049ca
216
26.13.12Replacing the fusing regulation gear /A and the fusing limiter
/C6501P/C65hc/C5501
bizhub PRO C6501

• Fusing regulation gear /A : Every 600,000 prints
• Fusing limiter : Every 600,000 prints
B. Procedure
2. Place the fusing unit softly on the level surface
with the paper feed side down.
3. Remove the E-ring [1].
[1] 8050ma3144
4. Slide the shaft [1] to the rear side, and remove the
[2] [1]
gear while matching the flat-cut surface [2] of the
shaft with the notch of the panel.
8050ma3145
[1] 8050ma3146
217
6. Remove the fusing regulation gear/A [1] and the

/C6501P/C65hc/C5501
fusing limiter [2].

bizhub PRO C6501
Note
• Be careful not to lose the pin [4] inserted in
the shaft [3].

steps in reverse.
[4] [3] [2] [1] 8050ma3147
218
26.14 OT-502
/C6501P/C65hc/C5501
bizhub PRO C6501
26.14.1 Replacing the paper retainer roller
• Paper retainer roller : Every 200,000 prints *1
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
1. Remove OT-502.
[1]
(Refer to P.280)
2. Remove the 2 screws [1] and remove the 2 paper
retainer roller assys [2].
[2]
a03uf2c076ca
3. Remove the E-ring [1], pull out the shaft [2], and
remove the paper retainer roller [3].
4. Remove the other paper retainer roller in the same
manner as step 3.
steps in reverse.
[2] [3] [1]

a03uf2c077ca
219 1
26.14.2 Replacing the paper exit roller

/C6501P/C65hc/C5501

bizhub PRO C6501
• Paper exit roller : Every 200,000 prints *1

*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
1. Remove OT-502.
(Refer to P.280)
Note
• When installing the gear, be sure that the
[3] [2] [1]
a03uf2c123ca
1 220
3. Remove the 2 E-rings [1] and the bearing [2].
/C6501P/C65hc/C5501
bizhub PRO C6501

paper exit roller mounting plate/Rr [6] and the
paper exit roller [7].
steps in reverse.
[2] [1] [6] [5]
[7] [6]
[3] [4]
a03uf2c124ca
221
26.14.3 Replacing the paper exit driven roller/2

/C6501P/C65hc/C5501

bizhub PRO C6501
• Paper exit driven roller/2 : Every 200,000 prints *1

*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
1. Remove OT-502.
(Refer to P.280)
2. Remove the 4 screws [1] and the 4 roller holders
[2].
3. Remove the 2 paper exit driven roller assys [4]
from the 4 springs [3].
[4] [2] [3]
[3] [1]
a03uf2c078ca
4. Remove the E-ring [1] bearing [2], and paper exit

driven roller/1 [3].
[1] [2] [3]

a03uf2c079ca
1 222
/C6501P/C65hc/C5501
6. Remove the 2 E-rings [2] and remove the first
bizhub PRO C6501

paper exit driven roller/2 [3].
[1] [2] [3]

a03uf2c080ca
7. Remove the 2 E-rings [2] and remove the 2nd

paper exit driven roller/2 [2].
8. Remove the other 2 paper exit driven rollers in the
same manner as step 4 - 7.
steps in reverse.
[1] [2] a03uf2c081ca
223
27. OTHER PROCEDURES Theory of Operation Ver.3.0 Jul. 2009
27. OTHER PROCEDURES

/C6501P/C65hc/C5501
bizhub PRO C6501
27.1 Items not allowed to be disassembled and adjusted

27.1.1 Scanner section
A. CCD unit
(1) Parts not allowed to be removed
• The 8 screws for the CCD unit.
• The 4 attaching screws of the lens reference plate assy
[1]
[2]
[2]
[3] [4] a03uf2c125ca
[1] Screws not allowed to be removed [4] CCD unit

[2] Screws not allowed to be removed [5] Lens reference plate assy
(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 is a reference for the positioning the CCD unit. If the lens reference plate assy is
removed, the optical axis of the CCD unit may become misaligned. Therefore, the attaching screws of the lens
reference assy must not be removed.
224
Theory of Operation Ver.3.0 Jul. 2009 27. OTHER PROCEDURES
B. Mirror unit/Exposure unit
/C6501P/C65hc/C5501
bizhub PRO C6501

• Positions of the mirror unit and the exposure unit.
[1]
[2]
a03uf2c126ca
[1] Exposure unit [2] Mirror unit

The distance between the mirror unit and the exposure unit relates to the magnification of the sub-scan direction
for scanning the original. Therefore, the positions of the mirror unit and the exposure unit must not be arbitrarily
adjusted. Should the exposure unit and the scanner wire need to be removed, reinstallation of them must be
made using the optics unit adjustment jig.
225
27.1.2 Write section

/C6501P/C65hc/C5501
A. Write unit cover

bizhub PRO C6501

• The 7 screws for the write unit installation
[1]
[1]
[2] a03uf2c127ca
[1] Screws not allowed to be removed [2] Write unit cover

A laser beam path runs through inside of the write unit. Opening the cover allows dust and dirt to enter deep into
the write unit and they may block the laser beam path. Therefore, the attaching screws of the write unit cover
must not be removed.
226
B. Installing section of the write unit
/C6501P/C65hc/C5501
bizhub PRO C6501

• The 4 attaching screws of the write unit mounting plate
[5] [6]
[1]
[2]
[4] [3] a03uf2c128ca
[1] Screws not allowed to be removed [4] Write unit /C

[2] Write unit mounting plate [5] Write unit /M
[3] Write unit /K [6] Write unit /Y

The write unit mounting plates are a reference for positioning the write units accurately with respect to the
drums. The removal of the write unit mounting plate may cause an image distortion by lack of parallelism
between the drum and the write unit. Therefore, the attaching screws of the write unit mounting plate must not
be removed.
227
27.1.3 Photoconductor section

/C6501P/C65hc/C5501
A. Parts not allowed to be removed

bizhub PRO C6501
• An attaching screw of the drum cartridge end plate /Fr

• An attaching screw of the drum cartridge end plate /Fr
[4] [3]
[1] [2]
[5]
a03uf2c129ca
[1] Screws not allowed to be removed [4] End plate /Rr

[2] End plate /Fr [5] Drum cartridge
[3] Screws not allowed to be removed
B. Reason for prohibition

Clearance between the drum and the developing roller has been precisely adjusted by the position of the end
plate /Fr and Rr. Therefore, the attaching screws of the end plate /Fr and Rr must not be removed.
228
27.1.4 Charging section
/C6501P/C65hc/C5501
A. Positions from which removing the screws is prohibited
bizhub PRO C6501

• Charging corona uneven density adjustment mechanism screws, 2 each.
[1] [2]
a0u0t3c005ca
[1] Screws not allowed to be removed [2] Uneven density adjustment mechanism
B. Reason of prohibition
The parallelism of the charging corona and the drum is adjusted by the uneven density adjustment mechanism.
Therefore, do not remove the uneven density adjustment mechanism screws.
229
27.1.5 Intermediate transfer section

/C6501P/C65hc/C5501

bizhub PRO C6501
• An attaching screw of the tension adjusting plate
[2]
[1]
[3] a03uf2c130ca
[1] Screws not allowed to be removed [3] Tension adjusting plate

[2] Belt

The belt tension has been precisely adjusted with the tension adjusting plate. Therefore, the attaching screw of
the tension adjusting plate must not be removed.
230
27.1.6 Fusing unit section
/C6501P/C65hc/C5501
bizhub PRO C6501

• The 2 attaching screws of the pressure roller arm /Fr
• The 2 attaching screws of the pressure roller arm /Rr
[4] [3] [2] [1]
a03uf2c131ca
[1] Screws not allowed to be removed [3] Screws not allowed to be removed
[2] Pressure roller arm /Fr [4] Pressure roller arm /Rr

The fusing belt position has been precisely adjusted by the pressure roller arm /Fr and /Rr. Therefore, the attach-
ing screw of the pressure roller arm /Fr and /Rr must not be removed.
231
27.2 Disassembly/reassembly parts list

/C6501P/C65hc/C5501
bizhub PRO C6501
Note
• The table below lists parts other than the periodically replaced part. The disassembly/reassembly
procedures of them are described on the following pages, however, except for the covers, they do
not need to be removed under normal conditions.
• For information on how to replace the periodically replaced parts, refer to "26.1 Housing section"
to "26.14 OT-502".
No. Section Part name Reference page

1 Cover Rear cover P.233
2 Left cover P.233
3 Right cover /Up1 P.234
6 Right cover /Lw1 P.234
7 Right cover /Lw2 P.234
8 Original glass assy P.235
9 Upper cover /Fr P.236
10 Upper cover /Rt P.236
11 Upper cover /Lt P.236
12 Upper cover /Rr1 P.237
14 Main board unit P.238
15 Scanner section CCD unit P.239
16 Exposure unit P.241
17 Exposure lamp P.244
18 Scanner wire (for removing) P.245
19 Scanner wire (for installing) P.247
20 Write section Write unit P.250
21 Process section Process unit P.252
22 Image correction unit P.253
23 Toner collection sec- Belt collection pipe P.254
24 tion Vertical conveyance pipe P.254
25 Horizontal conveyance pipe P.254
26 ADU section ADU P.267
27 Lock lever /1 P.269
28 Lock lever /2 P.269
29 Paper feed section Paper feed tray P.271
30 Tray up/down wire P.272
31 Fusing unit Temperature sensor /1 (TEMS/1) P.275
32 Thermostat /1 (TS1) P.275
34 Temperature sensor /3 (TEMS/3) P.278
36 OT OT P.280
232
27.3 Disassembly/reassembly procedure
/C6501P/C65hc/C5501
bizhub PRO C6501
27.3.1 Removing/reinstalling rear cover
A. Procedure
1. Remove the filter cover.
[2] [3] [2]
(Refer to P.138)
3. Remove the 13 screws [2] and then remove the
rear cover [3].
steps in reverse.
[2] [2] [1]

a03uf2c082ca
27.3.2 Removing/reinstalling left cover

A. Procedure
[2] [3]
2. Remove the 9 screws [2] and then remove the left
cover [3].
steps in reverse.
[2] [1] [2]

a03uf2c083ca
233
27.3.3 Removing/installing right cover/Up1, /Up2, /Up3, /Lw1 and /Lw2

/C6501P/C65hc/C5501
A. Procedure
bizhub PRO C6501
1. Remove the filter cover.

[7] [6] [5] [2]
(Refer to P.138)
2. Open the bypass feed tray [1].
3. Loosen the 2 screws [2] and remove the right
cover/Up3 [3].
4. Remove the 2 screws [4] and remove the right
cover/Up2 [5].
cover/Up1 [7].
[1] [4] [3]

a03uf2c084ca
6. Close the bypass feed tray [1].

[1] [4] [2]
7. Open the toner cellction door [2].
cover/Lw2 [4].
cover/Lw1 [6].
steps in reverse.
[6] [5] [3]

a03uf2c085ca
234
27.3.4 Removing/reinstalling original glass assy
/C6501P/C65hc/C5501
A. Procedure
bizhub PRO C6501

1. Remove the three screws [1] and remove the orig-
[1] [2] [4] [3]
inal positioning plate /Rr [2].
2. Remove the 2 screws [3] and remove the scanner
cover /Rt [4].
3. Remove the 2 screws [5] and remove the original
glass assy [6].
[5] [6]
a03uf2c086ca
Note
[10] [7]
• When removing the original glass assy, do not
hold the original positioning plate /Lt [8], or
the glass [7] may come off since the plate and
glass are attached with each other only with
2-side tape. Be sure to hold the original glass
assy by its [9] and [10] portions.

steps in reverse.
[8] [9]
a03uf2c087ca
235
27.3.5 Removing/reinstalling upper cover/Fr, /Rt, and Lt

/C6501P/C65hc/C5501
A. Procedure
bizhub PRO C6501
1. Remove the original glass assy.

[4] [3] [2] [1]
(Refer to P.235)
(Refer to P.140)
3. Remove the screw [1] and remove the scanner
cover/Fr2 [2].
4. Remove the screw [3] and remove the scanner
cover/Fr1 [4].
a03uf2c088ca

upper cover/Fr [2].
[1] [2]
a03uf2c089ca
6. Remove the screw cap [1].

[1] [2] [3]
7. Remove the 2 screws [2] and [3] and remove the
upper cover/Rt [4].
[4]
a03uf2c091ca
236
/C6501P/C65hc/C5501
[1][2]
bizhub PRO C6501

upper cover/Lt [4].
steps in reverse.
[4] [3]
a03uf2c091ca
27.3.6 Removing/reinstalling upper cover /Rr1 and /Rr2

A. Procedure
[5][6] [8] [7] [3] [4] [1][2]
upper cover /Rr2 [4].
(Refer to P.235)
5. Remove the 2 screws [6] and [7], and remove the
upper cover /Rr1 [8].
steps in reverse.
a03uf2c092ca
237
27.3.7 Removing/installing main board unit

/C6501P/C65hc/C5501
A. Procedure
bizhub PRO C6501
1. Remove the rear cover.

[2] [1]
(Refer to P.233) .
2. Remove the right cover/Up3.
(Refer to P.234)
3. Remove the upper cover/Rr2.
(Refer to P.237)
4. Remove the 2 screws [1] and remove the connec-
tor cover/1 [2].
5. Remove the 4 screws [3] and remove the connec-
tor cover/2 [4].
[3] [4] a03uf2c095ca

[1] [2]
Note
• Be careful not to damage the connector [1] or
the wires when removing the main board unit.
[2] [1]
a03uf2c096ca
8. Put a screw driver [2] through the hook [1] and

[1] [4]
insert the tip [3] of the driver into the clearance.
Pull the screw driver toward you while pivoting it
on the tip to pull out the main board unit [4].
steps in reverse.
Note
• Be sure not to pinch the wires.
[3] [2]
a03uf2c097ca
238
27.3.8 Removing/installing CCD unit
/C6501P/C65hc/C5501
A. Procedure
bizhub PRO C6501

(Refer to P.235)
3. Remove the 9 screws [2] and remove the CCD
cover [3].
4. Remove the screw [4] and remove the ribbon
cable cover [5].
[4] [5] [3]
[1] [2]
8050ma3141
5. Open the lock lever [1] to unlock the ribbon cable

[2], and disconnect the cable.
Note
• Connect the ribbon cable following the proce-
dure below.
• Open the lock lever [1] and insert the ribbon
cable [2] as far as it will go. Make sure the
conductive surface of the cable does not face
to the lock lever.
• Close the lock lever [1] to lock the ribbon
[1] [2] cable [2].
a03uf2c098ca
239
6. Remove the 4 screws [1] and remove the CCD

/C6501P/C65hc/C5501
[1] [2]
unit [2].
bizhub PRO C6501
Note
• Never remove any screws other than the 4
screws [1]. If they are removed, optical
adjustments that cannot be made in the field
service or stores are required.
• Never touch the lends with your hand, other-
wise it causes image quality problems.

[2] a03uf2c099ca
steps in reverse.
240
27.3.9 Removing/installing exposure unit
/C6501P/C65hc/C5501
A. Disassembly procedure
bizhub PRO C6501

[2] [1] [1]
(Refer to P.235)
2. Remove the upper cover/Fr, /Rt and Lt.
(Refer to P.236)
3. Remove the 14 screws [1] and remove the stay
[2].
[1]
a03uf2c0100ca
4. Remove the screws [1],1 each, and remove the 2

[2] [1] [1] [2]
wire holdings [2].
5. Turn the exposure unit [3] a little to take it upward
while keeping it in a horizontal position, and put
the unit on the scanner frame [4].
[4] [3]
a03uf2c101ca
241

/C6501P/C65hc/C5501
[4] [1]
7. Remove the screw [2] and release the cable [4]
bizhub PRO C6501
from the cable clamp [3].

8. Remove the exposure unit [5].
[2] [3] [5]
a03uf2c102ca
242
B. Reassembly procedure
/C6501P/C65hc/C5501
1. Install the exposure unit to the main body.
bizhub PRO C6501

[5] [4] [4] [5]
2. Move the V mirror unit [2] toward paper eject side
and put the optic unit positioning jigs [3] 1 for
each V mirror unit [2] and exposure unit [1]
through the holes on the frame at the front side
and through the holes on the other side frame.
Note
• Use the optic positioning jigs when reinstall-
ing the exposure unit.
3. Secure the exposure unit with the screws [4] and

the wire holdings [5], 1 for each side of the unit.
4. Remove the 2 optic positioning jigs [3].
5. Follow the removal steps in reverse from here.
[2] [1] [3]

a03uf2c103ca
243
27.3.10 Removing/installing exposure lamp

/C6501P/C65hc/C5501
A. Procedure
bizhub PRO C6501
1. Remove the exposure unit.

[3] [4]
(Refer to P.241)
2. Cut the wire binding band [1] to release the cable
[2].
3. Remove the 2 screws [3] and remove the HP
detection plate [4].
4. Remove the 2 screws [5] and remove the expo-
sure lamp (L1) [6].
steps in reverse.
[2] [1] [5]
[6] [5]
a03uf2c104ca
244
27.3.11 Removing scanner wire
/C6501P/C65hc/C5501
A. Procedure
bizhub PRO C6501

1. Remove the exposure unit.
[2]
(Refer to P.241)
2. Loosen the screws [1] for each of 2 spring fixing
plates [2] and release the plates.
[1]
a03uf2c105ca
245
3. Release the wire terminal [3] of the scanner wire/

/C6501P/C65hc/C5501
Rr [2] from the spring fixing plate [1]. And then

bizhub PRO C6501
remove the scanner wire/Rr [2] from each parts in

the following order: 1. Pulley/3 [4] 2. Outer side of
the V mirror pulley [5] 3. Pulley/2 [6]
4. Release the metal ball [8] of the scanner wire/Rr
[5] [2] from the wire stopper [7]. And then remove the
scanner wire/Rr [2] from each part in the following
order: 1. Inner side of the V mirror pulley [5] 2. Pul-
[4] [6] [3]
ley/1 [9]
5. Remove the scanner wire/Rr [2] from the drive
[9]
pulley [10].
6. Remove the scanner wire/Fr [11] following the
[10]
step 3 to 5.
[2]
Note
• The scanner wire /Fr and /Rr should be sym-
metrically installed.
[2] [7] [8]

[2]
[3]
[1]
[11]
8050ma3024
246
27.3.12 Reinstalling the scanner wire
/C6501P/C65hc/C5501
A. Procedure
bizhub PRO C6501

1. Move the V mirror unit [1] toward paper eject side
and put the optic unit positioning jig [2] for the V
mirror unit [1] through the hole on the front side
frame and through the V mirror unit.
Note
• Be careful not to damage the mirror with the
optic positioning jig.
• When reinstalling the scanner wire, secure
the V mirror unit with the optic positioning jig.
[1] [2]
a03uf2c106ca
2. Put the metal ball [3] provided at each intermedi-

[6] [5] [1] ate section of the scanner wires/Fr [1] and /Rr [2]
into the drive pulley [4] installation hole. With this
[4]
as a starting point, wind the wire 3.5 turns [5] out-
wards and 3.5 turns [6] inwards.
[3] [8]
[7]
Note
• The scanner wire /Fr and /Rr are common
parts.
[8]
• Wind each scanner wire so that the wire ter-
[4] minal comes outer side of the drive pulley
while the metal ball [7] comes inner side of
the drive pulley.
• When winding each scanner wire, be sure to
[2] [5] [6]
pull out the both edges of wire from beneath
[4] the drive pulley.
• Be sure to wind the scanner wires to each
drive pulley intimately and in a single layer.
[3] [7]
8050ma3026 3. After winding the scanner wire/Fr [1] and /Rr [2],
secure each wire with the tape [8] to prevent the
wires from becoming unfastend.
247
4. Pass the scanner wire/Rr [2] (metal ball [3] side)

/C6501P/C65hc/C5501
wound to the drive pulley [1] through the pulley/1

bizhub PRO C6501
[9]
[4] and inward the V mirror pulley [5] in that order,
and then hook the metal ball [3] to the wire stop-
[10] per [6].
5. Pass the scanner wire/Rr [2] (wire terminal [7] side)
[2]
wound to the drive pulley [1] through the pulley/2
[8], outward the V mirror pulley [5] and the pulley/3
[9] in that order, and then hook the wire terminal
[7] to the spring fixing plate [10].
6. Reinstall the scanner wire/Fr [11] following the
[5] step 4 to 5.
[4] [6] [3]
FRONT
[2] [7] [8]

[2]
[3]
[1]
[11]
8050ma3027
248
7. Fasten the screws [1] for each of 2 spring fixing
/C6501P/C65hc/C5501
[2]
plates [2] and secure the plates.
bizhub PRO C6501

[1]
a03uf2c105ca
249
27.3.13 Removing/installing write unit

/C6501P/C65hc/C5501
bizhub PRO C6501
WARNING
• Do not power the product when the write unit is not in its original position.
• Never remove the covers of the write unit with the product powered. If a laser beam is emitted and
strikes your eye, it may result in permanent vision loss.
Note
• Never remove the covers of the write unit, and even loosening the screws of the cover must be
avoided.
• Be careful not to touch the dust-proof glass when removing the write unit.
• Never remove the write unit for at least 2 minutes after turning the main power switch (SW1) off.
A. Procedure
1. Remove the right cover/Up1 and /Up2.
[2] [2]
(Refer to P.234)
3. Remove the 10 screws [2] and remove the fan
mounting plate/Rt [3].
[2] [1] [3] [1]

a03uf2c107ca
4. Remove the 2 screws [1] and remove the write

[6] [8] [7] [1] [4] [3]
unit pressing plate [2].
Note
• When removing the write unit pressing plate,
be sure to do that while holding the upper of
the plate.

unit duct/Rr [4].
unit duct/Fr2 [6].
[10] [9] [5] [2] 7. Remove the 2 screws [7] and remove the write
a03uf2c108ca
unit duc/Fr1[8].
unit duct/Fr3 [10].
250
9. Disconnect the three connectors [1] and remove
/C6501P/C65hc/C5501
[4][3] [2] [1]
the write unit/Y [2], /M [3] and /C [4].
bizhub PRO C6501

10. Disconnect the 4 connectors [5] and remove the
write unit/K [6].
Note
• The write unit/C, /M and /Y are common
parts.
• The write unit/C, /M, /Y and the write unit/K
differs in the number of connector.
• Never install the other write units to the place
where the write unit/K is to be installed.
[6] [5]
a03uf2c109ca
steps in reverse.
251
27.3.14 Removing/installing process unit

/C6501P/C65hc/C5501
A. Procedure
bizhub PRO C6501

(Refer to P.147)
2. Remove all drum cartridges.
(Refer to P.143)
3. Remove all developing units.
(Refer to P.164)
[4] [5] [2] [8] [1] [6] 4. Remove the 2 screws [1].
Note
• The transfer belt unit, drum cartridges, and
the developing units must have been removed
before removing the process unit.
• Do not remove the black screws.
5. Push back the process unit until the screw [5]

appears through each hole [4] of the guide rail/Lt
[2] and /Rt [3].
6. Remove the 2 screws [5], 1 each on the guide rail/
Lt [2] and /Rt [3].
Note
[6] 7. Pull out the process unit [6] again. And remove the
[7]
process unit from the guide rail/Lt [2] and /Rt [3]
following the procedure below.
Projections [7] on the guide rail /Lt are inserted in
the notches [8] of the process unit. And the
notches [10] on the process unit are engaged with
the projections [9] on the guide rail/Rt. Release
the process unit from the guide rail/Lt while sliding
the guide rail/Lt a little against the process unit,
then lift the process unit to release it from the
guide rail/Rt, and remove the process unit.
[9]
[1] [3] [5] [4] steps in reverse.
[10] a03uf2c110ca
252
27.3.15 Removing/reinstalling image correction unit
/C6501P/C65hc/C5501
A. Procedure
bizhub PRO C6501

1. Remove the process unit.
(Refer to P.252)
3. Remove the 2 screws [2] and remove the image
[4]
correction unit [3].
[2]
Note
• When removing the image correction unit, be
sure to remove the process unit beforehand.
• When removing the image correction unit,
avoid touching or exerting any force on the
[3] [1] [4] 8050ma3071
drum drive shaft [4].

steps in reverse.
253
27.3.16 Removing/installing belt collectin pipe, vertical conveyance pipe and horizontal conveyance
/C6501P/C65hc/C5501
pipe
bizhub PRO C6501
A. Procedure
Note
• If a paper feed motor error (C-0101) or a transfer belt motor error (C-2220) occurs, clean the inside
of the pipes following the procedure below.
1. Remove the process unit.

(Refer to P.252)
2. While releasing the lock [1] of the ADU release
lever [2], turn the lever counterclockwise.
3. While releasing the lock [3], hold the ADU release
lever and pull out the ADU [4].
Note
• With the process unit removed, ADU cannot
be pulled out without releasing the lock [3] in
order to avoid rollover accidents.
[2] [1] [3] [4]
a03uf2c111ca
4. Spread a sheet [2] just below the horizontal con-

veyance pipe /1 [1] since waste toner may spill out
from the pipe.
[2] [1] 8050ma3192
254
5. Remove the 7 screws [1] and loosen the screw
/C6501P/C65hc/C5501
[1]
[2].
bizhub PRO C6501

[1]
[1] [2] 8050ma3193
255
6. Hold the belt waste toner inlet [1] and the drum/K
/C6501P/C65hc/C5501
[1]
waste toner inlet [2], and remove the belt collec-
bizhub PRO C6501
tion pipe [3], the vertical conveyance pipe /1 [4], /

2 [5], /3 [6] and /4 [7] with all those pipes con-
nected each other.
Note
• When removing the belt collection pipe and
the vertical conveyance pipe, be sure to
remove them while slightly tilting the belt
waste toner inlet side toward you.
• When installing the belt collection pipe and
the vertical conveyance pipe, insert the pro-
[3] jections located on rear side of each inlet into
holes of the main body.
[4]
[5]
[6]
[7]
[2] 8050ma3194
256
7. Remove the toner collection pipe [2] from the ver-
/C6501P/C65hc/C5501
[3] [2]
tical conveyance pipe/1 [1], and pull out the toner
bizhub PRO C6501

oscillating plate [3].
[1]
8050ma3195
257
/C6501P/C65hc/C5501 27. OTHER PROCEDURES Theory of Operation Ver.3.0 Jul. 2009
Note
[2]
bizhub PRO C6501
• When installing the toner oscillating plate,

insert the drive hole [4] of the toner oscillating
plate [3] over the guide pin [2] on the toner
collection pipe [1]. Turn the gear [5] to check
if the toner oscillating plate moves up and
down properly.
[4] [3] [1] [1]
[5] 8050ma3196
258
8. Remove the toner collection pipe/2 [2] from the
/C6501P/C65hc/C5501
[2] [5] [1]
toner collection pipe/1 [1].
bizhub PRO C6501

10. Pull out the toner collection screw [5] from the
toner collection pipe/1.
11. Clean off the waste toner in the toner collection
pipe/1 and /2.
Note
• When cleaning the toner collection pipe /2, be
careful not to lose the sponge [6] and [7].
[6] [7]
[4] [3] 8050ma3197
259
12. After uncoupling the vertical conveyance pipe into

/C6501P/C65hc/C5501
[4] [6] [3] [6] [2] [6] [1]

4 parts [1][2][3][4], remove each inlet cap [5], and
bizhub PRO C6501
clean off the waste toner inside the pipes.
Note
• When cleaning each vertical conveyance
pipe, be careful not to lose the 4 sponges [6].
• When installing each inlet cap, match the
concave part [7] of the inlet cap with the con-
vex part [8] of the vertical conveyance pipe.
[6] [8] [7]
[5] 8050ma3198
260
13. Remove the toner collection box assy.
/C6501P/C65hc/C5501
(Refer to P.166)
bizhub PRO C6501

(Refer to P.233)
15. Remove the screw [1] and the flywheel/C [2].
16. Remove the screw [3] and the flywheel/K [4].
[1] [2]
[4] [3] 8050ma3199
17. Spread a sheet [3] below the joint part between

the horizontal conveyance pipe/1 [1] and the hori-
zontal conveyance pipe assy [2].
Note
• Waste toner may spill out of when the hori-
zontal conveyance pipe/2 is removed from
the conveyance pipe/1. Be sure to spread a
sheet to prevent the waste toner from spilling
on the internal components.
[1]
[2] [3] 8050ma3200
261
18. Remove the 2 screws [1] and pull out the horizon-
/C6501P/C65hc/C5501
[1]
tal conveyance pipe assy [3] from the horizontal
bizhub PRO C6501
conveyance pipe /1 [2].
[3]
[3] [2] 8050ma3201
262
/C6501P/C65hc/C5501
[2] [1]
bizhub PRO C6501

Note
• When installing the gear, insert the D-cut
head [4] of the screw [3] into the D-shaped
hole [5] of the gear.
[4][5] [3] 8050ma3202

[3]
Note
• Insert the bearing into the hole of the horizon-
tal conveyance pipe assy [2] checking their
shapes [3].
[2] [1] 8050ma3203
263
21. Pull out the screw [2] from the horizontal convey-
/C6501P/C65hc/C5501
[2] [1]
ance pipe assy [1].
bizhub PRO C6501
Note
• The spacer [3] is installed to the gear side of
the screw. If the spacer come off or is
removed, be sure to reattach it as shown.
[2] [3] 8050ma3204
264
22. Remove the 2 screws [1] and remove the horizon-
/C6501P/C65hc/C5501
[1]
tal conveyance pipe/4 [2].
bizhub PRO C6501

23. Remove the 2 screws [3] and remove the horizon-
tal conveyance pipe/3 [4].
24. Clean off the waste toner in each horizontal con-
veyance pipe/2 [5], /3 [4] and /4 [2].
[2] [2] [4] [5]
[4] [5]
[3] 8050ma3205
265
25. Remove the screw [1] and remove the horizontal

/C6501P/C65hc/C5501
conveyance pipe/1 [2].

bizhub PRO C6501
26. Clean off the waste toner in the horizontal convey-

ance pipe/1.
steps in reverse.
[1] [2] 8050ma3206
266
27.3.17 Removing/reinstalling ADU
/C6501P/C65hc/C5501
A. Procedure
bizhub PRO C6501

[1]
(Refer to P.140)
(Refer to P.184)
[2]
(Refer to P.194)
[3]
4. Remove the ADU cover/Rt, ADU release lever,
and ADU cover/Lt.
(Refer to P.175)
5. Remove the paper feed solenoid cover.
(Refer to P.172)
7. Remove the screw [2] and release the ADU wire
binding assy [3].
8050ma3085
267

/C6501P/C65hc/C5501
[1] [9] [1] [9]

9. Remove the screw [2].
bizhub PRO C6501
10. Push back the ADU [6] until the screw [5] appears
through each hole [4] of the guide rail/Lt [3], and
remove the screws [5] one by one.
Note
11. Pull out the ADU [6] again and move the guide
pins [8] of the guide rail/Rt [7] within the elongate
hole so that the guide rail does not interfere with
removal of the ADU.
[7] [8] [10] 12. Remove the ADU [6] from the guide rail/Lt [3] and
/Rt [7].
Note
• When removing the ADU [6], be sure to per-
form the work with 2 people, one is on the
paper feed side, another is on the paper eject
side.
• When removing the ADU [6], the person who
performs on the paper feed side should hold
the ADU handle/Rt [10].
• When removing the ADU [6], the person who
[4] [5] [11] [2] [3] [6]
performs on the paper eject side shold hold
a03uf2c112ca
the stay [11].

steps in reverse.
268
27.3.18 Replaceing the lock lever/1, /2
/C6501P/C65hc/C5501
bizhub PRO C6501
Note
• Do not pull out the process unit and the ADU at a time or the main body may topple over. In order
to prevent rollover accidents, the lock lever/1 and /2 do not allow the process unit and the ADU to
be pulled out at the same time.
If you cannot pull out the process unit or the ADU, the lock lever/1 and /2 may be deformed as a
result of some operational error. Check the lock lever/1 and /2 for deformation and replace them
as necessary.
• Since the lock lever/1 and /2 are not the regular maintenance parts, they were located without
considering the convenience of replacement. You must remove the levers without directly viewing
them. Therefore, when replacing the lock lever/1 and /2, refer to the pictures for each steps to fig-
ure out their locations and how they are installed beforehand.
269
A. Procedure
/C6501P/C65hc/C5501

bizhub PRO C6501
[6] [5]
(Refer to P.140)
2. While releasing the lock of the ADU release lever,
turn the lever counterclockwise, and pull out the
ADU unit the screw [1] becomes accessible.
Note
• The ADU may not be pulled out smoothly
depending on deformation condition of the
lock lever/1 [2] and /2 [3]. If so, pull it slightly
harder to make space to access the screw
[1].
[3] [5] [1] [2] 3. Remove the screw [1] and remove the stopper [4].
Note
[4]
• When installing the stopper [4], match the
projection [5] with the positioning hole [6].
4. When the stopper [4] is removed, the force of the

[2] lock lever/1 [2] and /2 [3] disappears. Then pull
[3] only the ADU [7] further out.
[7] WARNING
[1] [3] [8]
• Never pull out the process unit or the main
body may topple over.
5. Remove the ring [8] and remove the lock lever/2

[3].
6. Remove the spring [9] from the lock lever/2 [3].
[9]
Note
• When replacing the levers, be sure to check if
[12] [10] [11] the direction of the spring [9] and the position
of the hook are correct.

lever strengthening plate [11].
8. Remove the E-ring [12] and remove the lock lever/
[13]
1 [2].
9. Remove the spring [13] from the lock lever/1 [2].
Note
• When replacing the levers, be sure to check if
[2] 8050ma3220
the direction of the spring [13] and the posi-
tion of the hook are correct.

steps in reverse.
270
27.3.19 Removing/reinstalling paper feed tray /1, /2 and /3
/C6501P/C65hc/C5501
A. Procedure
bizhub PRO C6501

Note
• Configuration of paper feed tray/1 is the same for those of paper feed trays /2 and /3. The explana-
tion here is made by the example of paper feed tray/1.
1. Pull out the paper feed tray/1.

[1]
(Refer to P.167)
3. Remove the 4 screws [1] and lift the paper feed
tray /1 [2] to remove it.
steps in reverse.
[1] [2]
8050ma3162
271
27.3.20 Removing/reinstalling tray up/down wire

/C6501P/C65hc/C5501
Wire length
bizhub PRO C6501
• Tray up/down wire/A and /C: 531mm

• Tray up/down wire/B and /D: 160mm
A. Procedure for removing the tray up/down wires
Note
• The tray/1 was used to illustrate the disassembly procedure. The procedure is the same for the
tray/2 and tray/3.
1. Pull out the paper feed tray/1.

[8] [7] [5] [6] [1]
3. Remove the paper feed tray/1.
4. Remove the three screws [1] and remove the wire
cover/FR [2].
5. Remove the 2 screws [3] and remove the wire
cover/FL [4].
6. Remove the three screws [5] and remove the wire
cover/RR [6].
7. Remove the 2 screws [7] and remove the wire
cover/RL [8].
[4] [3] [2] a03uf2c119ca
272
/C6501P/C65hc/C5501
[7] 9. Slide the drive pulley [2] in the direction of the
bizhub PRO C6501

[6]
[3]
arrow and remove the wire/C [3] and /D [4].
[5] 10. After removing the E-ring [5], remove the pulley [6]
and release the wire/C [3] and /D [4] from the wire
[8]
[4] cover [7].
11. Remove the screw [8] from the bottom of the
[1] paper feed tray/1 and remove the wire/D [4].
[2]
12. After removing the E-ring [9], remove the pulley
[15] [19] [18]
[10] and release the wire/C [3] from the wire cover
[11].
[17]
paper feed tray/1 and remove the wire/C [3].
[20]
15. Slide the drive pulley [14] in the direction of the
[16] arrow and remove the wire/A [15] and /B [16].
[18] and release the wire/A [15] and /B [16] from
[14] [13] the wire cover [19].
paper feed tray/1 and remove the wire/B [16].
[22] and release the wire/A [15] from the wire
cover [23].
paper feed tray/1 and remove the wire/A [15].
[23] [22]
[21]
[15] [24]
[11]
[10]
[3]
[9] [12] 8050ma3168
273
B. Wiring procedure
/C6501P/C65hc/C5501
bizhub PRO C6501
Note
[12] • The tray/1 was used to illustrate the following
[11] procedure. The procedure is the same for the
[4] [3] tray/2 and tray/3.
[13]
[8] 1. Secure the wire /C [3] to the fixing wire shaft [2] on
[10]
[9] the bottom of the paper feed tray with the screw
[16]
[1].
2. After winding the wire /C [3] to the pulley [4], insert
[14] [15] the wire/C over the shaft [6] and cover it with the
wire cover [5]. Then secure them with the E-ring
[7].
3. Secure the wire/D [10] to the fixing wire shaft [9]
[17] on the bottom of the paper feed tray with the
screw [8].
[18] 4. After winding the wire/C [3] and /D [10] to the pul-
ley [11], insert the wire/C and /D over the shaft
[13] and cover it with the wire cover [12]. Then
secure them with the E-ring [14].
Note
• Place the wire/C [3] on the outer side while
the wire/D [10] on the inner side to wind them
to the pulley [11].
5. Insert the wire/C [3] and /D [10] into the up/down

drive shaft [14]. After sliding the drive pulley [15] in
the direction of the arrow, secure it with the E-ring
[16].
Note
• Insert the wire/C [3] through the outer hole of
the up/down drive shaft while the wire/D [10]
through the inner hole.
6. Follow the step1 to 5 to install the wire/A [17] and

/B [18].
[17] Note
• After replacing the wires, manually turn the
[7] [5] up/down drive shaft to check if the up/down
[4] ptate moves smoothly.
[6]
[3] 7. Follow the removal steps in reverse from here.
[2] [1] 8050ma3169
274
27.3.21 Removing/installing temperature sensor /1 (TEMS/1), thermostat /1 (TS1) and /2 (TS2)
/C6501P/C65hc/C5501
bizhub PRO C6501
[1]
(Refer to P.194)
2. Remove the fusing cover /Up assy.
(Refer to P.202)
3. Remove the fusing cover /Rr.
(Refer to P.196)
4. Remove the cover.
(Refer to P.213)
5. Remove the screw [1] and the 4 cable clamps [2].
7. Remove the screw [4] and remove the tempera-
ture sensor /1 (TEMS/1) [5].
[5] [1] [2] [2]
[4] [1]
a03uf2c113ca
8. Remove the screw [1], 1 each, and the three

[4] [2] [4]
cable clamps [2].
9. Disconnect fastons [3], 2 for each thermostat.
Note
• When disconnecting the fastons, be sure to
hold the base of the faston to pull it out. Never
hold the wire bindings to pull the faston out.
10. Remove the 4 screws [4] and remove the thermo-

stat/1 (TS1) and /2 (TS2) [6].
[1] [3] [6] [1] [3] [5] [1]

a03uf2c114ca
275
/C6501P/C65hc/C5501
bizhub PRO C6501
Note
• Be sure to adjust the positions of the thermostat/1 (TS1) and /2 (TS2) with a thermostat jig/UC /UF
before securing them. Be sure to apply threadlocker to the fixing screws.
• Be sure to adjust the positions with the fixing belt cooled down.
1. Secure the TS1 [1] and the TS2 [2] temporarily

[6] [1] [5] [7] [2] [3]
with the screws [3] 2 each.
2. Install 4 fastons [4] to the TS1 and TS2 (two for
each).
3. Insert the thermostat jig /UF [6], /UC [7] in
between the TS1 and the fusing belt [5].
4. Adjust the position of the TS1 so that the gap
between the TS1 and the fusing belt becomes the
same as the thickness of the thermostat jig /UC, /
UF, and secure with the screws [3].
5. Follow the step3 to 4 to secure the TS2.
[3] [4] [3] [4] a03uf2c120ca Note

• Be sure to adjust the positions of the TS1 and
TS2 so that the gap “a” between the TS1 or
the TS2 and the fusing belt becomes the
same as the thickness of the the thermostat
jig/UC /UF.
Standard value (UC): a = 1.2 ± 0.2 mm
Standard value (UF): a = 1.8 ± 0.2 mm
6. Apply the threadlocker to the 4 screws [3].

276
[1] Section to be adjusted
/C6501P/C65hc/C5501
[2] Part that should not be in between the thermostat
bizhub PRO C6501

and the fusing belt
[1]
[3] Part that should be in between the thermostat
and the fusing belt
[2]
[3]
[1]
[2]
[3]
a03uf2c136ca
277
27.3.22 Removing/installing temperature sensor /2 (TEMS/2) and thermostat /3 (TS3)

/C6501P/C65hc/C5501
bizhub PRO C6501

[3] [4]
(Refer to P.194)
2. Remove the fusing access guide plate.
(Refer to P.207)
4. Remove the 2 screws [2] and remove the temper-
ature sensor/2 (TEMS/2) [3].
Note
• Before installing the TEMS/2, make sure that
there is no contacts between the binding wire
and the fusing roller/Lw [4].
[2] [1]
a03uf2c115ca
5. Remove the screw [1] and remove the cable

[1] [3]
clamp [2].
6. Disconnect the 2 fastons [3].
Note
• When disconnecting the fastons, be sure to
hold the base of the faston to pull it out. Never
hold the wire bindings to pull the faston out.
7. Remove the 2 screws [4] and remove the thermo-

stat/3 (TS3) [5].
[2] [4] [5] a03uf2c116ca
278
/C6501P/C65hc/C5501
bizhub PRO C6501
Note
• Be sure to adjust the position of the thermostat/3 (TS3) with a thermostat jig/L before securing it.
Be sure to apply the threadlocker to the fixing screws.
• Be sure to adjust the position with the fusing belt cooled down.
1. Secure the TS3 [1] temporarily with the 2 screws

[4] [1] [5]
[2].
2. Connect the 2 fastons [3] to the TS3.
3. Insert the thermostat jig/L [5] in between the TS3
and the fusing roller/Lw [4].
4. Adjust the position of the TS3 so that the gap
between the TS3 and the fusing roller/Lw
becomes the same as the thickness of the jig, and
secure with the screw [2].
Note
• Be sure to adjust the position of the TS3 so
[3] [2] [3] a03uf2c121ca that the gap “a” between the TS3 and the fus-
ing roller/Lw becomes the same as the thick-
ness of the thermostat jig/L.
Standard value : a = 3 ± 0.2 mm
5. Apply the threadlocker to the 2 screws [2].
[1] Section to be adjusted

[2] Part that should not be in between the thermostat
and the fusing roller/Lw
[1]
[3] Part that should be in between the thermostat
and the fusing roller/Lw
[2]
Note
• Before installing the TS3, make sure that
there is no contacts between the binding wire
and the fusing roller/Lw.
[3]
a03uf2c137ca 6. Follow the removal steps in reverse from here.
279
27.3.23 Removing/reinstalling OT
/C6501P/C65hc/C5501
bizhub PRO C6501
A. Procedure
1. Remove the left cover.
[1]
(Refer to P.233)
2. Remove the 4 screws [1] and remove the OT
cover.
[2]
[1]
a03uf2c117ca

4. Remove the 4 screws [2] and remove the OT [3].
steps in reverse.
[2] [2]
[1] [3]
a03uf2c118ca
280
27.4 Commercially available parts
/C6501P/C65hc/C5501
bizhub PRO C6501
27.4.1 Installing the status indicator light
A. Configuration
Status indicator light Screws (x2)

a03uf2c145ca
281
B. Connector
/C6501P/C65hc/C5501
(1) Connector locations

bizhub PRO C6501
[1]
a03uf2c146ca
[1] CN495
(2) Connector specifications
Connector Pin no. Signal Description Output timing Signal type

495 1 PAT1_DR Light on signal L signal output when Open collector
printing is possible.
2 PAT2_DR L signal output during
scanning or printing.
3 PAT3_DR L signal output when
the product stops
abnormally due to paper
jam, malfunction code,
no paper, no toner, etc.
4 PAT4_DR L signal output when
toner low message is
displayed.
5 24V DC24V power sup- At all times 24V, 500mA
ply
6 GND Ground — —
282
C. Procedure
/C6501P/C65hc/C5501
1. Remove the upper cover /Rr2.
bizhub PRO C6501

(Refer to P.237)
2. Remove the cracked cover for pulling out the
cables [2] from the upper cover /Rr2 [1].
[1] [2] a03uf2c147ca
3. Remove the right cover /Up3.

(Refer to P.234)
4. Insert the cables [2] of the status indicator light
through the upper part of the main board unit [1].
[1] [2] a03uf2c148ca
5. Connect the connector [2] of the status indicator

[1] [4] [5]
light to CN495 [1].
Note
• Route the cables [3] so that they do not make
contact with the flywheel [5] of the scanner
motor (M1) [4].
[2] [3]
a03uf2c149ca
283
6. Install the right cover/Up3 [1] and the upper

/C6501P/C65hc/C5501
[2] [6]
cover/Rr2 [2].
bizhub PRO C6501
Note
• Pull out the cables [3] of the status indicator
light through the cracked cover for pulling out
the cables [4] of the upper cover/Rr2.
7. Install the status indicator light [6] with the 2

screws [5].
steps in reverse.
[4] [1] [6]
[5]
[3] a03uf2c150ca
284
27.4.2 Installing the key counter (KCT)
/C6501P/C65hc/C5501
A. Configuration
bizhub PRO C6501

Key counter
Counter socket
a03uf2c151ca
B. Connector locations
[2]
[1]
a03uf2c152ca
[1] CN493 [2] Jumper connector (CN494)
285
C. Procedure
/C6501P/C65hc/C5501
1. Remove the upper cover/Rr2.

bizhub PRO C6501
(Refer to P.237)
2. Remove the cracked cover for key counter [2] of
the upper cover/Rr2 [1].
[1] [2] a03uf2c153ca
3. Remove the 2 screws [1] and the shield plate [2].
[2] [1] a03uf2c154ca
4. Install the counter socket [1] with the 2 screws

[1] [2]
[2].
Note
• Be sure to use the 2 screws removed in Step
3.
• Install the counter socket so that the arrow
mark [3] is facing upward.
[3] a03uf2c155ca
286
5. Disconnect the jumper connector (CN494) [2]
/C6501P/C65hc/C5501
from CN493 [1].
bizhub PRO C6501

Note
• Be sure to keep the removed jumper connec-
tor (CN494).
[2] [1] a03uf2c156ca
6. Connect the connector [3] of the counter box [2]

[2] [1] [3]
to CN493 [1].
Note
• Route the cables [4] so that they do not make
contact with the flywheel [6] of the scanner
motor (M1) [5].
[4] [6] [5]

a03uf2c157ca
287
7. Install the upper cover /Rr2 [1].

/C6501P/C65hc/C5501
[1]
8. Attach the key counter [3] to the counter socket
bizhub PRO C6501
[2].
Note
• Install the key counter so that the arrow mark
[4] is facing upward.

steps in reverse.
[2]
[4] [3] a03uf2c158ca
288
DF-609
2008.07
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
DF-609
DF-609
OUTLINE
2. UNIT CONFIGURATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Single-sided mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Double-sided mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. PAPER FEED SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3.1 Paper feed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3.2 Original size detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3.3 No paper detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5. CONVEYANCE SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.3.1 Scanning and conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6. REVERSE/PAPER EXIT SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.3.1 Paper exit control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.3.2 Reverse paper exit control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
MAINTENANCE
7. MAINTENANCE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1 Paper feeding section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1.1 Removing/installing paper feed unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1.2 Replacing pick-up roller/paper feed roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.1.3 Replacing separation roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.1.4 Cleaning timing sensor (PS302) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.1.5 Removing/reinstalling registration roller cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.1.6 Cleaning registration roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.1.7 Cleaning registration sensor (PS301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8. OTHER PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8.1 Disassembly/reassembly parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8.2 Disassembly/reassembly procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.2.1 Removing/reinstalling DF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.2.2 Removing/reinstalling front cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.2.3 Removing/reinstalling rear cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.2.4 Removing/reinstalling conveyance belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
i
DF-609
Blank page
ii
OUTLINE
DF-609
A. Type
Type Belt conveyance type original auto feeder
B. Functions
Original size A3, B4, A4, A4S, B5, B5S, A5, A5S, B6S
11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2, 51/2 x 81/2S
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
8K, 16K, 16KS
Max. original size 297 x 431.8mm
Min. original size 128 x 139.7mm
• Various sizes of paper can be accommodated
C. Original type
Paper type Plain paper High quality paper of 35 to 210 g/m2 (single side)
High quality paper of 50 to 210 g/m2 (double side)
Paper of less than 49g/m2: conveyed in thin paper mode
Paper of more than 129g/m2: conveyed in thick paper
mode
Special paper Same as plain paper. However, paper feed and convey-
ance performance are not guaranteed.
• Recycled paper, coarse paper, thermal paper, binding-
holed paper, user-defined paper, paper with smooth
surface, paper with rough surface, and paper with folds
Following types of special paper cannot be used.
• OHP film, blueprint master paper, label paper, off-set
master, bonded original, high quality paper (paper
weight: Less than 34g/m2 or more than 211g/m2)
Paper curl amount Up to 10 mm with 5 originals overlapped one another
[1]
a
15sat1c001na
a Curing: 10 mm or less
[1] Original
Max. tray capacity 100 sheets (80g/m2 paper)
1
Scan speed Single-sided mode (including thin-paper mode): 39 sheets/min.

(81/2 x 11) Double-sided mode (including thin-paper mode): 26 sheets/min.
Single-sided mode (thick-paper mode): 28 sheets/min.
DF-609
Double-sided mode (thick-paper mode): 14 sheets/min.

Scanning system After the original that is conveyed on the belt stops, the scanner moves and
scans the original.
D. Machine data
Power source 24/5V DC (supplied from the main body)

Power consumption Max. 60W or less
Weight Approx. 14.5kg
Dimensions 588 (W) x 519 (D) x 135 (H) mm (Excluding paper feed tray)
E. Maintenance
Maintenance Same as the main body.
F. Operating environment
Note
2
Theory of Operation Ver.1.0 Jul. 2008 2. UNIT CONFIGURATION DIAGRAM
2. UNIT CONFIGURATION DIAGRAM
DF-609
[3]
[1]
[2]
a052t1c001ca
[1] Reverse/paper exit section [3] Paper feed section

[2] Conveyance section
3
3. PAPER PATH Theory of Operation Ver.1.0 Jul. 2008
3. PAPER PATH
3.1 Single-sided mode
DF-609
[1]
[4]
[3] [2]
a052t1c003ca
[1] Reverse/paper exit [3] Swing-back

[2] Conveyance to the reverse stacker [4] Paper feeding
4
3.2 Double-sided mode

A. Double-sided mode (front side scan)
DF-609
[3]
[1]
[2]
a052t1004ca
[1] Reverse conveyance/back side [3] Paper feeding

[2] Position shift in front side scanning (swing-back)
B. Double-sided mode (back side scan)
[1]
[2] a052t1c005ca
[1] Paper exiting [2] Conveyance to the back side scanning posi-
tion
5
DF-609
Blank page
6
DF-609
4.1 Configuration
[1]
[2]
[3]
[4]
[5] a052t2c001ca
[1] Pick-up roller [4] Separation roller

[2] Paper feed roller [5] Registration roller
[3] No paper sensor
7
4.2 Drive
[5] [6]
DF-609
[4]
[3]
[2] [1] a052t2c002ca

[1] Registration clutch (MC301) [4] Separation roller (with torque limiter)
[2] Registration roller [5] Paper feed roller (with one-way clutch)
[3] Paper feed motor (M301) [6] Pick-up roller
8
4.3 Operation
DF-609
• The pick-up roller [7], paper feed roller [6], and registration roller [3] are driven by the paper feed motor
(M301).
• M301 drives in both directions, forward and reverse. When it drives in forward, the pick-up roller and the
paper feed roller rotate to transfer papers, while the registration roller does not rotate.
• When M301 drives in reverse, only the registration roller rotates to feed papers while the pick-up roller goes
up to the shelter, and one-way clutch keeps the paper feed roller from rotating.
• The separation roller, which is not driven by the motor, is provided with a torque limiter. When a piece of
paper is transferred, the separation roller moves in synchronization with the paper feed roller. On the other
hand, when two or more papers are fed, the separation roller remains stationary and separates the papers.
• The registration clutch (MC301) functions as the brake to stop the registration roller, not to turn ON or OFF
the drive force transmission.
• The registration sensor (PS301) [4] and the timing sensor (PS302) [2] detect the timing of the original.
[6] [7] [8]
[5]
[4]
[3] [2] [1] a052t2c003ca
[1] Conveyance belt [5] Separation roller

[2] Timing sensor (PS302) [6] Paper feed roller
[3] Registration roller [7] Pick-up roller
[4] Registration sensor (PS301) [8] No paper sensor (PS304)
9
A. Single-sided mode
1. The paper feed motor (M301) switches to high speed [1] and the pick-up roller is pressed against the origi-
nals set to the original feed tray.
DF-609
2. The pick-up roller conveys the originals to the paper feed roller and the separation roller.
3. The paper feed roller conveys a piece of original at the top, and the separation roller keeps the rest of the
originals from being transferred.
4. The original is conveyed until it hits the registration roller, and the original forms a loop to correct skew [2].
5. M301 pauses after the specified time, and the registration clutch (MC301) turns OFF to release the registra-
tion roller [3].
6. After the specified time, M301 rotates in reverse at low speed and the registration roller nips the original [4].
7. After the specified time has elapsed from when the timing sensor (PS302) has turned ON, M301 is turned off
once [5] and starts rotating again in reverse at high speed [6] at the same time as the conveyance motor
(M302) is turned on. Then the original is conveyed to the conveyance belt of the conveyance section.
8. After the specified time has elapsed from when PS302 has turned ON, M301 turns off [7].
9. The rest of the originals are conveyed in the same manner.
[2] [5] [6] [7]

Registration clutch (MC301)
High
For-
ward Low
Paper feed motor
(M301) Low
Reve
rse High
Timing sensor (PS302)
Forward
Conveyance motor
Reve Low
(M302)
rse High
[1] [3] [4] a052t2c004ca
[1] Paper feed motor high-speed ON [6] Start conveying the original to the convey-
[2] Loop formation ance section
[3] Registration roller released [7] Conveyance to the conveyance section
[4] Nipping by the registration roller completed
[5] A pause (M301)
10
B. Double-sided mode
1. The first sheet of original is conveyed in the same manner as in single-sided mode [1].
2. While front side of the first sheet is being scanned [2], the second sheet is conveyed from the tray and is
DF-609
formed a loop to corrected its skew [3], and the registration roller nips the original [4].
3. When paper exit operation starts [6] after the back side scan [5] of the first sheet is completed, the second
sheet on standby at the registration roller is conveyed to the conveyance section by the paper feed motor
(M301) [7] and the conveyance motor (M302) [8].
[1] [3][4] [7]
No paper sensor (PS304)

High
For-
ward Low
Paper feed
motor (M301)
Reve Low
rse High

Forward
Conveyance
Low
motor (M302) Reve
rse High
[2] [5] [6] [8]

a052t2c005ca
[1] First sheet conveyance [6] Start conveying of the first sheet for paper
[2] Front side scanning of first sheet exit
[3] Loop formation of the second sheet [7] Conveyance of the second sheet (M301)
[4] Nipping by the registration roller [8] Conveyance of the second sheet (M302)
[5] Back side scanning of first sheet
11
4.3.2 Original size detection

• Original size detection signal is detected by scanning in the main direction and sub direction.
• The original size detection method differs between normal copy mode and mixed original copy mode.
DF-609
A. Normal copy mode

• Main scan direction is detected by the resistance value of the size VR (VR301) interlocked with the guide
plate position on the paper feed tray
• Sub-scanning direction is detected by the combination of the size sensor/S (PS309) and size sensor/L
(PS310) when they are turned on and off.
B. Mixed original copy mode

• Maximum original size in main scan direction is detected by the resistance value of the size VR (VR301)
interlocked with the guide plate position on the paper feed tray.
• Sub scan direction is detected by the time when the original passes by the timing sensor (PS302).
• Allowed size combinations are as shown in the table below.
For metric area

Other Standard originals (max. original size detected by guide plate)
originals
A3 A4 B4 B5 A4S A5 B5S A5S B6S
A3 — — — — — — —
A4 — — — — — — —
B4 — — — — —
Thick Thick
paper paper
B5 — — — — —
A4S — — —
Thick Thick Thick Thick
paper paper paper paper
A5 — — —
B5S — —
Thick Thick
paper paper
A5S *1 *1 —
B6S *2 *2
12
For inch area

Other Standard originals (max. original size detected by guide plate)
originals
DF-609
A3 A4 B4 B5 A4S A5
11 x 17 — — — —
81/2 x 11 — — — —
81/2 x 14 —
Thick Thick
paper paper
81/2 x 11S —
Thick Thick
paper paper
81/2 x 51/2 —
Thick Thick
paper paper
81/2 x 51/2S *1 *1
: same size, : same series, : different series, : different series (out of guaranteed paper through
performance), : no mixed loading, —: not supported
*1 Detects not as an error but as A4

*2 Detects not as an error but as B5
4.3.3 No paper detection

No paper detection signal is detected by the no paper sensor (PS304).
13
5. CONVEYANCE SECTION Theory of Operation Ver.1.0 Jul. 2008
5. CONVEYANCE SECTION
5.1 Configuration
DF-609
[1]
[2] [2] [2]

a052t2c006ca
[1] Conveyance belt [2] Conveyance roller
14
Theory of Operation Ver.1.0 Jul. 2008 5. CONVEYANCE SECTION
5.2 Drive
DF-609
[3]
[2] [1] [2]

a052t2c007ca
[1] Conveyance belt [3] Conveyance motor (M302)
[2] Conveyance roller
15
5.3 Operation
5.3.1 Scanning and conveyance control
DF-609
• The conveyance belt is driven by the conveyance motor (M302).

• In single-sided mode, a swing-back to position the original for scanning is performed after the original is
conveyed from the paper feed section to the conveyance belt.
• In double-sided mode, the original returned from the reverse/paper feed section is conveyed at low speed,
and is positioned for scanning.
• Thin paper mode is provided in the original size setting as the positioning control method differs between
thin paper and the other papers (plain and thick).
A. Single-sided mode
(1) Swing-back
1. The original is conveyed from the paper feed section [2].
2. The original is conveyed [3] to the point that the rear end of the original comes over the positioning plate [1].
3. The conveyance motor (M302) rotates in reverse at low speed and returns the original [4], and the original is
stuck against the positioning plate [5].
4. The original is scanned.
[2]
[3]
[4]
[5]
[1] a052t2c008ca
[1] Stuck position [4] Swing-back

[2] Original conveyance [5] Positioning completed
[3] Stops after going through the stuck position
16
(2) Control
1. After the registration roller nips the original [1], the original is conveyed [2] from the paper feed section.
2. After the specified time has elapsed from when the timing sensor (PS302) has turned off (Rear end detec-
DF-609
tion), M302 is turned off and the original is conveyed to the point that the rear end of the original comes over
the positioning plate, and then the conveyance stops [3].
3. After the specified time, M302 rotates in reverse at low speed and returns the original [4], and the original is
stuck against the positioning plate (Swing-back).
4. The scanning is performed in the main body [5].
5. After scanning the second sheet (small size paper) or the first sheet (large size paper), the reverse/paper exit
motor (M303) is turned on at the same time as M302. Then the scanned original is conveyed to the reverse/
paper exit section [6] while the next original is conveyed to the conveyance section.
6. When the scanning of the last page is completed and after the specified time has elapsed from when the
reverse sensor (PS305) is turned on, M302 is turned off [7].
[1] [7]
High
For-
war Low
Paper feed motor
(M301)
Rev Low
erse High

Forward
Conveyance
motor (M302) Rev Low
erse High
Reverse sensor (PS305)
[2] [3][4] [5] [6] a052t2c009ca
[1] Nipping the original [6] Conveyance from the paper feed section
[2] Conveyance from the paper feed section and paper exit
[3] Pausing for swing-back [7] Conveyance to the reverse/paper exit sec-
[4] Swing-back tion completed
[5] Scanning the original
17
B. Double-sided mode
(1) Operation
• The paper path of the reverse paper exit section is created by the paper exit gate [1] and the reverse gate
DF-609
[8]. Both gates are set by turning off the paper exit solenoid (SD301) and turning on the reverse solenoid
(SD302).
1. The front side scan is performed in the same operating method as in the single-sided mode.
2. The original is conveyed to the reverse/paper exit section [5] to perform back side scan by driving the
reverse/paper exit motor (M303) and the conveyance motor (M302). At this time, the leading edge of the
original (Back side) that is conveyed in reverse [7] overlaps with the rear end of the original (Front side) [4] on
the right side of the conveyance belt [6] near the reverse/paper exit section.
[7] [8]
[1]
[2]
[6] [5] [4] [3] a052t2c010ca
[1] Paper exit gate [6] Conveyance belt

[2] Reverse sensor (PS305) [7] Pushing direction of the scanning section
[3] Reverse roller (Back side)
[4] Rear end of the original (Front side) [8] Reverse gate
[5] Conveyance direction to the reverse/paper
exit section
18
3. While operating the reverse conveyance [2], the original is conveyed at low speed [4] after a short pause [3]
and the original is stuck [5] against the positioning plate [1].
4. The back side scan is performed.
DF-609
[2]
[3]
[4]
[5]
[1] a052t2c011ca
[1] Stuck position [4] Pushing at low speed (Reverse conveyance)

[2] Reverse/paper exit from the reverse section [5] Positioning completed
[3] A pause before being stuck against the
positioning plate
19
(2) Control
1. The front side scan is performed [1] in the same operating method as in the single-sided mode.
2. M302 starts driving forward at the same time as M303 is turned on. Then the original is conveyed to the
DF-609
reverse/conveyance section [2].

3. After the specified time has elapsed from when the reverse sensor (PS305) has turned on, M302 and M303
turn off [3]. Then only M302 starts rotating again in reverse at high speed [4], and the original is conveyed
toward the stuck position (Leftward) by the conveyance belt.
4. M302 pauses [3] after the specified time has elapsed from when M302 has turned on (in reverse at high
speed) and switches speed to low speed [5]. Then the original is conveyed to the stuck position against the
positioning plate [1].
5. After the positioning is completed, the scanner (main body side) performs scanning.
6. After the back side scan [6] is completed, the paper exit is performed [7] in the same operating method as in
single-sided mode.
7. When there are any originals that follow, the paper feed motor (M301) keeps operating to continue the con-
veyance [9].
[3] [8]
High
For-
Paper feed motor war Low
(M301)
Rev Low
erse High
Forward
Conveyance
motor (M302) Rev Low
erse High
Reverse/paper For- High
exit motor (M303) war Low
[1] [2] [4] [5] [6] [7] [9]

a052t2c012ca
[1] Front side scanning [6] Back side scanning

[2] Conveyance to the reverse/paper exit sec- [7] Paper exit
tion [8] Conveyance of the following originals from
[3] A pause to reverse the paper feed section
[4] Reverse [9] Continued action (paper feeding and exiting
[5] Pushing at low speed (Reverse conveyance) operation) of M302
20
6. REVERSE/PAPER EXIT SECTION

6.1 Configuration
DF-609
[7] [8] [1]
[2]
[3]
[6] [5] [4]
a052t2c013ca
[1] Paper exit sensor (PS306) [5] Reverse gate

[2] Paper exit gate [6] Reverse stacker
[3] Reverse sensor (PS305) [7] Paper exit stacker
[4] Reverse roller [8] Paper exit roller
21
6.2 Drive
[5] [6] [7]

DF-609
[1]
[4] [3] [2] a052t2c014ca

[1] Paper exit gate [5] Reverse/paper exit motor (M303)

[2] Reverse solenoid (SD302) [6] Paper exit roller (with one-way clutch)
[3] Reverse gate [7] Paper exit solenoid (SD301)
[4] Reverse roller
22
6.3 Operation
• The reverse roller and the paper exit roller are driven by the reverse/paper exit motor (M303).
DF-609
• One-way clutch rotates the paper exit roller only in the paper exit direction when M303 drives both forward
and reverse.
• The paper exit gate and the reverse gate switch the path of the reverse paper exit.
• The paper exit gate [1] is driven by the paper exit solenoid (SD301). The path is switched to the reverse
path [2] when SD301 is turned off while the path is switched to the straight paper exit path [6] when SD301
is turned on.
• The reverse gate [3] is driven by the reverse solenoid (SD302). The path is switched to the reverse stacker
path [5] when SD302 is turned off while the path is switched to the back side reverse path [4] when SD302
is turned on.
[6]
[5]
[1]
[4] [3] [2] a052t2c015ca
[1] Paper exit gate [4] Back side reverse path

[2] Reverse path [5] Reverse stacker path
[3] Reverse gate [6] Straight paper exit path
23
6.3.1 Paper exit control
A. Straight paper exit

DF-609
(1) Operation
• When the paper exit solenoid (SD301) is turned on, the paper exit gate [1] is set in the straight paper exit
path [3].
• The original [5] is detected by the reverse sensor (PS305) [2] and the paper exit senor (PS306) [4].
[3] [4] [5]
[1]
[2]
a052t2c016ca
[1] Paper exit gate (ON) [4] Paper exit sensor (PS306)
[2] Reverse sensor (PS305) [5] Original
[3] Paper exit conveyance path
24
(2) Control
1. When the paper exit solenoid (SD301) is turned on [2] after the scanning [1] is completed, the paper exit gate
is set in the straight paper exit path.
DF-609
2. The reverse/paper exit motor (M303) is turned on at the same time as the conveyance motor (M302), and
the original conveyed by the conveyance belt is conveyed to the paper exit roller of the reverse/paper exit
section.
3. After the specified time has elapsed from when the reverse sensor (PS305) is turned off, M303 slows down
[4] to make the original aligned when it is ejected and the original is ejected to the paper exit stacker at low
speed.
4. After the specified time has elapsed from when the paper exit sensor (PS307) is turned off, M303 is turned
off [5].
[1] [3] [4] [5]
Forward
Conveyance motor
(M302) Reve Low
rse
High
High
For-
ward Low
Reverse/paper exit
motor (M303)
Reve Low
rse
High
Reverse solenoid (SD302)
Paper exit solenoid (SD301)
[2] a052t2c017ca
[1] Scanning [4] Switching at low speed (M303)

[2] Sets the paper exit gate in the straight paper [5] Paper exiting completed
exit path
[3] M302 and M303 starts operating for paper
exit
25
B. Reverse/paper exit
(1) Operation
• The paper exit solenoid (SD301) and the reverse solenoid (SD302) are off in this mode.
DF-609
1. The original [4] from the conveyance section is fed around the reverse roller [3] through the paper exit gate
[1], and conveyed to the reverse stacker [5] by the reverse gate [7].
2. The original stops proceeding with its rear end nipped by the reverse roller [8].
[5] [6] [7] [8]
[1]
[2]
[4] [3] a052t2c018ca
[1] Paper exit gate (OFF) [5] Reverse stacker

[2] Reverse sensor (PS305) [6] Conveyance direction
[3] Reverse roller [7] Reverse gate (OFF)
[4] Original [8] Nipping rear end of the original
3. The reverse roller stops rotating once, then starts reverse rotating and feed the original to the reverse paper
exit conveyance path.
4. The paper exit roller slows down when feeding the rear end of the original, and ejects the original with no
skew.
26
[1] [2] [3]
DF-609
a052t2c019ca
[1] Original [3] Paper exit roller
[2] Reverse/paper exit
27
(2) Control
1. The original from the conveyance section is conveyed to the path of the reverse stacker [1] that is set by
paper exit gate and the reverse gate.
DF-609
2. When the reverse sensor (PS305) detects the rear end of the original [2] and turns off, M303 reduces its
speed.
3. After the specified time, the original stops proceeding [3] with its rear end nipped by the reverse roller.
4. M303 rotates in reverse and the original is conveyed to the reverse paper exit path [4].
5. After the specified time has elapsed from when the paper exit sensor (PS306) has turned ON, M303 slows
down [5] and the original is ejected in reverse at low speed to the paper exit stacker.
6. After the specified time from when PS306 has turned off, M303 is turned off [6].
[2] [3] [4] [5] [6]
Conveyance motor (M302) Forward

High
Forward
Low
Reverse/paper exit motor
(M303)
Low
Reverse
High
[1] a052t2c020ca
[1] Conveyance to the reverse stacker [4] Reverse paper exit (with reverse rotation at high speed)
[2] Slowing down (M303) [5] Slowing down to align original
[3] Stops with rear end nipped [6] Reverse paper exit completed
28
6.3.2 Reverse paper exit control
(1) Operation
DF-609
• In reverse conveyance mode, the paper exit solenoid (SD301) is set to OFF while the reverse solenoid
(SD302) is set to ON.
• The original [3] from the conveyance section wraps around the reverse roller [2] by the paper exit gate [1].
Then through the reverse gate that is turned ON [6], the original slides under [5] the conveyance belt [4] and
is returned to the conveyance section.
[5] [6]
[1]
[4] [3] [2] a052t2c021ca
[1] Paper exit gate (OFF) [4] Conveyance belt

[2] Reverse roller [5] Sliding under the conveyance belt
[3] Original [6] Reverse gate (ON)
29
(2) Control
1. After the front side scan is performed [1], the conveyance motor (M302) [2] conveys the original from the
conveyance section, and then the reverse/paper exit motor (M303) conveys it to the reverse path that is set
DF-609
the paper exit solenoid (SD301) OFF and the original is fed around the reverse roller [3].
2. When the reverse solenoid (SD302) is turned on [4], the reverse gate sets the conveyance direction toward
the conveyance belt. Then the original starts returning [5] to the conveyance section while sliding under the
conveyance belt.
3. After the specified time from when the reverse sensor (PS305) has turned ON, M302 and M303 stop rotating
once at the same moment. Then M302 switches to rotate in reverse [6] while M303 rotates forward [7] and
the original is returned further toward the scanning position.
4. After the specified time from PS305 has turned OFF, M303 [8] turns off. However, the belt keeps conveying
[9].
[1] [2] [6]
Forward
Conveyance
motor (M302) Low
Reve
rse
High
For- High
ward
Low
Reverse/paper
exit motor
(M303) Low
Reve
rse
High
Reverse solenoid (SD302)
[3] [4] [5][7] [8] [9] a052t2c022ca
[1] Front side scanning [6] Reverse conveyance of the belt

[2] Conveyance to the reverse paper exit sec- [7] Conveyance toward the reverse conveyance
tion (M302)
[3] Conveyance to the reverse paper exit sec- [8] Conveyance completed (M303)
tion (M303)
[4] Reverse gate setting [9] Reverse conveyance by the conveyance
belt
[5] Sliding under the conveyance belt
30
MAINTENANCE
DF-609
Caution:
• Be sure to unplug the power cord from the power outlet.
7.1 Paper feeding section

7.1.1 Removing/installing paper feed unit
A. Procedure
1. Open the paper feed cover [1]

[2] [2] 2. Release 2 locks [2].
3. Turn the paper feed guide [4] in the direction of the
arrow [5] while pushing in the paper feed unit [3]
to the paper feed cover [1] side, and remove the
paper feed guide [4] upward.
Note
• When installing the paper feed guide, fit 3
tabs [6] in each positioning hole [7].
• When installing the paper feed guide, be sure
[5] [1] [4] [3] [5]
to put the no paper detection actuator [8] so
that it protrudes out of the paper feed guide
[4] as shown in the figure on the left.
[8] [6] [7]
a052f2c001ca
31
4. Remove the screw [1] and remove the shaft

[1] securing plate [2].
5. Remove 2 C-clips [3].
DF-609
6. Slide 2 bearings [4] inward, and remove the paper

[2] feed unit [5].
[5]
[3] [4]
[4] [3]
a052f2c002ca
Note
[4] [3] [2] [1] • When removing the paper feed unit, be sure
not to damage the arm [2] with the shaft [1].
• When installing the paper feed unit, make
sure the arm [2] is mounted on the shaft [1].
• When installing the paper feed unit, insert the
tab [3] under the cover plate [4] as shown in
the figure.

steps in reverse.
a052f2c003ca
32
7.1.2 Replacing pick-up roller/paper feed roller

• Paper feed roller : Every 1,800,000 prints (actual replacement cycle: every 625,000 feed)
DF-609
B. Procedure
1. Remove the paper feed unit. (Refer to P.31)

[1] [2]
a052f2c004ca
4. Slide the gear [1] in the direction of the arrow [2]

[5] [4] [1] [3] [2] and remove the pin [3]. Then remove the gear [1]
and the belt [4] in the direction of the arrow [5].
a052f2c005ca
5. Remove the C-clip [1], then remove the gear [2]

[1] [2] [3]
and the pin [3].
Note
• Be careful not to lose the pin [3] as it may
drop off the shaft when removing the gear [2].
a052f2c006ca
33
6. Remove the arm [1] and the pin [2].

[1] [2]
Note
DF-609

drop off the shaft when removing the arm [1].
a052f2c007ca
7. Remove the C-clip [1], and remove the pick-up

[2] [3] [1]
roller assy [3] from the paper feed roller assy [2].
a052f2c008ca
8. Remove the C-clip [1] and pull out the paper feed
[1] [2] [4]
roller [2] from the shaft to replace it with new one.
Note
• When installing the paper feed roller, make
sure that the arrow mark [3] on the paper feed
roller is facing the gear [4].
[3]
a052f2c009ca
34

[2]
Note
DF-609
drop off the shaft when removing the C-clip
[3] [1].
10. Remove the pin [2] and remove the pick-up roller
[3].
[4] [1]
Note
drop off the shaft when removing the C-clip
[4].
12. Remove the pin [5] and remove the pick-up roller
[6].
[6]
steps in reverse.
[5]
a052f2c010ca
35
7.1.3 Replacing separation roller

• Separation roller: Every 1,800,000 prints (actual replacement cycle: every 625,000 feed)
DF-609
B. Procedure
2. Push 2 tabs [2] inward to release the lock and
[2] remove the separation unit cover.
[1]
[2]
a052f2c011ca
3. Pinch both ends of the roller shaft and raise the

[1]
separation roller [1] straight up.
a052f2c012ca
36
4. Remove the separation unit [1] and replace it with

[1]
a new one.
DF-609
steps in reverse.
a052f2c013ca
7.1.4 Cleaning timing sensor (PS302)

A. Periodically cleaned parts/cycle
• Timing sensor (PS302) : Every 200,000 prints *1
*1 PRO C6501
*2 PRO C5501
B. Procedure
1. Secure the hinge adjustment bracket at 90
[1] [2] [4] [5] [3] [2]
degrees.
2. Open the DF [1] vertically.
3. Remove 2 screws [2] and open the metal frame
[3] in the direction of the arrow [4].
Note
• 2 screws [2] are different from each other, so
try not to mix them up.
4. Clean the timing sensor (PS302) through the hole

[5] with a blower brush or a similar tool.
a052f2c014ca
37
7.1.5 Removing/reinstalling registration roller cover

A. Procedure
DF-609
2. Raise the paper feed tray [2] straight up.

[3]
3. Remove 4 screws [3] and remove the registration
roller cover [4].
steps in reverse.
[4] [1]
[2]
[3]
a052f2c015ca
7.1.6 Cleaning registration roller

• Registration roller : Every 200,000 prints *1
*1 PRO C6501
*2 PRO C5501
B. Procedure
1. Remove the registration roller cover. (Refer to
[1]
P.38)
2. Soak cotton waste with alcohol and wipe 3 regis-
tration rollers [1] with it.
a052f2c016ca
38
7.1.7 Cleaning registration sensor (PS301)

• Registration sensor : Every 200,000 prints *1
DF-609
*1 PRO C6501
*2 PRO C5501
B. Procedure
1. Remove the registration roller cover. (Refer to
[1] P.38)
2. Clean the registration sensor (PS301) [1] with a
blower brush or a similar tool.
a052f2c017ca
39
8. OTHER PROCEDURES
DF-609

1 Main body DF P.41
2 Cover section Front cover P.43
3 Rear cover P.43
4 Conveyance section Conveyance belt unit P.44
40
8.2 Disassembly/reassembly procedures
Caution:
DF-609
8.2.1 Removing/reinstalling DF
Note
• Before removing the DF, be sure to secure the hinge adjustment bracket of the DF at 90 degrees.
When removing the parts from the scanner section with the DF opened, secure the hinge adjust-
ment bracket at 90 degrees as well. Not doing so may deform the metal frame in the DF installa-
tion section.
A. Procedure
[2]
2. Read the explanation below and secure 2 hinge
adjustment brackets [2] at 90 degrees.
There are 2 types of the bracket installed in the
DF; one for 70 degrees and the other for 40
degrees, and they can be distinguished by the
scratched number on each surface.
Brackets for 70 degrees: Loosen 4 screws [3] and
slide 2 brackets [2] downward, and then secure
them with 4 screws [3] again.
Brackets for 40 degrees: Remove the four screws
[3] [1] [3]
[3]. Turn 2 brackets [2] upside down and reinstall
them to DF and secure 4 screws [3] again.
a052f2c018ca
41

[1]
5. Remove 2 screws [3] and remove the metal plate
DF-609
[4].
[2] [3]
[4]
a052f2c019ca
6. Holding the DF [1], slide 2 stoppers [2] to disen-

[1]
gage them from the holes [3], and remove the DF
upward.
Note
• When releasing the stoppers [2], be sure to
support the DF firmly so as not to fall over
backward.

steps in reverse.
[3] [2]
[2] [3]
Note
• After installing DF, perform the service mode
"ADF original stop position adjustment".
a052f2c020ca
42
8.2.2 Removing/reinstalling front cover

A. Procedure
DF-609
[6] [7]
degrees.
2. Open the DF [1] and remove 2 screws [2].
3. After closing the DF [1], open the paper feed
cover [3] and paper exit cover [4].
Note
[5] [3] [1] [4] • Be sure to close the DF [1] gently since the
front cover [5] is not secured and is unstable
at this moment.
• Do not open the DF [1] with the paper exit
cover opened so as to avoid the paper exit
cover [4] from being damaged.
4. Lift the front cover [5] a little so that the tab [6] is
released through the hole [7], and remove the
[2] front cover [5].
steps in reverse.
a052f2c021ca
8.2.3 Removing/reinstalling rear cover

A. Procedure
1. Open the paper feed cover [1] and the paper exit
[3] [1] [5] [4] [3] [2] cover [2].
2. Remove 2 screws [3].
3. Tilt the rear cover [4] in the direction of the arrow
[5] and remove it upward.
steps in reverse.
a052f2c022ca
43
8.2.4 Removing/reinstalling conveyance belt
Note
DF-609
• Do not touch, fold, or damage the belt roller. If necessary, be sure to hold it within the range of
20mm from each end of the belt in sub-scanning direction.
A. Procedure
[3] [3]
degrees.
3. Slide 2 stoppers [3] located on the upper inner
side of the conveyance belt unit [2] to the right
[1] [2] [4] and remove them.
4. Pull out the upper part of the conveyance belt unit
in the direction of the arrow [4], and remove it
upward.
Note
• When installing the conveyance belt unit, be
sure to install the linking drive belt [5] into the
conveyance belt unit securely.

steps in reverse.
[5]
a052f2c023ca
6. Remove 2 screws [1], and raise the roller section

[1]
upward.
7. Remove the conveyance belt.
steps in reverse.
[1] a052f2c024ca
44
PF-602/HT-504
2008.07
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
PF-602/HT-504
PF-602/HT-504
OUTLINE
1.1 PF-602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 HT-504 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2.1 Tray lift drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2.2 Paper feed drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2.3 Pick-up drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3.1 Plate up/down control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3.3 Pick-up mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3.4 Separation mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.3.5 Air assist mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3.8 Tray lock control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.3.1 Pre-registration control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.3.3 Multi feed detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.3.4 Centering detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6. OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1 Dehumidifier heater control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2 Tray damper mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.3 Main body assist mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.3.1 Filter replacement assy retaining mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.3.2 Filter replacement assy ventilation mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.3.3 Environment temperature detection assist mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7. HT-504 (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.2.1 Dehumidifier fan heater control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.2.2 AC power control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
i
MAINTENANCE
PF-602/HT-504
8.1 Tray section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

8.1.1 Replacing the Pick-up rubber/paper feed roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.1.3 Replacing the paper feed clutch (MC1/MC4) and the separation clutch (MC2/MC5) . . . . . . . . . 41
8.2 Conveyance section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.2.1 Replacing the vertical conveyance clutch/1 (MC7), /2 (MC8), and /3 (MC9) . . . . . . . . . . . . . . . 43
8.2.2 Replacing the horizontal conveyance clutch/1 (MC10), /2 (MC11),
and pre-registration clutch (MC12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.2 Disassembly/reassembly procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
9.2.1 Removing/installing the right cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
9.2.2 Removing/installing the rear cover/Lt2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.2.3 Removing/installing the rear cover/Lt1 /Rt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9.2.4 Removing/reinstalling the front cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.2.5 Removing/reinstalling the tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9.2.6 Removing/installing the lift wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

9.2.7 Removing/installing the paper lift motor/1 (M2) and /2 (M3) . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9.2.8 Removing/installing the vertical conveyance units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
9.2.9 Removing/installing the horizontal conveyance unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.2.10 Removing/installing the multi feed detection board (MFDTB/R and /S) . . . . . . . . . . . . . . . . . . . 69
ii
OUTLINE
PF-602/HT-504
1.1 PF-602
A. Type
Type Front loading type two-tray paper feeder
B. Functions
Number of trays Two trays (All trays universal)

Tray capacity 6,000 sheets (80 g/m2 standard paper) = 3,000 sheets x 2 trays
C. Paper type
Paper size SRA3, A3, B4, SRA4, SRA4S, A4, A4S, B5, B5S, A5*1, A5S, B6S, A6S*1
13 x 19, 12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
8K, 16K, 16KS
Tray /4: Custom paper (Max. 330 x 487mm, Min. 100 x 182 mm)
Tray /5: Custom paper (Max. 330 x 487mm, Min. 100 x 148 mm)
Applicable paper Plain paper, high quality paper, coated paper
Paper weight Tray /4 64 to 256g/m2
Tray /5 64 to 300g/m2
*1 A5 and A6S are fed only from the tray/5.
D. Maintenance
E. Machine data
Power source 24/12/5VDC, 200 to 240VAC (supplied both from the main body)
Maximum power consump- DC: 90W or less, AC: 100W or less
tion
Dimensions 947 (W) x 750 (D) x 1045 (H) mm
Weight Approx. 170kg
Temperature 10 to 30°C
1
1.2 HT-504
PF-602/HT-504
A. Type
Type Fan heater type dehumidifier heater
B. Machine data
Power source 24/5VDC (supplied from the main body), 200 to 240VAC*1
tion
Dimensions Dehumidifier fan heater unit: 197 (W) x 82 (D) x 293 (H) mm
Power supply unit: 121 (W) x 80 (D) x 160 (H) mm
Weight Dehumidifier fan heater unit: Approx. 1.5kg/1 unit
Power supply unit: Approx. 0.9kg
*1 North America model: Supplied from the main body.

Europe model: Supplied from external.
C. Operating environment
2
PF-602/HT-504
[1] [3]
[2]
a03xt1c001ca
[1] Paper feed section [3] HT-504 (Optional)

[2] Conveyance section
3
3. PAPER PATH
PF-602/HT-504
[1] [2]
[3]
a03xt1c002ca
[1] From tray/4 [3] From tray/4 and /5 to the main body
[2] From tray/5
4
PF-602/HT-504
4.1 Configuration
Pick-up roller
Paper feed
roller
Separation
Paper empty sensor roller
/1 (PS3), /2 (PS11)
Paper feed assist fans Paper size VR/1 (VR1) and VR/2 (VR3) (Main scan direction)
Paper size sensors /Rt1 (PS5), /Lt1 Remaining paper VR/1

(PS6), /Rt2 (PS13), and /Lt2 (PS14) (VR2) and VR/2 (VR4)
(Sub scan direction)
Paper lift plate
Paper up/down
assist mechanism
a03xt2c001ca
5
4.2 Drive
PF-602/HT-504
4.2.1 Tray lift drive
[1] [2]
[3]
[4]
a03xt2c002ca
[1] Lift wire/Fr2 and /Rr2 [3] Paper lift plate

[2] Lift wire/Fr1 and /Rr1 [4] Paper lift motor/1 (M2) and /2 (M3)
6
4.2.2 Paper feed drive
PF-602/HT-504
[5]
[6]
[1] [2]
[7]
[8]
[9]
[10]
[4] [3]
[11]
a03xt2c003ca
[1] Paper feed roller [7] Separation clutch /1 (MC2)

[2] Pick-up roller [8] Paper feed clutch /2 (MC4)
[3] Separation roller [9] Coupling (transmission of driving force to
[4] Torque limiter the tray/5)
[5] Paper feed clutch/1 (MC1) [10] Separation clutch /2 (MC5)
[6] Coupling (transmission of driving force to [11] Paper feed motor (M1)
the tray/4)
7
4.2.3 Pick-up drive

PF-602/HT-504
[2]
[1]
a03xt2c004cb
[1] Pick-up solenoid/1 (SD1) and /2 (SD5) [2] Pick-up roller
8
4.3 Operation
PF-602/HT-504
A. Plate-up mechanism
• The paper lift motors/1 (M2) and /2 (M3) drive the pulley to wind up the lift wires in order to lift the paper lift
plate.
B. Plate-down mechanism
• The paper lift plate [1] goes down by the down button [2].
• Loading papers on the paper lift plate presses the plate-down button [2] on the side of the tray, and release
lever [4] releases the coupling in the torque limiter [5]. The pulley drive shaft [6] keeps rotating while the
plate-down button is pressed.
• When the paper lift plate [1] is at its uppermost position, the tray-down stopper [7] is on the rear side [8] of
the tray, and the gear [9] prevents the paper lift plate from going down.
[1] [2] [3] [4]
[5]
[6] [8] [9] [7]

a03xt2c005ca
[1] Paper lift plate [6] Shaft

[2] Down button [7] Tray-down stopper
[3] Papers [8] Rear side of the tray
[4] Release lever [9] Gear
[5] Torque limiter
C. Operation timing
(1) When tray is set
• The paper lift motors/1 (M2) and /2 (M3) are activated and lift the paper lift plate.
• The M2 and M3 motors are stopped when the upper limit sensors/1 (PS1) and /2 (PS9) detect the upper-
most status of the paper lift plate.
(2) During printing
• When the PS1 and PS9 sensors turn off, the M2 and M3 motors are activated.
• When the PS1 and PS9 sensors turn on upon detection of the upper most status of the paper lift plate (with
the paper lift plate up), M2 and M3 are stopped.
9

A. Main scan/Sub scan direction detection
PF-602/HT-504
• The detection methods differ between main scanning direction and sub-scanning direction.
(1) Main scan direction

• The size in the main scan direction is detected by the paper size VR/1 (VR1) and /2 (VR3) that move
together with the paper guide. The detected size is sent to the main body within a fixed time period after the
tray is set.
(2) Sub scan direction

• The size detection in the sub scan direction is made by the following each pair of the sensors: the paper
size sensors/Rt1 (PS5) [3] and /Lt1 (PS6) [4] for tray /4, /Rt2 (PS13) [3] and /Lt2 (PS14) [4] for tray /5.
• When the paper rear guide [6] is moved, the detection cams /Up [1] and /Lw [2] that are different in shape
are pressed by the knob [5]. Depends on the position of the paper rear guide, the paper size sensors/Rt1
[4], /Rt2 [4] and /Lt1 [3], /Lt2 [3] are turned on and off.
[5] [6]
[1]
[2]
[3] [4]
a03xt2c006ca
[1] Detection cam/Up [4] Paper size sensors/Lt1 (PS6) and /Lt2
[2] Detection cam/Lw (PS14)
[3] Paper size sensors/Rt1 (PS5) and /Rt2 [5] Knob
(PS13) [6] Paper rear guide
10
Paper size Paper size sensor
PF-602/HT-504
/Lt1 (PS5) and /Lt2 (PS14) /Rt1 (PS5) and /Rt2 (PS13)
A6S, B6S, A4S, B5, A3, OFF (light blocking) OFF
11 x 17, 13 x 19
81/2 x 11S, 8K, 16KS OFF ON
A5S, B5S, A4, SRA4, B4, ON (exposure) ON
51/2 x 81/2S, 81/2 x 11, 81/2 x 14
A5, SRA4S, SRA3, 81/4 x 13, ON OFF
81/8 x 131/4, 81/2 x 13, 8 x 13,
12 x 18, 16K
* For the paper sizes below, it is necessary to set the paper size on the touch panel.
Make a selection among “SRA4, A5S”, “8x13”, “81/8 x 131/4”, “81/4 x 13” and “81/2 x 13”
Make a selection among “A5” and “51/2 x 81/2S”
Make a selection among “B4, B5S, B5, 11x17, 81/2 x 11” and “8K, 16KS, 16K”
11
B. Assist guide detection control

• The paper size sensors /Fr1 (PS7), /Fr2 (PS15) [2], /Rr1 (PS8), and /Rr2 (PS16) [3] detect opening or clos-
PF-602/HT-504
ing of the auxiliary guide [1] when A6S size paper are set.
• When the auxiliary guide [1] is in use, PS15 and PS16 are turned off.
• Tray/4 does not support A6S paper.
[2]
[3]
[1]
[1]
a03xt2c007ca
[1] Auxiliary paper guide [3] Paper size sensors /Rr1 (PS8), and /Rr2
[2] Paper size sensors /Fr1 (PS7), and /Fr2 (PS16)
(PS15)
12
4.3.3 Pick-up mechanism

• Paper is picked up when the pick-up solenoids/1 (SD1) and /2 (SD5) are turned off.
PF-602/HT-504
• When the solenoids SD1and SD5 are turned off, the pick-up roller goes down to press paper by its own
weight.
• When the paper feed clutches /1 (MC1) and /2 (MC4) turn on, the pick-up roller starts to rotate and feed
paper to the paper feed roller.
[3] [5]
Paper feed sensor/1 (PS2) and /2 (PS10)
Paper feed clutch/1 (MC1) and /2 (MC4)

Pick-up solenoid/1 (SD1) and /2 (SD5)
[1] [2] [4] a03xt2c008ca
[1] START button ON [4] Pick-up of the 2nd sheet of paper
[2] Pick-up of the 1st sheet of paper [5] Conveyance of the 2nd sheet of paper
[3] Conveyance of the 1st sheet of paper
13
4.3.4 Separation mechanism

• Papers are separated by the separation roller [5].
PF-602/HT-504
• The separation roller [5] rotates in the direction [10] opposite to the paper conveyance direction [9] by
means of the torque limiter [8]. The roller is pressed against the paper feed roller by force exerted by the
spring [7] and the torque limiter.
• When no paper exists between the separation roller and the paper feed roller or when the only one sheet of
• When multiple sheets of paper are fed, the separation roller reverses the direction of rotation [10] (opposite
to the paper feed roller) and feeds the lower paper [2] that contacts with the separation roller back to the
tray [3]. The drop in frictional force between the two rollers due to the multiple sheets causes the counter
rotating of the separation roller.
[10] [9] [1]

[8]
[2]
[7] [6] [5] [4] [3]
a03xt2c009ca
[1] Paper feed roller [6] Pressing force

[2] Lower (2nd) sheet of paper [7] Spring
[4] Direction to feed paper normally [9] Paper feed direction
[5] Separation roller [10] Direction to separate sheets
14
4.3.5 Air assist mechanism

• The paper feed assist fans that are provided on the paper guides in the trays/4 and /5 blow air [7] onto
PF-602/HT-504
paper [9] in order to assist the separation of paper.
• Tray/4 is provided with paper feed assist fans/Fr11 (FM1) [6], /Fr12 (FM3) [5], /Rr11 (FM2) [1] and /Rr12
(FM4) [3]. Tray /5 is provided with paper feed assist fans/Fr21 (FM5) [6], /Fr22 (FM7) [5], /Rr21 (FM6) [1], /
Rr22 (FM8) [3].
• When feeding from the tray specified as a tray for coated paper, the assist fans of the tray start to operate.
[7] [8] [9]
[6]
[1]
[5]
[2]
[3]
[4]
a03xt2c010ca
[1] Paper feed assist fans /Rr11 (FM2) and / [5] Paper feed assist fans /Fr12 (FM3) and /
Rr21 (FM6) Fr22 (FM7)
[2] Shutter solenoids /Rr1 (SD3) and / Rr2 [6] Paper feed assist fans /Fr11(FM1) and /Fr21
(SD7) (FM5)
[3] Paper feed assist fans /Rr12 (FM4) and / [7] Air-blowing
Rr22 (FM8) [8] Shutter solenoids /Fr1 (SD2) and /Fr2 (SD6)
[4] Shutter [9] Papers
15
A. Operation timing
• When the coated paper is selected in the paper setting, the paper feed assist fans/Fr11 (FM1), /Fr12 (FM3),
PF-602/HT-504
/Rr11 (FM2) and /Rr12 (FM4) or the paper feed assist fans/Fr21 (FM5), /Fr22 (FM7), /Rr21 (FM6) and /Rr22
(FM8) of corresponding tray start to operate when the START button is pressed.
B. Open/close shutter control

• Amount of air blow is adjusted by the shutter solenoids /Fr1 (SD2) [8], /Rr1 (SD3) [2], /Fr2 (SD6) [8], and /
Rr2 (SD7) [2]. When the SD2/ SD3/ SD6/ SD7 turn on, the shutters are closed to increase the air blow.
• The SD2/SD3/SD6/SD7 keep turning off and on for a specified period of time after the start button is turned
on.
• Air blow operation is performed once between turning on of the start button and start of paper feed [2].
• The SD2, SD3, SD6 and SD7 can be forced off using DipSW4-0.

Paper feed assist fans /Fr11
(FM1), /Fr12 (FM3), /Rr11
(FM2), /Rr12 (FM4), /Fr21
(FM5), /Fr22 (FM7), /Rr21

(FM6), /Rr22 (FM8)
Shutter solenoids /Fr1 (SD2), /

Rr1 (SD3), /Fr2 (SD6), /Rr2
(SD7)
[1] [2]
a03xt2c011ca
[1] START button ON [2] Start feeding
16

• Paper empty detection on the tray is made according to on/off statuses of the upper limit sensors/1 (PS1)
PF-602/HT-504
and /2 (PS9) [6], and the paper empty sensors/1 (PS3) and /2 (PS11) [1].
• When the paper lift plate [4] goes up while paper is on the tray, the paper pushes up the actuator [2] and
then the PS3 and PS11 [1] are turned off.When the paper lift plate further goes up, the pick-up roller section
[5] is pushed up to turn off the PS1 and PS9 [6].
• When there is no paper, the actuator is inserted in the hole [3] in the paper lift plate and is not lifted up. On
the other hand, the pick-up roller section[5] is lifted up to turn off the PS1/ PS9 [6]. If PS1/PS9 turn off when
the paper lift plate is being lifted, the product detects that paper is empty and shows the message on the
touch panel.
• While feeding paper, the PS3 and PS11 are switched from OFF to ON while the PS1 and the PS9 is OFF,
and paper empty is detected.
[1] [6] [5]
[4]
[3] [2]
a03xt2c012ca
[1] Paper empty sensors /1 (PS3) and /2 (PS11) [4] Paper lift plate
[2] Actuator of the paper empty sensors /1 [5] Pick-up roller section
(PS3) and /2 (PS11) [6] Upper limit sensors /1 (PS1) and /2 (PS9)
[3] Hole
17

• Remaining paper detection is made by the remaining paper VR/1 (VR2) and /2 (VR4) that are interlocked
PF-602/HT-504
with the up/down operation of the paper lift plate via the pulley and the gear.
• The following 8 levels are detected according to the resistance value, and the detected information is sent
to the main body.
[1]
a03xt2c013ca
[1] Remaining paper VR/1 (VR2) and VR/2 (VR4)
4.3.8 Tray lock control

• Each of the tray is locked by the tray locked lever.
• When the tray lock release sensors /1 (PS4) and /2 (PS12) of the either trays /4 or /5 are turned off, the tray
lock solenoids /1 (SD4) and /2 (SD8) of the corresponding tray are turned on. This causes the tray lock lever
to go up and the tray is unlocked.
• In order to avoid pulling multiple trays out at a time, the SD4 and SD8 solenoids other than those which has
already been turned on do not become on even when an off-status of another lock release sensor is
detected while PS4 or PS12 sensor is off.
• When a jammed paper is lying over the tray and the exit conveyance section, the tray remains locked until
the jammed paper is removed. This prevents the paper from being torn off.
18
PF-602/HT-504
5.1 Configuration
Vertical conveyance
roller/2
Vertical conveyance roller/1
Vertical conveyance
roller/3
Horizontal conveyance Small size roller

roller/2
Multi feed
Horizontal conveyance roller/1
detection board
/R (MFDTB/R),
/S (MFDTB/S) Pre-registration roller
Centering sen-
sor (PS25)
a03xt2c014ca
19
5.2 Drive
PF-602/HT-504
[4] [1]
[5]
[6]
[7]
[8]
[9]
[2]
[13] [12] [11] [10]

[14]
[15]
[3]
a03xt2c015ca
[1] Coupling (transmission of driving force to [8] Vertical conveyance clutch/3 (MC9)
the tray/4) [9] Vertical conveyance roller/3
[2] Coupling (transmission of driving force to [10] Horizontal conveyance clutch/1 (MC10)
the tray/5) [11] Horizontal conveyance roller/1
[3] Paper feed motor (M1) [12] Pre-registration clutch (MC12)
[4] Vertical conveyance clutch/1 (MC7) [13] Pre-registration roller
[5] Vertical conveyance roller/1 [14] Horizontal conveyance clutch/2 (MC11)
[6] Vertical conveyance clutch/2 (MC8) [15] Horizontal conveyance roller/2
[7] Vertical conveyance roller/2
20
5.3 Operation
PF-602/HT-504
5.3.1 Pre-registration control
• In order to correct skew of paper, paper fed from the tray strikes against the pre-registration roller that is
stopping at that time.
• The pre-registration clutch (MC12) is turned on, the driving force of the paper feed motor (M1) is transmitted
to the pre-registration roller to feed paper inside the main body.
21

• For the vertical conveyance, the driving force of the paper feed motor (M1) [1] is transmitted by turning on
PF-602/HT-504
and off the vertical conveyance clutches /1 (MC7) [4], /2 (MC8) [7], and /3 (MC9) [8].
• For the horizontal conveyance, the driving force of paper feed motor (M1) is transmitted by turning on and
off the horizontal conveyance clutches /1 (MC10) [10], /2 (MC11) [14], and the pre-registration clutch
(MC12) [12].
• Paper fed from tray/4 is conveyed to the vertical conveyance rollers /1 [5], /2 [6], and /3 [9] driven through
MC7, MC8, and MC9, and then conveyed to the horizontal conveyance section.
• Paper fed from tray/4 vertically or fed from tray/5 is conveyed to the pre-registration roller [13] by the hori-
zontal conveyance roller/1 [11] driven via the MC10. Then, the pre-registration control described above is
performed and the paper is fed inside the main body.
• When the vertical conveyance sensors /2 (PS27) [3] and /3 (PS26) [2] detect the paper trailing edge, the
sensors read it twice within the specified time. The paper trailing edge once passed through the sensors
may return to the sensor detection position due to slack in the paper, and detected by the sensors again
unexpectedly. To prevent the mis-detection, the sensors carry out the detection operation twice every time.
[4]
[5]
[6]
[7]
[3]
[8]
[1]
[9]
[11] [2]
[13] [10]
[12]
[14]
a03xt2c015ca
[1] Paper feed motor (M1) [8] Vertical conveyance clutch/3 (MC9)
[2] Vertical conveyance sensor/3 (PS26) [9] Vertical conveyance roller/3
[3] Vertical conveyance sensor/2 (PS27) [10] Horizontal conveyance clutch/1 (MC10)
[4] Vertical conveyance clutch/1 (MC7) [11] Horizontal conveyance roller/1
[5] Vertical conveyance roller/1 [12] Pre-registration clutch (MC12)
[6] Vertical conveyance roller/2 [13] Pre-registration roller
[7] Vertical conveyance clutch/2 (MC8) [14] Horizontal conveyance clutch/2 (MC11)
22
5.3.3 Multi feed detection control

• The multi feed sensor is provided in the horizontal conveyance section to detect multi feed.
PF-602/HT-504
• The multi feed sensor is a ultrasonic sensor consisted of a sending and receiving section. The ultrasonic
waves sent from the multi feed detection board/S (MFDTB/S) are received at the multi feed detection
board/R (MFDTB/R).
• The intensity of the ultrasonic waves received by the receiving section differs according to the number of
sheets passed between the MFDTB/S and MFDTB/R. Therefore, the sensor can detect multi feed by the
intensity.
• When multi feed is detected, the paper feeding operation will stop, however, the next sheet of paper is fed
as usual.
• The multi feed detection function can be enabled/disabled using DipSW19-4.
5.3.4 Centering detection control

• While paper being fed, centering sensor (PS25) detects the paper edges in the main scan direction.
• The detected information is written in the image processing section so that a scanned image is precisely
located and printed on the paper as intended.
• In order to increase the life of the PS25, the sensor is not always "On"; it turns off after sending the detected
information to the main body and turns on when it detects the paper reached to the pre-registration sensor.
23
6. OTHERS Theory of Operation Ver.1.0 Jul. 2008
6. OTHERS
PF-602/HT-504

• Dehumidifier heaters /1 (HTR1) and /2 (HTR2) are provided under the trays /4 and /5, one for each tray, to
prevent paper from damping.
• When the sub power switch (SW2) is turned off, the HTR1 and HTR2 are turned on.
[1]
[2]
a03xt2c016ca
[1] Dehumidifier heater/1 (HTR1) [2] Dehumidifier heater/2 (HTR2)
24
Theory of Operation Ver.1.0 Jul. 2008 6. OTHERS
6.2 Tray damper mechanism
PF-602/HT-504
• The damper [1] is provided in the tray to prevent the pile of paper from becoming misaligned due to the
vibration caused when inserting the tray.
[1]
a03xt2c017ca
[1] Damper
25
6.3 Main body assist mechanism

PF-602/HT-504
6.3.1 Filter replacement assy retaining mechanism

• When PF is installed to the main body, the filter replacement assy retaining mechanism [1] of PF presses
down the filter replacement assy of the main body to prevent the filter replacement assy from coming loose.
[1]
a03xt2c018ca
[1] Filter replacement assy retaining mechanism
26
6.3.2 Filter replacement assy ventilation mechanism

• When PF is installed to the main body, the ventilation fan/1 (FM10) [1] and /2 (FM9) [2] operate to exhaust
PF-602/HT-504
heated air around the writing section of the main body.
• When the sub power switch (SW2) of the main body is on, FM10 and FM9 keep turned on.
[1]
[2]
a03xt2c019ca
[1] Ventilation fan/1 (FM10) [2] Ventilation fan/2 (FM9)
6.3.3 Environment temperature detection assist mechanism

• When PF is installed to the main body, the temperature-humidity sensor (TEM/HUMS) of PF is used to
check the environment temperature and humidity instead of the sensor of the main body since the temper-
ature-humidity sensor/1 (TEM/HUMS/1) on the right side of the main body is disabled.
27
7. HT-504 (OPTIONAL) Theory of Operation Ver.1.0 Jul. 2008
7. HT-504 (OPTIONAL)
PF-602/HT-504
7.1 Configuration
[4] [5]
[1]
[2]
[3]
[6]
a03xt2c020ca
[1] Dehumidifier fan heater unit/Up [4] Dehumidifier fan/1 (FM13) and /3 (FM11)
[2] Dehumidifier fan heater unit/Lw [5] Dehumidifier fan/2 (FM14) and /4 (FM12)
[3] Power unit [6] Fan heater/Up (HTR3) and /Lw (HTR4)
28
Theory of Operation Ver.1.0 Jul. 2008 7. HT-504 (OPTIONAL)
7.2 Operation
PF-602/HT-504
7.2.1 Dehumidifier fan heater control
A. Dryness preparation control
• When the Dryness preparation control is set to [On] in the user settings, preliminary drying operation is per-
formed before printing after opening/closing the tray.
• When the dehumidifier fan heater preliminary drying control is set to [Off] in the user settings, preliminary
drying operation is performed before printing after opening/closing the tray when the amount of remaining
papers are changed. The drying operation is not conducted unless the amount of remaining papers are
changed.
• To prevent paper feed jam in the paper feed section, the fan heaters /Up (HTR3), /Lw (HTR4), dehumidifier
fans /1 (FM13), /2 (FM14), /3 (FM11), and /4 (FM12) control dehumidification by circulating warm air.
• When the temperature-humidity sensor (TEM/HUMS) of PF detects the environment humidity is more than
56%, HTR3, HTR4, FM11, FM12, FM13 and FM14 are turned on.
B. Dehumidifier control operation start conditions

• When turning the sub power switch (SW2) off with the dehumidifier fan heater setting set to [Automatic] or
[On (compulsory)] in the user settings and coated paper is selected.
• When opening/closing the tray with the dehumidifier fan heater setting set to [Automatic] or [On (compul-
sory)] in the user settings and coated paper is selected.
• When changing the original setting to coated paper from other types with the dehumidifier fan heater set-
ting set to [Automatic] or [On (compulsory)] in the user settings.
• When changing the dehumidifier fan heater setting to [Automatic] or [On (compulsory)] from [Off (compul-
sory)].
C. Operation details
• Detects the temperature in the trays with the temperature sensors /1 (TEMS/1) and /2 (TEMS/2) and con-
trols the dehumidification until the temperature reaches the target level.
• During the dehumidification, the printing from the tray is prohibited.
Ambient humidity Target temperature rise in the tray

Less than 55% Not controlled
56 to 60% 6°C
61 to 65% 7°C
66 to 70% 8°C
71 to 75% 9°C
More than 76% 10°C
D. Dehumidifier control operation stop conditions

• When a original setting other than the coated paper is selected during dehumidifier control operation.
• When the dehumidifier fan heater setting is changed to [Off (compulsory)] during dehumidifier control oper-
ation.
29
7. HT-504 (OPTIONAL) Theory of Operation Ver.1.0 Jul. 2008
7.2.2 AC power control

• When the temperature sensor in the dehumidifier fan heater unit detects an error, a relay in the AC board [3]
PF-602/HT-504
is cut off to prevent abnormal temperature from occurring.

• AC voltage is supplied either from the main body [1] or external [2]. Parts whose voltage is supplied from
external are equipped with an inlet [4] and a circuit breaker switch [5] in the power supply unit.
[4]
[3]
[5]
[1] [2] a03xt2e001ca
[1] The AC voltage supplied from the main [3] AC drive board (ACDB)
body [4] Inlet
[2] The AC voltage supplied from external [5] Circuit breaker switch
30
MAINTENANCE
PF-602/HT-504
8.1 Tray section
Caution:
Note
• The replacement procedures for the pick-up roller, paper feed roller, and the separation roller in
tray/4 are the same for those in tray/5. The explanation here is made by the example of tray/4.
• After the installation is completed, rotate the pick-up roller in the paper feed direction (clockwise
as seen from the front side) to see if the paper feed roller rotates smoothly. The rotation is
restricted only in the paper feed direction (clockwise as seen from the front side) and be careful
not to rotate the roller counterclockwise.
• The orientation of the pick-up roller assy and the separation roller assy in the main unit differs
from that of the rollers in the PF.
31
8.1.1 Replacing the Pick-up rubber/paper feed roller

PF-602/HT-504
• Pick-up rubber : Every 600,000 prints (actual replacement cycle: every 300,000 feed)
• Paper feed roller B : Every 600,000 prints (actual replacement cycle: every 300,000 feed)
B. Procedure
Note
• The appearance of the collars is the same for the paper feed roller and the separation roller. How-
ever, the collar of the paper feed roller has a one-way mechanism inside, be sure not to mix up
these two rollers.

[3] [4] 2. Open the vertical conveyance unit guide plate [2]
(Tray/4 only).
3. Insert a screwdriver or a similar tool into the hole
[3], lift up the tray lock lever [4] slightly, and pull out
the tray [5].
[2] [1] [5]
a03xf2c001ca
32
Note
PF-602/HT-504
• Do not pull out tray [1] all the way. Hold tray
[1] so that the stopper [3] on the left side of
the tray pushed in, and make the pick-up
[3] holder assy [2] placed horizontally (paper
feed position).
[2] [1]
a03xf2c002ca
33
4. Rotate the pick-up roller [1] in the direction of the

[8] [7] [5] [6]
arrow (clockwise as seen from the front side) and
PF-602/HT-504
bring the coupling [2] to the lengthwise direction.
Note
• Be sure not to rotate the pick-up roller
against the direction of the arrow forcibly, as
the roller is designed not to rotate in that
direction.
5. Remove the two C-clips [3].

6. Remove the bearing/Fr [4].
7. Move the bearing/Rr [5] to the rear side.
[3] [2] [1]
Note
• When installing the bearing, hold down the
metal plate [6] of the pick-up roller assy
slightly, and insert the flat part [7] of the bear-
ing/Rr [5] while keeping it horizontally into the
notch [8] of the metal plate. Then, insert the
bearing/Fr [4] in the same manner.
[4] [5]
a03xt3c001ca
34
8. Hold the pick-up roller assy [1] by hand and lift

and tilt the paper feed roller [3] so that it rotates on
PF-602/HT-504
the shaft [2] of the pick-up roller to remove it from
both the notch of the bearing [4] and the coupling
[5].
Note
• When removing the pick-up roller assy [1], be
careful not to damage the sensor [6] with the
metal plate.
[6]
[4] [5] [1]
[3] [2] a03xt3c002ca
35
9. Remove the pick-up roller shaft [2] from the arm

[3]
[1] of the paper feed guide plate and remove the
PF-602/HT-504
pick-up roller assy [3].
[2] [1]
a03xt3c003ca
[1] [3] [2]
remove the pick-up roller [3].
11. Remove the pick-up rubber from the pick-up
roller.
12. Replace the pick-up rubber.
a03xt3c004ca
36
13. Remove the C-clip [1] and remove the bearing [2].
[1] [2] [4] [3] [5] 14. Slide the bearing [3] and remove the paper feed
PF-602/HT-504
roller [4] together with the shaft [5].
a03xf2c007cb
15. Remove the actuator [2] from the shaft [1].

[1] [2] [3] [4] [5]
16. Remove the C-clip [3] and pull out the paper feed
roller [4] from the collar [5].
a03xf2c008cb
[2] [1] 17. Replace the paper feed roller.
Note
• The appearance of the collars is the same for
the paper feed roller and the separation roller.
However, the collar [1] of the paper feed roller
has a one-way mechanism inside while the
collar [2] of the separation roller has no one-
way mechanism, be sure not to mix up these
two rollers.
a03xf2c009ca
steps in reverse.
37

PF-602/HT-504
• Separation roller : Every 600,000 prints (actual replacement cycle: every 300,000 feed)
B. Procedure
Note
• The appearance of the collars is the same for the paper feed roller and the separation roller. How-
ever, the collar of the paper feed roller has a one-way mechanism inside, be sure not to mix up
these two rollers.

(Tray/4 only).
the tray [5].
[2] [1] [5]
a03xf2c010ca
38
4. Remove two screws [1].

5. Disengage the coupling pin [4] from the joint [5]
PF-602/HT-504
[3]
while pressing down the metal plate [3] of the sep-
aration roller assy [2], and remove the separation
roller assy [2].
Note
• When installing the separation roller assy,
press down the metal plate [3] of the separa-
[5] [4] [2] tion roller assy [2] and engage the coupling
pin [4] to the joint [5].
[1]
a03xf2c011ca
6. Remove the C-clip [1] of the separation roller assy

[2] [3] [1] and remove the separation roller [3] together with
the shaft [2].
a03xf2c012cb
39
7. Pull out the gear [2], the collar [3] and the separa-
[1] [4] [3] [2]
tion roller [4] from the shaft [1] to the arrow-
PF-602/HT-504
marked direction, and remove them.

8. Replace the pick-up roller [4].
steps in reverse.
Note
• The appearance of the collars is the same for
the paper feed roller and the separation roller.
However, the collar [5] of the paper feed roller
has a one-way mechanism inside while the
[6] [5] collar [6] of the separation roller has no one-
way mechanism, be sure not to mix up these
two rollers.
a03xf2c013cb
40
8.1.3 Replacing the paper feed clutch (MC1/MC4) and the separation clutch (MC2/MC5)
PF-602/HT-504
Note
• The replacement procedures for the paper feed clutch and the separation clutch in tray/4 are the
same for those in tray/5. The explanation here is made by the example of tray/5.

• Paper feed clutch/1 (MC1), /2 (MC4) : Every 2,400,000 prints (actual replacement cycle: every 2,000,000
feed)
• Separation clutch/1 (MC2), /2 (MC5) : Every 2,400,000 prints (actual replacement cycle: every 2,000,000
feed)
B. Procedure
1. Remove the stopper and pull out the tray. (Refer
[1] [3] to P.52)
2. Remove two screws [1], bend the stopper [2] in
the direction of the arrow, and remove the paper
feed cover [3].
Note
• For easier operation, lilft up the underpart [4]
of the cover when installing the paper feed
cover [3].
• When installing the paper feed cover [3], be
sure to insert the tab [6] into the hole [5] of
the metal plate.
[2] [3]
[6]
[4]
[5]
a03xf2c014ca
41
3. Disconnect the two connectors [1].

[3] [4] 4. Remove the two C-clips [2], and remove the
PF-602/HT-504
paper feed clutch (MC1/MC4) [3] and the separa-

tion clutch (MC2/MC5) [4].
Note
• When installing the clutch, be sure to engage
the stopper [5] of the clutch with the projec-
tion [6] of the metal plate.

steps in reverse.
[2] [5] [6] [1]
[5] [6] [2] [1]
a03xf2c015ca
42
8.2 Conveyance section
PF-602/HT-504
8.2.1 Replacing the vertical conveyance clutch/1 (MC7), /2 (MC8), and /3 (MC9)
• Vertical conveyance clutch/1 (MC7), /2 (MC8), and /3 (MC9):
Every 2,400,000 prints (actual replacement cycle: every 2,000,000 feed)
B. Procedure
1. Remove the following parts.
[2] [1]
• Rear cover/Rt (Refer to P.50)
• Rear cover/Lt1 (Refer to P.50)
2. Remove the four screws [1] and remove the gear
mounting plate [2].
a03xf2c016ca
3. Disconnect the three connectors [1].

[6] [7] [8] 4. Remove the three screws [2] and the three wire
binding covers [3].
Note
• When installing the wire binding [4], pass the
binding through the hole in the wire binding
cover [3].
5. Remove the three C-clips [5] and remove the ver-

tical conveyance clutch/1 (MC7) [6], /2 (MC8) [7],
and /3 (MC9) [8].
[5] [2]
[1]
[3]
[4]
a03xf2c017ca
43
Note
[1]
PF-602/HT-504

the stopper [1] of the clutch with the projec-
tion [2] of the metal plate.

steps in reverse.
[2]
a03xf2c018ca
44
8.2.2 Replacing the horizontal conveyance clutch/1 (MC10), /2 (MC11), and pre-registration clutch
(MC12)
PF-602/HT-504
• Horizontal conveyance clutch/1 (MC10), /2 (MC11), and pre-registration clutch (MC12):
Every 2,400,000 prints (actual replacement cycle: every 2,000,000 feed)
B. Procedure
[1] [2]
• Rear cover/Rt (Refer to P.50)
mounting plate [2].
a03xf2c019ca
45
3. Disconnect the three connectors [1].

[1] 4. Remove the three screws [2] and the three wire
PF-602/HT-504
[4]
[3] [10] binding covers [3].
[9]
Note
[2] • When installing the wire binding [4], pass the
binding through the hole in the wire binding
cover [3].
[5]
5. Remove the three C-clips [5] and remove the hori-
zontal conveyance clutch/1 (MC10) [6], /2 (MC11)
[6] [8] [7]
[7], and the pre-registration clutch (MC12) [8].
Note
• When installing the cluthes, be sure to match
the stoppers [9] with the cutout of the rear
panel [10].
the stopper [9] of the clutch with the pin [11].

steps in reverse.
[1]
[4] [11]
[2]
[3]
[9]
[5]
a03xf2c020ca
46
9. OTHER PROCEDURES
PF-602/HT-504
1 Cover Right cover P.48
2 Rear cover/Lt2 P.49
3 Rear cover/Lt1, /Rt P.50
4 Front door P.51
5 Tray section Tray P.52
6 Lift wire P.55
7 Paper lift motor/1 (M2) and /2 (M3) P.62
8 Conveyance section Vertical conveyance unit P.64
9 Horizontal conveyance unit P.67
10 Multi feed detection board (MFDTB/R and /S) P.69
47

PF-602/HT-504
Caution:
9.2.1 Removing/installing the right cover

A. Procedure
1. Remove the four screws [1] and remove the right
[2] [1]
cover fixing plate [2].
a03xf2c021ca
[1] [1]
right cover [2].
[2] [1]
a03xf2c022ca
48
Note
[1] [2]
PF-602/HT-504
• When installing the right cover, be sure to
match the metal plate [2] on the lower part of
the PF main unit with the groove [1] on the
right cover.

steps in reverse.
a03xf2c023ca
9.2.2 Removing/installing the rear cover/Lt2

A. Procedure
1. Remove the nine screws [1] and remove the rear
[2] [1] cover/Lt2 [2].
[1]
a03xf2c024ca
Note
[1] [2]
• When installing the rear cover/Lt2, be sure to
match the metal plate [2] of the lower part of
the PF main unit with the groove [1] of the
rear cover.

steps in reverse.
a03xf2c025ca
49
9.2.3 Removing/installing the rear cover/Lt1 /Rt

A. Procedure
PF-602/HT-504
1. Remove the rear cover/Lt2.(Refer to P.49)

[3] [4] [3] [1] 2. Remove the six screws [1] and remove the rear
cover/Lt1 [2].
3. Remove the eleven screws [3] and remove the
rear cover/Rt1 [4].
[3] [2]
a03xf2c026ca
Note
[2] [1]
• When installing the rear cover/Rt, be sure to
match the metal plate [2] on the lower part of
the PF main unit with the groove [1] on the
rear cover.

steps in reverse.
a03xf2c028ca
Note
• When HT-504 is installed, also remove the
four screws [1] in step 3.
[1]
50
9.2.4 Removing/reinstalling the front cover

A. Procedure
PF-602/HT-504
[2] 3. Remove the two screws [3] and the mounting
plate [4], and remove the front door [1] releasing it
from the pin [5].
[1]
steps in reverse.
[3]
[4]
[5]
a03xf2c030ca
51
9.2.5 Removing/reinstalling the tray

PF-602/HT-504
Caution:
• As the trays are very heavy, the following work should be performed by two people.
• Do not pull out the two trays at a time or the PF may topple over.
Note
• The removal and installation procedures of tray/4 is the same for those of tray/5. The explanation
here is made by the example of tray/4.
• When lifting up the tray, be sure to hold it at the specified positions. Not doing so may cause dam-
age to the trays or result in a paper jam.
A. Procedure
(Tray/4 only).
the tray [5].
[2] [1] [5]
a03xf2c031ca
52
4. Remove the cushion/3 [1].

[3] [1] 5. Remove the three screws [2] and remove the
PF-602/HT-504
upper cover/1 [3].
Note
• When replacing the cushion/3, also replace
the double-sided tape that secure the cush-
ion/3 with a new one.
[2] a03xf2c060ca
6. Remove the three screws [1] on the right side of

[3] the tray and remove the rail stopper [2].
7. Pull the tray [3] further out.
[2]
[1]
a03xf2c032ca
53
8. Remove the six screws [1], three each on the left

[6] and right rails, hold the tray [2] by the specified
PF-602/HT-504
positions [5], and remove it straight up.

[2]
[1] Note
• When reinstalling the tray, make sure that the
four knobs [3] on the rails are properly fitted
in the notches [4] of the tray.
[5] • When lifting up the tray, be sure to hold it by
the specified positions [5] by two people. Do
[2] not hold the part indicated with [6] as the part
may easily deform and this causes a paper
[1] jam.
[3] [4]
a03xf2c033ca
Note
[1] [2] • When installing tray/4, make sure not to let
the lower part [1] of the tray cover contact the
rail [2].

steps in reverse.
a03xf2c034ca
54
9.2.6 Removing/installing the lift wire
PF-602/HT-504
Note
• The removing/installing procedure of the lift wire is the same for tray/4 and tray/5.
A. Procedure
1. Press the down button [1] to let the lift plate [2] go
[2] [1]
down to the bottom of the tray.
a03xf2c035ca
55
2. Remove the tray. (Refer to P.52)

3. Loosen the three screws [1], and remove the three
PF-602/HT-504
[3] screws [2].

4. Disconnect the connector [3], and remove the
front cover [4] of the tray.
[4]
[1]
[2]
a03xf2c036cb
56
Note
[1]
PF-602/HT-504
• The front cover of tray/4 has the ancillary
cover [1], whereas that of tray/5 does not.
When installing the front covers of each tray,
make sure not to mix them up.
a03xf2c037ca
5. Remove the nine screws [1] and remove the cover

[1] [2]
[2].
[1] [1]
a03xf2c061ca
Note
• When installing the cover [1], make sure to
fasten the gear [3] and the spring [4] with the
plate [2] of the tray-down stopper.
[2] [3] [4]
[1] a03xf2c062ca
57

7. Slide the bearing [2].
PF-602/HT-504
[1]
[2]
a03xf2c063ca
8. Slide the pulley/Fr1 [1] and /Fr2 [2], and pull out
the wire ends of the lift wire/Fr1 [3] and /Fr2 [4]
[4] [2] [1]
from each hole of the shaft [5].
Note
• When inserting the wire ends to the shaft
holes, be sure to insert each wire into the cor-
responding shaft holes. The shaft hole near
the center of the tray is used for the shorter
wire/Fr2 [3].
• When installing the pulley, raise the lift plate
slightly to give slack to the wire, insert the
wire ends one at a time into the shaft hole,
and secure them with the pulley/Fr1 [1] and /
[3] [5]
Fr2 [2]. The wires can be inserted easily in this
a03xf2c064ca
way.
• When installing the pulley, be sure to fasten
the pulley/Fr1 [1] in advance, and then install
the pulley/Fr2 [2].
58
9. Remove the four E-rings [1], and remove the four-

[1] [2] [3] [5] [4]
wire covers [2].
PF-602/HT-504
10. Remove the wires/Fr1 [4] and /Fr2 [5] from the
four pulleys [3].
Note
• When installing the wires, be sure that the
wires are placed under the wire covers [2] and
do not cross each other.
[5] [4]
a03xf2c040ca
59
11. Pull out the wire ends [4] of the wire/Fr1 [2] and /
[3] [2] Fr2 [3] through the lift plate arm [1].
PF-602/HT-504
Note
• When pulling out the wire, pull it out gently
and be careful not to damage it with the cor-
ner of the metal plate.
[1]
[4]
a03xf2c041ca
[1]
a03xf2c065ca
60
13. Remove the lift wire/Rr1 [1] and /Rr2 [2] in the
[1] [2]
same manner as step 8 to 11.
PF-602/HT-504
steps in reverse.
Note
• When the installation is completed, make
sure that the lift plate is horizontal.
a03xf2c042ca
61
9.2.7 Removing/installing the paper lift motor/1 (M2) and /2 (M3)

A. Procedure
PF-602/HT-504

[1] [2] • Rear cover/Rt (Refer to P.50)
mounting plate [2].
3. Disconnect the two connectors [3].
4. Remove the six screws [4], and remove the paper
lift motor assy/1 [5] and /2 [6] toward the rear of
the main unit.
[5] [1] [6]
[4]
[3]
a03xf2c043ca
62

[3] [1] [2]
PF-602/HT-504
a03xf2c044ca

[2] [1]
paper lift motor cover [2].
a03xf2c045ca
8. Remove the two screws [1] and remove the paper

[2] [1]
lift motor/1 (M2) [2] and /2 (M3) [2].
steps in reverse.
a03xf2c046ca
63
9.2.8 Removing/installing the vertical conveyance units

A. Procedure
PF-602/HT-504
1. Remove the PF from the main unit.

[1] [2] [3] 2. Remove the vertical conveyance clutch/1 (MC7), /
2 (MC8), and /3 (MC9) (Refer to P.43)
3. Remove the front door. (Refer to P.51)
4. Remove the two screws [1] and remove the vent
duct [2].
5. Remove the two screws [3] and remove the cover
[4].
[4]
a03xf2c047ca
64
6. Loosen the screw [1], and release the filter

[1] [8] replacement assy retaining mechanism stopper
PF-602/HT-504
[2].
7. Remove the E-ring [3], pull the shaft [4] toward
you, and pull out the shaft [4] through the hole [6]
in the connector cover [5].
8. Release the lock [7] of the wire clamp and press it
in toward the rear panel.
9. Remove the two screws [8] and remove the con-
nector cover [5].
[7] [5]
[1] [2] [4] [5]
[3] [6]
a03xf3c048ca

[1]
a03xf2c049ca
65
11. Remove the four screws [1] and remove the verti-
cal conveyance unit [2].
PF-602/HT-504
[1]
Note
• When installing the vertical conveyance unit
[2], be sure that the two tabs [3] on the verti-
cal conveyance unit are fitted in the holes [4]
in the PF main unit.

steps in reverse.
[4] [1]
[2]
[3]
a03xf2c050ca
66
9.2.9 Removing/installing the horizontal conveyance unit

A. Procedure
PF-602/HT-504
1. Remove the vertical conveyance unit. (Refer to
[1] P.64)
2. Remove the horizontal conveyance clutch/1
(MC10), /2 (MC11), and the pre-registration clutch
(MC12). (Refer to P.45)
3. Disconnect the two connectors [1] and release the
wires from the clamps.
a03xf2c051ca
[1]
a03xf2c052ca
67
5. Remove the two screws [1].

[3]
6. Loosen the two screws [2] and remove the hori-
PF-602/HT-504
zontal conveyance unit [3].
[1]
[2]
a03xf2c053ca
Note
[2] [1] • When installing the horizontal conveyance
unit, make sure that the pin [2] is fitted in the
notch [1] of the unit.

steps in reverse.
a03xf2c054ca
68
9.2.10 Removing/installing the multi feed detection board (MFDTB/R and /S)
PF-602/HT-504
Note
• When replacing the multi feed detection board/S (MFDTB/S), be sure to replace the multi feed
detection board/R (MFDTB/R) at the same time.
• When the multi feed detection board is replaced, be sure to conduct the adjustment when replac-
ing multi feed detection board (PF). (Refer to "9.3.12 Adjustment when replacing multi feed detec-
tion board (PF)" in Field Service.)
A. Procedure
1. Loosen the screw [1], and release the filter
[1] [8] replacement assy retaining mechanism stopper
[2].
2. Remove the E-ring [3], pull the shaft [4] toward
you, and pull out the shaft [4] through the hole [6]
in the connector cover [5].
3. Release the lock [7] of the wire clamp and press it
in toward the rear panel.
4. Remove the two screws [8] and remove the con-
nector cover [5].
[7] [5]
[1] [2] [4] [5]
[3] [6]
a03xf3c048ca
69
5. Remove the two screws [1].

[1] 6. Open the jam precessing lever PF5 [2], and
PF-602/HT-504
remove the cover [3].
[2] [3]
a03xf2c056ca

[2] [1] [3] 8. Remove the two screws [2] and the multi feed
detection board/R (MFDTB/R) [3].
a03xf2c057ca
70
9. Remove the screw [1], slide the cover [2] in the

[2] direction of the arrow, and remove the cover
PF-602/HT-504
downward.
Note
• When installing the cover, be sure to insert
the tab [3] on the cover into the hole of the
horizontal conveyance unit [4].
[1] [3] [4] [2]
a03xf3c058ca

[1] [2] [3] 11. Remove the two screws [2] and the multi feed
detection board/S (MFDTB/S) [3].
steps in reverse.
a03xf2c059ca
71
PF-602/HT-504
Blank page
72
LU-202/HT-503
2009.03
Ver. 2.0
Revision history
Revision mark:
corresponding page.
NOTE

Theory of Operation Ver.2.0 Mar. 2009 CONTENTS
CONTENTS
LU-202/HT-503
LU-202/HT-503
OUTLINE
1.1 LU-202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 HT-503 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2.1 Paper feed drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2.2 Pick-up drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3.1 Paper feed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3.5 Centering detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5. UP/DOWN SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6. OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1 Dehumidifier heater control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2 Interlock control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7. HT-503 (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.2.1 Dehumidifier fan heater control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
MAINTENANCE
8.1 Paper feed section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.1.1 Cleaning/pre-registration roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.1.2 Removing/installing paper feed roller Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.1.3 Replacing the paper feed roller/pick-up roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.1.5 Replacing paper feed clutch (MC101) /pre-registration clutch (MC102) . . . . . . . . . . . . . . . . . . 33
9.1 Disassembly/Reassembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.2 Disassembly/Reassembly Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.2.1 Removing/reinstalling the upper door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
i
CONTENTS Theory of Operation Ver.2.0 Mar. 2009
9.2.2 Removing/reinstalling the clutch cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

9.2.3 Removing/reinstalling the paper feed cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
LU-202/HT-503
9.2.4 Removing/installing the right cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

9.2.5 Removing/reinstalling the front cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.2.6 Removing/reinstalling the rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.2.7 Replacing the lift wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.2.8 Removing/reinstalling the paper size VR (VR1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
ii
Theory of Operation Ver.2.0 Mar. 2009 1. PRODUCT SPECIFICATIONS
OUTLINE
LU-202/HT-503
1.1 LU-202
A. Type
Type Side mount type large volume paper feed tray
B. Functions
Max. tray capacity 2500 sheets (80 g/m 2)*1
*1 Stacked height 275 mm
C. Paper type
Paper size SRA3, A3, B4, SRA4, SRA4S, A4, A4S, B5

13 x 19, 12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S
8K, 16K
Custom paper (Max. 330 x 487mm, Min. 210 x 182 mm)*1
64 to 300 g/m2 *1
*1 Available types of paper weighing 300 g/m2 are limited to specific types.
D. Maintenance
E. Machine data
Maximum power consump- DC: 70W or less, AC: 50W or less (not including HT-503)
tion
Weight Approx. 42kg
Humidity 10 to 80% RH (with no condensation)
1
1. PRODUCT SPECIFICATIONS Theory of Operation Ver.2.0 Mar. 2009
1.2 HT-503
LU-202/HT-503
A. Type
Type Fan heater type dehumidifier device
B. Machine data
Power source 24/5VDC, 200 to 240VAC (supplied both from the main body)
tion
Power unit: 121 (W) x 80 (D) x 160 (H) mm
Weight Dehumidifier fan heater unit: Approx. 1.5 kg
Power supply unit: Approx. 0.9 kg
Note
2
Theory of Operation Ver.2.0 Mar. 2009 2. UNIT CONFIGURATION DIAGRAM
LU-202/HT-503
[3] [1]
[2]
a03wt1c001ca
[1] Up/down section [3] Paper feed section

[2] HT-503 (Optional)
3
3. PAPER PATH Theory of Operation Ver.2.0 Mar. 2009
3. PAPER PATH
LU-202/HT-503
[2] [3] [4] [5]
[1]
a03wt1c002ca
[1] Separation roller [4] Pick-up roller

[2] Pre-registration roller [5] Paper lift plate
[3] Paper feed roller
4
Theory of Operation Ver.2.0 Mar. 2009 4. PAPER FEED SECTION
LU-202/HT-503
4.1 Configuration
Centering sensor (PS1) Separation roller
Pick-up roller Pre-registration roller
Paper feed roller
Paper feed assist fans
Paper empty sensor (PS108)
Paper size detection mechanism Paper size detection mechanism (Main scan direction)
(Sub scan direction)
Remaining paper detection mechanism a03wt2c001ca
5
4. PAPER FEED SECTION Theory of Operation Ver.2.0 Mar. 2009
4.2 Drive
LU-202/HT-503
[1]
[10]
[9]
[2]
[8] [5]
[6]
[3]
[7] [4]
[9]
a03wt2c002ca
[1] Paper feed motor (M1) [6] Separation roller

[2] Paper feed clutch (MC101) [7] Front side
[3] Pick-up roller [8] Torque limitter
[4] Paper feed roller [9] Pre-registration roller
[5] One-way mechanism [10] Pre-registration clutch (MC102)
6
4.2.2 Pick-up drive
LU-202/HT-503
[4]
[1]
[2]
[3]
a03wt2c003ca
[1] Pick-up roller [3] Front side

[2] Pick-up solenoid (SD100) [4] Paper feed roller
7
4.3 Operation
LU-202/HT-503

A. Pick-up control
(1) Outline
• Paper is picked up when the pick-up solenoid (SD100) is turned off.
• The pick-up roller rotates with the paper feed roller.
(2) Operation
1. At the time printing is started [1], SD100 is off and the pick-up roller presses against loaded paper with its
own weight.
2. Then the paper feed clutch (MC101) turns on [2] to transmit drive force of the paper feed motor (M1) to the
pick-up roller, and the pick-up roller starts to rotate and picks up a sheet of paper to be fed by the paper
feed roller.
3. When the Pre-registrations sensor (PS106) located just before the pre-registration roller detects the leading
edge of the paper [3], SD100 turns on to make the pick-up roller separate from the paper, and the paper is
fed only by the paper feed roller.
4. When the LU exit sensor (PS107) turns on [4], MC101 is turned off to stop the paper feed roller and the pick-
up roller.
5. When a predetermined time period has elapsed after PS107 detects the first paper and turns off, SD100
turns off to bring the pick-up roller into contact with the loaded paper, and at the same time, MC101
becomes on to make the pick-up roller rotate and pick up the second sheet of paper [5].
[2] [4] [5]

[1] [3]
Paper feed clutch (MC101)
Pick-up solenoid (SD100)
Pre-registrations sensor (PS106)
LU exit sensor (PS107)
a03wt2c004ca
[1] START button (ON) [4] Pick-up roller separates from loaded paper
[2] Pick-up roller presses paper with its own [5] Pick-up roller goes down
weight.
[3] Drive force transmission to the pick-up roller
and paper feed roller.
8
• The separation roller [5] rotates in the direction [10] opposite to the paper conveyance direction [9] by
LU-202/HT-503
means of the torque limiter [8].
• The separation roller is pressed against the paper feed roller [1] by the force [6] exerted by the spring [7] and
the torque generated by the torque limiter. The friction force between the separation roller and the paper
feed roller is limited by the torque limiter in order to prevent multi-feed.
• When no paper exist between the separation roller and the paper feed roller, and when the only 1 sheet of
paper is present, the separation roller is driven by the paper feed roller in the direction of the arrow [4] since
the torque is over the limit.
• When multiple sheets of paper are fed, the friction force between the 2 rollers drops causing counterrotat-
ing [10] of the separation roller, and the lower paper [2] that contacts with the separation roller is fed back to
the tray [3].
[10] [1]
[9]
[2]
[3]
[4]
[8]
[7] [6] [5] a03wt2c005ca
[1] Paper feed roller [6] Spring force

[2] 2nd sheet of paper [7] Spring
[4] Driven rotation [9] Conveyance direction
[5] Separation roller [10] Rotation of separation direction
9
C. Pre-registration control
(1) Outline
LU-202/HT-503
• The pre-registration roller [3] is driven by the paper feed motor (M1) via the pre-registration clutch (MC102).
M1 drive force is transmitted/shut off by MC102 to rotate/stop the roller.
• The pre-registration control for the second and subsequent papers differs depending on the paper size
(whether the paper is small-sized or large-sized) because of the difference in interval between papers.
• This control is carried out mainly by the pre-registration sensor (PS106) [4], LU exit sensor (PS107) [1], the
intermediate conveyance sensor/1 (PS27 in the mainbody), and the intermediate conveyance sensor/2
(PS28 in the mainbody).
[3] [4] [5]
[2]
[1]
a03wt2c006ca
[1] LU exit sensor (PS107) [4] Pre-registrations sensor (PS106)

[2] Centering sensor (PS1) [5] Paper feed roller
[3] Pre-registration roller
10
(2) Control for small-sized paper

1. Paper fed by the paper feed roller hits against the pre-registration roller that is stopping due to the off-status
LU-202/HT-503
[1] of MC102, and the skew of paper is corrected.
2. Then, after a predetermined time period has elapsed, MC102 turns on [2] to rotate the pre-registration roller
to convey the paper.
3. When a predetermined time period has elapsed after PS106 detects the rear end of the paper, MC102 turns
off to stop the pre-registration roller [3].
4. The same operation is carried out for the second and subsequent papers.
[2] [3]
Pre-registration clutch (MC102)
[1] a03wt2c007ca
[1] Paper skew correction [3] MC102 turns off upon completion of 1st
[2] Paper conveyance into the main body paper conveyance
11
(3) Control for large-sized paper

1. The pre-registration for the 1st sheet of paper is carried out in the same manner as that for small-sized
LU-202/HT-503
paper.
2. MC102 turns on again [1] after the 2nd paper hits against the pre-registration roller, and turns off [2] when a
predetermined time period has elapsed after the LU exit sensor (PS107) detects the leading edge of paper,
then keeps the off-status until the rear end of the 1st paper is detected by PS27 in the main body.
3. When PS27 detects the rear end of the 1st paper, the MC102 turns on [3] to convey the 2nd paper, and
turns off [4] when the leading edge of the 2nd paper is detected by the PS27.
4. The MC102 turns on again [5] when PS28 detects the rear end of the 1st paper, and turns off [6] when PS28
detects the leading edge of the 2nd paper.
5. When a predetermined time period has elapsed after a V-TOP signal is issued (when a printing process for
the 1st paper is finished), MC102 turns on again [7] to convey the 2nd paper, and turns off to stop the con-
veyance when a predetermined time period has elapsed after PS106 detects the rear end of the paper.
[4] [6] [8]

[1] [2] [3] [5] [7]
Pre-registration clutch (PS102)
V-TOP signal of the main body
a03wt2c008ca
[1] Paper skew correction [5] Starts conveyance of the 2nd paper to
PS28
[2] Waits until PS27 detects the 1st paper [6] Turns off when the 2nd paper reaches PS28
[3] Starts conveyance of the 2nd paper to [7] Restarts conveyance
PS27
[4] Turns off when the 2nd paper reaches PS27 [8] MC102 turns off upon completion of 2nd
paper conveyance
12
D. Air assist control

• The paper feed assist fan/Fr (FM1) and /Rr (FM2) are mounted to the side guide/Fr and /Rr respectively in
LU-202/HT-503
order to assist the separation of paper.
• When coated paper has been selected at the paper setting, FM1 and FM2 turns on upon receiving a print
start signal.
• The air-blowing level of the FM1 and FM2 can be selected from Auto, ON (strong), ON (weak), and OFF at
the paper setting.
[6]
[1]
[5]
[2]
[4]
[3]
a03wt2c009ca
[1] Side guide/Rr [4] Paper feed assist fan/Fr (FM1)

[2] Paper feed assist fan/Rr (FM2) [5] Side guide/Fr
[3] Paper [6] Airflow
13

• A paper empty status can be detected by on/off statuses of the upper limit sensor (PS109) [6] and the
LU-202/HT-503
paper empty sensor (PS108) [1].

• When paper is loaded on the tray, the paper pushes the actuator [2] up as the paper lift plate [4] moves
upward and PS108 [1] turns on. Further upward movement of the plate pushes the actuator [5] up and
turns PS109 [6] on.
• When no paper exist on the tray, the actuator [2] of PS108 [1] goes into the hole [3] of the paper lift plate [4]
instead of being pushed up, and only the actuator [5] is pushed up to turn PS109 [6] on. The status (PS108
is off and PS109 is on) is judged as a paper empty status, and an arrow mark ( ) appears on the tray mark
displayed on the touch panel of the main unit.
• When the tray runs out of paper while feeding paper, the status is detected when the PS108 becomes off
with PS109 kept on.
[1]
[6]
[2]
[3]
[5] [4]
a03wt2c010ca
[1] Paper empty sensor (PS108) [4] Paper lift plate

[2] Actuator of PS108 [5] Actuator of PS109
[3] Hole [6] Upper limit sensor (PS109)
14

• The remaining amount of paper is detected by the position of the remaining paper detection gear [6] moved
LU-202/HT-503
together with the shaft [5] of the paper lift motor (M100) which drives the paper lift plate.
• The remaining paper detection gear incorporates the actuator [9], and the actuator position is detected by
the 4 remaining paper sensors; /1 (PS102) [1], /2 (PS103) [2], /3 (PS104) [3], and /4 (PS105) [4].
• According to on/off statuses of the 4 sensors, the remaining amount of paper can be figured out.
[8] [9] [1] [2] [3]
[4]
[5]
[7]
[6] a03wt2c011ca
[1] Remaining paper sensor /1 (PS102) [6] Remaining paper detection gear
[2] Remaining paper sensor /2 (PS103) [7] Rotational direction when the paper lift plate
goes up
[3] Remaining paper sensor /3 (PS104) [8] Rotational direction when the paper lift plate
goes down
[4] Remaining paper sensor /4 (PS105) [9] Actuator
[5] Shaft of the paper lift motor (M100)
15
(1) Sensor detection and remaining paper

• The remaining amount of paper is detected in 8 levels according to on/off statuses of the 4 sensors.
LU-202/HT-503
• The number of horizontal lines, or an arrow mark appear on the tray mark displayed on the touch panel of
the main unit in order to indicate the remaining amount of paper in the tray.
Remaining paper sensor /1, /2, /3, /4 statuses and remaining amount of paper
Number of sheets (80g/m2) PS102 PS103 PS104 PS105 Indication on the touch
panel
1 to 600 OFF OFF OFF OFF 2 lines light
600 to 850 ON OFF OFF OFF 2 lines light
850 to 1100 ON ON OFF OFF 3 lines light
1100 to 1400 ON ON ON OFF 4 lines light
1400 to 1700 ON ON ON ON 5 lines light
1700 to 1950 OFF ON ON ON 6 lines light
1950 to 2250 OFF OFF ON ON 7 lines light
2250 or more OFF OFF OFF ON 7 lines light
Note
• The number of sheets shown on the table is approximate values when the paper weight (thick-
ness) is 80g/m2. It varies depending on the thickness of paper.
16

A. Outline
LU-202/HT-503
• The detection method differs between main scan direction and sub scan direction.
• Paper size in main scan direction is detected by the position of the gear of the paper size VR (VR1) [1] which
is rotated by the detection guide plate/Rr [2] mounted on the side guide/Fr [6].
• Paper size in sub scan direction is detected by the paper size sensors /Rr (PS110) [7] and /Fr (PS111) [8].
When the paper rear guide [4] moves, the detection guide plates /1 [5] and /2 [6] are moved upward/down-
ward according to their shape, and the actuators turn PS110 and PS111 on or off.
[1]
[2]
[10]
[9] [3]
[8] [4]
[5]
[7]
[6]
a03wt2c012ca
[1] Paper size VR (VR1) [6] Detection guide plate/2

[2] Detection guide plate/Rr [7] Paper size sensor/Rr (PS110)
[3] Side guide/Rr [8] Paper size sensor/Fr (PS111)
[4] Paper rear guide [9] Side guide/Fr
[5] Detection guide plate/1 [10] Detection guide plate/Fr
17
B. Sensor detection and paper size

• The tables below lists how paper sizes are detected by the paper size VR (VR1), the paper size sensor/Rr
LU-202/HT-503
(PS110) and /Fr (PS111).
Main scan direction Sub scan direction

VR1 PS110 ON OFF ON OFF
PS111 ON ON OFF OFF
291.1° or lower 13 x 19 SRA3 SPECIAL SRA4
291.0 to 241.5° A3 12 x 18 SPECIAL A4
241.4 to 200.5° 11 x 17 16K 8KS 81/2 x 11
200.4 to 141.1° B5 16K 8KS B4S
141.1 to 96.9° SPECIAL SRA4S 81/2 x 11S 81/2 x 14S
96.9° or more A4S SPECIAL 81/2 x 11S 81/2 x 14S
ON: Blocks light of the sensor

OFF: Transmits light of the sensor
4.3.5 Centering detection control

A. Outline
• The position of paper being conveyed is detected by the centering sensor (PS1) [3] and the LU exit sensor
(PS107), and the detected result is used in the image processing section to adjust timing to start printing so
that the scanned image is properly centered on the paper.
• PS1 detects the edge of the paper in the main scan direction.
• PS107 detects the edge of the paper in the sub scan direction.
[4]
[3]
[1]
[2]
a03wt2c013ca
[1] Separation roller [3] Centering sensor (PS1)

[2] Pre-registration roller (driven side) [4] Front side
18
B. Detection area
• The detection range [5] of the centering sensor (PS1) [6] is 216 mm in the main scan direction.
LU-202/HT-503
• The gap between the center [4] of paper [1] in the main scan direction and the origin point [2] of PS1 is
21.85 mm [3].
• The resolution is 0.125 with 1728 dots.
[5]
[6]
[1]
[2]
[4] [3]
a03wt2c014ca
[1] Paper [4] Center of the paper
[2] Origin point of the sensor [5] Detection range
[3] Gap between sensor origin and paper cen- [6] Centering sensor (PS1)
ter
19
5. UP/DOWN SECTION Theory of Operation Ver.2.0 Mar. 2009
5. UP/DOWN SECTION
LU-202/HT-503
5.1 Configuration
Upper limit
sensor
(PS109)
Paper lift plate

Lower limit
sensor
Paper
(PS101)
lift motor
(M100)
Lift wire
a03wt2c015ca
20
Theory of Operation Ver.2.0 Mar. 2009 5. UP/DOWN SECTION
5.2 Drive
LU-202/HT-503
[10]
[9]
[8]
[1]
[2]
[3]
FRONT
[4]
[5]
[6]
[7] a03wt2c016ca
[1] Lift wire/Rr1 [6] Lift wire/Fr2

[2] Lift wire /Rr2 [7] Lift wire/Fr1
[3] Lift wire/Rr3 [8] Paper lift plate
[4] Drive shaft [9] Paper lift motor (M100)
[5] Lift wire/Fr3 [10] Remaining paper detection gear
21
5. UP/DOWN SECTION Theory of Operation Ver.2.0 Mar. 2009
5.3 Operation
LU-202/HT-503

A. Mechanism
• Moving the paper lift plate up/down is made by winding/releasing the lift wires with the pulleys driven by the
paper lift motor (M100).
• Six lift wires are connected to the paper lift plate (three each on front and back). 2 wires each on the front
and back of the plate; lift wire/Fr2, /Fr3, /Rr2, /Rr3, lift the paper lift plate, and the other 2 (one each on front
and back); lift wire/Fr1 and /Rr1, pull the plate downward.
• The pulling force of the lift wire/Fr1 and /Rr1 is exerted by the springs and it works to stabilize the paper lift
plate.
B. Up operation
• When the upper door sensor (PS100) turns on [1] upon closing of the upper door, the paper lift motor
(M100) rotates in forward direction to lift the paper lift plate [2] until the upper limit sensor (PS109) turns on
[3].
• When the height of paper stacked in the tray becomes lower as the paper is fed, PS109 becomes off [4]
and M100 starts to rotate again in forward direction to lift the paper lift plate until PS109 becomes on [5]
again.
[6][7]
Forward
Paper lift
motor (M101) Reverse
Upper door sensor (PS100)
Upper limit sensor (PS109)
[1] [2] [3] [4] [5] [4] [5] a03wt2c017ca
[1] Closing of upper door [4] The height of stacked paper lowers due to
[2] Paper lift plate goes up paper feeding
[3] Paper lift plate stops at the upper limit posi- [5] Paper lift plate reaches the upper limit posi-
tion tion
C. Down operation
• When the upper door sensor (PS100) turns off upon opening of the upper door, the paper lift motor (M100)
starts to rotate in reverse direction to make the paper lift plate go down by a predetermined amount.
• When the tray down switch (SW100) is pressed while PS100 is off, M100 starts to rotate in reverse direction
to lower the paper lift plate by 90 mm.
• After SW100 is pressed, M100 stops when the lower limit sensor (PS101) turns on (detects that the paper
lift plate reaches the lower limit position). The paper lift plate does not go down while PS101 is on even if
SW100 is pressed.
22
Theory of Operation Ver.2.0 Mar. 2009 6. OTHERS
6. OTHERS
LU-202/HT-503
• The LU is equipped with the dehumidifier heater (HTR1) to reduce the moisture inside the LU.
• HTR1 is powered with 220 VAC supplied from the main body, and activated by turning on the dehumidifier
heater switch (SW3) on the main body and turning off the sub power switch (SW2)
[1]
a03wt2c018ca
[1] Dehumidifer heater (HTR1)
23
6. OTHERS Theory of Operation Ver.2.0 Mar. 2009
6.2 Interlock control

LU-202/HT-503
• The interlock switch/1 (MS1) and the front door sensor (PS115) are mounted on the front door, and the
interlock switch/2 (MS2) and the upper door sensor (PS100) are mounted on the upper door.
• The power to drive the paper feed motor (M1) is transmitted via MS1 and the MS2. If the front door or the
upper door is opened, MS1 and MS2 turn off to cut the power supply to the paper feed motor (M1).
• When PS115 and PS100 turn off while paper being fed, the LU drive board (LUDB) changes M1 drive signal
into off in order to stop the paper feeding.
24
Theory of Operation Ver.2.0 Mar. 2009 7. HT-503 (OPTIONAL)
7. HT-503 (OPTIONAL)
LU-202/HT-503
7.1 Configuration
Dehumidifier Dehumidifier Dehumidifier

Temperature sensor (TEMS) fan/1 (FM3) fan/2 (FM4) heater/3(HTR/2)
AC drive board (ACDB)
a03wt2c019ca
25
7. HT-503 (OPTIONAL) Theory of Operation Ver.2.0 Mar. 2009
7.2 Operation
LU-202/HT-503
7.2.1 Dehumidifier fan heater control

A. Outline
• The fan heater (HTR3) and the dehumidifier fan/1 (FM3) and /2 (FM4) generate hot airflow inside the LU and
reduce moisture in order to prevent jam of coated paper due to dampness.
• The dehumidifier control has 2 processes; a dehumidifier fan heater pre-drying and the temperature limiting
dehumidification control. The first one (pre-drying) is made with HTR3 , FM3 and FM4. Once the target tem-
perature rise is achieved, the pre-drying process is finished and further dehumidification control limiting the
temperature is carried out only by HTR3.
• The dehumidification control is carried out according to the temperature inside the tray detected by the
temperature sensor (TEMS), and continued until the target temperature rise is achieved.
• Feeding paper from the LU cannot be made while the dehumidification control being performed. (this can
be allowed by changing DIPSW setting)
B. Dehumidifier fan heater pre-drying control

• The user setting menu has an option to activate pre-drying with the dehumidifier fan heater before printing
every time the upper door is opened/closed.
• When the pre-drying with the dehumidifier fan heater is set not to be activated in the user setting menu, the
pre-drying before printing is carried out if the upper door is opened/closed and a change in remaining
amount of paper is detected.
• HTR3, FM3, and FM4 turn on when 56% or higher ambient humidity is detected by the temp/humidity sen-
sor/1 (TEM/HUMS/1) of the main unit.
• FM3 and FM4 are turned on at regular intervals, and kept on for a specified time period.
C. Triggers for dehumidification control

• When the sub power switch (SW2) is turned on with the dehumidifier fan heater setting set to [Automatic] or
[On (compulsory)], and with the paper type set to coated paper.
• After the upper door is opened/closed with the dehumidifier fan heater setting set to [Automatic] or [On
(compulsory)], and with the paper type set to coated paper.
• When the paper type is changed to coated paper from other paper type with the dehumidifier fan heater
setting set to [Automatic] or [On (compulsory)].
• When the dehumidifier fan heater setting is changed to [Automatic] from [Off (compulsory)], or changed to
[On (compulsory)].
D. Temperature limiting dehumidification control

• After the pre-drying is finished, the HTR3 is turned on or off to keep the target temperature.
Ambient humidity Target temperature rise in the tray

Lower than 55% Not controlled
56 to 60% 6°C
61 to 65% 7°C
66 to 70% 8°C
71 to 75% 9°C
Higher than 76% 10°C
E. Conditions to stop the dehumidification control

• When other than coated paper is selected as the paper type while the control is in progress.
• When the dehumidifier fan heater setting is changed to [Off (compulsory)] while the control is in progress.
26
Theory of Operation Ver.2.0 Mar. 2009 8. MAINTENANCE PROCEDURE
MAINTENANCE
LU-202/HT-503
8.1 Paper feed section
Caution
8.1.1 Cleaning/pre-registration roller

• Paper dust removing brush: Actual cleaning cycle : Every 200,000 prints *1
Every 150,000 prints *2
• Pre-registration roller: Actual cleaning cycle : Every 200,000 prints *1
Every 150,000 prints *2
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
1. Remove the upper door.

[1] [2] [3]
(Refer to P.35)
2. Remove the paper feed cover.
(Refer to P.36)
dust cleaner brush [2].
4. Clean the paper dust removing brush [2] and the
pre-registration roller [3].
steps in reverse.
a03wf2c001ca
27 1
8. MAINTENANCE PROCEDURE Theory of Operation Ver.2.0 Mar. 2009
8.1.2 Removing/installing paper feed roller Assy

A. Procedure
LU-202/HT-503

[1] [2] [3] [5] [10] [9][4][2][1] [6] [8]
(Refer to P.35)
(Refer to P.36)
3. Remove the 2 C-clips [1], and slide the 2 bearings
[2] outward.
4. After rotating the paper feed roller assy [5] to the
position free from upper limit sensor (PS109) [3]
and the paper empty sensor (PS108) [4], remove
the coupling [8] while avoiding notch [6] and the
arm [7] of paper feed guide plate, and remove the
paper feed roller assy [5].
[6] [7] a03wf2c002ca Note

• When removing/installing, be careful not to
damage the upper limit sensor (PS109) [3] and
the paper empty sensor (PS108) [4].
• When installing, make sure that the arm [9] is
underneath the lever [10].

steps in reverse.
28
8.1.3 Replacing the paper feed roller/pick-up roller
LU-202/HT-503
• Paper feed roller : Every 600,000 prints (actual replacement cycle: every 300,000 feed)
• Pick-up roller : Every 600,000 prints (actual replacement cycle: every 300,000 feed)
B. Procedure
[2] [3] 1. Remove the paper feed roller assy.

(Refer to P.28)
2. Turn over the paper feed roller assy.
4. Remove the 2 C-clips [2], and remove the cou-
pling bearing [3].
[1] [2] a03wf2c003cb
5. Slide the coupling bearing [1] and remove the

[2] [5] [1]
mounting bracket [2].
roller [4].
Note
• Be sure to reinstall in the same direction with
the removing direction.
7. Remove the pick-up roller [5].
[3] [4]
a03wf2c004cb
29
8. Remove the collar [2] from the pick-up roller [1].

[2] [1]
LU-202/HT-503
steps in reverse.
a03wf2c005cb
30
LU-202/HT-503
• Separation roller : Every 600,000 prints (actual replacement cycle: every 300,000 feed)
B. Procedure
1. Open the upper door.
2. Remove the 2 screws [1] and remove the cover
[2].
[2] [1] a03wf2c006ca
3. Remove the 2 screws [1], pull out the front side

while pressing down the separation roller [2],
remove the coupling [3], and remove the separa-
[3] tion roller assy [4].
[2]
[4] [1] a03wf2c007ca
31
4. Remove the 2 C-clips [1].

5. Rotate the shaft to match its D-shape end with
LU-202/HT-503
the D-cut of the metal plate [2], and remove the

separation roller [3].
[1] [3] [4]
Note
[2] • When removing/installing, be careful not to
damage the protection sheet [4].
[1]
a03wf2c008cb
6. Remove the separation roller [1] from the collar [2].

[1] [2]
Note
• Be sure to insert the claw [4] of the gear [3] to
the hole [5] of the separation roller [1] in
securely.
• Be careful not to let any grease spill or drip on
the separation roller.

steps in reverse.
[3]
[1]
[5]
[4]
a03wf2c009cb
32
8.1.5 Replacing paper feed clutch (MC101) /pre-registration clutch (MC102)
LU-202/HT-503
• Paper feed clutch (MC101) : Every 2,400,000 prints (actual replacement cycle: every 2,000,000 feed)
• Pre-registration clutch (MC102) : Every 2,400,000 prints (actual replacement cycle: every 2,000,000 feed)
B. Procedure
1. Remove the clutch cover.
[2] [3] [5] [6] [7] [5] [4] [2]
(Refer to P.35)
3. Remove the 2 C-clips [2] and remove the paper
feed clutch (MC101) [3], and remove the pre-reg-
istration clutch [4].
Note
• When installing, be sure to insert the stoppers
[5] of the clutches over the screw [6] and the
metal plate [7].

steps in reverse.
[1] a03wf2c010ca
33
9. OTHER PROCEDURES Theory of Operation Ver.2.0 Mar. 2009
9. OTHER PROCEDURES
LU-202/HT-503
9.1 Disassembly/Reassembly Parts List

1 Cover section Upper door P.35
Clutch cover P.35
Paper feed cover P.36
Right cover P.36
Front cover P.37
Rear cover P.38
2 Up/down section Lift wire P.39
34
Theory of Operation Ver.2.0 Mar. 2009 9. OTHER PROCEDURES
9.2 Disassembly/Reassembly Procedures
LU-202/HT-503
Caution
9.2.1 Removing/reinstalling the upper door

A. Procedure
1. Open the upper door [1].
[1] [7] [2]
2. Remove the hook [3] of spring [2] from the paper
feed guide plate [4].
Note
• When attaching the spring, be sure to put its
hook through the hole on the plate from the
outside.
3. Remove the 2 screws [5], slide the door [1] in the

direction of the arrow [6], and remove it while tilt-
ing it in the direction of the arrow [7].
[5] [4] [3] [5] [6] a03wf2c011ca
steps in reverse.
9.2.2 Removing/reinstalling the clutch cover

A. Procedure
[1] [2]
clutch cover [3].
steps in reverse.
[3] [2] a03wf2c012ca
35
9.2.3 Removing/reinstalling the paper feed cover

A. Procedure
LU-202/HT-503

[3] [1]
(Refer to P.35)
2. Remove the 2 screws [1] and the 2 screws [2],
and remove the paper feed cover [3].
steps in reverse.
[2] a03wf2c013ca
9.2.4 Removing/installing the right cover

A. Procedure
[1] [3]
cover [3].
steps in reverse.
[2] a03wf2c014ca
36
9.2.5 Removing/reinstalling the front cover

A. Procedure
LU-202/HT-503
2. Remove the right cover.
(Refer to P.36)
[1] 3. Open the front door [1] and remove the 5 screws
[2].
4. Close the front door [1], and remove the front
cover [3].
[2]
steps in reverse.
[3] [2]
a03wf2c015ca
37
9.2.6 Removing/reinstalling the rear cover

A. Procedure
LU-202/HT-503

[2] [1] [1] [3]
(Refer to P.36)
3. Remove the 18 screws [1] and remove the rear
cover [2] with the clutch cover [3].
Note
[1] • When the HT (option) is installed, remove the
4 screws [4].

steps in reverse.
[1] [1] [4]
a03wf2c016ca
38
9.2.7 Replacing the lift wire
LU-202/HT-503
Note
• When the HT-503 (option) is installed, remove it before performing the replacement.
• Be sure to lower the paper lift plate to its lower most position in advance by pressing the tray
down switch (SW100) with electricity supplied.
• Remove the lift wire in the order of "A. Removing/installing the paper feed motor assy" "B. Remov-
ing/installing the paper lift drive section" "C. Removing/reinstalling the lift wire". Reinstall the lift
wire following the removal steps in reverse.
• After replacing the lift wire, carry out the paper lift plate horizontal adjustment.
• There are 6 lift wires; Fr1[2], Fr2 [3], Fr3 [4], Rr1 [5], Rr2 [6], and Rr3 [7]. All of them are wound on
the pulleys attached to the drive shaft [1] as shown.
The 4 lift wires; Fr2, Fr3, Rr2, Rr3 are the same in length, and are referred to as drive wire/A which
lifts the paper lift plate [8]. The other 2 lift wires; Fr1 and Rr1 are different in length and attached to
the spring/Fr [9] and the spring/Rr [10] as shown. The Fr1 and Rr1, referred to as assist wire/C and
/D respectively, pull the paper lift plate downward to stabilize the plate.
Drive wire/A (1450 mm) :lift wire/Fr2 [3], /Fr3 [4], Rr2 [6], /Rr3 [7]
Assist wire/C (1240 mm) :lift wire/Fr1 [2]
Assist wire/D (820mm) :lift wire/Rr1 [5]
• Attach the cylindrical-shaped end [11] of the wire to the drive shaft, and attach the other ball
shaped end [12] to the metal plate or the spring.
[8] [10]
[5]
[6]
[7]
[11]
[4] [1]
[12]
FRONT [9] [3]
[2] a03wf2c017ca
[1] Drive shaft [6] Lift wire /Rr2

[2] Lift wire/Fr1 [7] Lift wire/Rr3
[3] Lift wire/Fr2 [8] Paper lift plate
[4] Lift wire/Fr3 [9] Spring/Fr
[5] Lift wire/Rr1 [10] Spring/Rr
39
A. Removing/installing the paper feed motor assy

1. Remove the LU from the main body.
LU-202/HT-503
[1] [2]
(Refer to P.36)
3. Remove the front cover.
(Refer to P.37)
(Refer to P.38)
5. Remove the paper feed clutch (MC101) [1] and
pre-registration clutch (MC102) [2].
(Refer to P.33)
6. Remove the 2 screws [3] and remove the duct [4].
[4] [3]
a03wf2c018ca
7. Remove the wire binding [1] from the saddle [2].

[1] [2] [12] [11] [6] [3] [4]
9. Loosen the screw [4] 1 or 2 turns.
Note
• Do not loosen the screw [4] too much. Doing
so may damage the clearance sponge [5].
10. Push the lower part of the bulkhead plate [6] a few
millimeters in the direction of the arrow [7], then
while avoiding actuator [8], push the tab [9] to
remove the lower limit sensor (PS101) [10].
Note
[3] [5] [7] [3] • When removing/installing PS101, be careful
not to damage it.
• When installing, make sure that the tab [9] is
securely inserted.
11. Slide the upper part of the bulkhead plate [5] in

the direction of the arrow [11], and tilt it until it
comes off from the metal plate [12].
[8] [10] [9]
a03wf2c019ca
40
12. Remove the 3 connectors [1] and remove the wire

[6] [3] [4] [6] [8]
binding [2] from the saddle.
LU-202/HT-503
feed motor assy [7] in the direction of the arrow
[8].
Note
• The screws [6] are shoulder screws. Make
sure to properly attach the screws so that the
metal plate is fitted securely.
[5] [1] [2] [7] [5] 16. Reinstall the above parts following the removal
a03wf2c020ca
steps in reverse.
B. Removing/installing the paper lift drive section

[2] [1] [4]
(Refer to P.36)
(Refer to P.38)
3. Remove the screw [1], and remove the sensor
cover [2].
4. Remove the 5 connectors [3] and remove the wire
binding [4].
[3] a03wf2c021ca
41

[3]
6. Remove the 3 screws [3] and the 2 screws [4].
LU-202/HT-503
Note
7. Remove the metal plate [5] and the bearing [6].
Note
• When installing the bearing [6], install it from
the inner side of the metal plate [5].
[2] [1] [6] [5] [4]
a03wf2c022ca
8. Remove the positioning gear [1].

[1] [2]
Note
• When installing the gear [1] with the paper lift
plate located at its lowest position, align the
edge surface of the actuator [3] of the
remaining paper detection gear [2] with the
surface [5] of the remaining paper sensor/4
(PS105) [4].
• Make sure to attach the gear [1] in the correct
direction.
[2]
[5]
[4]
[3] a03wf2c023ca
42
9. Remove the E-ring [1], then remove the gear [2]

and the pin [3].
LU-202/HT-503
and the outer/inner bearings [6].
[2] [3] [1] [6] [4] [5]

a03wf2c024ca
and the pin [3].
[5] [4] [3] [2] [1]

a03wf2c025ca
13. Remove the 4 screws [1] and the 2 screws [2],

[3] [2]
and remove the paper lift drive section [3].
Note
• Be careful not to damage the clearance
sponge [4].

steps in reverse.
[1] [4]
a03wf2c026ca
43
C. Removing/reinstalling the lift wire

1. Remove the paper feed motor assy.
LU-202/HT-503
[4] [3] [1] [2] (Refer to P.40)

2. Remove the paper lift drive section.
(Refer to P.41)
3. Release the hook [2] of the spring/Rr [1] provided
at the back, and remove the ball shaped wire end
[3].
4. Remove the lift wire/Rr1 [7] from the pulley [4], [5]
and [6].
5. Remove the E-ring [8] and the pulley [9], and then
remove the lift wire/Rr1 [7].
[5]
[6] [7]
[8] [9] [6]

a03wf2c027ca
44
Note
[2] [5] [4] [3] [9] [10] [1]
LU-202/HT-503
• When installing the lift wire/Rr1 [1], insert the
cylindrical-shaped end of the wire [3] into the
hole of the drive shaft [2], and insert the pul-
ley [5] letting the wire through the cutout [4],
and then wind the wire 7 turns clockwise [6]
(from the panel [7] side to outward [8]) in a
single layer.
• When installing the lift wire/Rr1, be sure that
the lift wire/Rr2 [9] and /Rr3 [10] are not on
either side edge of the pulley, and the lift wire/
Rr1 [1] is wound 1 turn at the panel side [7].
[8] [7]
[6] a03wf2c028ca
6. Release the hook [2] of the spring/Fr [1] provided

[4] [6] [7] [8]
at the front, and remove the ball shaped wire end
[3].
7. Remove the lift wire/Fr1 [6] from the pulley [4] and
[5].
remove the lift wire/Fr1 [6].
[1] [2] [3] [5]
a03wf2c029ca
45
Note
LU-202/HT-503
[5] [4] [2] [3] [1]

• When installing the lift wire/Fr1 [1], insert the
cylindrical-shaped end of the wire [3] into the
hole of the drive shaft [2], and insert the pul-
ley [5] letting the wire through the cutout [4],
and then wind the wire 7 turns counterclock-
wise [6] (from the panel [7] side to outward
[8]) in a single layer.
• Before Installing the lift wire/Fr1, rotate the
shaft counterclockwise to prevent the lift
[7] [10] [9] [8] [6] wire/Fr2 [9] and Fr3 [10] from getting loose.
• Be sure to check that the wires are not loos-
ened and are not on either side edges of the
pulleys.
a03wf2c030ca
46
[11] [10] [12]
pull out the wire end [3].
LU-202/HT-503
10. Remove the lift wire/Fr2 [4] from the pulley [5], [6]
and [7].
Note
• When removing the wire from the pulley [5],
[6] and [7], pull the wire out from the convex
[9]
portion [8] of the wire cover [9], then slide the
[5] wire cover.
[8]
11. Remove the screw [10], and remove the wire pro-
tective cover [11].
12. Remove the ball shaped wire end [12] by pulling it
[4] [6] straight up, and remove the lift wire/Fr2 [4].
Note
• When removing/installing the lift wire, be
careful not to damage it with the metal plate.
[5] [7]
[1]
[2] [3]
a03wf2c031ca
47
13. Remove the 2 E-rings [1] and pulley [2], and

[8] [7]
remove the lift wire/Fr3 [3].
LU-202/HT-503
14. In the same manner as Step 10, remove the lift

wire/Fr3 [3] from the pulley [4], [5] and [6].
15. In the same manner as Steps 11 and 12, remove
the screw [7] and the wire cover [8], and remove
the lift wire/Fr3 [3].
[5]
[6] [4] [3]
[2] [1] a03wf2c032ca
48
16. Remove the E-ring [1] provided at the back and

[7] [8]
the pulley [2], and remove the lift wire/Rr2 [3].
LU-202/HT-503
wire/Rr2 [3] from the pulley [4], [5] and [6].
the screw [7] and the wire protective cover [8],
and remove the lift wire/Rr2 [3].
[5]
Note
• After installing the lift wire, make sure that the
lift wire does not contact with the metal
plates or some other parts.
[4] [3] [6]
[1] [2] a03wf2c033ca
49
19. Remove the 2 E-rings [1] and pulley [2], and

[7] [8]
remove the lift wire/Rr3 [3].
LU-202/HT-503

wire/Fr3 [3] from the pulley [4], [5] and [6].
the screw [7] and the wire protective cover [8],
and remove the lift wire/Rr3 [3].
[5]
Note
• After installing the lift wire, make sure that the
lift wire does not contact with the metal
plates or some other parts.

steps in reverse.
Note
• After installing, carry out the paper lift plate
horizontal adjustment.
[6] [3] [4] (Refer to Field Service P.441)
[1] [2] a03wf2c034ca
50
9.2.8 Removing/reinstalling the paper size VR (VR1)
LU-202/HT-503
A. Procedure for removal
1. Remove the paper from LU and close the upper
[2] [1] [3] [4] door.
2. Turn ON the main power switch (SW1) and the
sub power switch (SW2) of the main body. Con-
firm that the paper lift plate stops at its uppermost
position (listen to the sound of the paper lift motor
to figure out the stop status), and then turn the
power switches OFF.
4. Loosen 2 screws [2] of the guide plate /Fr [1] and
2 screws [4] of the guide plate /Rr [3], and widen
the guide plates /Fr, /Rr to the max. width.
5. Remove 3 screws [5] of the paper size VR (VR1)
and remove the VR1.
[5]
a03wf2c035ca
51
B. Procedure for reinstallation

1. Widen the guide plates /Fr [1], /Rr [2] to the max.
LU-202/HT-503
[1] [2]
width.
2. Adjust the engagement of the gears of paper size
VR (VR1) and detection plate /Rr so that the holes
[3] and [4] are aligned. Then tighten the screw [5].
3. After installing, set the paper in LU and check that
the paper size is properly detected.
[5]
[3] [4]
a03wf2c036ca
52
RU-504
2008.07
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
RU-504
RU-504
OUTLINE
3. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. CONVEYANCE SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2.1 Conveyance drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3.1 Conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3.2 Decurler control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3.3 Fan control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
MAINTENANCE
5.2 Disassembly/reassembly procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2.1 Removing/reinstalling the conveyance units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2.2 Removing/reinstalling the upper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2.3 Removing/reinstalling the decurler gate solenoid /1 (SD2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2.4 Removing/reinstalling the decurler gate solenoid /2 (SD3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2.5 Note to keep in mind when replacing the board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
i
RU-504
Blank page
ii
OUTLINE
RU-504
A. Type
Type Conveyance unit with paper cooling and decurler functions
B. Functions
(1) Functions
Accelerated conveyance To accelerate for the finisher standard line speed.

mode
Decurler conveyance mode Reduces paper curl and conveys at an accelerating rate with posttreatment lin-
ear velocity.
(2) Operation capacity

65PPM (A4, B5, 81/2 x 11, 16K)
C. Paper type
Paper size SRA3, A3, B4, SRA4, SRA4S, A4, A4S, B5, B5S, A5, A5S, B6S, A6S
13 x 19, 12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 8 1/2S
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
8K, 16K, 16KS
Custom paper (Max. 330 x 487mm, Min. 100 x 148 mm)
Paper type Plain paper, high quality paper, color paper, coated paper, tab paper (five-tab
type): same as the main body.
Paper weight Accelerated con- 64 to 300g/m2
veyance mode
Decurler convey- 64 to 209g/m2
ance mode
D. Maintenance
1
E. Machine data
Power source RU-504 AC100 to 240V/5V DC*1

RU-504
Maximum power consump- 90VA or less

tion
Dimensions Including main body: 175 (W) x 723 (D) x 1 (H) mm
Weight RU-504 Approx. 35 kg
*1 5VDC is supplied from the main body.
Note
2
RU-504
Conveyance section
Power source section
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3
3. PAPER PATH
A. Accelerated conveyance mode (Normal mode)
RU-504
[1]
[8]
[2]
[7]
[3]
[4]
[6] [5]
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[1] Decurler gate /1 [5] Intermediate roller /3

[2] Intermediate roller /1 [6] Paper exit roller
[3] Entrance roller /2 [7] Decurler gate /2
[4] Entrance roller /1 [8] Intermediate roller /2
4
B. Decurler conveyance mode (straightening the upward curling)
RU-504
[11] [1]
[10]
[9]
[8]
[2]
[7]
[3]
[4]
[6] [5]
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[1] Decurler gate /1 [7] Decurler gate /2

[2] Intermediate roller /1 [8] Intermediate roller /2
[3] Entrance roller /2 [9] Decurler belt /1
[4] Entrance roller /1 [10] Decurler roller /1
[5] Intermediate roller /3 [11] Decurler roller /2
[6] Paper exit roller
5
C. Decurler conveyance mode (straightening the downward curling)

RU-504
[1]
[11]
[2]
[3]
[10]
[4]
[9]
[5]
[6]
[8] [7]
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[1] Decurler gate /1 [7] Intermediate roller /3

[2] Intermediate roller /1 [8] Paper exit roller
[3] Decurler belt /2 [9] Decurler roller /2
[4] Decurler roller /3 [10] Decurler gate /2
[6] Entrance roller /1
6
RU-504
4.1 Configuration
Decurler roller /2 Decurler gate /1

Decurler roller /1
Decurler belt /1
Decurler gate /2 Decurler belt /2
Decurler roller /3
Decurler roller /4
Paper fan
/1, /2, /3
(M2, M3, M4)
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7
4.2 Drive
4.2.1 Conveyance drive
RU-504
[1]
[2]
[14]
[3]
[13]
[12]
[4]
[16]
[11]
[5]
[6]
[15]
[7]
[8]
[10] [9]
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[1] Decurler gate solenoid /1 (SD2) [9] Entrance conveyance motor (M1)
[2] Decurler gate /1 [10] Paper exit roller
[3] Gear [11] Intermediate roller /3
[4] Paper exit motor (M5) [12] Intermediate roller /2
[5] Decurler roller /2 [13] Intermediate roller /1
[6] Entrance roller /2 [14] Decurler roller /1
[7] Belt [15] Decurler gate solenoid /2 (SD3)
[8] Entrance roller /1 [16] Decurler gate /2
8
4.3 Operation
RU-504
• The entrance conveyance motor (M1) controls the rotation of the entrance rollers /1 [6] and /2 [5].
• The paper exit motor (M5) controls the rotation of the intermediate rollers /1 [2], /2 [12], /3 [1] and the paper
exit roller [9].
• The paper ejected from the main body is conveyed to the RU section by the entrance roller /1 [8]. Then the
intermediate roller conveys the paper [4], and then paper exit roller exits it [10].
• The intermediate sensor (PS2) [3] detects paper jam.
[1]
[2]
[12]
[3]
[4] [4]
[11] [5]
[6]
[7]
[10] [8]
[9]
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[1] Intermediate roller /3 [7] Entrance sensor (PS1)

[2] Intermediate roller /1 [8] Conveyance to the RU section
[3] Intermediate sensor (PS2) [9] Paper exit roller
[4] Conveyance by the intermediate roller [10] Paper exit from the RU section
[5] Entrance roller /2 [11] Paper exit sensor (PS3)
9
A. Straight mode
1. The entrance conveyance motor (M1) and the paper exit motor (M5) turn ON when a start-printing signal is
sent from the main body. Then, M1 rotates at the same rate as the line speed of the main body while M5
RU-504
rotates at high speed.

2. The M5 reduces the speed at the same rate as that of the M1 after the predetermined time has passed since
the entrance sensor (PS1) detected the edge of the paper.
3. The M5 rotates at high speed again after the predetermined time has passed since the PS1 detected the
rear end of the paper.
4. M1 and M2 stop the operation after predetermined time has passed since the paper exit sensor (PS3)
detected the trailing edge of the last paper.
[1] [2] [3]
Entrance sensor (PS1)

Entrance Middle
conveyance motor
(M1) Low
High
Paper exit motor
(M5) Middle
Low
(speed)
[4] [5]
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[1] Start-printing signal ON [4] Decelerating at low speed

[2] Paper leading edge detection [5] Accelerating at high speed
[3] Paper trailing edge detection
10
B. Reverse paper exit mode

• Each control timing is the same as in the straight mode.
RU-504
[1] [2] [3]

Entrance Middle
conveyance motor
(M1) Low
High
Paper exit motor Middle
(M5)
Low
(speed)
[4] [5]
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[1] Start-printing signal ON [4] Decelerating at middle speed

[2] Paper leading edge detection [5] Accelerating at high speed
[3] Paper trailing edge detection
11
4.3.2 Decurler control

• The paper exit motor (M5) controls the rotation of the decurler rollers /1 [15] and /3 [14]
• Conveys paper into between the decurler belt /1 [7], /2 [10], and decurler roller /2 [8], /4 [12] and gives
RU-504
pressure to remove the curl of the paper.

• The decurler /Up [9] exerts a pressure on the paper curled upward (valley curl) [6] while the decurler /Lw [11]
exert a pressure on the paper curled downward (mount curl) [16].
• There are 3 modes for paper curl straightening: Upward paper curl straightening ON (Conveys toward the
decurler /Up [5]), Downward paper curl straightening ON (Conveys toward the decurler /Lw[17]), Decureler
OFF (The paper through the normal path [4])
• Switching paper curl straightening mode is made in the service mode and Adjustment Menu-Finisher
Adjustment.
12
RU-504
[6]
[1]
[5]
[2]
[3]
[4]
[7]
[15]
[8]
[9]
[16]
[3]
[10]
[4]
[11]
[14] [12]
[19]
[17]
[18] [13]
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[1] Decurler gate solenoid /1 (SD2) ON [11] Decurler /Lw

[2] Decurler gate solenoid /1 (SD2) [12] Decurler roller /4
[3] Switching paper through path [13] Paper exit sensor (PS3)
[4] Paper through path (normal path) [14] Decurler roller /2
[5] Paper through path (toward the decurler / [15] Decurler roller /3
Up) [16] The paper curled downward
[6] The paper curled upward [17] Paper through path (toward the decurler /
[7] Decurler belt /1 Lw)
[8] Decurler roller /2 [18] Decurler gate solenoid /2 (SD3)
[9] Decurler /Up [19] Decurler gate solenoid /2 (SD3) ON
[10] Decurler belt /2
13
A. Decurler /Up control

• When the upward paper curl straightening ON in the service mode and Adjustment Menu-Finisher Adjust-
ment setting, a start-printing signal is sent form the main body and the decurler gate solenoid /1 (SD2)
RU-504
starts operating. Then it switches the direction of paper conveyance path toward the decurler /Up.
• The paper conveyance path is switched to the normal path when the SD2 is OFF. When the SD2 is ON, the
path is switched toward the decurler /Up.
• SD2 stop the operation after predetermined time has passed since the paper exit sensor (PS3) detected
the trailing edge of the last paper.
B. Decurler /Lw control

• When the downward paper curl straightening ON in the service mode setting, a start-printing signal is sent
form the main body and the decurler gate solenoid /2 (SD3) starts operating. Then it switches the direction
of paper conveyance path toward the decurler /Lw.
• The paper conveyance path is switched to the normal path when the SD3 is OFF. When the SD3 is ON, the
path is switched toward the decurler /Lw.
• SD2 stop the operation after predetermined time has passed since the paper exit sensor (PS3) detected
the trailing edge of the last paper.
14
4.3.3 Fan control

• There are 5 fans: Paper fan /1, /2 and /3 (M2, M3 and M4) [2] [4] [5] Ventilation assist fan /1 and /2 (M6 and
M7) [3] [1]
RU-504
• The paper fans reduce unevenness of the wax on the paper by blowing and cooling down the paper with
air.
• The ventilation assist fan intakes fresh air and exhausts heat around the paper exit section.
[5]
[4]
[1]
[3]
[2]
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[1] Ventilation assist fan /2 (M7) [4] Paper fan /2 (M3)

[2] Paper fan /1 (M2) [5] Paper fan /3 (M4)
[3] Ventilation assist fan /1 (M6)
A. Paper fan control

• When a start-printing signal is sent from the main body, the paper fans (M2, M3 and M4) start to rotate.
• As the paper exit sensor (PS3) detects the trailing edge of the last paper, M2, M3 and M4 are turned off.
B. Exhaust assist fan control

• When a start-printing signal is sent from the main body, the ventilation assist fans (M6 and M7) start to
rotate.
• As the paper exit sensor (PS3) detects the trailing edge of the last paper, M6 and M7 are turned off.
15
RU-504
Blank page
16
MAINTENANCE
RU-504
5. OTHER PROCEDURES
1 Conveyance section Conveyance unit P.18
2 Upper cover P.23
3 Decurler gate solenoid /1 (SD2) P.23
4 Decurler gate solenoid /2 (SD3) P.25
17

RU-504
Caution:
5.2.1 Removing/reinstalling the conveyance units

A. Procedure
2. Loosen the 2 screws [2] and detach them from
the holes [3], release the projection [5] through the
hole [4], and then remove the front cover [6].
[2]
[3]
[1]
[6]
[5]
[4]
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18
Note
[1] [3] [4] [5] [2] • After reinstalling the front door [1], loosen the
2 screws [2] and match the position of the
RU-504
actuator [5] with the interlock [4] while mov-
ing the fixing plate [3] in the direction of the
arrow. Do not open the front door [1] forcibly.
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19
3. Remove the 2 screws [1], release the 2 tabs [2]

through the holes [3], and then remove the rear
cover [4].
RU-504
[2]
[3]
[4]
[1]
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20

[1] [2] cover [2].
RU-504
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5. Disconnect the 2 connectors [1] and the 2 clamps

[1] [2] [3] [2], and then release the wire binding [3].
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6. Pull out the conveyance unit [1] toward you and

[2] [1]
remove the 2 screws [2].
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21
7. Push the conveyance unit [1] back to the main

body, and pull it out again together with the upper
[2] cover [2].
RU-504
[4]
[3] Note
• Do not carry the main body with the convey-
[5] ance unit [1] pulled out without the upper
cover [2].
• When installing the conveyance unit, put the
[2] [1] upper cover [2] on the guide rail [3] properly
and engage the hole [4] on the rear side of the
conveyance unit with the pin [5] at the back of
the guide rail.
Caution:
• Be sure to install the lock shaft that you have
removed during unpacking, or the convey-
ance unit may pop up and you may get hurt.
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Note
• When handling the conveyance unit, do not
hold the unit by its handle [1] or the guide
plate [2]. Be sure to grasp the sturdy parts
such as the frame [3] or the shaft [4].
[4]

steps in reverse.
[3] [1] [2]
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22
5.2.2 Removing/reinstalling the upper cover

A. Procedure
1. Remove the conveyance unit from the main body
RU-504
[2] [1]
and the option. (Refer to P.18)
2. Remove the 8 screws [1], slide the cover [2] of the
main body backward, and remove the cover.
steps in reverse.
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5.2.3 Removing/reinstalling the decurler gate solenoid /1 (SD2)

A. Procedure
1. Remove the conveyance unit from the main body
[1] [4] [5] [2] [3]
and the option. (Refer to P.18)
2. Remove the upper cover. (Refer to P.23)
4. Remove the screw [3] of the solenoid lever [2].
5. Remove the 3 screws [5] of the solenoid mounting
plate [4], and remove the solenoid lever [2] and
the solenoid mounting plate [4] by pulling them
out all together toward you.
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23
6. Remove the solenoid lever [1].

[3] [2] [4] [1]
Note
RU-504
• Mind the correct direction when installing the

solenoid lever.
7. Remove the 2 screws [3] of the solenoid mounting

plate [2], and replace the solenoid [4] with a new
one.
8. Follow the steps 7 to 3, and carry out the adjust-
ment below.
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9. Adjust the position of the solenoid mounting plate

[4] [1] [3] [2] [3] so that the clearance of the gate outlet [2]
becomes to the specified value “a” when the gate
solenoid [1] is moved as shown by the arrow, and
then secure the plate with the screw [4].
Specified value: a = 3 ± 0.5 mm
steps in reverse.
a=3 0.5mm
[4]
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24
5.2.4 Removing/reinstalling the decurler gate solenoid /2 (SD3)

A. Procedure
1. Remove the conveyance unit. (Refer to P.18)
RU-504
[1] [3] [2] [1] 2. Remove the 3 screws [1], and remove the covers
[2] and [3].
a04jf2c013ca

[1] [5] [4] [2] [3] [4] 4. Remove the 2 screws [2].
Note
• Be careful when handling the solenoid [3] as it
is not fixed at this moment.
5. Remove the 2 screws [4] and the solenoid mount-

ing plate [5], and then remove the solenoid [3].
Note
• Be careful not to drop the solenoid [3].
6. After installing the solenoid [3] by following the

steps 5 to 3, carry out the adjustment below.
a04jf2c014ca
25
7. With the gate solenoid [1] powered on, measure

the gap between the edge of decurler gate [2] and
[3]
the guide plate [3]. Next, adjust the position of the
RU-504
solenoid mounting plate [4] so that the gap

a=4.5 0.5mm becomes the specified value “a”, and then secure
it with the screws [5].
[2] Specified value: a = 4.5 ± 0.5 mm
steps in reverse.
[1]
[4]
[5]
[4] [5]
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26
5.2.5 Note to keep in mind when replacing the board

When the RU control board (RUCB) is replaced, be
sure to replace the EEPROM (IC3).
RU-504
Remove the EEPROM (IC3) from the old RU control
board [1] and install it into the new RU control board
[2].
Note
• The setting of the SW1 should be the same as
that of the old RUCB.
[1]
[2]
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Note
A • Be sure to install the "A" sections of the EEP-
ROM (IC3) in the same direction.
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27
RU-504
Blank page
28
RU-506
2009.07
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
RU-506
RU-506
OUTLINE
3. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. CONVEYANCE SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2.1 Conveyance drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2.2 Straight gate drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.3.1 Conveyance path switching operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5. STACKER SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2.1 Stacker exit shutter drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2.2 Stack switching drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2.3 Stacker entrance guide plate drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.2.4 Alignment drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.3 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.3.1 Alignment control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.3.2 Reverse/exit control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3.3 Stack assist fan control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
MAINTENANCE
6.1.1 Replacing the entrance conveyance motor (M1), the paper exit motor (M2),
the paper exit conveyance belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1.2 Replacing the conveyance pulley, the paper exit conveyance pulley . . . . . . . . . . . . . . . . . . . . . 26
6.1.3 Replacing the entrance roller /1, the bearing /K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1.4 Replacing the entrance roller /2, the stacker entrance roller,
the stacker entrance conveyance belt, the stacker entrance roller pressure springs /Fr
and /Rr, the bearing /K. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.1.5 Replacing the paper refeed roller, the merging section roller, the paper exit roller,
the bearing /K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.1.6 Replacing the straight gate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.1.7 Replacing the straight gate solenoid (SD1) and the straight gate spring . . . . . . . . . . . . . . . . . . 36
6.2 Stacker section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.2.1 Replacing the stacker exit shutter solenoid (SD2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.2.2 Replacing the stack switching solenoid (SD3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.2.3 Replacing the stacker entrance guide plate solenoid (SD4). . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
i
7.1 List of disassembling and assembling parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.2 Removal procedure of disassembling and assembling parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.2.1 Front cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
RU-506
7.2.2 Rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

7.2.3 Left cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.2.4 Note to keep in mind when replacing the board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
ii
OUTLINE
RU-506
A. Type
Type Paper conveyance unit with paper overlap and reverse functions
B. Functions
Double sheets reverse/exit Reverses 2 sheets of paper exited from the main body, PI-PFU or GP-501 and
conveyance mode*1 conveys to finishing unit.
Single sheet reverse/exit Reverses a single sheet of paper exited from the main body, PI-PFU or GP-501
conveyance mode and conveys to finishing unit.
Straight conveyance mode Conveys papers exited from the main body, PI-PFU or GP-501 to finishing unit
without any process.
*1 1200/1200P only
C. Paper type
Paper size SRA3, A3, JISB4*1, ISOB4*2*3, SRA4S, A4, A4S, JISB5*1, ISOB5*2*3, JISB5S*1,
ISOB5S*2*3, A5, 13 x 19*4, 12 x 18, 11 x 17, 9 x 11*3, 81/2 x 14, 81/2 x 11,
81/2 x 11S, 51/2 x 81/2, 81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13, 8K*5, 16K*5, 16KS*5
Wide paper (A3W, B4W, A4W, A4SW, B5W, B5SW, A5W, 12 x 18W, 11 x 17W,
81/2 x 11W, 81/2 x 11SW, 51/2 x 81/2W, Max. 324mm x 463mm*3, Max. 324mm x 487mm*4)
Custom size paper (Max. 324mm x 463mm*3, Max. 324mm x 487mm*4, Min. 95mm x 133mm)
Tab paper (A3, B4, A4, A4S, B5, B5S, 11 x 17, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2,
Max. 324mm x 463mm*3, Max. 324mm x 487mm*4)
Paper type Plain, Fine, Coat, recycled paper: same as the main body.
Paper weight 40g/m2 to 350g/m2 *3,64g/m2 to 300g/m2 *4
2 pages reverse/exit 40g/m2 to 216g/m2 *6
conveyance mode
*1 Default for North America

*2 Default for Europe
*3 1200/1200P/1051 only
*4 C6501/C6501P/C65hc only
*5 For China/Taiwan only
*6 1200/1200P only
D. Maintenance
E. Machine data
Maximum power consumption 63VA or less
Weight Approx. 45 kg
1
RU-506
Note
2
RU-506
Conveyance
section
Stacker
section
a0get2c001ca
3
3. PAPER PATH
A. Straight conveyance
RU-506
[1]
a0get2c002ca
[1] Straight conveyance path
4
B. Reverse/exit conveyance
RU-506
[1]
a0get2c003ca
[1] Reverse/exit conveyance path
5
RU-506
Blank page
6
RU-506
4.1 Configuration

Straight gate
Entrance jam sensor (PS6)
Entrance roller /2 Entrance roller /1
Paper refeed roller
Exit roller Stacker entrance roller
Merging section roller
a0get2c001ca
7
4.2 Drive
RU-506
[6] [7] [8]
[5]
[4]
[3]
[1]
[2]
a0get2c002ca
[1] Entrance conveyance motor (M1) [5] Exit roller

[2] Stacker entrance roller [6] Merging section roller
[3] Paper exit motor (M2) [7] Entrance roller /2
[4] Paper refeed roller [8] Entrance roller /1
8
4.2.2 Straight gate drive
RU-506
[1] Front side direction [3] Straight gate
[2] Rear side [4] Straight gate solenoid (SD1)
9
4.3 Operation
4.3.1 Conveyance path switching operation
RU-506
A. Straight gate solenoid (SD1) control

The straight gate switches the path to the straight conveyance and the path to the reverse/exit conveyance. The
straight gate solenoid (SD1) switches them. When SD1 is OFF, it is set to the reverse/exit conveyance. When
SD1 turns ON, the top of the straight gate goes down and works as the straight conveyance path.
(1) In the straight conveyance mode

When the start button turns ON, the straight gate solenoid (SD1) turns ON to switch the conveyance path to the
straight conveyance.
SD1 turns OFF when the job completes.
(2) In the reverse/exit conveyance mode

In the reverse/exit conveyance mode, the straight gate solenoid (SD1) keeps being OFF and the conveyance
path is always set to the reverse/exit conveyance.
10

A. Mechanism
The entrance conveyance motor (M1) and the paper exit motor (M2) conduct the conveyance.
RU-506
M1 drives the entrance rollers /1, /2 and the stacker entrance roller through the timing belt. M2 drives the paper
refeed roller, the paper exit roller, and the merging section roller through the timing belt.
B. Conveyance line speed switch control

The paper conveyance to RU is conducted in accordance with the conveyance line speed of the previous
device, and the paper is exited at the speed 1000mm/s.
In the simplex mode, the double sheets reverse/exit conveyance is conducted to the paper conveyed at the
speed 1250mm/s or 570mm/s (in case the continuous copy speed of 1200/1200P is 120 sheets/min.).
In the cases other than mentioned above, the straight conveyance or the single sheet reverse/exit conveyance is
conducted depending on the configuration and the mode of the post-process options.
(1) Straight conveyance

When the start button turns ON, the entrance motor (M1) and the paper exit motor (M2) turn ON [1] correspond-
ing to the line speed of previous devise. A specified period of time after the paper exit sensor of previous devise
detects the paper leading edge and turns ON, M1 and M2 accelerate to 1,000mm/s to convey the paper [2]. A
specified period of time after the entrance sensor (PS1) detects the paper trailing edge and turns OFF, M1 slows
down in accordance with the paper exit speed from previous devise. A specified period of time after the paper
exit sensor (PS2) detects the paper trailing edge and turns OFF, M2 slows down in accordance with the paper
exit speed from previous devise. A specified period of time after the paper exit sensor of previous devise detects
the 2nd paper leading edge, M1 and M2 accelerate to 1,000mm/s again [5]. It repeats these operations until the
job completes.
[1] [2] [3] [4] [5]
1,000mm/s
Entrance
motor (M1) Previous device speed
Paper exit 1,000mm/s

Paper exit sensor of previous device
a0get2c004ca
[1] ON at the speed of previous devise paper exit [4] Slow down to the speed of previous devise paper exit (M2)
[2] Accelerate to 1,000mm/s [5] Accelerate to 1,000mm/s
[3] Slow down to the speed of previous devise
paper exit (M1)
11
(2) In the double sheets reverse/exit conveyance (1200/1200P only)

When the start button turns ON, the entrance motor (M1) turns ON at the line speed 570mm/s [1]. After the
specified time since the paper exit sensor (PS3) of the main body detects the paper leading edge, M1 accelerate
RU-506
to 1,250mm/s [2]. A specified period of time after the entrance sensor (PS1) detects the paper trailing edge and
turns OFF, M1 slows down [3]. M1 repeats these operations for each paper.
A prescribed period of time after PS1 detects the trailing edge of the 2nd sheet and turns OFF, the paper exit
motor (M2) turns ON [4]. After a prescribed period of time, M2 turns OFF [5] and at this time the alignment in FD
direction is performed. After another prescribed period of time, M2 turns ON again [6] and refeeds the double
sheets of paper and exits them [7].
[1] [2] [3] [4][5] [6]
1,250mm/s
Entrance motor (M1)
570mm/s
Paper exit motor (M2) 1,000mm/s
Main body paper exit sensor (PS3)

[7] a0get2c005ca
[1] Start button ON [5] M2 OFF

[2] Switching to 1,250mm/s [6] M2 ON by paper refeed start
[3] Deceleration [7] Paper exit
[4] M2 ON
12
(3) In the single sheet reverse/exit conveyance

When the start button turns ON, the entrance motor (M1) turns ON corresponding to the line speed of previous
devise [1]. After the specified time since the paper exit sensor of previous devise detects the paper leading
RU-506
edge, M1 accelerate to 1,250mm/s [2]. A specified period of time after the entrance sensor (PS1) detects the
paper trailing edge and turns OFF, M1 slows down [3]. M1 repeats these operations for each paper.
A prescribed period of time after PS1 detects the paper trailing edge and turns OFF, the paper exit motor (M2)
turns ON [4]. After a prescribed period of time, M2 turns OFF [5] and the alignment in FD direction is performed
during the time. After another prescribed period of time, M2 turns ON again [6]. Then it refeeds and exits the
paper [7].
[4]
[1] [2] [3] [5] [6]
Entrance 1,250mm/s
Paper exit 1,000mm/s
motor (M2)
Paper exit sensor of previous device
[7] a0get2c014ca
[1] Start button ON [5] M2 OFF

[2] Switching to 1,250mm/s [6] M2 ON by paper refeed start
[3] Deceleration [7] Paper exit
[4] M2 ON
13
5. STACKER SECTION Theory of Operation Ver.1.0 Jul. 2009
5. STACKER SECTION
5.1 Configuration
RU-506
Stacker exit shutter

Stack switching guide plate
Front side
Stack switch-
ing guide plate
Stacker exit
shutter
Stacker
entrance guide
plate
Front side Rear side
Stacker entrance
guide plate
Front side
Stack assist fan /Fr
(FM1), /Rr (FM2)
CD alignment plate /Fr
CD alignment plate /Rr
FD alignment plate
Stacker jam sensor (PS5)
14
Theory of Operation Ver.1.0 Jul. 2009 5. STACKER SECTION
5.2 Drive
5.2.1 Stacker exit shutter drive
RU-506
[1] Stacker exit shutter solenoid (SD2) [4] Rear side

[2] Stacker exit shutter [5] Front side direction
[3] Front side
15
5.2.2 Stack switching drive

RU-506
[1] Front side [4] Stack switching solenoid (SD3)

[2] Stack switching guide plate [5] Rear side
[3] Driven roller [6] Front side direction
16
5.2.3 Stacker entrance guide plate drive
RU-506
[1] Front side [5] Stacker entrance guide plate solenoid (SD4)
[2] Rear side [6] Connection roller
[3] Front side direction [7] Stacker entrance roller
[4] Stacker entrance guide plate [8] Entrance roller /2
17
5.2.4 Alignment drive

RU-506
[1] CD alignment plate /Fr [6] CD alignment plate /Rr

[2] Front side direction [7] CD alignment home sensor (PS4)
[3] FD alignment plate [8] CD alignment motor (M4)
[4] FD alignment motor (M3) [9] Stacker jam sensor (PS5)
[5] FD alignment home sensor (PS3)
18
5.3 Drive
5.3.1 Alignment control
RU-506
A. Alignment in the main scan direction
The CD alignment motor (M4) [8]drives the CD alignment plate /Rr [6] and /Fr [1] via the timing belt to perform
the alignment in the main scan direction. The CD alignment home sensor (PS4) [7] detects the home position.
While the paper entering, the plates stay at 10mm away from each paper edge. The alignment is performed for
each stack of paper.
B. Alignment in the sub scan direction

For the alignment in the sub scan direction, the FD alignment motor (M3) [4] lifts the FD alignment plate [3] via
the timing belt to press it against the stacker exit shutter [9]. The FD alignment home sensor (PS3) [5] detects
the home position.
[1] CD alignment plate /Fr [6] CD alignment plate /Rr

[2] Front side direction [7] CD alignment home sensor (PS4)
[3] FD alignment plate [8] CD alignment motor (M4)
[4] FD alignment motor (M3) [9] Stacker exit shutter
[5] FD alignment home sensor (PS3)
19
5.3.2 Reverse/exit control

A. Movement control in the sub scan direction
According to the movement of the FD alignment plate [2], the trailing edge (upper direction) in stacking moves to
RU-506
either of the 3 positions other than the home position.

Position A [6]: The position at which the paper trailing edge is 50mm lower than the stacker exit shutter [1].
Paper which conveyed to the stacker is stacked at this position first.
Position B [7]: The position at which the paper trailing edge is 28mm lower than the stacker exit shutter [1] by
raising the paper from the position A [6]. The position of the paper trailing edge is higher than
the position of the lower edge of the stack switching guide plate [2]. This position is used when
in the double sheets reverse/exit mode, to feed the paper leading edge of the 1st page into the
paper exit path and stand by for entering of the 2nd page.
Position C [8]: Alignment in the FD direction is conducted at the position where the paper trailing edge
touches to the stacker exit shutter [1]. After the alignment, refeeding is conducted.
[1]
[8]
[7]
[2]
[6]
[5]
[4]
[3]
a0get2c012ca
[1] Stacker exit shutter [5] Paper length in the sub scan direction
[2] Stack switching guide plate [6] Position C (50mm lower than the reference)
[3] FD alignment plate [7] Position B (28mm lower than the reference)
[4] The position of the paper leading edge [8] Position A (stacker exit shutter, reference)
20
B. Double sheets reverse/exit conveyance control

When the start button turns ON [1], the FD alignment motor (M3) turns ON to move the FD alignment plate to
the position in accordance with the paper size (position A) and turns OFF. The CD alignment motor (M4) turns
RU-506
ON to move the CD alignment plate /Rr and /Fr to the positions 10mm away from each paper edge and then
turns OFF.
A specified period of time after the entrance sensor (PS1) turns OFF and the 1st paper trailing edge is detected,
the stack switching solenoid (SD3) and the stacker entrance guide plate solenoid (SD4) turn ON [2] and open
the paper exit path.
M3 lifts the FD alignment plate [3] to feed the 1st paper trailing edge into the paper path opened (position B). At
this time, M4 performs the alignment in main scan direction [4].
After the specified time since PS1 detects the leading edge of the 2nd sheet and turns ON, M3 lowers [6] and
moves the trailing edge of the 1st and 2nd sheet under the stack switching guide plate (position A).
M3 lifts the double sheets of the paper toward the paper exit path opened again when SD3 and SD4 turn ON [7]
and the paper is pressed against the stacker exit shutter to be aligned in the sub scan direction [8] (position C).
When the stacker exit shutter solenoid (SD2) turns ON, the stacker exit shutter opens [9] and the conveyance to
the paper exit path starts [10].
[1] [2] [3] [6] [7] [9]
Stacker exit shutter solenoid
(SD2)
Stack switching solenoid
(SD3)
Stacker entrance guide
plate solenoid (SD4)
FD alignment Up
motor (M3)
Down
CD alignment Close
motor (M4) Open
[4] [5] [8] [10]
a0get2c013ca
[1] Start button ON [6] Lowering of the double sheets of paper

[2] Opening the paper exit path [7] Opening the paper exit path
[3] Lifting up of the paper [8] FD alignment operation
[4] CD alignment operation [9] Opening the stacker exit shutter
[5] Entering 2nd page [10] Double sheets reverse/exit conveyance
21
C. Single sheet reverse/exit control

When the start button turns ON [1], the FD alignment motor (M3) turns ON to move the FD alignment plate to
the position in accordance with the paper size (position A) and turns OFF. The CD alignment motor (M4) turns
RU-506
ON to move the CD alignment plate /Rr and /Fr to the positions 10mm away from each paper edge and then
turns OFF.
After the specified time since the entrance sensor (PS1) turns OFF and the trailing edge is detected, the stack
switching solenoid (SD3) and the stacker entrance guide plate solenoid (SD4) turn ON [2] and open the paper
exit path.
M3 lifts the FD alignment plate to feed the paper trailing edge into the paper path opened. Alignment in the sub
scan direction is conducted at the position where the paper trailing edge touches to the stacker exit shutter [3]
(position C). At this time, M4 performs the alignment in the main scan direction [4].
When the stacker exit shutter solenoid (SD2) turns ON, the stacker exit shutter opens [5] and the conveyance to
the paper exit path starts [6].
Moreover, M3 lowers [8] to the position A for receiving the succeeding paper.
Repeat this operation after the succeeding paper.
[1] [2][3] [8] [5]

Stacker exit shutter solenoid

(SD2)
Stack switching solenoid
(SD3)
Stacker entrance guide
FD alignment Up
motor (M3)
Down
CD alignment Close
motor (M4) Open
[4] [7] [6]
a0get2c015ca
[1] Start button ON [5] Stacker exit shutter

[2] Opening the paper exit path [6] Exit conveyance
[3] FD alignment operation [7] Conveyance of the succeeding paper
[4] CD alignment operation [8] Lowering of the FD alignment plate
5.3.3 Stack assist fan control

A. Control
Stack assist fan /Fr (FM1) and /Rr (FM2) function only in the reverse/exit mode.
When the paper exit sensor (PS3) of the main body detects the 1st paper leading edge and turns ON, FM1 and
FM2 turn ON.
22
MAINTENANCE
RU-506
6.1.1 Replacing the entrance conveyance motor (M1), the paper exit motor (M2), the paper exit
conveyance belt
• Entrance conveyance motor (M1), Paper exit motor (M2) : Every 30,000,000 prints *1
• Entrance conveyance belt, Paper exit conveyance belt : Every 20,250,000 prints *1
*1 1200/1200P/1051
B. Procedure of removing the entrance conveyance motor assy, Procedure of replacing the
entrance conveyance belt
[3] [4] 1. Remove the rear cover. (Refer to P.47)

3. Remove 3 screws [2] and then remove the
entrance conveyance motor assy [3] and the
entrance conveyance belt [4].
Note
• When reinstalling, temporary tighten 3 screws
[2] and apply tension to the entrance convey-
ance belt [4] by own weight of the entrance
conveyance motor [3]. Then tighten 3 screws
[2].
4. Reinstall the parts by following the removal steps

in reverse.
[2] [1] [2]

a0get3c001ca
23
C. Procedure of removing the paper exit conveyance motor assy and replacing the paper exit con-
veyance belt
1. Remove the rear cover. (Refer to P.47)
RU-506
[3] [5] [6] [4]

2. Disconnect the connector [1] and then remove the
wiring harness from the wiring harness clamp.
3. Remove the straight gate spring [3].
4. Remove 3 screws [4] and then remove the paper
exit motor assy [5] and the paper exit conveyance
belt [6].
Note
• When reinstalling, temporary tighten 3 screws
[4] and apply tension to the paper exit con-
veyance belt [6] by own weight of the paper
exit motor assy. Then tighten 3 screws [4].

in reverse.
[4] [1] [2]

a0get3c002ca
24
D. Replacing procedure of the entrance conveyance motor (M1), the paper exit motor (M2)
[2] [1] 1. Remove the entrance conveyance motor assy

and the paper exit motor assy.
RU-506
(Refer to step B., C.)
2. Remove 4 screws [1], and then remove the
Note
• When reinstalling, be sure to put the connec-
tor [3], be sure to install it in the direction
shown in the picture.
[1] [3]
a0get3c003ca
3. Loosen 2 screws [1] to remove the pulley gear [2].

[3] [4] [2]
Then remove the entrance conveyance motor
(M1) and the paper exit motor (M2) [3].
Note
• When reinstalling, insert the pin [5] to the
shallower groove [4] until it comes in contact,
and then tighten 2 screws [1].

in reverse.
[5] [1] a0get3c004ca
25
6.1.2 Replacing the conveyance pulley, the paper exit conveyance pulley
• Conveyance pulley, Paper exit conveyance pulley : Every 20,250,000 prints*1
RU-506
*1 1200/1200P/1051
B. Procedure
• Rear cover (Refer to P.47)
[2] • Entrance conveyance motor, Entrance con-
[3]
veyance belt, Paper exit motor, Paper exit
conveyance belt (Refer to P.23)
[1]
2. Remove the screws [1], 2 for each of 4 places, 4
conveyance pulleys [2], and 4 pulley guides [3].
3. Remove the E-ring [4], the paper exit conveyance
pulley [5] and the pulley guide [6].
Note
• Reinstall the paper exit conveyance pulley [5]
with the gear inside.

in reverse.
[5]
[4]
[6]
a0get3c005ca
26
6.1.3 Replacing the entrance roller /1, the bearing /K

• Entrance roller /1, Bearing /K : Every 20,250,000 prints *1
RU-506
*1 1200/1200P/1051
B. Procedure
[1] [3] [5] [4]
• Entrance conveyance motor, Entrance con-
veyance belt (Refer to P.23)
• Conveyance pulley /1 of the entrance pulley.
(Refer to P.26)
3. Remove the screws [2], 2 for each position, and
then remove the E-rings [3], and the bearings /K
[4], 1 for each.
[2] Note
• When reinstalling the bearing /K [4], be sure
to set so that the notch of the bearing /K
comes in the position [5] as shown in the pic-
ture.
• To prevent the notch from opening, when
tighten the screws [2], 2 for each, in counter-
clockwise order.
to apply the Molykote EM-30L on all over
around the spring pins [6] on front and rear of
the shaft.
[3] [5] [4]
[7] 4. Remove the pick-up roller /1 [7].
in reverse.
[2] [6]
a0get3c006ca
27
6.1.4 Replacing the entrance roller /2, the stacker entrance roller, the stacker entrance convey-
ance belt, the stacker entrance roller pressure springs /Fr and /Rr, the bearing /K
RU-506

• Entrance roller /2, Stacker entrance roller : Every 20,250,000 prints *1
• Stacker entrance conveyance belt : Every 20,250,000 prints *1
• Stacker entrance roller pressure springs /Fr and /Rr, Bearing /K : Every 20,250,000 prints *1
*1 1200/1200P/1051
B. Procedure
[3] [1] [2] [3] • Rear cover (Refer to P.47)
• Entrance conveyance motor/entrance con-
veyance belt (Refer to P.23)
• Conveyance pulley of the entrance roller /2
(Refer to P.26)
2. Remove the stacker entrance roller pressure
springs /Fr [1] and /Rr [2].
then remove 2 coupling brackets [4].
Note
• When reinstalling, push the stacker entrance
[6] [4] [6] [5] a0get3c007ca roller assy [5] against the coupling receiver
bracket [6] and then install the coupling
bracket [4].
28

[2] [1] [7] 5. Remove the E-ring [3].
6. Remove the screws [2], 2 for each front and rear
RU-506
[6] sides, and then remove the E-rings [3] and the
[5] bearings /K [4], 1 for each.
Note
[4] ture.
clockwise order.
the shaft.
7. Remove the stacker entrance roller assy [9].
[9]
[7]
[6]
[5]
[4] [3] [8]
a0get3c008ca
29

[1] [1] then remove the E-rings [2] and the bearings /K
[3], 1 for each.
RU-506
[2] Note
[2] [3] • When reinstalling the bearing /K [3], be sure
[3] to set so that the notch of the bearing /K
[4]
[4]
ture.
clockwise order.
9. Remove the stacker entrance roller[5].
Note
• When reinstalling, be sure to set so that the
[6] [5] flange section [6] of the pulley comes in the
a0get3c009ca direction shown in the picture.

[1] [1] then remove the E-rings [2], 1 each. Then slide the
bearings [3], 1 for each.
Note
• When reinstalling the bearing [3], be sure to
set so that the notch of the bearing comes in
the position [4] as shown in the picture.
[4] [3] [2] [2] [3] [4] tighten the screws [1], 2 for each, in counter-
clockwise order.
11. Remove the entrance roller /2 [5] and the stacker

entrance conveyance belt [6] from the bracket [7].
Note
• When reinstalling, be sure to set so that the
flange section [8] of the pulley comes in the
[6] [8] [5] [7] direction shown in the picture.
a0get3c010ca
in reverse.
30
6.1.5 Replacing the paper refeed roller, the merging section roller, the paper exit roller, the bearing /
K
RU-506
• Paper refeed roller, Merging section roller, Paper exit roller, Bearing /K : Every 20,250,000 prints *1
*1 1200/1200P/1051
B. Procedure
[2] [4] [1] [6] • Front door (Refer to P.46)
• Left cover (Refer to P.47)
• Paper exit motor, Paper exit conveyance belt
(Refer to P.23)
• Conveyance pulleys of the paper refeed
roller, the merging section roller and the
paper exit roller (Refer to P.31)
2. Loosen the screw [1] and remove the screw [2].
Then remove the FD alignment belt [3] from the
pulley [4].
[3] [7] [8] [7]
Note
• When reinstalling the FD alignment belt [3], be
sure to insert it to the pulleys [4] and [5], and
place it under the tension of the spring [6] and
then tighten the screw [1].
3. Remove 4 screws [7] and the pulley fixing plate

[8].
[5]
a0get3c011ca
31

[6] [5] [4] 5. Remove the screws [3], 2 for each of 3 positions,
and then remove the E-rings [4] and the bearings /
RU-506
K [5], 1 for each.
Note
ture.
[3]
clockwise order.
the shaft.
[2] [1]
[7]
a0get3c012ca
32
6. Remove 2 E-rings [1].

[5] [4] [3] 7. Remove the screws [2], 2 for each of 3 positions,
and then remove the E-rings [3], and the bearings
RU-506
/K [4], 1 for each.
Note
ture.
clockwise order.
to apply Molykote EM-30L on all over around
the spring pins [6] on front and rear of the
[2] shaft.
[1] [6]
a0get3c013ca
33
8. Remove the paper exit roller [1], the merging sec-

[2] [1] tion roller [1] and the paper refeed roller [3].
RU-506
Note
• When reinstalling, be sure to set each roller in
the following conditions; the paper exit roller
[1] with the side which has a step on the top
of the shaft faced rear, the merging section
roller [2] with its screw hole faced rear and
the paper refeed roller [3] with its D-cut faced
front.
[3] a0get3c014ca 9. Reinstall the parts by following the removal steps

in reverse.
34
6.1.6 Replacing the straight gate

A. Spotted replaced parts/cycle
• Straight gate : Every 20,250,000 prints *1
RU-506
*1 1200/1200P/1051
B. Procedure
[7] [6] [4] [5] [3] 2. Remove the straight gate spring [1].
3. Remove the C-clip [2] and remove the straight
gate solenoid arm [3].
4. Remove the screw [4] and remove the straight
5. Remove the E-ring [6] and then remove the bear-
ing [7].
[2] [1] a0get3c015ca
6. Open the straight conveyance guide plate [1].

[1] [4] 7. Remove the E-ring [2] and remove the bearing [3]
and the straight gate [4].
in reverse.
[3]
[2]
a0get3c016ca
35
6.1.7 Replacing the straight gate solenoid (SD1) and the straight gate spring
• Replacing the straight gate solenoid (SD1) and the straight gate spring : Spot replacement (Actual replacement
RU-506
cycle: every 5,000,000 operations)
B. Procedure
[6] [4] [5] 2. Remove the straight gate spring [1].
3. Remove the C-clip [2] and remove the straight
4. Remove the connector [4].
straight gate solenoid assy [6].
[3] [2] [1] a0get3c020ca
36
Note
[1] [2] • When reinstalling the parts, be sure to fix the
straight gate solenoid assy so that the leading
RU-506
edge [1] of the straight gate without pulling
the plunger comes to upper than the guide
plate [2] and the leading edge [3] of the
straight gate with pulling the plunger comes
to lower than the guide plate [4] after install-
ing the straight gate spring.
[3] [4] a0get3c021ca
6. Remove 3 screws [1] and remove the mounting

[6] [1] [2] [3] bracket [2] and the plunger [3]. Then, remove the
straight gate solenoid (SD2) [4].
Note
• When reinstalling this part, be sure to install it
so that the wiring harness [5] is on the side of
the screw hole [6] of the mounting bracket [2].

in reverse.
[5] [4] a0get3c022ca
37
6.2 Stacker section

6.2.1 Replacing the stacker exit shutter solenoid (SD2)
RU-506

• Stacker exit shutter solenoid (SD2) : Spot replacement (Actual replacement cycle: every 5,000,000 operations)
B. Procedure
[4] [6] 2. Remove the C-clip [1] and remove the stacker exit
shutter arm [2]. Then remove the plunger [3].
Note
• Be careful that the plunger [3] falls down
when removing the C-clip [1].

stacker exit shutter solenoid assy [6].
[5] [3] [2] [1] a0get3c023ca
38
Note
[2] • When reinstalling the parts, be sure to fix the
stacker exit shutter solenoid assy so that the
RU-506
leading edge [3] of the stacker exit shutter [2]
comes to the inner area [6] of the folding part
of the guide plate [5] on the refeed roller [4]
when pulling the plunger of the stacker exit
shutter solenoid (SD2) to which the stacker
exit shutter arm [1] is connected.
• Check it from the opening [7].
[3] [6] [5] [4]
[1] [7] a0get3c024ca
39

[1] [2] [5]
stacker exit shutter solenoid (SD2) [3] from the
RU-506
Note

in reverse.
[4] [3] a0get3c025ca
40
6.2.2 Replacing the stack switching solenoid (SD3)

• Stack switching solenoid (SD3) : Spot replacement (Actual replacement cycle: every 5,000,000 operations)
RU-506
B. Procedure
[4] [6] [5] [2] [1]
2. Remove the C-clip [1] and remove the stack
switching arm [2].
plunger [5] and the stack switching solenoid assy
[6].
[3] a0get3c026ca
41
Note
stack switching solenoid assy so that the
RU-506
driven roller [2] touches with the refeed roller

[3] when not pulling the plunger [1] of the
stack switching solenoid (SD3), and when
pulling it, the gap between them is larger than
the standard value "a".
Standard value "a": The gap between the
driven roller [2] and the
re-feed roller [3] is 2mm
or more.
a
[1] [4] a0get3c027ca
5. Remove 4 screws [1] and then remove the stack

[2] [1]
switching solenoid (SD3) [3] from the mounting
bracket [2].
Note

in reverse.
[3] [5] [4] a0get3c028ca
42
6.2.3 Replacing the stacker entrance guide plate solenoid (SD4)

• Stacker entrance guide plate solenoid (SD4) : Spot replacement (Actual replacement cycle: every 5,000,000 operations)
RU-506
B. Procedure
[4] [2] [1] 2. Remove the C-clip [1] and remove the stacker
entrance guide plate arm [2].
stacker entrance guide plate solenoid assy [5].
[3] [5] a0get3c029ca
43
Note
stacker entrance guide plate solenoid assy at
RU-506
the position where the roller [4] installed to

the drive shaft [3] of the solenoid starts push-
ing the mounting bracket [6] of the stacker
entrance roller [5] with the plunger [1] touch-
ing with the mounting bracket [2].
[6] [3]
[2] [1] [7] a0get3c030ca
5. Remove 3 screws [1] and remove the mounting

[6] [2]
bracket [2] and the plunger [3]. Then, remove the
stacker entrance guide plate solenoid (SD4) [3].
Note

in reverse.
[5] [1] [4] [3] a0get3c031ca
44
7. OTHER PROCEDURES
7.1 List of disassembling and assembling parts
RU-506
No. Section Parts name Page referred to
1 Cover Front cover P.46
2 Rear cover P.47
3 Left cover P.47
45
7.2 Removal procedure of disassembling and assembling parts

RU-506
CAUTION:
• Be sure to unplug the power plug from the power outlet.
7.2.1 Front cover

A. Procedure
1. Open the front door [1] and remove the screw [2]
[1] [3] [2] and release the wire [3].
2. Remove 3 screws [4] and then remove the door
support bracket [5] and the front door [1].
Note
• The front door [1] is heavy. Support it
securely when removing it.

in reverse.
[4]
[5] [4]
a0get3c017ca
46
7.2.2 Rear cover

A. Procedure
1. Remove 4 screws [1] and then remove the rear
RU-506
[1] [2] cover.
in reverse.
[1] a0get3c018ca
7.2.3 Left cover

A. Procedure
1. Remove 6 screws [1] and then remove the left
cover [2].
in reverse.
[1] [2] a0get3c032ca
47

When the RU control board (RUCB) is replaced, be
RU-506
Install EEPROM (IC19) of the old control board [1] to

the new control board [2].
[1]
[2]
a0get2c033ca
48
Note
A • Be sure to install the "A" sections of EEPROM
(IC19) in the same direction.
RU-506
A
a04jf2c017ca
49
RU-506
Blank page
50
FD-503
2009.07
Ver. 2.0
Revision history
Revision mark:
corresponding page.
NOTE
Revision due to the commonization of the options of

2009/07 2.0 1 bizhub PRO 1200/1200P/1051.
CONTENTS
FD-503
FD-503
OUTLINE
2. UNIT CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2.1 Conveyance drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2.2 Gate drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2.3 Alignment drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.3.1 Conveyance path switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.3.2 Conveyance line speed control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.3.4 Gap recovery control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5. PUNCH SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2.1 Rear registration drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2.2 Punch drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6. FOLDING CONVEYANCE SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2.1 Conveyance drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2.2 Folding drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.3.1 Registration control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.3.2 Conveyance path switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.3.3 1st folding control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.3.4 2nd folding control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.3.5 3rd folding control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7. MAIN TRAY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.3.1 Main tray up/down control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8. SUB TRAY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.3.1 Sub tray full-status detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
i
8.3.2 Line speed switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

9. PI SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.1 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
FD-503
9.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9.2.1 Tray lift drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9.2.2 Paper feed drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.2.3 Pick-up drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9.3.1 Size detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9.3.2 Up/down control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
9.3.4 Separation mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9.3.5 Multi feed detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
MAINTENANCE
10.1 Punch section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

10.1.1 Cleaning the punch shaft and the punch support board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
10.1.2 Lubricating the punch drive section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10.2 Main tray section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10.2.1 Replacing the tray up down motor (M11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10.3 PI section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10.3.1 Replacing the pick-up rubber (upper stage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10.3.2 Replacing the paper feed rubber (upper stage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.3.3 Replacing the separation rubber (upper stage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10.3.4 Replacing the pick-up rubber (lower stage). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
10.3.5 Replacing the paper feed rubber (lower stage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
10.3.6 Replacing the separation rubber (lower stage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
11.1 Items not allowed to be disassembled and adjusted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
11.1.1 Folding/conveyance switching position adjustment section. . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
11.3 Removal procedure of disassembling and assembling parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
11.3.1 Upper cover /Fr + PI cover /Fr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
11.3.2 Upper cover /Rr + PI cover /Rr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
11.3.3 Upper door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
11.3.4 Rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
11.3.5 Left cover /Fr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
11.3.6 Left cover /Rr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
11.3.7 Paper exit stopper cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
11.3.8 Right cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
11.3.9 Left cover /Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
11.3.10 Stand cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
11.3.11 Front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
11.3.12 Punch unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
11.3.13 Cleaning the 2nd folding conveyance sensor (PS53). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
11.3.14 Cleaning the 3rd folding conveyance sensor (PS54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
11.3.15 Cleaning the 3rd folding roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
11.3.16 Folding conveyance section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
ii
11.3.17 Roller solenoids /1 (SD5) to /4 (SD8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

11.3.18 2nd folding roller solenoid (SD18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
11.3.19 Main tray up/down wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
FD-503
11.3.20 Multi feed detection board /1 (MFDB/1), /2 (MFDB/2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
11.3.21 Note to keep in mind when replacing the board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
iii
FD-503
Blank page
iv
OUTLINE
FD-503
A. Type
Type Multi folding device with punch and PI functions
B. Functions
(1) Functions
Normal paper exit function Transfer paper exited from the main body is exited into the main tray/sub tray.
Punching function Transfer paper that is exited by the main body or fed to the PI is punched for
each sheet of paper and exited into the main tray/sub tray.
Folding functions Transfer paper that is exited from the main body or fed to the PI is handled for
folding (either one of the following: Z-Fold, Letter fold-out, Letter fold-in, Double
parallel fold, Gate fold, and folding) for each sheet of paper, and exited into the
sub tray/main tray (The Z-Fold exit to the main tray while in the FS connection is
limited only to B4, A3, 81/2 x 14, 11 x 17, 12 x 18 and 8K.)
PI insertion function PI tray paper is inserted in the transfer paper exited from the main body.
Manual mode PI tray paper is punched, folded and stapled, and then exited into the sub tray/
main tray. (The stapling function is available only when the other option (with
staple function) is connected to the downstream of the FD.)
1
(2) Maximum tray capacity
Main tray 2,500 sheets : A4, A4S, JISB5*3, ISOB5*1*4, B5S, B5

2 2 *1
9 x 11*1, 81/2 x 11, 81/2 x 11S, 16K*2*5, 16KS*2*5
FD-503
(Weighing 40g/m - 350g/m ,

64g/m2 - 300g/m2 *2) 1,500 sheets : SRA3, A3, JISB4*3, ISOB4*1*4, SRA4, SRA4S
13 x 19*2, 12 x 18, 11 x 17, 81/2 x 14, 81/2 x 13, 81/4 x 13,
81/8 x 131/4, 8 x 13, 8K*2*5
500 sheets : A5, A5S*2, B6S*2, 51/2 x 81/2*1, 51/2 x 81/2S*2
Tab paper*6 (A3, B4, A4, A4S, B5, B5S, 11 x 17, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2,
Max. 324mm x 463mm)
Wide Paper*1 (A3W, B4W, A4W, A4SW, B5W, B5SW, A5W, 12 x 18W,
11 x 17W, 81/2 x 11W, 81/2 x 11SW, 51/2 x 81/2W, Max. 324 x 463 mm)
Custom size paper (Max. 324mm x 463mm*1, Max. 331mm x 483mm*2,
Min. 95mm x 139mm*1, Min. 128mm x 148mm*2)
Sub tray Folding type : Letter fold-in, Letter fold-out, Double parallel fold, Gate fold
(with folding tray) Paper size : A3, B4, SRA4S, A4S, 12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11S
8K*2*5
Custom size paper (Max. 305mm x 458mm,
Min. 210mm x 279mm)
Paper weight : Letter fold-in, Letter fold-out 50g/m2 - 130g/m2 *1,
64g/m2 - 130g/m2 *2
Double parallel fold, Gate fold 50g/m2 - 91g/m2 *1,
64g/m2 - 91g/m2 *2
Tray capacity of folding paper : 30 copies or more (less than 80g/m2, all of folding type)*6
Sub tray Maximum tray capacity : 200 Sheets
(without folding tray) SRA3, A3, JISB4*3, ISOB4*1*4, SRA4S, A4, A4S, JISB5*3, ISOB5*1*4, B5S, A5,
(Weighing 40g/m2 - 350g/m2 *1 *8, A5S*2, B6S*2, A6S*2
64g/m2 - 300g/m2 *2) 13 x 19*2, 12 x 18, 11 x 17, 9 x 11*1, 81/2 x 14, 81/2 x 11, 81/2 x 11S,
51/2 x 81/2*1, 51/2 x 81/2S*2, 81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
Tab paper*6 (A3, B4, A4, A4S, B5, B5S, 11 x 17, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2)
11 x 17W, 81/2 x 11W, 81/2 x 11SW, 51/2 x 81/2W, Max. 324mm x 463mm)
*1 1200/1200P/1051 only
*2 C6501/C6501P/C65hc only
*6 Operation of paper exit with tab area at the trail edge side is not warranty.
*7 Paper is stacked in the exiting sequence.
*8 Loading paper weight 49g/m2 or less is not warranty.
1 2
C. Type of paper
(1) Punching function
Paper size 2 holes : SRA3, A3, JISB4*1, ISOB4*2*3, SRA4S, A4, A4S, JISB5*1,
FD-503
ISOB5*2*3, B5S, A5, A5S*4
12 x 18 , 11 x 17, 9 x 11*3, 81/2 x 14, 81/2 x 11, 81/2 x 11S,
51/2 x 81/2*3, 81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13, 8K*4*5,
16K*4*5, 16KS*4*5
Tab paper (A3, B4, A4, A4S, B5, B5S, 11 x 17, 81/2 x 11,
81/2 x 11S, 51/2 x 81/2, Max. 324mm x 463 mm)
3 holes/4 holes : SRA3, A3, JISB4*1, ISOB4*2*3*6, A4, JISB5*1, ISOB5*2*3*6
12 x 18 , 11 x 17, 9 x 11*3, 81/2 x 11, 8K*4*5, 16K*4*5
Tab paper (A3, A4, B4, B5, 11 x 17,
Max. 324mm x 463 mm)
Applicable paper Plain paper, tab paper
Paper weight 50g/m2 - 216g/m2 (Conveyance of 2 pages at a time : 50g/m2 - 91g/m2 )*3,
64g/m2 - 216g/m2 *4
(2) Folding functions

Paper size A3, JISB4*1, ISOB4*2*3, SRA4S, A4S
12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11S, 8K*4*5
Custom size paper : Max. 305mm x 458mm, Min. 210mm x 279mm
Applicable paper Plain paper
Paper weight Folding, Letter 50g/m2 - 130g/m2 *3,
fold-in, Letter 64g/m2 - 130g/m2 *4
fold-out, Z-Fold
Double parallel 50g/m2 - 91g/m2 *3,
fold, Gate fold 64g/m2 - 91g/m2 *4
(3) PI functions
Paper size SRA3, A3, JISB4*1, ISOB4*2*3, SRA4, SRA4S, A4, A4S, JISB5*1, ISOB5*2*3,
B5S, A5
13 x 19*4, 12 x 18, 11 x 17, 9 x 11*3, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2,
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13, 8K*4*5, 16K*4*5, 16KS*4*5
Custom size paper*7: Max. 331mm x 483mm, Min. 182mm x 279mm
Applicable paper Plain, recycled paper, Fine, special paper
Paper weight 50g/m2 - 300g/m2
Maximum tray capacity 500 sheets (80g/m2) x 2 trays

*3 1200/1200P/1051 only
*4 C6501/C6501P/C65hc only
*6 ISOB4 and ISOB5 can not use 4 holes punch
*7 When use custom size paper as a cover in the perfect binding mode: up to 307 mm x 483 mm
3 1
D. Maintenance
MAINTENANCE Same as the main body.

FD-503
E. Machine data
Power source AC100V - 240V, DC5V (DC5V is supplied from the main body) *1
(The main tray is not included in the width)
*1 For C6501/C6501P/C65hc, only DC5V is supplied from the main body.
Temperature 10°C - 30°C

Humidity 10% - 80%RH (with no condensation)
Note
1 4
Theory of Operation Ver.2.0 Jul. 2009 2. UNIT CONFIGURATION
FD-503
[1]
[6]
[2]
[5]
[3]
[4]
fd501to1001c
[1] PI section [4] Folding conveyance section

[2] Conveyance section [5] Main tray section
[3] Punch section [6] Sub tray section
5
3. PAPER PATH
A. Straight mode
FD-503
[1]
[2]
fd501to1002c
[1] Paper through from the PI [2] Paper through from the main body paper exit
6
B. Sub tray mode
FD-503
[1]
[2]
fd501to1003c
[1] Paper through from the PI [2] Paper through from the main body paper exit
7
C. Punch mode (L and S sizes)

FD-503
[1]
[6]
[2]
[5]
[4]
[3]
fd501to1004c
[1] Paper through from the PI [5] Paper exit to the main tray, paper through to
[2] Paper through from the main body paper exit the next option
[3] For an L size [6] Paper exit to the sub tray
[4] For an S size
8
D. Z-Fold mode
FD-503
[1]
[6]
[2]
[5]
[4]
[3]
fd501to1005c
[1] Paper through from the PI [4] 2nd folding

[2] Paper through from the main body paper exit [5] Paper exit to the main tray, paper through to
[3] 1st folding the next option
[6] Paper exit to the sub tray
9
E. Letter fold-out mode

FD-503
[1]
[6]
[2]
[5]
[4]
[3]
fd501to1006c

[2] Paper through from the main body paper exit [5] Paper exit to the main tray
[3] 1st folding [6] Paper exit to the sub tray
10
F. Letter fold-in /double parallel fold mode
FD-503
[1]
[6]
[2]
[5]
[4]
[3]
fd501to1007c

11
G. Gate fold mode

FD-503
[1]
[7]
[2]
[6]
[5]
[4]
[3]
fd501to1008c
[1] Paper through from the PI [5] 3rd folding

[4] 2nd folding
12
H. Folding mode
FD-503
[1]
[5]
[2]
[4]
[3]
fd501to1009c
[1] Paper through from the PI [4] Paper exit to the main tray, paper through to
[2] Paper through from the main body paper exit the next option
[3] Folding [5] Paper exit to the sub tray
13
FD-503
Blank page
14
FD-503
4.1 Configuration
Entrance gate
Sub tray gate
Alignment plate /
Fr, /Rr
S size gate
L size gate
fd501to2001c
15
4.2 Drive
FD-503
[1]
[2]
[3]
[4]
fd501to2002c
[1] Main tray paper exit motor (M17) [3] Entrance conveyance motor (M1)
[2] Intermediate conveyance motor (M3) [4] Punch conveyance motor (M2)
16
4.2.2 Gate drive
FD-503
[18]
[1]
[17]
[16]
[2]
[3]
[15]
[4]
[14]
[5]
[13] [6]
[7]
[12]
[8]
[9]
[11] [10]
fd501to2003c
[1] Entrance gate [10] Vertical conveyance roller /4

[2] Entrance gate solenoid (SD1) [11] L size gate solenoid (SD4)
[3] Vertical conveyance roller /Rt [12] L size gate
[4] Roller solenoid /1 (SD5) [13] S size gate solenoid (SD3)
[5] Roller solenoid /2 (SD6) [14] S size gate
[6] Vertical conveyance roller /2 [15] Sub tray gate solenoid (SD9)
[7] Vertical conveyance roller /3 [16] Sub tray gate
[8] Roller solenoid /3 (SD7) [17] Sub tray paper exit roller
[9] Roller solenoid /4 (SD8) [18] Paper exit solenoid (SD12)
17

FD-503
[1]
[2]
[4] [3] fd501to2004c
[1] Alignment motor (M12) [3] Alignment plate /Rr

[2] Belt [4] Alignment plate /Fr
18
4.3 Operation
4.3.1 Conveyance path switching
FD-503
The conveyance path of the paper that has been conveyed to the entrance guide plate varies according to the
presence of a punch or folding, the tray into which paper is exited, and the paper size. The entrance gate, the
sub tray gate, the S size gate, the L size gate and the folding gate make the switching of the conveyance path.
(For the folding gate, refer to 6. FOLDING CONVEYANCE SECTION)
A. Entrance gate
Switching is made between the straight conveyance and the punch/folding conveyance by the entrance gate
solenoid (SD1). In the straight mode, the SD1 remains OFF.
When conveying the 1st sheet of paper for punching/folding operation, SD1 is energized a specified period of
time after the start button is turned ON.
For the 2nd and the succeeding sheets of paper, SD1 is energized in accord with the conveyance direction of
the succeeding page after the preceding page passes through the FD entrance sensor (PS1).
[3]
[1]
[2]
fd501to2005c
[1] Entrance gate [3] Straight mode

[2] Punch mode or folding mode
19
B. Sub tray gate

Switching is made between the main tray paper exit and the sub tray paper exit by the sub tray gate solenoid
(SD9). In the mode of the main tray paper exit, the SD9 remains OFF.
FD-503
When exiting the 1st sheet of paper into the sub tray, switch the SD9 a specified period of time after the start
button is turned ON.
For the 2nd and the succeeding sheets of paper, SD9 is energized in accord with the paper exit direction of the
succeeding page after the preceding page passes through the intermediate conveyance sensor (PS13).
[1]
[3]
[2]
fd501to2006c
[1] Sub tray gate [3] Sub tray exit

[2] Main tray exit
20
C. S size gate
Switching is made according to the paper size and the presence of folding. S size gate solenoid (SD3) makes
the drive of the gate. In the punch mode with no folding and in the case of the S size paper, SD3 remains OFF.
FD-503
When conducting the folding operation or when feeding the 1st sheet of large-size paper, switch SD3 a speci-
fied period of time after the start button is turned ON.
For the 2nd and the succeeding sheets of paper, switch the SD9 in accord with the paper exit direction of the
succeeding page after the preceding page passes through the punch conveyance sensor (PS5).
S size paper: The length in the sub scan direction is 216mm or less.
[1]
[4]
[2]
[3]
fd501to2007e
[1] S size gate [3] Punch conveyance sensor (PS5)

[2] For the folding mode (regardless of the presence of a punch) [4] For the S size paper with a punch only
21
D. L size gate
When folding the paper, the conveyance path is switched back and forth for each paper conveyance to prevent
the succeeding paper from coming into contact with the trailing edge of the L size paper that is in folding pro-
FD-503
cess.
The L size gate solenoid (SD4) makes the drive of the gate.
L size paper: The length in the sub scan direction is 216mm or more.
[1]
[2]
fd501to2008c
[1] L size gate (SD4-OFF position) [2] Punch registration sensor (PS6)
22
For the control of the L size gate, SD4 stands by at the OFF position (outer path) for the 1st sheet of paper to
pass through.
The 1st sheet of paper turns ON SD4 a specified period of time after the punch registration sensor (PS6) turns
FD-503
ON, and makes the switch to the inner path.
When the 2nd sheet of paper turns ON PS6, SD4 turns OFF after a specified period of time to make the switch
to the outer path.
The above operations are repeated for each sheet of paper.
L size gate solenoid (SD4)

Paper passes Outside
through the L
size gate Inside
Punch registration sensor (PS6)
fd501to2039c
4.3.2 Conveyance line speed control
The conveyance line speed of each conveyance section varies according to the type of paper and paper weight.
A. Line speed switching

The following list shows each of conveyance sections and the range of the conveyance line speed.
Conveyance section Conveyance line speed

Entrance conveyance 290mm/s to 1000mm/s
section
Intermediate convey- 800mm/s to 1000mm/s
ance section
Punch conveyance sec- 490mm/s to 1000mm/s
tion
Main tray paper exit 205mm/s to 1000mm/s
section
Sub tray paper exit sec- 500mm/s
tion
23

On paper conveyed to the punching position, the 2 alignment plates make a alignment operation to improve the
accuracy of the punch hole positioning and the folding. The forward and reverse rotation of the alignment motor
FD-503
(M12) drives the alignment plate. The alignment plate home sensor (PS10) detects its home position.
When the start button is turned ON, M12 rotates in the forward direction to move the alignment plates /Fr and /
Rr to the standby position of the paper size.
When the paper is conveyed to the punch position in a specified number of steps after it passes through the FD
entrance sensor (PS1), the roller solenoid /1 (SD5), the roller solenoid /2 (SD6), the roller solenoid /3 (SD7) and
the roller solenoid /4 (SD8) release the pressure of each roller and M12 conducts the alignment operation.
The roller solenoids that release each of the rollers from pressure are modified according to the size and the direction of paper aligned.
A specified period of time after completion of punching the last paper, M12 rotates in the reverse direction to
bring the alignment plate back to the home position.
FD entrance sensor (PS1)
Punch conveyance motor (M2)
Forward
Alignment
motor (M12) Reverse
Roller solenoid (SD5, 6, 7, 8)
[1] [2] [3] [4] fd501to2040c
[1] Start button ON [3] Alignment operation

[2] Move to the standby position [4] Move to the home position
4.3.4 Gap recovery control

When conveying 2 pages at a time, conduct the gap recovery control after alignment.
[1] [2] [3]
[4]
[6]
[5]
a0h0t2c005ca
[1] Vertical conveyance roller /Lt [4] Punch conveyance motor (M2)
[2] Vertical conveyance roller /Rt [5] Roller solenoid /1 (SD5)
[3] Drive shaft [6] One-way clutch
1 24
A. Small-size paper
Once the roller solenoid /1 (SD5) turns OFF after the alignment and presses each roller, the punch conveyance
motor (M2) [4] rotates in the reverse.
FD-503
The drive of the punch conveyance motor (M2) [4] is passed to the vertical conveyance roller /Rt [2] to rotate it in
the reverse. At this time, the vertical conveyance roller /Lt [1] does not rotate in the reverse but keeps stopping
since it has the one-way clutch [6]. According to this operation, only the vertical conveyance roller /Rt [2] side of
the overlapped paper is returned to adjust the gap of paper.
Punch convey- Forward

ance motor (M2)
Reverse
Alignment motor Forward

(M12)
Reverse
Roller solenoid /1 (SD5)
a0h0t2c006ca
B. Large-size paper
Once the roller solenoid /1 (SD5) turns OFF after the alignment and presses each roller, the punch conveyance
motor (M2) [4] rotates in the reverse.
The drive of the punch conveyance motor (M2) [4] is passed to the vertical conveyance roller /Rt [2] to rotate it in
the reverse. At this time, the vertical conveyance roller /Lt [1] does not rotate in the reverse but keeps stopping
since it has the one-way clutch [6]. According to this operation, only the vertical conveyance roller /Rt [2] side of
the overlapped paper is returned to adjust the gap of paper.
At the same time as the punch conveyance motor (M2) [4] stops, the roller solenoids /2 and /3 (SD6/SD7) turn
OFF and press each roller.
Punch convey- Forward

ance motor (M2)
Reverse
Alignment motor Forward

(M12)
Reverse
Roller solenoids /2 and /3 (SD6, SD7)
a0h0t2c007ca
25 1
5. PUNCH SECTION Theory of Operation Ver.2.0 Jul. 2009
5. PUNCH SECTION
5.1 Configuration
FD-503
Punch rear claw

Punch hole
Punch scraps switching
box mechanism
fd501to2009c
26
Theory of Operation Ver.2.0 Jul. 2009 5. PUNCH SECTION
5.2 Drive
5.2.1 Rear registration drive
FD-503
[1]
[3]
[2]
fd501to2010c
[1] Punch registration motor (M13) [3] Punch rear claw

[2] Paper
27
5.2.2 Punch drive

FD-503
[8] [9] [10]
[1]
[7]
[6] [3] [2]

[5] [4] a0h0t2c001ca
[1] Rotation when punching 3 holes (as seen from the front) [6] Eccentric cam
[2] Rotation when punching 2-holes (as seen from the front) [7] Front side direction
[3] Punch motor (M10) [8] 3-hole punch edge
[4] 2-hole punch edge [9] Eccentric cam
[5] One-way clutch (2-hole punch) [10] One-way clutch (3-hole punch)
5.3 Operation
A. Punch control
The punch registration motor (M13) drives the punch rear claw to hold down the trailing edge of paper, and the
punch motor (M10) drives the eccentric cam for punching.
After alignment operations, the roller solenoids /1 to /4 are turned ON to let paper be placed in the unfixed con-
dition. The paper, however, is held by the curvature of the conveyance section. Then, the punch registration
motor (M13) rotates a specified number of steps and the punch rear claw holds the trailing edge of paper to
move it to the punching position. After a specified period of time, the punch motor (M10) drives for punching.
After completion of punching, M13 returns the punch rear claw to the home position. The position of the home
position is detected by the punch registration home sensor (PS11).
B. Punch hole switching control

The punch hole is switched according to the rotational direction of the punch motor (M10).
For 2-holes, M10 rotates counterclockwise to drive the 2-hole punch edge. For 3-holes, M10 rotates clockwise
to drive the 3-hole punch edge.
The 2-hole punch home sensor (PS8) detects the position of the 2-hole punch edge, and the 3-hole/4-hole
punch home sensor (PS9) detects the position of the 3-hole punch edge.
28
C. Punch scraps box control

The punch scraps box set sensor (PS12) detects the setting of the punch scraps box, and the punch scraps full
sensor (PS26) detects the full condition of the punch scraps box.
FD-503
29
6. FOLDING CONVEYANCE SECTION Theory of Operation Ver.2.0 Jul. 2009
6. FOLDING CONVEYANCE SECTION

6.1 Configuration
FD-503
3rd folding
mechanism
2nd folding
mechanism
Folding gate
1st folding
mechanism
Registration
roller
fd501to2012c
30
Theory of Operation Ver.2.0 Jul. 2009 6. FOLDING CONVEYANCE SECTION
6.2 Drive
FD-503
[1]
[2]
M6
M5
[4]
[3]
M4
fd501to2013c
[1] Coupling [3] Folding gate

[2] The pulley operates as an idler due to the [4] Folding gate solenoid (SD15)
bearing
31
6.2.2 Folding drive

FD-503
[1]
M16
[2]
[3]
M15
[4]
[5]
M14
[6]
fd501to2014c
[1] 3rd folding roller /1 mounting board [4] 2nd folding guide
[2] 3rd folding guide [5] 1st folding roller /1 mounting plate
[3] 2nd folding roller /1 mounting board [6] 1st folding guide
32
6.3 Operation
6.3.1 Registration control
FD-503
The paper that has passes through the punch registration sensor (PS6) and arrives at the folding conveyance
section is pressed against the registration roller to make adjustments for skew. A specified period of time after
the PS6 turns ON, the 1st folding motor (M4) resumes the conveyance of paper. When no folding operation is
made, no registration control is made.
However, no folding is made on the paper that has entered the folding conveyance section from the folding
entrance sensor side. The paper is conveyed vertically as is and exited to the main tray or the sub tray.
[3]
[1]
[2]
fd501to2015c
[1] Punch registration sensor (PS6) [3] Folding entrance sensor (PS52)
[2] Registration roller
33

Switching is made between the 2nd folding conveyance path and the 3rd folding conveyance path by the fold-
ing gate solenoid (SD15).
FD-503
Except for the Z-Fold mode, a specified period of time after the 1st folding conveyance sensor (PS51) turns ON,
SD15 turns ON to convey the paper to the 2nd folding after the 1st folding. In the Z-Fold mode, SD15 remains
OFF and the paper is conveyed to the 3rd folding after the 1st folding.
[3]
[2]
[1]
fd501to2016c
[1] Except for the Z-Fold mode [3] In the Z-Fold mode
[2] Folding gate
34
Timing chart of the 1st folding roller /1 (Other folding rollers are also controlled in the same manner.)
FD-503
1st folding conveyance sensor (PS51)
1st folding motor (M4)

Conveyance
1st folding roller /1
Folding
1st folding release motor (M14)
2nd folding motor (M5)
[1] [2] fd501to2041c
[1] Change of the 1st folding roller /1 to the [2] Change of the 1st folding roller /1 to the
folding position conveyance position
35
6.3.3 1st folding control

A. Conveyance/folding switching control
The switching between conveyance and folding is made by moving the 1st folding roller /1. The 1st folding
FD-503
release motor (M14) drives the eccentric cam for this switching.
After the 1st folding conveyance sensor (PS51) turns ON, the paper is conveyed by a specified number of steps.
While the paper is being conveyed, the 1st folding roller gears /1 [1] and /2 [4] rotate in the same direction since
these 2 gears are interlocked each other through the idle gear [2].
After conveying the paper by the prescribed number of steps, M14 rotates until it gets to a specified number of
steps. It rotates the eccentric cam [5] to allow the idle gear arm [3] to separate the idle gear [2] from the 1st fold-
ing roller gears /1 [1] and /2 [4]. At the same time, when M14 starts up, the cam provided on the inside of the 1st
roller gear /2 [4] rotates to allow the 1st folding roller /1 and 1st folding roller /2 to contact each other closely to
rotate 1st folding roller /1.
The phases of the 1st folding roller gears /1 [1] and the 1st folding roller gears /2 [3] are not aligned in the depth
direction. Therefore, they do not engage with each other after the idle gear [2] has been separated.
[1]
[1]
[2]
[2]
[3] [4]
[4]
[6]
[5]
fd501to2017c
[1] 1st folding roller gear /1 [4] 1st folding roller gear /2
[2] Idle gear [5] Eccentric cam
[3] Idle gear arm [6] Seen from the FD side
36
In parallel with this, when the 1st folding release motor (M14) starts up, the winding-up of the wire that pulls the
folding guide [2] to the right side is loosened to allow the folding guide [2] to push out the paper in the clearance
between the 1st folding rollers /1 [1] and /2 [3]. As a result, the paper gets caught in the rollers to be folded.
FD-503
[1]
[2]
[3]
fd501to2018c
[1] 1st folding roller /1 [3] 1st folding roller /2

[2] Folding guide
37
6.3.4 2nd folding control

The switching between conveyance and folding is made by moving the 2nd folding roller /1. This switching is
FD-503
made when the 2nd folding release motor (M15) drives the eccentric cam.
After the 2nd folding conveyance sensor (PS53) turns ON, the paper is conveyed by a specified number of
steps. While the paper is being conveyed, the 2nd folding roller gears /1 [1] and /2 [4] rotate in the same direc-
tion since these 2 gears are interlocked each other through the idle gear [2].
steps. It rotates the eccentric cam [5] to allow the idle gear arm [3] to separate the idle gear [2] from the 2nd
folding roller gears /1 [1] and /2 [4]. At the same time, when M14 starts up, the cam provided on the inside of the
2nd roller gear /2 [4] rotates to allow the 2nd roller /1 [1] and 2nd roller /2 to contact each other closely to rotate
the 2nd roller /1.
The phases of the 2nd folding roller gears /1 [1] and the 2nd folding roller gears /2 [3] are not aligned in the
depth direction. Therefore, they do not engage with each other after the idle gear [2] has been separated.
[1]
[1]
[2]
[2]
[4]
[3]
[4]
[5] [6]
fd501to2019c
[1] 2nd folding roller gear /1 [4] 2nd folding roller gear /2
38
In parallel with this, when the 2nd folding release motor (M15) starts up, the winding-up of the wire that pulls the
folding guide [2] to the right-side is loosened to allow the folding guide [2] to push out the paper in the clearance
between the 2nd folding rollers /1 [1] and /2 [3]. As a result, the paper gets caught in the rollers to be folded.
FD-503
[4]
[1]
[2]
[3]
fd501to2020c
[1] 2nd folding roller /1 [3] 2nd folding roller /2

[2] Folding guide [4] Direction of paper exit
39
B. Gate fold assist control

In the Gate fold mode, the 2nd folding roller solenoid (SD18) turns ON a specified period of time after the 1st
folding motor (M4) starts folding. When SD18 starts up, the 2nd roller is pressed firmly. This is a measure taken
FD-503
to avoid a multiple fold that is apt to occur at the folding section of paper when the 2nd folding is made.
fd501to2021c
40
6.3.5 3rd folding control

The switching between conveyance and folding is made by moving the 3rd folding roller /1. This switching is
FD-503
made when the 3rd folding release motor (M16) drives the eccentric cam.
After the 3rd folding conveyance sensor (PS54) turns ON, the paper is conveyed by a specified number of steps.
While the paper is being conveyed, the 3rd folding roller gears /1 [1] and /2 [4] rotate in the same direction since
these 2 gears are interlocked each other through the idle gear [2].
steps. It rotates the eccentric cam [5] to allow the idle gear arm [3] to separate the idle gear [2] from the 3rd fold-
ing roller gears /1 [1] and /2 [4]. At the same time, when M16 starts up, the cam provided on the inside of the
3rd roller gear /2 [4] rotates to allow the 3rd roller /1 [1] and 3rd roller /2 to contact each other closely to rotate
the 3rd roller /1.
The phases of the 3rd folding roller gears /1 [1] and the 3rd folding roller gears /2 [4] are not aligned in the depth
direction. Therefore, they do not engage with each other the idle gear [2] has been separated.
[1]
[2]
[1]
[2]
[4]
[3]
[6]
[4]
[5]
fd501to2022c
[1] 3rd folding roller gear /1 [4] 3rd folding roller gear /2
41
In parallel with this, when the 3rd folding release motor (M16) starts up, the winding-up of the wire that pulls the
folding guide [2] to the left side is loosened to allow the folding guide [2] to push out the paper in the clearance
between the 3rd folding rollers /1 [1] and /2 [3]. As a result, the paper gets caught in the rollers to be folded.
FD-503
[1]
[2]
[3]
[4]
fd501to2023
[1] 3rd folding roller /1 [3] 3rd folding roller /2

[2] Folding guide [4] Direction of paper exit
42
Theory of Operation Ver.2.0 Jul. 2009 7. MAIN TRAY SECTION
7. MAIN TRAY SECTION

7.1 Configuration
FD-503
Main tray
Main tray
paper exit sen-
sor (PS18)
Main tray upper limit

sensor (PS20)
Main tray folding paper full sen-

sor (PS7)
Main tray lower limit

sensor (PS22)
fd501to2035c
43
7. MAIN TRAY SECTION Theory of Operation Ver.2.0 Jul. 2009
7.2 Drive
FD-503
[1]
[2]
[3]
fd501to2036c
[1] Main tray [3] Tray up down motor (M11)

[2] Up/down wire
44
7.3 Operation
7.3.1 Main tray up/down control
FD-503
The up/down operation of the main tray is controlled by rotating the tray up/down motor (M11) in the normal or
reverse direction.
A. Main tray paper detection

A specified period of time after the main tray paper exit sensor (PS18) turns ON, M11 starts up to bring down
the main tray until the main tray upper limit sensor (PS20) turns OFF, and then bring it up again until PS20 turns
ON.
After the paper is exited, PS20 maintains the distance between the upper surface of the paper exited in the main
tray (the surface of the main tray when no paper exited) and the paper exit opening at a fixed distance to prevent
the paper exited from having an uneven edge.
B. Switching the operation of the main tray

The main tray is set so that it normally does not operate.
When letting the main tray operate, insert the short connector [2] into the CN90 [1].
CAUTION:
• Letting the main tray operate with the next option connected has a risk of damaging the machine.
Be sure not to connect the short connector.
[2]
[1]
fd501to2037c
45
8. SUB TRAY SECTION Theory of Operation Ver.2.0 Jul. 2009
8. SUB TRAY SECTION

8.1 Configuration
FD-503
Sub tray folding paper full sensor (PS46)
Sub tray paper full sensor (PS17)

a0h0t2c002ca
46
Theory of Operation Ver.2.0 Jul. 2009 8. SUB TRAY SECTION
8.2 Drive
FD-503
[1]
[3]
M3
[2]
a0h0t2c003ca
[1] Paper exit solenoid (SD12) [3] Sub tray paper exit roller (driven)
[2] Sub tray paper exit roller (drive)
47
8.3 Operation
8.3.1 Sub tray full-status detection control
FD-503
The plate of the sub tray (with folding tray) has lift structure, so it moves down with its left edge as the axis of the
movement when the paper is exited to the sub tray. When the paper that has been exited in the sub tray gets to
a specified thickness, the sub tray paper full sensor (PS17) [2] turns ON, and the "sub tray paper full" information
is sent to the main body. Then, the main body displays the message on its operation panel. When the folded
paper on the sub tray is unfolded and the sub tray folding paper full sensor (PS46) [1] turns ON, the "sub tray
paper full" information is also sent to the main body.
[1]
[2]
a0h0t2c004ca
[1] Sub tray folding paper full sensor (PS46) [2] Sub tray paper full sensor (PS17)
8.3.2 Line speed switching

Paper conveyed by the intermediate conveyance motor (M3) is decelerated for each sheet of paper to be exited
into the sub tray.
Sub tray paper exit sensor (PS16)
Intermediate Hi-speed
conveyance Deceleration
[1] fd501to2042c
[1] Deceleration of the intermediate convey-

ance motor (M3)
* The process speed on the main body side can change the time period up to the deceleration.
48
Theory of Operation Ver.2.0 Jul. 2009 9. PI SECTION
9. PI SECTION
9.1 Configuration
FD-503
Paper pick-up mechanism
Manual operation
Paper separation
mechanism
Multi feed sensor
Paper set sensor
Paper size VR
(main scan direc-
tion)
Paper size sensor
Lift plate (sub scan direc-
tion)
fd501to2027c
49
9. PI SECTION Theory of Operation Ver.2.0 Jul. 2009
9.2 Drive
FD-503
[1]
[4]
[2]
[3]
fd501to2028c
[1] Paper lift motor /Up (M8) [3] PI lift plate /Lw
[2] Paper lift motor /Lw (M9) [4] PI lift plate /Up
50
FD-503
[10] [11]
[1]
[2]
[9]
[8]
[7]
[6]
[5]
[4]
[3]
fd501to2029c
[1] Separation roller /Up [7] Pick-up roller /Lw

[2] PI registration clutch /Up (CL1) [8] PI conveyance motor (M7)
[3] PI registration clutch /Lw (CL2) [9] Rotational direction of separation roller /Up
[4] Separation roller /Lw [10] Pick-up roller /Up
[5] Rotational direction of separation roller /Lw [11] Paper feed roller /Up
[6] Paper feed roller /Lw
51
9.2.3 Pick-up drive

FD-503
[5] [1]
[2]
[3]
[4] fd501to2030c
[1] Spring [4] PI pick-up solenoids /Up (SD13) and /Lw

[2] Direction of the spring force (SD14)
[3] Release arm [5] Pick-up rollers /Up and /Lw
52
9.3 Operation
9.3.1 Size detection control
FD-503
For the size detection of a paper, there are the following 2 directions for each of the tray /Up and the tray /Lw:
that is, the main scan direction and the sub scan direction.
When the PI paper set sensors /Up (PS44) and /Lw (PS45) [6] are ON, 3 sensors; the PI maximum size sensor /
Up (PS47), /Lw (PS48) [1], the large-size sensor /Up (PS35), /Lw (PS41) [2], and the small-size sensor /Up
(PS36), /Lw (PS42) [3] detect the size in the sub scan direction.
When the PS44 and PS45 are OFF, the tray is judged "paper empty."
The paper size VR /Up (VR31) and /Lw (VR32) [4] which are interlocked with the paper regulation plate [5] detect
the size in the main scan.
[1]
[2]
[3]
[6]
[4]
[5] fd501to2031c
[1] PI maximum size sensors /Up (PS47) and /Lw (PS48) [4] Paper size VR /Up (VR31) and /Lw (VR32)
[2] L size sensors /Up (PS35) and /Lw (PS41) [5] Paper regulation plate
[3] S size sensors /Up (PS36) and /Lw (PS42) [6] PI paper set sensors /Up (PS44) and /Lw (PS45)
53
9.3.2 Up/down control

For the up/down of the tray, when the paper lift motors /Up (M8) [1] and /Lw (M9) [7] rotate in the normal and
reverse directions, the lift arms /Up [11] and /Lw [9] start up to bring up and down the PI lift plates /Up [12] and
FD-503
/Lw [10]. The PI lift plate home sensors /Up (PS34) [2] and /Lw (PS40) [8] detect the lower limit position. The PI
upper limit sensors /Up (PS32) [4] and /Lw (PS38) [6] detect the upper limit position at the position to which the
actuators /Up [3] and /Lw [5] are pushed up by the PI lift plate.
When the PI paper set sensors /Up (PS44) and /Lw (PS45) are ON with the main body start button ON, M8 and
M9 turn ON to bring up the PI lift plate. When PS32 and PS38 turn ON, M8 and M9 stop.
While in the copy/print operation, when PS32 and PS38 turn OFF from ON, M8 and M9 turn ON again to bring
up the plate until PS32 and PS38 turn ON.
When PS44 and PS45 turn OFF with no paper left, M8 and M9 make a reverse rotation to move down the PI lift
plate until PS34 and PS40 turn ON.
[12] [1] [2]
[3]
[4]
[11]
[5]
[10]
[6]
[9] [8] [7] fd501to2032c
[1] Paper lift motor /Up (M8) [7] Paper lift motor /Lw (M9)
[2] PI lift plate home sensor /Up (PS34) [8] PI lift plate home sensor /Lw (PS40)
[3] Actuator /Up [9] Lift arm /Lw
[4] PI upper limit sensor /Up (PS32) [10] PI lift plate /Lw
[5] Actuator /Lw [11] Lift arm /Up
[6] PI upper limit sensor /Lw (PS38) [12] PI lift plate /Up
54

The picking-up of the paper [6] is made when the PI pick-up solenoids /Up (SD13) and /Lw (SD14) [5] turn ON.
The release arm that is pressed down by the spring [1] in the direction of [2] presses down the paper feed arm
FD-503
[4] to place the pick-up rollers /Up and /Lw [7] in the release condition. When SD13 and SD14 [5] turn ON, the
release arm is released upward and the pick-up rollers /Up and /Lw [7] go down by their own weight. The pick-
up roller that is rotated by the PI conveyance motor (M7) presses down the paper to pick it up.
[6] [7] [1]
[2]
[3]
[4]
[5] fd501to2033c
[1] Spring [5] PI pick-up solenoids /Up (SD13) and /Lw
[2] Direction of the spring force (SD14)
[3] Release arm [6] Paper
[4] Paper feed arm [7] Pick-up rollers /Up and /Lw
Paper feed arm retaining lever [1] is provided in the pick-up roller section to prevent multi feed. By moving the
paper feed arm retaining levers [1] on the front and back to inside, the pick-up rollers on the front and back are
secured while the roller in the middle presses against paper. Multi feed is prevented by reducing the pressure
against paper when feeding papers.
[1]
[2] fd501to2044c
55

The separation roller [4] is driven in the direction opposite to the paper conveyance [2]. However, when no paper
is conveyed or only 1 sheet of paper is conveyed, the frictional force generating between the paper feed roller [1]
FD-503
and the separation roller [4] or the paper and the separation roller is greater than the frictional force of the torque
limiter [3]. Accordingly, the separation roller [4] rotates in the direction of the paper conveyance [2] to convey
paper to the vertical conveyance section.
When 2 or more sheets of paper are conveyed, the frictional force between these sheets of paper is smaller than
the frictional force of the torque limiter [3] and the separation roller [4] rotates in the reverse direction to prevent
the lower most paper from being conveyed.
When the PI registration clutches /Up (CL1) and /Lw (CL2) turn ON according to the PI paper feed demand sig-
nal, the paper feed roller [1], the separation roller [4], and the pick-up roller [7] rotate to convey the paper one at
a time.
[7] [1]
[6]
[2]
[5] [4]
[3]
fd501to2034c
[1] Paper feed rollers /Up and /Lw [5] 2nd sheet of paper
[2] Paper conveyance direction [6] 1st sheet of paper
[3] Torque limiter [7] Pick-up rollers /Up and /Lw
[4] Separation rollers /Up and /Lw
56
9.3.5 Multi feed detection control

To detect a multi feed while in the PI paper feed, the PI conveyance path is provided with the multi feed sensor.
The multi feed sensor is an ultrasonic sensor made up of a pair of a sender and a receiver. This sensor receives
FD-503
ultrasonic waves sent from the multi feed detection board /1 (MFDB1) [1] by the multi feed detection board /2
(MFDB2) [2].
Based on the difference in the amount of ultrasonic waves received when a single sheet of paper [3] and the plu-
ral sheets of paper [4] pass through between the sender and the receiver, a check is made to see if paper has
been multi fed or not.
The multi feed detection function turns ON (operates) when the LED on the lower side is turned on by the multi
feed detection function selection button on the FD operation board (FDOB) and when no selection is made. It
turns OFF (does not operate) when the LED on the upper side is turned on.
[3] [4]
[2] [1] [5] fd501to2038c
[1] Multi feed detection board /1 (MFDB1) [4] More than 1 sheet of paper
[2] Multi feed detection board /2 (MFDB2) [5] Layer of air
[3] 1 sheet of paper

The PI empty sensors /Up (PS33) and /Lw (PS39) detect the presence of paper in the tray section while in the
print stop.
PI set sensors /Up (PS44) and /Lw (PS45) detect the paper empty while in the print to stop the paper feed from
the trays /1 to /5 when PS44 and PS45 detect the trailing edge of the last paper.
57
FD-503
Blank page
58
MAINTENANCE
FD-503
CAUTION:
10.1 Punch section

10.1.1 Cleaning the punch shaft and the punch support board
• Punch shaft : Every 1,400,000 prints (Actual cleaning count: Every 1,000,000 punches) *1
• Punch support board : Every 1,400,000 prints (Actual cleaning count: Every 1,000,000 prints) *1
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Procedure
1. Disconnect 2 connectors [1].
[1] 2. Remove 4 screws [2].
[3] 3. Remove the punch unit [3].
[2]
fd501fs2003c
4. Remove the plastic stopper [1], and remove the

[2] pin [2].
5. Remove the punch shaft [3], and clean the periph-
[1] ery.
(Isopropyl alcohol/Cleaning pad)
[3]
a0h0t3c001ca
59 1
6. Clean the inner periphery of the hole [2] of the

[2] punch support board [1].
(Isopropyl alcohol/Cleaning pad)
FD-503
[1]
a0h0t3c002ca
60
10.1.2 Lubricating the punch drive section

A. Periodically lubricated parts/cycle
• Punch drive section : Every 1,400,000 prints (Actual lubricating cycle: Every 1,000,000 punches) *1
FD-503
: 750,000 prints *2
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Procedure
[2]
fd501fs2003c
4. Lubricate 2 stopper cams [1] and 8 gears [2].

[1]
(Molykote EM-30L)
[2]
a0h0t3c003ca
61 1
10.2 Main tray section

10.2.1 Replacing the tray up down motor (M11)
FD-503

• Tray up down motor (M11) : Every 5,200,000 prints (Actual replacement cycle: Every 5,000,000 prints) *1
: Every 10,500,000 prints (Actual replacement cycle: Every 5,000,000 prints) *2
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Procedure
Note
• Be sure to remove the tray up down motor (M11) while supporting the up/down stay with your
hands.
1. Remove the rear cover (Refer to P.77) and the left

[2]
cover /Rr (Refer to P.78).
2. Open the front door and pull out the folding unit.
4. Remove 2 screws [2] and then remove the tray up
down motor (M11) [3].
steps in reverse.
[3]
[1]
fd501fs2005c
1 62
10.3 PI section
10.3.1 Replacing the pick-up rubber (upper stage)
FD-503
• Pick-up rubber : Every 5,200,000 prints (Actual replacement cycle: every 200,000 feeds) *1
: Every 5,250,000 prints (Actual replacement cycle: every 200,000 feeds) *2
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Procedure
[1] 2. Remove 2 screws [1] and then remove the protec-
tive cover [2].
[2]
fd501fs2006c

[4] [1] 4. Remove 4 screws [2] and then remove the pick-
up unit /Up [3].
Note
[3]
• The rear side of the shaft is inserted into the
coupling [4]. Be sure to remove the pick-up
[5] [2] unit /Up [3] from the front side.
• Be careful not to damage 2 actuators [5] of
the pick-up unit /Up.
fd501fs2007c
63 1
5. Remove the hook of the spring [1] from the

[1] [2] [4]
mounting plate [2].
6. Remove 2 C-clips [3] and then remove the shaft
FD-503
[4].
[3] fd501fs2008c

[4] [3] [2]
8. Remove the shaft fixing piece [2], and then
remove the shaft [3] from the mounting plate [4].
[1] fd501fs2009c
[1] fd501fs2010c
10. Remove the spacer [1] and the belt restriction

[1] [2]
plate [2].
fd501fs2011c
64
11. Remove the belt [3] from the gear [2], [4] and then
[1] [2] [3]
remove the gear [2], [4] and the pin [1], [5] from
the pick-up roller shaft [4].
FD-503
[4]
[5] fd501fs2012c
12. Pull out the pick-up roller shaft [1] to the front side,
and remove the pick-up roller assy [2].
[1]
[2] fd501fs2013c
13. Remove the pick-up roller [1] and replace the

pick-up rubber [2].
Note
• Be sure to install the pick-up roller so that the
one-way clutch [8] (blue) is on the front side.
[3]
[2] [1] fd501fs2014c
65

[4] [7]
16. Remove the belt restriction plate [3].
FD-503
17. Remove the belt [4] from the gear [5], and then
remove the gear [5] and the pin [6] from the pick-
up roller shaft [7].
18. Pull out the pick-up roller shaft [7] to the rear side,
and remove the pick-up roller assy [8].
19. Remove the pick-up roller and replace the pick-up
rubber.
[2] [3] [5] [6] [8] [9] [1]
Note
fd501fs2015c

[3] [4] [7]
21. Remove the belt restriction plate [2].
22. Remove the belt [3] from the gear [4], and then
[2] remove the gear [4] and the pin [5] from the pick-
[6] up roller shaft [6].
23. Pull out the pick-up roller shaft [6] from the rear
side, and remove the pick-up roller assy [7].
24. Remove the pick-up roller and replace the pick-up
rubber.
Note
[1] [5] [8] [1] • Be sure to install the pick-up roller so that the

steps in reverse.
fd501fs2016c
66
10.3.2 Replacing the paper feed rubber (upper stage)

• Paper feed rubber : Every 2,200,000 prints (Actual replacement cycle: Every 100,000 feeds) *1
FD-503
: Every 2,250,000 prints (Actual replacement cycle: Every 100,000 feeds) *2
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Procedure
1. Conduct the steps 1 to 8 in "10.3.1 Replacing the
pick-up rubber (upper stage)" and remove the
[8]
pick-up roller unit.
[7] 2. Remove the C-clip [1].
[3] 3. Remove the belt restriction plate [2].
4. Remove the spacer [3].
[4] 5. Remove the belt [4].
6. Remove the gear [5] and the pin [6].
[1] 7. Remove the gear [7] and the pin [8].
[6] [5] [2]
fd501fs2017c
8. Remove 2 C-clips [1] and then remove the entire

[2] [3]
paper feed arm [2] from the paper feed shaft [3].
[1] fd501fs2018c
67 1

[4] [3] [2] [1]
10. Remove the actuator [2].
FD-503
fd501fs2019c
13. Remove the paper feed arm [1].

[3] [2] [1]
15. Remove the paper feed roller assy [3].
fd501fs2020c
16. Remove the paper feed roller [1] and replace the
[1]
[2] paper feed rubber[2].
steps in reverse.
Note
fd501fs2021c
68
10.3.3 Replacing the separation rubber (upper stage)

• Separation rubber : Every 2,200,000 prints (Actual replacement cycle: every 100,000 feeds) *1
FD-503
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Procedure
[1] [2]
pick-up unit /Up.
[1] 3. Remove 2 bearings [2].
4. Remove the C-clip [3] and then remove the entire
roller shaft from the mounting plate while pressing
the separation roller assy [4] against the front gear
[5].
Note
• Pins are employed on the inside of the sepa-
[3] [4] [5] [6] fd501fs2022c
ration roller assy [4] and the gear [5] respec-
tively. When removing them, be careful that
these pins do not get lost. With the C-clip [6]
on the front side of the gear left as it is, press-
ing the roller onto the gear prevents the pins
from dropping off.

[1] [2]
separation roller [2] and replace it.
steps in reverse.
fd501fs2023c
69 1
10.3.4 Replacing the pick-up rubber (lower stage)

• Pick-up rubber : Every 5,200,000 prints (Actual replacement cycle: every 200,000 feeds) *1
FD-503

*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Procedure
Note
• A shaft fixing screw is inserted when removing the PI tray /Up. Be sure to remove this shaft fixing
screw from the PI tray /Up after completion of the replacement of the pick-up roller /Lw. Operating
the machine with the shaft fixing screw inserted to the PI tray /Up damage to the PI section.
1. Make sure that the PI lift plate /Up [1] has come
[2] [3]
down fully. If it has not come down completely,
conduct the I/O check (output) (PI/Up: 70-11, PI/
Lw: 70-13) in the service mode.
pick-up unit /Up.
[2]
feed stopper plate /Up [3].
[1] fd501fs2024c
4. Remove the shaft fixing screw [1] and insert it in

[1] the shaft fixing hole [2].
Note
• Be sure to turn the shaft fixing screw [1] until
its stem section disappears completely.
• After completion of the replacement of the
pick-up rubber (lower stage), be sure to
remove the shaft fixing screw [1] from the
position [2] and get it back to the position [1].
Operating the machine with the shaft fixing
screw inserted to the position [2] damage to
the PI section.
[2] fd501fs2025c
1 70
5. Remove the spring [2] hooked between the sepa-

[5] [3] [1] [2]
ration roller unit [1] and the PI tray /Up [3].
FD-503
7. Remove 4 screws [4] and then remove the PI tray
/Up [3].
Note
• When removing the PI tray /Up [2], be sure to
pull it diagonally up to the left.
[4] [4] fd501fs2026c

[3]
9. Remove 4 screws [2] and then remove the pick-
up unit /Lw [3].
[1] 10. For the subsequent operations, conduct the pick-
up rubber (upper stage) (steps 4 to 25). (Refer to
P.63)
[2] [2]
11. Replace it with a new pick-up rubber.
steps in reverse.
Note
fd501fs2027c
• When installing the PI tray /Up, be sure to
remove the shaft fixing screw and get it back
to the original position.
71
10.3.5 Replacing the paper feed rubber (lower stage)

• Paper feed rubber : Every 2,200,000 prints (Actual replacement cycle: Every 100,000 feeds) *1
FD-503

*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Procedure
1. Conduct the steps 1 to 9 in "10.3.4 Replacing the pick-up rubber (lower stage)"
2. The subsequent operations are the same as the operations for the paper feed rubber (upper stage).
(Refer to P.67)
3. Reinstall a new paper feed rubber following the removal steps in reverse.
10.3.6 Replacing the separation rubber (lower stage)

• Separation rubber : Every 2,200,000 prints (Actual replacement cycle: Every 100,000 feeds) *1
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Procedure
[1]
pick-up rubber (lower stage)" .
paper feed stopper plate /Lw [2].
3. For the subsequent operations, conduct the sep-
aration rubber (upper stage) (steps 2 to 6). (Refer
to P.69)
4. Replace it with a new separation rubber.
steps in reverse.
[2]
fd501fs2028c
1 72

FD-503
CAUTION:
11.1.1 Folding/conveyance switching position adjustment section
Note
• Be sure to avoid removing or loosening the screws [1], [2], [3] of the folding/conveyance switching
position adjustment section provided on the front of the folding conveyance unit. The adjustment
scale marked on the folding conveyance frame are used in the factory.
[1] [3]
[2]
fd501fs2079c
73

No. Section Parts name Reference page
FD-503
1 Cover section Upper cover /Fr + PI cover /Fr P.75

2 Upper cover /Rr + PI cover /Rr P.76
3 Upper door P.76
4 Rear cover P.77
5 Left cover /Fr P.77
6 Left cover /Rr P.78
7 Paper exit stopper cover P.78
8 Right cover P.79
9 Left cover /Up P.79
10 Stand cover P.80
11 Front cover P.81
12 Punch section Punch unit P.82
13 Folding conveyance 2nd folding conveyance sensor (PS53) P.82
14 section 3rd folding conveyance sensor (PS54) P.83
15 3rd folding roller P.84
16 Folding conveyance section P.86
17 Conveyance section Roller solenoids /1 (SD5) to /4 (SD8) P.91
18 2nd folding roller solenoid (SD18) P.92
19 Main tray section Main tray up/down wire P.95
20 PI section Multi feed detection board /1, /2 P.104
1 74
11.3 Removal procedure of disassembling and assembling parts

11.3.1 Upper cover /Fr + PI cover /Fr
FD-503
A. Procedure
1. Open the upper door [1] and the front door [2].
[1]
2. Remove 3 screws [3], pull out the PI cover /Fr [5]
to the front side while raising it together with the
[5] upper cover /Fr [4].
[4]
[2]
[3] fd501fs2029c
3. Disconnect the connector [1] and remove the PI

[1]
cover /Fr [3] together with the upper cover /Fr [2].
[3]
[2]
fd501fs2030c
75
11.3.2 Upper cover /Rr + PI cover /Rr

A. Procedure
FD-503
[1] 2. Remove 3 screws [2] and pull out the PI cover /Rr
[4] to the rear side while raising it together with the
upper cover /Rr [3].
[4]
[3]
[2]
fd501fs2031c
11.3.3 Upper door

A. Procedure
1. Remove the upper cover /Fr, the PI cover /Fr, the
[1]
upper cover /Rr and the PI cover /Rr.
[5] 2. Close the upper door [1].
3. Remove the E-ring [2] and then remove the bear-
ing [4] of the upper door open/close shaft [3].
4. With the bearing [5] shifted to the front side,
remove the upper door [1].
[4]
[2]
[3]
fd501fs2032c
76
11.3.4 Rear cover

A. Procedure
FD-503
cover /Lw [2].
[1]
[2]
fd501fs2033c
11.3.5 Left cover /Fr

A. Procedure
cover /Fr [2].
[1]
[2]
[1]
fd501fs2034c
77
11.3.6 Left cover /Rr

A. Procedure
FD-503
cover /Rr [2].
[1]
[2]
[1] fd501fs2035c
11.3.7 Paper exit stopper cover

A. Procedure
[2] exit stopper cover [2].
[1]
fd501fs2036c
78
11.3.8 Right cover

A. Procedure
1. Remove 4 screws [1] and then remove the right
FD-503
[2] cover [2].
[1]
fd501fs2037c
11.3.9 Left cover /Up

A. Procedure
1. Remove the upper cover /Fr, the PI cover /Fr, the
[1]
upper cover /Rr and the PI cover /Rr.
cover /Up [2].
[2]
[1]
fd501fs2038c
79
11.3.10 Stand cover

A. Procedure
FD-503
2. Remove 3 screws [2] of the handle and then

remove the handle.
3. Remove 4 screws [3] and then remove the stand
cover [4].
[1]
[4]
[2]
[3]
fd501fs2039c
80
11.3.11 Front door
Note
FD-503
• When removing the front door, be sure to support it so that it does not fall down.
A. Procedure
2. Remove the screws [2].
3. Remove the stand cover [3].
[2] 4. Remove 3 screws [4] while pushing up the front
door so that it does not fall down, and then
remove the support plate [5].
5. Remove the front door [1].
[1]
[3]
[4]
[5]
fd501fs2040c
81
11.3.12 Punch unit

A. Procedure
FD-503

[2]
fd501fs2003c
11.3.13 Cleaning the 2nd folding conveyance sensor (PS53)

A. Procedure
1. Remove the front door and pull out the folding
unit.
[1] 2. Open the guide plates [1] and [2].
3. Clean the 2nd folding conveyance sensor (PS53)
[3].
[2]
[3]
fd501fs2041c
1 82
11.3.14 Cleaning the 3rd folding conveyance sensor (PS54)

A. Procedure
1. Remove the front door and pull out the folding
FD-503
[1] unit.
2. Remove the screw [1] and turn over the sensor
mounting plate [2].
[2]
fd501fs2042c
3. Clean the 3rd folding conveyance sensor (PS54)

[1].
[1]
fd501fs2043c
83
11.3.15 Cleaning the 3rd folding roller

A. Procedure
1. Open the front door and pull out the folding unit.
FD-503
[2] [1] 2. Remove the stand cover.

3. The 2 springs [2] are hooked to the shaft [1].
Remove them from the shaft [1].
4. Remove the screw [3] and then remove 2 springs
[2], the support plate [4] and the guide plate [5].
[5]
[4]
[3]
fd501fs2044c
5. Remove 3 screws [1] and then remove the guide

[1]
plate [2].
[2]
fd501fs2045c
84
6. Clean the 3rd folding roller [1].
FD-503
[1]
fd501fs2046c
85
11.3.16 Folding conveyance section

FD-503
CAUTION:
• Be sure to perform this operation with 2 people because the folding conveyance section is heavy.
A. Procedure
1. Remove the front door and the rear cover.
2. Disconnect 3 connectors [1] and then remove the
wiring harnesses from the 7 wiring harness guides
[3] of the coupling arm /Rr [2].
[2]
[1]
[3]
fd501fs2047c

[1]
4. Remove the shaft [2] and separate the coupling
[3] arm /Fr [3] and the coupling arm /Rr [4].
[4] [2]
fd501fs2048c
86
5. Remove the stopper screws [1], 1 each, from the

[1]
left and right rails and pull further out the folding
conveyance section.
FD-503
[1] fd501fs2049c
87
6. Remove screws [1], 3 each, from the left and right

[1]
rails.
FD-503
[1]
fd501fs2050c
88
7. Hold the folding conveyance section [3] at the

specified places [1] and [2] and remove it while lift-
[3] ing it up.
FD-503
CAUTION:
• Be careful of your posture when removing it.
Be sure to conduct this operation with 2 peo-
[1]
ple so that you do not suffer backache.
Note
• When lifting up the folding conveyance sec-
tion, be sure to hold the shaft at the places [1]
and [2]. Holding it at other places such as the
roller shaft or the guide plate may cause
deformation to these places.
[2]
fd501fs2051c
8. Stand the folding conveyance section [1] upright

[1] when it has been removed, or lay it down on the
right-side [2].
[2] Note
• Be careful not to lay it with the left side [3]
down. The guide plate may get deformed.

steps in reverse.
fd501fs2052c
89
Note
[2]
• When installing the folding conveyance sec-
tion, make sure that all 4 hooks [1] of the rails
FD-503
have engaged the attaching holes [2] of the

folding conveyance section.
• The top should be attached by pushing it to
[1] the right to engage the upper rail and the bot-
tom pushed to the left to engage the lower
rail.
[1]
[2] fd501fs2053c
Note
• When installing the folding conveyance sec-
tion, pull out the rail further than the length of
the stopper [1]. Use the stopper screw [2] to
[2]
fasten it tentatively at its fully pulled-out posi-
tion and fix the rail on the opposite side with
[1]
tape [3]. It prevents the rail from moving to
inside for an easy and smooth operation.
[3] fd501fs2054c
90
11.3.17 Roller solenoids /1 (SD5) to /4 (SD8)

A. Procedure
1. Remove 4 screws [1] and then remove the cord
FD-503
[1]
support board /A [2].
2. Unhook the hook of the spring [3] from the shaft
[4].
[2]
[4]
[3] fd501fs2001c

4. Remove each of 2 screws [2] and then remove the
roller solenoids /1 (SD5) to /4 (SD8) [3].
steps in reverse.
[1]
6. Make adjustments of the installation position.
[2]
[3]
[2]
[1]
fd501fs2002c
91 1
11.3.18 2nd folding roller solenoid (SD18)

A. Procedure
FD-503

wiring harnesses from the 7 wiring harness guides
[3] of the coupling arm /Rr [2].
[2]
[1]
[3]
fd501fs2047c

[1]
4. Remove the shaft [2] and separate the coupling
[3] arm /Fr [3] and the coupling arm /Rr [4].
[4] [2]
fd501fs2048c
5. Open the front door [1] and then remove the

[1] [2]
screw [2].
6. Pull out the folding unit [3].
[3] a0h0t3c004ca
1 92
7. Remove the stopper screws [1], 1 each, from the

[1]
left and right rails and pull further out the folding
conveyance section.
FD-503
[1] fd501fs2049c
[2] 8. Open the guide plate [1].

9. Remove 2 screws [2] and then remove the wiring
mounting cover [3].
[3] [1] a0h0t3c005ca
93 1
[2] [1] 10. Disconnect the connector [1].

11. Remove 2 screws [2] and then remove the 2nd
folding roller solenoid (SD18) [3].
FD-503

steps in reverse.
13. Make adjustments of the installation position.
[3] a0h0t3c006ca
1 94
11.3.19 Main tray up/down wire

A. Procedure
Note
FD-503
• The following procedure for replacing the up/
[1] down wire shows the examples on the rear
side. The figuration and the winding of wires
on the front side are symmetrical to those on
the rear side.
• There are 2 types of up/down wires provided,
one [1] on the front side and the other [3] on
[2] the rear side. Be sure to use the wire with the
correct wire mounting plate direction when
installing it. The direction of the wire mount-
ing plate distinguished between these 2 wires
when the shorter wire [2] is placed under the
longer wire.

Rear cover (Refer to P.77)
Left cover /Fr (Refer to P.77)
Left cover /Rr (Refer to P.78)
Front door (Refer to P.81)
[3]
[2]
fd501fs2056c
95
2. Remove 2 connectors [1] and 5 screws [2], and

then remove the gear box [4] together with the up
[3] down motor (M11) [3].
FD-503
[1] CAUTION:
• When the gear box is removed, the up/down
stay may fall down. So, when removing the
gear box, be sure to support the stay with
your hands.
[4]
[2]
fd501fs2057c
3. Remove 2 screws [1] and then remove the wire

[2] mounting plate [3] of the up/down wire /Rr [2]
from the up/down stay [4].
[4]
[3]
[1]
fd501fs2058c
96
4. Remove the E-ring [1] and then remove the gear

[5]
[5] [3] together with the 2 bearings [2].
FD-503
[4] [6] together with the 2 bearings [5].
[8] and the pin [9].
[6]
Note
• When removing the gear [8], be careful not to
drop the pin [9].
[2]
[1]
[3]
[7] [9]
[8]
fd501fs2059c
97
7. Loosen 3 screws [2] of the belt tensioner [1].

FD-503
[1]
[2]
fd501fs2060c
8. Remove the E-ring [1] and then remove the up/

down pulley /RrLw [2] and the pin [3].
Note
• When removing the up/down pulley /RrLw [2],
be careful not to drop the pin [3].
[3]
[2]
[1]
fd501fs2061c
98
9. Temporarily tighten the wire mounting plate [2] of

a new up/down wire /Rr [1] to the up/down stay
[3] with 2 screws [4].
FD-503
Note
• Install the up/down wires placing the shorter
[1] wire below the longer one with the wire sup-
[4] porting part of the mounting plate outside.
[2] • There are 2 types of up/down wires, one for
the front side and the other for the rear side,
[3]
but these 2 wires are different in the direction
of the wire mounting plates. Be sure to use a
wire that fits in with the direction of a wire
mounting plate.
fd501fs2062c
99
10. Fasten the new up/down wire /Rr [1] with the wire
end [3] provided on the inside of the up/down pul-
ley /RrLw [2] and insert it into the shaft [6]. Rotate
FD-503
the up/down pulley /RrLw [2] and wind it 5.5 turns

clockwise from inside to outside around the up/
[2] [1] down pulley with no slack, and then insert the up/
down pulley /RrLw [2] fully onto the shaft so that it
coincides with the pin [4] and fasten it with the E-
ring [5]. If the angle does not coincide with the pin
[3] [4], move up and down the front side of the up/
down tray to change the angle of the shaft [6].
[4]
[6]
[5]
fd501fs2063c
100
11. Hook up the up/down wire /Rr [1] onto the up/
down pulley /RrUp [3] through the relay pulley /Rr
[2].
FD-503
[3] [1]
[2]
fd501fs2064c
12. Wind the up/down wire /Rr [1] 2 turns counter-

clockwise from inside to outside around the up/
down pulley /RrLw [2] with no slack and fasten it
[1] with the wire end [3].
[2]
[3]
fd501fs2065c
101
The route along which the up/down wire /Rr passes

is, on the whole, as shown in the drawing left.
FD-503
fd501fs2066c
13. Use a tension gauge or spring balance to pull up

the wire tensioner [1] upward with a designated
force "A," and fasten it with the 3 screws [2].
Specified value: A = 2.5kg ± 0.25kg
[2]
[1]
fd501fs2067c
102
14. Reinstall the 3 gears [1] following the removal

steps in reverse.
FD-503
[1]
fd501fs2068c
15. With the up/down stay [1] held in a horizontal

[4] position, tighten the 2 screws [3] of the wire
[1] mounting plate [2].
Note
[5]
• Move the up/down stay up and down and
check to see if it moves smoothly. If it does
not move smoothly, adjust it again so that it
[3] [2] becomes horizontal.
• Check the up/down wire [4] if it gets behind
the actuator plate [5]. If it gets behind the
actuator plate, an unnecessary load is applied
to the up/down wire [4] when the up/down
fd501fs2069c
stay [1] goes up.

steps in reverse.
103
11.3.20 Multi feed detection board /1 (MFDB/1), /2 (MFDB/2)
Note
FD-503
• When replacing the multi feed detection board /1 (MFDB/1), be sure to replace the multi feed
detection board /2 (MFDB/2) at the same time.
• When the multi feed detection board is replaced, be sure to conduct the adjustment in replacing
multi feed detection board (PI) (Refer to Field Service P.322)
A. Procedure
1. Remove 2 screws [1] and then remove the multi
feed detection board /1 (MFDB/1) cover [2].
[2] [1] fd501fs2070c

feed detection board /1 (MFDB1) [3].
[1]
[3] [2] fd501fs2071c
104
4. Open the front door and then open the convey-

ance guide plate /2 [1] in the upper right direction.
FD-503
[1] fd501fs2072c

[1]
6. Remove the wiring harness of the multi feed
detection board /1 (MFDB/1) from the wiring har-
ness guide [2].
[2] fd501fs2073c
7. Turn around the conveyance guide plate /2 assy

[2]
[1] inside the machine and pull it to the outside.
feed detection board /2 cover [3].
Note
• When turning it around, or when disassem-
bling or reassembling it, be careful not to
damage the wiring harness.
[1] [3] fd501fs2074c
105

feed detection board /2 (MFDB/2) [3].
FD-503

steps in reverse.
[3] [2] [1] a0h0t3c007ca
B. Notes to keep in mind when installing the multi feed detection boards /1 (MFDB/1) and /2 (MFDB/2)
• The multi feed detection boards /1 (MFDB/1) and
[2]
/2 (MFDB/2) are installed on the same type board.
Be careful not to confuse one with the other when
installing them.
• Be sure to confirm the marking on the board when
installing it.
Multi feed detection board /1 (MFDB/1) [1]: 15AG
Multi feed detection board /2 (MFDB/2) [2]: 56UA
• The connector shape is different for the multi feed
detection boards /1 (MFDB/1) and /2 (MFDB/2).
So, even if it is installed, the connector cannot be
connected.
[1] fd501fs2076c
1 106

When the FD control board (FDCB) is replaced, be
sure to remove the EEPROM (IC68) from the old con-
FD-503
trol board [1] and install it into the new control board
[2].
Remove the EEPROM (IC68) from the old control
board [1] and install it into the new control board [2].
Note
• Be sure to set the SW3 [3] same as the old
FDCB. (Refer to Field Service P.782)
[1]
[2] [3]
fd501fs2077c
Note
A • Be sure to set the "A" sections of the EEP-
ROM (IC68) in the same direction for installa-
tion.
A
fd501fs2078c
107
FD-503
Blank page
108
LS-505
2009.07
Ver. 2.0
Revision history
Revision mark:
corresponding page.
NOTE

2009/07 2.0 1 bizhub PRO 1200/1200P/1051.
CONTENTS
LS-505
LS-505
OUTLINE
3. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. COUPLING CONVEYANCE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3.1 Door open/close mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3.2 Jam release lever lock mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5. ENTRANCE CONVEYANCE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.3.1 Path switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.3.2 Conveyance line speed control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.3.3 Paper cooling mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.2.1 Entrance conveyance drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.2.2 Stacker tray conveyance drive (M3 reverse) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.2.3 Sub tray conveyance drive (M3 forward). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2.4 Coupling conveyance/grip belt/paper press arm drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.2.5 Stacker tray up down drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.2.6 Shift unit/alignment plate drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2.7 Rear stopper/job partition plate drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2.8 Front stopper/paper press arm drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.3.1 Stacker tray conveyance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.3.2 Coupling conveyance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.3.3 Sub tray conveyance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
MAINTENANCE
7.2 Removing procedure of disassembling and assembling parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.2.1 Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.2.2 Replacing the stacker tray up/down wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.2.3 Stacker tray up down motor (M1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.2.4 Paper press solenoid /3 (SD8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
i

7.2.7 Rear stopper solenoid (SD3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.2.8 Caution when setting models using toggle SW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
LS-505
ii
OUTLINE
LS-505
A. Type
Type Grip conveyance type horizontal stacker

Conveyance method Entrance Roller conveyance method
conveyance
Stacker tray Grip conveyance method
conveyance
Sub tray Roller conveyance method
conveyance
Coupling Roller conveyance
conveyance
Alignment method Movable alignment lever (stacker tray only)
Method of stacking Horizontal Mixing of original sizes not allowed (stacker tray only)
stacking
Shifting method Conveyance Shift amount: 20mm (stacker tray only) *1
direction shift
*1 The use of the shift is unavailable with tab paper.
B. Functions
(1) Functions
Stacker tray non-sort mode Exited into the stacker tray with no processing made.
Sub tray mode Exited into the sub tray with no processing made.
Stacker tray sort mode Exited into the stacker tray after being shifted (20mm).*1
Coupling mode Exited into the post-processing unit with no processing made.
Maximum tray capacity Stacker tray • 5,000 sheets

(weighing 80g/m2 ) SRA3, A3, JISB4*1, ISOB4*2*3, SRA4, SRA4S, A4, A4S,
13 x 19, 12 x 18, 11 x 17, 9 x 11*3, 81/2 x 14, 81/2 x 11,
81/2 x 11S, 81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13, 8k*4*5, 16K*4*5
• 3,000 sheets
Coat (Sub-scan direction is 380mm or longer)
• 2,000 sheets
JISB5*1, ISOB5*2*3, A5
Sub tray Straight exit :200 sheets
Z-Folding paper :20 sheets
Center folding paper :40 sheets
*1 Default for North America (1200/1200P/1051 only)

*3 1200/1200P/1051 only
*4 C6501/C6501P/C65hc only
1 1
C. Type of paper
Paper size Stacker tray SRA3, A3, JISB4*1, ISOB4*2*3, SRA4S, A4, A4S, JISB5*1,
ISOB5*2*3, B5S, A5
LS-505
13 x 19*4, 12 x 18, 11 x 17, 9 x 11, 81/2 x 14, 81/2 x 11,

81/2 x 11S, 81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13, 8K*5, 16K*5
Wide Paper*3 (A3W, B4W, A4W, A4SW, B5W, B5SW, A5W,
12 x 18W, 11 x 17W, 81/2 x 11W, 81/2 x 11SW, 51/2 x 81/2W,
Max. 324mm x 463mm)
Custom size paper (Max. 324mm x 463mm*3,
Max. 330mm x 483mm*4, Min. 210mm x 148mm)
Tab paper*6 (A3, B4, A4, A4S, B5, B5S, 11 x 17, 81/2 x 11,
81/2 x 11S, Max. 324mm x 463mm)
Sub tray SRA3, A3, JISB4*1, ISOB4*2*3, SRA4S, A4, A4S, JISB5*1,
ISOB5*2*3, B5S, A5, A5S*4, B6S*4, A6S*4
13 x 19*4, 12 x 18, 11 x 17, 9 x 11, 81/2 x 14, 81/2 x 11, 81/2 x 11S,
51/2 x 81/2*3, 51/2 x 81/2S*4, 81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13,
8K*4*5, 16K*4*5, 16KS*4*5
12 x 18W, 11 x 17W, 81/2 x 11W, 81/2 x 11SW, 51/2 x 81/2W,
Max. 324mm x 463mm)
Max. 330mm x 487mm*4, Min. 95mm x 133mm*3,
Min. 100mm x 148mm*4)
81/2 x 11S, 51/2 x 81/2, Max. 324mm x 463mm)
*3 *4
Paper weight Stacker tray 50g/m2 - 244g/m2 , 64g/m2 - 256g/m2
*8 *4
Sub tray 40g/m2 - 350g/m2 , 64g/m2 - 300g/m2

*3 1200/1200P/1051 only
*4 C6501/C6501P/C65hc only
*6 1 to 15 tab (4 tab and 10 tab are unavailable.) The use of the shift is unavailable with tab paper.
D. Maintenance
E. Machine data
Power source AC100 - 240V, DC5V (DC5V is supplied from the main body)*1
Maximum power consumption 143W or less
Dimensions 785 (W) x 723 (D) x 1,020 (H) mm
Temperature 10 - 30°C
Humidity 10 - 80%RH
Note
1 2
LS-505
[8] [9] [10] [1]
[7]
[2]
[3]
[4]
[6]
[5] ls502to1001c
[1] Conveyance unit [6] Stacker tray conveyance section

[2] 1st gate [7] Coupling conveyance section
[3] Entrance conveyance section [8] Sub tray
[4] Stacker tray [9] Sub tray conveyance section
[5] Hand cart [10] 2nd gate
3
3. PAPER PATH
LS-505
[3]
[2]
[1]
ls502to1002c
[1] Stacker tray non-sort/sort mode [3] Sub tray mode

[2] Coupling mode
4
Theory of Operation Ver.2.0 Jul. 2009 4. COUPLING CONVEYANCE SECTION
LS-505
4. COUPLING CONVEYANCE SECTION
4.1 Configuration
Entrance convey-
Coupling conveyance lock ance lock sole-
solenoid (SD11) noid (SD5)
Front door lock

solenoid (SD4)
ls502to2001c
4.2 Drive
[4] [1]
[3] [2] ls502to2002c
[1] Entrance conveyance lock solenoid (SD5) [3] Coupling jam release lever
[2] Entrance jam release lever [4] Coupling conveyance lock solenoid (SD11)
5
4. COUPLING CONVEYANCE SECTION Theory of Operation Ver.2.0 Jul. 2009
4.3 Operation
4.3.1 Door open/close mechanism
LS-505
While the LS is in operation, the front door lock solenoid (SD4) locks the front door, thus making it impossible to
open and close it. However, while in the coupling conveyance (coupling mode) or while exiting paper into the
sub tray (sub tray mode), the front door can be opened and closed.
Pressing the paper removing switch on the stacker tray operation board (TOB) brings down the stacker tray.
When the stacker tray arm release sensor (PS15) is turn on, SD4 turns off immediately.
The lock is released due to SD4 being turned off and the front door can be opened and closed.
4.3.2 Jam release lever lock mechanism

The entrance guide plate and the coupling guide plate are provided with a jam release lever to release jams. The
entrance conveyance lock solenoid (SD5) and the coupling conveyance lock solenoid (SD11) operate each of
the jam release levers.
ON/OFF timing of SD5 and SD11
Operation timing
ON When the stacker tray goes up, and while in printing

(Lock)
OFF While in standing by, when the stacker tray goes down after completion
(Release) of printing, when the front door opens (except in coupling mode and in
sub tray mode)
6
Theory of Operation Ver.2.0 Jul. 2009 5. ENTRANCE CONVEYANCE SECTION
5. ENTRANCE CONVEYANCE SECTION

5.1 Configuration
LS-505
Motor cooling fan
Paper cooling fan motor (FM4)
2nd gate
motor /2 (FM6)
Paper cooling fan
motor /1 (FM2)
1st gate
Paper cooling fan
motor /Rr (FM5)
Paper cooling fan

motor /Fr (FM1)
Paper cooling fan motor /

Mi (FM3)
ls502to2003c
7
5. ENTRANCE CONVEYANCE SECTION Theory of Operation Ver.2.0 Jul. 2009
5.2 Drive
[1] [2]
LS-505
[3]
[4]
[8] [7] [6] [5] a0h1t2c002ca
[1] 2nd gate solenoid (SD10) [5] Entrance roller

[2] Coupling conveyance roller /2 [6] 1st gate
[3] Conveyance motor (M2) [7] Coupling conveyance roller /1
[4] 1st gate solenoid (SD1) [8] 2nd gate
1 8
5.3 Operation
5.3.1 Path switching
LS-505
The path along which paper conveyed to the entrance guide plate is conveyed varies according to the operation
mode. The 1st gate and the 2nd gate switch the conveyance path.
A. 1st gate
The switching of the conveyance path is made between the stacker tray paper exit (stacker tray non-sort mode
and stacker tray sort mode) and the sub tray paper exit (sub tray mode) and the coupling conveyance (coupling
mode).
[1]
[3] [2] ls502to2005c
[1] Sub tray mode/coupling mode [3] Stacker tray non-sort mode/stacker tray
[2] 1st gate sort mode
9
B. 2nd gate
The conveyance path is switched between the sub tray paper exit (sub tray mode) and the coupling conveyance
(coupling mode).
LS-505
[2] [3]
[1] ls502to2006c
[1] Coupling mode [3] 2nd gate

[2] Sub tray mode
10
5.3.2 Conveyance line speed control

The conveyance process speed of the entrance roller and the coupling conveyance rollers 1/ and 2/ that are
driven by the conveyance motor (M2) varies according to the conveyance process speed of the main body.
LS-505
These operations are common to all the modes.
A. When the main body process speed is 1,000mm/s:
[1] [2] [3] [4]
1,000mm/s
Conveyance motor
(M2) 490mm/s
ls502to2007c
[1] Main body paper exit sensor (PS3) ON [3] 2nd sheet of paper
[2] 1st sheet of paper [4] 3rd sheet of paper
B. When the main body process speed is 490mm/s:
[1] [2] [3] [4]
1,000mm/s
Conveyance motor
(M2) 490mm/s
ls502to2008c
[2] 1st sheet of paper [4] 3rd sheet of paper
11
5.3.3 Paper cooling mechanism

Paper conveyed to the LS is likely to curl up due to fusing heat.
Heat storage accumulated in paper stacked during continuous printing causes tacking (sheets of paper sticking
LS-505
hard each other by toner) when toner that has been fused is refused and adheres. So, fresh air is blown on the
paper from under the entrance guide plate and above the path guide of the upper surface of the paper stack
section, thus cooling down the paper to correct curling and prevent tacking.
[4] [5]
[3] [2] [1] ls502to2028c
[1] Paper cooling fan motor /Rr (FM5) [4] Paper cooling fan motor /1 (FM2)
[2] Paper cooling fan motor /Mi (FM3) [5] Paper cooling fan motor /2 (FM6)
[3] Paper cooling fan motor /Fr (FM1)
12
6.1 Configuration
LS-505
Paper press solenoid /3 (SD8)
De-curler roller
Paper press
Paper empty sensor (PS6) arm /1
Grip belt
Paper empty detection
Front stopper Job partition Paddler
actuator
solenoid (SD9) plate
Sub tray full sensor (PS9)
Conveyance sen-
sor /3 (PS17)
Paper detection
sensor (PS19)
Guide plate
Hand cart
ls502to2009c
13
6.2 Drive
6.2.1 Entrance conveyance drive
LS-505
[1]
[2]
[5] [3]
[4]
a0h1t2c003ca
[1] Coupling conveyance roller /2 [4] Coupling conveyance roller /1

[2] Conveyance motor (M2) [5] One-way clutch
[3] Entrance roller
1 14
6.2.2 Stacker tray conveyance drive (M3 reverse)
LS-505
[1]
[2]
[4] [3] a0h1t2c004ca
[1] One-way clutch [3] De-curler roller

[2] Sub tray exit motor (M3) [4] Paddler
15 1
6.2.3 Sub tray conveyance drive (M3 forward)

LS-505
[1]
[2]
[5]
[4]
[3]
a0h1t2c005ca
[1] One-way clutch [4] Sub tray conveyance roller

[2] Sub tray exit motor (M3) [5] Sub tray exit roller
[3] Coupling conveyance roller /3
1 16
6.2.4 Coupling conveyance/grip belt/paper press arm drive
[8] [9] [10] [11] [12] [13]
LS-505
[14]
[15]
[7]
[6]
[5] [4] [3] [2] [1] a0h1t2c006ca
[1] Paper press arm /1 [8] Coupling conveyance roller /6

[2] Stacker tray paper empty detection [9] Coupling conveyance roller /5
actuator [10] Paper press solenoid /2 (SD7)
[3] Grip belt [11] Coupling conveyance roller /4
[4] Grip conveyance motor (M4) [12] Paper press arm /2
[5] Coupling conveyance motor (M6) [13] Coupling conveyance roller /3
[6] Coupling paper exit roller [14] Sub tray exit motor (M3)
[7] Coupling conveyance roller /7 [15] Paper press solenoid /1 (SD6)
17 1
6.2.5 Stacker tray up down drive
[4] [5]
LS-505
[1]
[3]
[2] ls501t2c001a
[1] Wire [4] Stacker tray

[2] Belt [5] Stacker tray up down arm
[3] Stacker tray up down motor (M1)
18
6.2.6 Shift unit/alignment plate drive

LS drawing as seen from above. On the right-side is the main body.
LS-505
[5] [6]
[1]
[4] [3] [2] ls502to2013c
[1] Guide rail [4] Conveyance unit

[2] Alignment plate [5] Shift unit motor (M5)
[3] Alignment motor (M7) [6] Guide rail
19
6.2.7 Rear stopper/job partition plate drive

LS-505
[1]
[4]
[3] [2] ls502to2014c

[1] Rear stopper [3] Rear stopper solenoid (SD3)

[2] Job partition plate [4] Job partition solenoid (SD2)
20
6.2.8 Front stopper/paper press arm drive
[2] [1]
LS-505
[2] [1]
[3]
[6] [4]
[5]
[4]
ls502to2015c
[1] Spring [4] Spring

[2] Paper press solenoid /3 (SD8) [5] Front stopper
[3] Paper press arm /3 [6] Front stopper solenoid (SD9)
21
6.3 Operation
6.3.1 Stacker tray conveyance
LS-505
While in the stacker tray non-sort mode and the stacker tray sort mode, paper is conveyed into the stacker tray.
A. De-curler
Paper that has passed through the 1st gate is conveyed to the grip belt by the de-curler roller. At this time, the
de-curler roller corrects the curled paper.
B. Grip conveyance
Paper conveyed by the de-curler roller enters and is help by the grip provided on the grip belt. The paper held by
the grip is conveyed to the section above the stacker tray by the rotation of the grip belt.
2 grips are provided on the grip belt and each one of them conveys paper one after the other. The grip convey-
ance home sensor (PS5) controls the position where the grip is waiting for paper from the de-curler roller.
[5] [6] [7]

[4] [3] [2] [1] ls502to2016c
[1] Paper [5] Grip

[2] De-curler roller [6] Grip belt
[3] Grip [7] Grip conveyance home sensor (PS5)
[4] Stacker tray
22
C. Front stopper control

Paper conveyed by the grip strikes against the front stopper equipped to the shift unit and is released from the
grip. At this time, the shift unit has been moved to the position specified in advance for each paper size.
LS-505
2 types of the front stoppers, more specifically, a movable type and a stationary type, are employed. In stacker
tray non-sort mode, only the movable type front stopper is employed. A distance of 20mm is kept between the
position where the movable type front stopper stops and the position in which the stationary type front stopper
is, which is the shift distance.
When stacking tab paper, paper is aligned by either stationary type front stopper or movable type front stopper.
Therefore, it is impossible to shift tab paper for stacking.
For the front stopper solenoid (SD9) that drives the movable type front stopper, a latch-type solenoid is
employed that is not required to be energized to maintain the ON state. However, a latch-type solenoid requires
a different control signal for each ON and OFF action.
[8] [9] [10]
[7] [6] [5] [4] [3] [2] [1] ls502to2017c
[1] Entrance sensor (PS4) [6] Grip

[2] Paper [7] Stacker tray
[3] Movable type front stopper [8] Grip belt
[4] 20mm [9] Conveyance unit
[5] Stationary type front stopper [10] Grip
23
(1) Stacker tray non-sort mode
[1] [3] [5] [6] [7]

LS-505
Shift unit motor (M5)
Front stopper solenoid Latch ON signal

(SD9)
Latch OFF signal
[8]
[2] [4] ls502to2018c
[2] The shift unit starts to move [6] 3rd sheet of paper
[3] 1st sheet of paper [7] Last sheet of paper
[4] Movable type front stopper ON [8] Movable type front stopper OFF
(2) Stacker tray sort mode
[1] [3] [5] [6] [8]
Shift unit motor (M5)
Front stopper solenoid Latch ON signal

(SD9)
Latch OFF signal
[10]
[2] [4] [7] [9] ls502to2019c
[1] Main body paper exit sensor (PS3) ON [6] Shift of the 1st sheet of paper
[2] The shift unit starts to move [7] Movable type front stopper OFF
[3] 1st sheet of paper [8] Shift of the last sheet of paper
[4] Movable type front stopper ON [9] Movable type front stopper OFF secured
[5] Last sheet of paper [10] Movable type front stopper OFF secured
24
D. Job partition plate

In stacker tray sort mode, the trailing edge of the shift paper is restricted by the job partition plate and the paper
is exited onto the stacker tray 20mm shifted from the non-shift paper. At this time, the upper surface of the non-
LS-505
shift paper does not come to the same level as the lower edge of the job partition plate and the 1st sheet of the
shift paper is in possibility of getting into the lower side of the job partition plate. To prevent this, the job partition
plate is attached to the upper surface of the non-shift paper that has been exited to restrict the entry of the
paper.
For the job partition solenoid (SD2) that drives the job partition plate, a latch-type solenoid is employed that is
not required to be energized to maintain the ON state. However, a latch-type solenoid requires a different control
signal for each ON and OFF action.
[5]
[4] [3] [2] [1] ls502to2023c
[1] Entrance sensor (PS4) [4] Stacker tray

[2] Job partition plate [5] Shift paper
[3] Non-shift paper
25

Example: A4 4 sheets, 1 set
LS-505
[1] [2] [4] [6] [8]
Job partition Latch ON signal

Solenoid (SD2)
Latch OFF signal
[9]
[3] [5] [7] ls502to2021c
[1] Main body paper exit sensor (PS3) ON [6] 3rd sheet of paper
[2] 1st sheet of paper [7] Job partition plate close
[3] Job partition plate close [8] Last sheet of paper
[4] 2nd sheet of paper [9] Job partition plate close

[5] Job partition plate close

Example: A4 2 sheets, 2 sets
[1] [2] [4] [5] [7]
Job partition Latch ON signal

Solenoid (SD2)
Latch OFF signal
[3] [6] [8] ls502to2022c
[1] Main body paper exit sensor (PS3) ON [5] Non-shift of the 1st sheet of paper
[2] Shift of the 1st sheet of paper [6] Job partition plate close
[3] Job partition plate open (shift amount: 20mm) [7] Non-shift of the 2nd sheet of paper
[4] Shift of the 2nd sheet of paper [8] Job partition plate close
26
E. Rear stopper control

While in the stacker tray sort mode is in shifting, the rear stopper is left open and this plays as a guide for the
trailing edge of paper.
LS-505
To assist the separation of paper released from the grip, the paddle is rotated at a high speed.
For the rear stopper solenoid (SD3) that drives the rear stopper, a latch-type solenoid is employed that does not
need to be energized to maintain the ON state. However, a latch-type solenoid requires a different control signal
for each ON and OFF action.
[5] [1]
[4] [3] [2] ls502to2020c
[1] Paddler [4] Paper position while in the stacker tray sort mode
[2] Entrance sensor (PS4) [5] Paper position while in the stacker tray non-
[3] Rear stopper sort mode
27

Example: A4 4 sheets, 1 set
LS-505
[1] [2] [5] [8] [11]
Rear stopper sole- Latch ON signal

noid (SD3)
Latch OFF signal
[13]
[3] [4] [6] [7] [9] [10] [12] ls502to2029c
[2] 1st sheet of paper [9] Rear stopper open
[3] Rear stopper open [10] Rear stopper close
[4] Rear stopper close [11] 4th sheet of paper

[5] 2nd sheet of paper [12] Rear stopper open
[6] Rear stopper open [13] Rear stopper close
[7] Rear stopper close

Example: A4 2 sheets, 2 sets
[1] [2] [4] [6] [9]
Rear stopper sole- Latch ON signal

noid (SD3)
Latch OFF signal
[11]
[3] [5] [7] [8] [10] ls502to2024c
[1] Main body paper exit sensor (PS3) ON [7] Rear stopper open
[2] Shift of the 1st sheet of paper [8] Rear stopper close
[3] Rear stopper open [9] Non-shift of the 2nd sheet of paper
[4] Shift of the 2nd sheet of paper [10] Rear stopper open
[5] Rear stopper close [11] Rear stopper close
[6] Non-shift of the 1st sheet of paper
28
F. Paper press arm

The paper that has been released from the grip is pressed one at a time onto the stacker tray by the paper pres-
sure arms /1, /2 and /3 to be loaded on the stacker tray. However, the operation of the paper pressure arm /2 is
LS-505
limited only to the paper size larger than B4.
[1] [2] [3] [4]

ls502to2025c
G. Alignment plate control
The alignment plate aligns each sheet of paper loaded on the stacker tray.
[1] [3] [5] [7] [9]
Alignment motor (M7)
Alignment plate home sensor (PS12)
[10] [11]
[2] [4] [6] [8] ls502to2026c
[2] Movement to a position specified for each paper size [8] Alignment of the 3rd sheet of paper
[4] Alignment of the 1st sheet of paper [10] Alignment of the last sheet of paper
[5] 2nd sheet of paper [11] Returning to the home position
[6] Alignment of the 2nd sheet of paper
29
H. Stacker tray up down control

The paper empty sensor (PS6) detects the upper surface of paper loaded on the stacker tray through the paper
press arm /3. When PS6 is turned off by loading exited paper, the stacker tray up down motor (M1) turns on to
LS-505
lower the stacker tray down to the position at which PS6 turns on. The stacker tray is thus held at a fixed height
when paper is being exited.
The number of sheets of paper loaded on the stacker tray is detected by the 2,000 sheets stacked sensor
(PS13) and the 5,000 sheets stacked sensor (PS14) provided on the up down path of the stacker tray and dis-
played on the operation panel. (The main unit makes 3,000 sheets stacked detection.)
When the hand cart once pulled out is put back to its original position, the stacker tray moves up to return to its
home position. If the paper detection sensor (PS19) detects that papers are loaded on the stacker tray, the tray
stops moving up in order to prevent the uplifted paper from damaging the alignment plate.
I. Hand cart detection mechanism

The hand cart set switch (RS1) detects the set condition of the hand cart. The set condition of the stacker tray
is detected by checking to see if the light from the stacker tray set LED (LED1) gets to the stacker tray set sen-
sor (PS1).
6.3.2 Coupling conveyance

In coupling mode, paper is conveyed to the device connected to the subsequent stage of the LS through the
coupling conveyance section.

When paper is conveyed from the main body, the conveyance motor (M2) at the entrance conveyance section is
rotated at the same speed as the conveyance speed of the main body. When paper is conveyed to the LS, the
speed of rotation of M2 is increased up to 1,000mm/s to convey paper.
6.3.3 Sub tray conveyance

In sub tray mode, paper is exited into the sub tray.
[1] [2] [3] [4]
Sub tray exit sensor (PS10)
1,000mm/s
Sub tray exit motor
(M3) 490mm/s
450mm/s
ls502to2027c
B. Paper full control

When the number of the sheets of paper discharged on the sub-tray gets to 200, the sub tray full sensor (PS9)
turns on to give indication of "paper full" on the operation panel.
1 30
MAINTENANCE
LS-505
7. OTHER PROCEDURES
1 Front cover /Up P.33
2 Front cover /Lw P.33
3 Cover Rear cover /Up P.32
4 Rear cover /Lw P.32
5 Upper cover P.34
6 Stacker tray up/down wire P.35
7 Stacker tray up down motor (M1) P.40
8 Paper press solenoid/3 (SD8) P.41
Conveyance section
11 Rear stopper solenoid (SD3) P.46
31 1
7.2 Removing procedure of disassembling and assembling parts

LS-505
CAUTION:
7.2.1 Cover
A. Procedure
[1] [1]
cover /Up [2].
cover /Lw [4].
cover [6].
[2]
[1]
[1]
[4]
[3]
[3]
[6]
[5]
[5]
ls502fs2034c
32
4. Remove 5 screws [1] and slide the front cover /Up

[1] [1]
[2] to the upper side.
5. Disconnect the connector [3] and remove the
LS-505
front cover /Up [2].
[2]
[1] [1]
[3]
ls502fs2035c
6. Remove the screws [1], 1 each, and then remove

[3]
3 knobs [2].
7. Loosen 2 screws [3].
8. Remove 2 screws [4] and then remove the front
[5] cover /Lw [5].
[4]
[4]
[1]
[2]
ls502fs2036c
33
9. Remove 3 screws [1] and then remove the upper

[2]
cover [2].
LS-505
[1]
[1]
ls502fs2037c

11. Remove 2 screws [2] and then remove the front
door [1].
steps in reverse.
[1]
[2]
ls502fs2038c
34
7.2.2 Replacing the stacker tray up/down wire
Note
LS-505
• When conducting this operation, be sure to set the stacker tray at the home position (the upper
most position) in advance.
1. Remove the rear cover /Up, /Lw. (Refer to P.32)

[3] [1] [4]
3. Remove 2 screws [2] and remove the sensor
mounting plate [3].
4. Remove 4 screws [4] and remove the stacker tray
up down motor (M1) [5].
[2] [5] ls502fs2001c
Note
[5] • When reinstalling the stacker tray up down
motor (M1), be sure to check that the belt [2]
has been engaged with the gear [1], and then
engage it with the gear [3] before fastening
[4] the stacker tray up down motor (M1) [4].
• When the belt [2] is not horizontally attached
between the gear [1] and the gear [3], make
adjustments by rotating the encoder [5] coun-
terclockwise.
[1] [3]
[2] ls502fs2002c
35
5. Remove 2 screws [1] and remove the motor

[2] mounting plate [3] from the stacker tray up down
motor (M1) [2].
LS-505
[3]
[1]
ls502fs2003c
6. Remove the screws [1], 1 each, and remove the

[2] [1] [1] [2]
pulley covers [2], 1 each.
ls501f2c001a
36
7. Remove the screws [1], 1 each, and remove the

pulley covers [2], 1 each.
LS-505
[2] [1] [1] [2] ls501f2c002a
8. Remove the screw [1] and remove the wire retain-

[4] [3]
ing bracket [2].
9. Remove 4 screws [3] and remove the pulley assy
[4].
[1] 10. Remove the hexagon socket screw [6] and
remove the tip [7] of the wire /1 [5].
Note
• On the paper exit side, loosen 4 screws [3],
[2]
bring down the pulley assy [4] and release the
[5] tension of the wire /2 [5] before starting the
operation.
• When reinstalling it, the positions of the pulley
assy on the paper feed side and the paper exit
side become important. Be sure to check the
marked position in advance of the pulley assy
[7] on the paper exit side.
[6]
ls501f2c003a
37
11. Release the winding of the wire /1 [2] from the pul-
[1] [2] [4]
ley [1].
12. Remove the E-ring [3] and then remove the pulley
LS-505
[1] from the shaft [4].
[3] ls502fs2027c
13. Remove the wire retaining bracket [2] from the

wire /1 [1].
[1]
Note
• When installing the wire retaining bracket [2],
install it to the wire /1 [1] so that the bracket
comes to the rear side.
[2]
ls501f2c004a
14. Remove the wire /1 [2] from the pulley [1].

[1] [2]
15. Reinstall a new wire /1 following the preceding
steps 5 to 11 in reverse.
ls502fs2028c
38
Note
[2]
• When 2 wires at both sides are removed at
the same time, the stacker tray comes down.
LS-505
So, be sure to replace the wires one at a time
(so that the remaining wire holds the stacker
tray in place.)
• When attaching the pulley to the shaft, be
sure to align the groove [1] of the pulley with
the pin [2] that has been inserted into the
shaft.
• Be sure to set up it with the bead set portion
[3].
[1] [3] ls502fs2029c
• When winding the wire around the pulley, be

[1] [2]
sure to wind it 8 turns [3] so that the direction
of drawing-out [1] comes to the rear panel
side [2].
• The direction of drawing-out of the wire /1 is
symmetrical to that of the wire /2.
[3] ls502fs2030c
Note
• When fixing the pulley assy [1] on the paper
exit side, be sure to fix it at the same position
as it was removed from.
16. Replace the wire /2 with a new one following the

preceding steps 5 to 12.
17. Reinstall other parts following the steps 1 to 5 in
reverse.
[1] ls501f2c005a
39
7.2.3 Stacker tray up down motor (M1)

A. Procedure
1. Remove the rear cover /Lw. (Refer to P.32)
LS-505
[3] [1] [4]

3. Remove 2 screws [2] and remove the sensor
mounting plate [3].
4. Remove 4 screws [4] and remove the stacker tray
up down motor (M1) [5].
[2] [5] ls502fs2001c
Note
[5] • When reinstalling the stacker tray up down
motor (M1), be sure to check that the belt [2]
has been engaged with the gear [1], and then
engage it with the gear [3] before fastening
[4] the stacker tray up down motor (M1) [4].
• When the belt [2] is not horizontally attached
between the gear [1] and the gear [3], make
adjustments by rotating the encoder [5] coun-
terclockwise.
[1] [3]
[2] ls502fs2002c
5. Remove 2 screws [1] and remove the motor

[2] mounting plate [3] from the stacker tray up down
motor (M1) [2].
[3] steps in reverse.
[1]
ls502fs2003c
1 40
7.2.4 Paper press solenoid /3 (SD8)

A. Procedure
LS-505
Note
• When conducting this operation, be sure to bring the stacker tray down to the bottom in advance.

2. Slide the guide rail [2] in the arrow-marked direc-
[2] tion and release the fixing.
2
Note
1
• In this step, be careful not to release the fixing
[3] on the rear guide rail [3].
[1]
ls502fs2004c
3. Slant the shift unit [1] to the front side so that you
can see the upper surface of it.
Note
[1] • Be sure to slide the shift unit about 10cm to
the right in advance.
• Be careful that the belt [2] does not get
pushed down by the bottom of the shift unit.
[2]
4. Release the cable stopper [3] and remove the rib-
bon cable [5] from the connector [4].
[4]
[5]
[3] ls502fs2005c
41 1
Note
• Slide the lock [2] of the connector [1] for the
ribbon cable in the arrow-marked direction
LS-505
[1] and remove the ribbon cable [3]. When rein-

stalling the ribbon cable, slide the lock in the
[3]
reverse direction after inserting the cable.
[2]
[1]
[3]
[2]
ls502fs2006c

6. Slide the guide rail [2] in the arrow-marked direc-
tion and release the fixing.
7. Remove the belt [5] from the stopper section [4] of
the shift unit [3].
[4] [5]
[3]
2
[2]
1
[1] ls502fs2007c
1 42
Note
• When attaching the belt [2] to the stopper
[2] section [1], slide the shift unit [3] in the arrow-
LS-505
marked direction and engage the stopper
[1] section with the belt.
[2]
[1]
[3]
ls502fs2008c
8. Remove the conveyance unit [2] through the

[1] [4]
clearance between the belts [1].
Note
• When removing the conveyance unit [2], be
careful that the front edge of the stoppers [3]
[2] and the paper pressure arms /3 [4] do not
contact with the belt [1].
[4] [3] ls502fs2009c
43 1

10. Remove 2 springs [2].
11. Rotate the wire saddle [5] in the arrow-marked
LS-505
direction and remove it.

12. Remove 3 screws [3] and remove the paper press
solenoid /3 assy [4].
[1] [3] [5] [4]
[3]
[3] [2] ls502fs2010c
Note
• When reinstalling the paper press solenoid /3
assy, be sure to insert the pin [2] of the shaft
[1]
into the slit section [1] at the tip of the sole-
noid.
[2]
ls502fs2011c
1 44
13. Remove 2 screws [1] and remove the solenoid

[3]
mounting plate [3] from the paper press solenoid /
3 (SD8) [2].
LS-505
[2] ls502fs2012c

A. Procedure
1. Remove the front covers /Up and /Lw.
[3] [4]
(Refer to P.32)
[2] 3. Remove the spring [2].
solenoid /1 assy [4].
[6]
Note
assy, be sure to insert the actuator [6] pro-
vided at the tip of the shaft into the slit sec-
tion [5] at the tip of the solenoid.
[5] [1] a0h1t3c001ca
[1]
5. Remove 2 screws [1] and remove the solenoid
mounting plate [3] from the paper press solenoid /
1 (SD6) [2].
steps in reverse.
[3] [2] a0h1t3c002ca
45 1

A. Procedure
1. Remove the front covers /Up and /Lw.
LS-505
[2] [6]
[5] (Refer to P.32)
3. Remove the spring [2].
solenoid /2 (SD7) [4].
[3]
Note
(SD7), be sure to insert the actuator [6] pro-
[1] [4] ls502fs2033c

steps in reverse.
7.2.7 Rear stopper solenoid (SD3)

A. Procedure
[5] [6] [2]

1. Remove the rear cover /Lw. (Refer to P.32)
3. Remove the spring [2].
4. Remove 2 screws [3] and remove the rear stopper
[3] solenoid (SD3) [4].
Note
• When reinstalling the rear stopper solenoid
[4]
(SD3), be sure to insert the actuator [6] pro-
[1] ls502fs2016c
steps in reverse.
7.2.8 Caution when setting models using toggle SW
When using C6501/C6501P/C65hc/1200/1200P/

[1]
1051, be sure to set the toggle switch on the connec-
tor connection of the left side of the LS to SYS2 [2].
[2] 15atf2c001ca
1 46
FS-521
2009.07
Ver. 2.0
Revision history
Revision mark:
corresponding page.
NOTE

2009/07 2.0 1 bizhub PRO 1200/1200P/1051.
CONTENTS
FS-521
FS-521
OUTLINE
3. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. PAPER CONVEYANCE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3.1 Conveyance path switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3.2 Bypass roller /Lw pressure release control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5. SUB TRAY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6. STACKER SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2.1 Stacker entrance roller/paddle drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2.2 Stack assist plate/rear stopper drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.2.3 Intermediate roller/paper exit arm drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.2.4 Alignment drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.3.1 Stacker conveyance speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.3.2 Stacker entrance roller control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.3.3 Intermediate roller control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.3.4 Stack assist control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.3.5 Rear stopper control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.3.7 Stacker paper exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7. STAPLER SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.2.1 Stapler movement/rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.2.2 Stapler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.3.1 Stapler movement control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.3.2 Staple control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.2.1 Tray up/down drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.2.2 Main tray paper exit drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
i
8.2.3 Paper exit opening drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

8.2.4 Paper exit alignment plate drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.2.5 Paper exit alignment plate retraction drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
FS-521
8.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.3.1 Paper exit opening control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.3.2 Paper press arm control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.3.3 Main tray up/down control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.3.4 Paper exit alignment control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
MAINTENANCE
9.1.1 Lubrication to bypass roller /Lw pressure release cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9.2 Stacker section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9.2.1 Replacing the intermediate roller release solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9.2.2 Lubrication to worm gear and cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.3 Stapler section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.3.1 Replacing the stapler assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

9.3.2 Replacing the staples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.3.3 Cleaning the cut staple box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.4 Main tray section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.4.1 Replacing the paper exit roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.4.2 Replacing the paper exit opening solenoid assy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10.2 Removing procedure of disassembling and assembling parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
10.2.1 Front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
10.2.2 Sub tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
10.2.3 Upper cover /1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
10.2.4 Upper cover /2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10.2.5 Left cover /Fr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
10.2.6 Rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
10.2.7 Stacker unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
10.2.8 Main tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10.2.9 Lift wire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
10.2.10 Tray up down motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10.2.11 Handling of the clogged stapler 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10.2.12 Handling of the clogged stapler 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10.2.13 Note for replacing the board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
ii
OUTLINE
FS-521
A. Type
Type Staple-cut type multi staple device
B. Functions
(1) Functions
Straight mode Exited into the main tray with no processing made.
Shift mode Exited into the main tray after being shifted.
Sub tray mode Exits paper to the subtray without any process.
Staple mode Exited into the main tray after being flat-stapled.
Subset staple mode Bundles of flat-stapled sheets of paper and single sheets of paper being exited
at random into the main tray.
(2) Number of staple sheets

The maximum number of staple sheets is decided according to either conditions which is met first, the combina-
tion condition of the paper type/the paper lengtht/the number of sheets for every range of paper weight, or the
combination condition of the booklet length/the booklet thickness.
• Combination condition of the paper weight/the paper type/the paper length and the number of sheets for
every range of paper weight
Paper weight Number of staple sheets

(g/m2) Paper not coated Coat/color paper
Less than 400mm 400mm or more Less than 400mm 400mm or more
50 to 71 100 50 35 35
72 to 81 100 50 35 35
82 to 91 100 50 35 35
92 to 130 50 50 30 30
131 to 161 40 40 25 25
162 to 216 25 25 20 20
217 to 244 25 25 15 15
• Combination condition of the booklet length/the booklet thickness
Length (mm) Booklet thickness (mm)

219 or less 23 or less
220 or more 20 or less
1 1
(3) Staple position
Staple position 1 staple at the rear (45°), 1 staple at the front, and 2 staples at the center
FS-521
(4) Maximum tray capacity of the Main tray

Straight/Shift mode Large-size : A3, JISB4*3, ISOB4*1*4, 12 x 18, 11 x 17, 81/2 x 14, SRA3,
(Weight:40g/m2 - 350g/m2 SRA4 , SRA4S , 13 x 19*2 *5, 81/2 x 13, 81/4 x 13, 81/8 x 131/4,
*1
, 64g/m2 - 300g/m2 *2) 8 x 13, 8K*6
Wide paper*1 (Max. 324mm x 463mm)
Small-size : A4, A4S, JISB5*3, ISOB5*1*4, B5S, 9 x 11*1, 81/2 x 11, 81/2 x 11S,
16K*6, 16KS*6
Minimum-size : A5, A5S*2, 51/2 x 81/2S*2 *5
Others : Tab paper*7 (A3, B4, A4, A4S, B5, B5S, 11 x 17,
81/2 x 11, 81/2 x 11S, 51/2 x 81/2, Max. 324mm x 463mm),
Custom size paper (Max. 324mm x 463mm, Min. 148mm x 139mm*1,
Min. 148mm x 148mm*2, Max. 331mm x 483mm*2 *5,
Min. 128mm x 139mm*5)
Weight (g/m2) Tray capacity (sheets)
Large-size Small-size Minimum-size
40 to 71 500 750 100
72 to 81 1500 3000 (1500)*8 750
82 to 91 1000 2000 (1500)*8 500
92 to 130 750 1500 400
131 to 161 350
162 to 216 500 1000 250
217 to 300 375 750 200
301 to 350 250 500 100
Staple mode Staple sheet Number of sets
(Weight:50g/m2 - 244g/m2 2 to 9 150 (paper length 182mm to 364mm) 75 (other than paper
*1
, 64g/m2 - 244g/m2 *2) length 182mm to 364mm)
10 to 20 50
21 to 30 30
31 to 40 25
41 to 50 20
51 to 60 15
61 to 100 10
*1 1200/1200P/1051 only
*2 C6501/C6501P/C65hc only
*5 Straight mode only
*8 ( ) while in shifting
1 2
(5) Maximum tray capacity of the Sub tray

Maximum tray capacity 200 sheets (20 sheets for Z-Folding/40 sheets for center folding)
(Paper weight40g/m2 to 350g/m2
FS-521
*1 *3, 64g/m2 to 300g/m2 *2)
SRA3, A3, JISB4*4, ISOB4*1*5, SRA4, SRA4S, A4, A4S, JISB5*4, ISOB5*1*5, B5S, A5, A5S*2, B6S*2, A6S*2,
13 x 19*2, 12 x 18, 11 x 17, 9 x 11*1, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2*1, 51/2 x 81/2S*2, 81/2 x 13, 81/4 x 13,
81/8 x 131/4, 8 x 13, 8K*6, 16K*6, 16KS*6
Wide Paper*1 :A3W, B4W, A4W, A4SW, B5W, B5SW, A5W, 12 x 18W, 11 x 17W, 81/2 x 11W,
81/2 x 11SW, 51/2 x 81/2W, Max. 324mm x 463mm
Tab paper*7 :A3, B4, A4, A4S, B5, B5S, 11 x 17, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2,
Max. 324mm x 463mm
Custom size paper:Max. 324mm x 463mm*1,Max. 331mm x 483mm*2 ,Min. 95mm x 139mm*1,Min. 100mm x
148mm*2
*1 1200/1200P/1051 only
*2 C6501/C6501P/C65hc only
*3 Loading paper weight 49g/m2 or less is not warranty
*8 95mm x 133mm when post pocessing with FS only.
C. Type of paper
(1) Staple
Paper size SRA3, A3, JISB4*1, ISOB4*2*3, SRA4, SRA4S, A4, A4S, JISB5*1, ISOB5*2*3, A5
12 x 18, 11 x 17, 9 x 11, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2*3,
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13, 8K*4, 16K*4
Wide paper*3 :A3W, B4W, A4W, A4SW, B5W, B5SW, A5W,
12 x 18W, 11 x 17W, 81/2 x 11W, 81/2 x 11SW, 51/2 x 81/2W,
Max. 324mm x 463mm
Tab paper*5 :A3, B4, A4, A4S, B5, B5S, 11 x 17,
81/2 x 11, 81/2 x 11S, 51/2 x 81/2,
Max. 324mm x 463mm
Custom size paper :Max. 324mm x 463mm, Min. 203mm x 139mm
Applicable paper Same as the main body.
Paper weight Main tray 50g/m2 - 244g/m2 *3, 64g/m2 - 244g/m2 *6

*3 1200/1200P/1051 only
*6 C6501/C6501P/C65hc only
D. Maintenance
3 1
E. Machine data

FS-521
Maximum power consumption 110VA

Dimensions When the main tray is pulled out: 915 (W) x 723 (D) x 1020 (H) mm
When the main tray is set in: 798 (W) x 723 (D) x 1020 (H) mm
When the main tray is removed: 544 (W) x 723 (D) x 1020 (H) mm
Weight Approx. 80kg
Note
• The information herein may be subject - change for improvement without notice.
4
FS-521
[5]
[1]
[4]
[3]
[2]
fs503to1001c
[1] Paper conveyance section [4] Main tray section

[2] Stapler section [5] Sub tray section
[3] Stacker section
5
3. PAPER PATH
FS-521
[1]
[2]
[3]
fs503to1002c
[1] Sub tray paper path [3] Main tray paper path (only while in stapling)
[2] Main tray paper path (straight/sort/staple)
6
Theory of Operation Ver.2.0 Jul. 2009 4. PAPER CONVEYANCE SECTION
FS-521
4. PAPER CONVEYANCE SECTION
4.1 Configuration
FNS entrance sensor
(PS4)
Tray gate
Stacker entrance sensor (PS5) Bypass roller /Lw Bypass gate
a0gyt2c001ca
7
4. PAPER CONVEYANCE SECTION Theory of Operation Ver.2.0 Jul. 2009
4.2 Drive
[1]
FS-521
[2]
[3]
[6] [8] [7] [6] [5] [4] a0gyt2c002ca
[1] Conveyance motor (M1) [5] Bypass solenoid (SD5)

[2] Tray gate [6] Bypass roller /Lw
[3] Gate solenoid (SD2) [7] Bypass roller release motor (M12)
[4] Bypass gate [8] Bypass roller release home sensor (PS13)
8
4.3 Operation
FS-521
A. Tray gate control
The tray gate switches the paper conveyance path between the main tray and the sub tray.
The tray gate is normally specified to the conveyance path to the main tray. When paper is exited to the sub tray,
however, the gate is switched to the path to the sub tray through the drive of the solenoid (SD2).
B. Bypass gate control

The bypass gate is provided on the paper path to the stacker section. Even while in the staple operation, the
bypass gate conveys the next page to reduce a loss of time for a high productivity.
The drive of the bypass gate [1] is made by the bypass solenoid (SD5) [2]. The operation of SD5 is limited only to
the small-size paper (A4, B5 and 81/2 x 11) except for thick paper in the staple mode.
For the 1st page on and after the 2nd copy, paper is sent to the regular route [3]. SD5 operates only on the 2nd
page to send paper to the bypass route [4]. The 1st and 2nd pages are put upon one another to be conveyed to
the stacker simultaneously. On and after the 3rd page, SD5 is released and paper is sent on the regular route a
sheet of paper at a time.
[1] [4]
[1]
[3] [3]
[2] [2]
fs503to2003c
[1] Bypass gate [3] Regular route

[2] Bypass solenoid (SD5) [4] Bypass route
(1) For the 1st copy

The bypass solenoid (SD5) does not operate when the paper of the 1st copy is passing through it.
9
(2) For the 2nd and subsequent copies

A specified period of time after the FNS entrance sensor (PS4) detects the trailing edge of the 1st page of the
2nd copy, the bypass solenoid (SD5) turns ON to draw the 2nd page of the 2nd copy into the bypass route. A
FS-521
specified period of time after the PS4 detected the trailing edge of the 2nd page of the 2nd copy, the bypass
solenoid turns OFF.
SD5 does not turn on when the 3rd and subsequent pages are being conveyed.
[1] [2] [3]
FNS entrance sensor (PS4)
Conveyance motor(M1)
Bypass solenoid (SD5)
[4] fs503to2030c
[1] 1st copy [3] 3rd copy

[2] 2nd copy [4] Drawing of the 2nd page of the 2nd copy into
the bypass
10
4.3.2 Bypass roller /Lw pressure release control

The bypass roller is provided after the bypass gate of the paper conveyance path to the stacker section. The nip
status of the bypass roller has 3 steps, which are normal pressure, pressure release and high pressure.
FS-521
The status for normal 1 sheet conveyance is normal pressure.
The pressure of the bypass roller is released for the small-size paper (A5, B8 and 81/2 x 11) except thick paper in
the staple mode, because 1st and 2nd paper after the 2nd copy are overlapped on the bypass gate. Paper
other than the small-size paper is not overlapped even in the staple mode, therefore the pressure of the bypass
roller is not released in this case.
The status for thick paper is high pressure, because the paper conveyance in bypass gate section has a large
curvature.
The 3 steps of bypass roller /LW[8] nip status is driven by the bypass roller release motor (M12) [5]. The bypass
roller release home sensor (PS16) [6] detects the home position, and the pressure is normal pressure status by
the spring [9].
When M12 rotates in the reverse direction [2], the pressure release lever [4] is driven through the cam [7] and the
pressure of the bypass roller /Lw is released by leverage from the center of the shaft [1].
When M12 rotates in the forward direction [3], the elastically-deformed pressure spring plate [10] presses the
shaft of the bypass roller /Lw to be high pressed.
[10] [1]
[2]
[9]
[3]
[8]
[4]
[7]
[6] [5]
a0gyt2c021ca
[1] Shaft [6] Bypass roller release home sensor (PS13)

[2] Reverse rotation [7] Cam
[3] Forward rotation [8] Bypass roller /Lw
[4] Pressure release lever [9] Spring
[5] Bypass roller release motor (M12) [10] Pressure spring plate
11
A. Small-size paper in the staple mode

The bypass roller release motor (M12) does not work while passing the 1st copy.
FS-521
(2) For the 2nd and subsequent copies

After a specified period of time when the paper exit sensor of previous devise (RU paper exit sensor (PS3) if pre-
vious devise is RU) detects the leading edge of 1st page of 2nd copy, the bypass roller release motor (M12)
turns reverse rotation ON to move the bypass roller /Lw to the pressure release point, and then turns OFF. After
a specified period of time when the paper exit sensor of previous devise detects the leading edge of 2nd page of
2nd copy, M12 turns forward rotation ON at the timing the 2nd page of 2nd copy drawn into the bypass route
passes through on the bypass roller /Up side, and then M12 turns OFF with turning ON the bypass roller release
home sensor (PS13).
SD12 does not turn on when the 3rd and subsequent pages are being conveyed.
[1] [2] [5]
Conveyance motor(M1)
Paper exit sensor of previous

device (PS3 in the case of RU)
Bypass roller Forward
release motor rotation
(M12) Reverse
rotation
Bypass roller release home sen-
sor (PS13)
[3] [4] a0gyt2c003ca
[1] 1st copy [4] Pressure (Returning to the home position)

[2] 2nd copy [5] 3rd copy
[3] Pressure release
B. Thick paper control

When the paper exit sensor of previous device detects the leading edge of paper, the bypass roller release
motor (M12) turns forward rotation ON to move the bypass roller /Lw to the high pressure position, and then
turns OFF.
When the print operation completes, M12 turns reverse rotation ON, and then M12 turns OFF with turning ON
the bypass roller release home sensor (PS13).
12
Theory of Operation Ver.2.0 Jul. 2009 5. SUB TRAY SECTION
5. SUB TRAY SECTION

5.1 Configuration
FS-521
Sub tray Sub tray paper full sensor
Subtray exit roller
(PS30)
fs503to2004c
5.2 Drive
[1] [2]
fs503to2005c
[1] Sub tray exit motor (M6) [2] Subtray exit roller
13
5.3 Operation
A. Subtray paper full detection control
FS-521
When paper that has been exited into the sub tray gets to the specified thickness, the sub tray paper full sensor
(PS30) turns ON to send the "sub tray paper full" information to the main body. Then, the main body displays the
message on its operation panel.
[1] [2]
fs503to2006c
[1] Paper exited [2] Sub tray paper full sensor (PS30)
B. Conveyance speed switching control

Paper conveyed by the conveyance motor (M1) is decelerated for each sheet of paper to be exited into the sub
tray, thus preventing paper from having an uneven edge.
Sub tray paper exit sensor

(PS1)
Sub tray exit Hi-speed

motor (M6)
Deceleration
[1] fs503to2031c
[1] Deceleration of the sub tray paper exit

motor (M6)
14
6. STACKER SECTION
6.1 Configuration
FS-521
Alignment
plate
Stack assist plate
Stacker
empty sen-
sor (PS20)
Stacker Paddle
entrance belt
Swing roller
Rear stopper
Paper exit arm Flat-stapling
stopper
a0gyt2c004ca
15
6.2 Drive
6.2.1 Stacker entrance roller/paddle drive
FS-521
[8]
[7]
[6] [1]
[5]
[4] [2]
[3]
[8]
[9]
[7] a0gyt2c023ca
[1] Stacker entrance roller release motor (M16) [6] Stacker entrance belt
[2] Stacker entrance roller release home sensor (PS23) [7] Stacker entrance roller/Lw
[3] Swing roller [8] Stacker entrance roller /Up
[4] Paddle [9] Stacker entrance motor (M13)
[5] Paddle motor (M2)
1 16
6.2.2 Stack assist plate/rear stopper drive
FS-521
[1]
[2]
[3]
[6]
[4]
[5]
fs503to2009c
[1] Stack assist home sensor (PS32) [4] Rear stopper home sensor (PS35)
[2] Stack assist plate [5] Rear stopper motor (M26)
[3] Rear stopper [6] Stack assist guide motor (M24)
17
6.2.3 Intermediate roller/paper exit arm drive

FS-521
[10]
[1]
[8] [9]
[9]
[1]
[9] [2]
[3]
[4]
[8]
[7] [5]
[6]
a0gyt2c006ca
[1] Intermediate roller release solenoid (SD7) [6] Paper exit arm motor (M23)
[2] Intermediate roller open close motor (M25) [7] Paper exit arm home sensor (PS9)
[3] Eccentric cam [8] Intermediate roller /Lw
[4] Intermediate roller home sensor (PS33) [9] Intermediate roller /Up
[5] Paper exit arm [10] Coupling
18
FS-521
[6] [1]
[2]
[5]
[3]
[4]
fs503to2011c
[1] Alignment plate /Rr [4] Alignment motor /Fr (M22)

[2] Alignment motor /Rr (M5) [5] Alignment home sensor /Fr (PS31)
[3] Alignment home sensor /Rr (PS8) [6] Alignment plate /Fr
19
6.3 Operation
6.3.1 Stacker conveyance speed control
FS-521
Paper conveyed by the conveyance motor (M1) is sent to the stacker when the stacker entrance motor (M13) is
decelerated a specified period of time after the stacker entrance sensor (PS5) turns ON and before it runs
through the stacker entrance roller.
6.3.2 Stacker entrance roller control

Conduct the stacker entrance roller control to the paper conveyed with being overlapped.
A. 2 sheets conveyance
For 2 sheets of paper, the cam [4] of the stacker entrance roller release motor (M16) [3] release the pressure of the
stacker entrance roller /Up [1]. At this time, the stacker entrance roller /Up [1] drives at 1040mm/s and the stacker
entrance roller /Lw [6] drives at 1000mm/s. Therefore, the upper paper [8] is sent before the lower paper [7].
The stacker entrance roller release home sensor (PS23) [5] detects the home position when the stacker
entrance roller /Up [1] release the pressure.
[1] [2]
[8]
[7]
[3]
[6]
[5]
[4]
a0gyt2c024ca
[1] Stacker entrance roller /Up [5] Stacker entrance roller release home sensor (PS23)
[2] Holding material [6] Stacker entrance roller /Lw
[3] Stacker entrance roller release motor (M16) [7] Lower paper
[4] Cam [8] Upper paper
B. 1 sheet conveyance
When paper is 1 sheet, the stacker entrance roller /Up [6] is still pressed. At this time, since the stacker entrance
roller /Lw [6] has the torque limiter, it is driven with the stacker entrance roller /Up [6].
1 20
6.3.3 Intermediate roller control

The roller drive of the intermediate roller /Lw is transmitted from the main tray paper exit motor (M7) by the belt
and the coupling, and the transmission of the conveyance power to paper is made by the pressure/release of
FS-521
the intermediate roller /Up.
A. Non-staple control
While in the non-staple mode, when the start signal is turned ON, the intermediate roller /Up [1] is driven up to
the nip standby position by the cam [2] of the intermediate roller open close motor (M25).
The intermediate roller home sensor (PS33) [3] detects the home position of the intermediate roller /Up open/
close operation.
[1]
[2]
[3]
fs503to2039c
[1] Intermediate roller /Up [3] Intermediate roller home sensor (PS33)
[2] Cam of the intermediate roller open close
motor (M25)
21
While in the print operation, the intermediate roller release solenoid (SD7) [3] makes the pressure/release of the
intermediate roller /Up [1] onto the intermediate roller /Lw [2].
When paper is being conveyed to the stacker, SD7 turns ON to release the nip, and paper that passes through
FS-521
the opening between the intermediate roller /Up [1] and the intermediate roller /Lw [2] is conveyed to the stacker.
When paper is being exited, SD7 turns OFF and the intermediate roller /Up [1] is pressed against the intermedi-
ate roller /Lw [2] by the pressure of the spring. The paper is nipped before being exited.
[1]
[3]
[2]
[4]
fs503to2012c
[1] Intermediate roller /Up [3] Intermediate roller release solenoid (SD7)
[2] Intermediate roller /Lw [4] Paper
(1) Straight mode

The intermediate roller release solenoid (SD7) turns ON to release pressure with the start signal ON, and stands
by for conveying paper to the stacker.
After the alignment operation completes, SD7 turns OFF, and the intermediate roller /Up and /Lw press paper
and eject it. It conducts the same operation to each paper.
[2]
Intermediate roller open close motor (M25)
Alignment motors /Fr (M22), /Rr (M5)
Intermediate roller release solenoid (SD7)
[1] [3] [4] [5] [5] [5]

fs503to2032c
[1] Start signal ON [4] Alignment operation

[2] Movement of the intermediate roller /Up to [5] Paper nip by the intermediate rollers /Up
the nip standby position and /Lw
[3] Nip release of the intermediate roller /Up
22
(2) Shift mode

1st and 2nd pages of 2nd and subsequent copies are overlapped on the stacker for securing time of moving the
paper exit alignment plate to the shift position in the shift mode of small-size (A4, B5, 81/2 x 11) which paper
FS-521
intervals are conveyed within the specified period of time. SD7 does not turn OFF after 1st page of 2nd and sub-
sequent copies in this case.
When pages are not overlapped on the stacker, it conducts the same operation as straight mode.
23
B. Staple control
While in the staple mode operation, through the initial operation made when the start signal turns ON, the inter-
mediate roller /Up [1] is moved to the evacuation position by the eccentric cam [2] driven by the intermediate
FS-521
roller open close motor (M25).
[1]
[2]
[3]
fs503to2013c
[1] Intermediate roller /Up [3] Intermediate roller home sensor (PS33)
[2] Eccentric cam
24
6.3.4 Stack assist control

The stack assist plate is a paper pressure plate that is used to increase the speed to put paper in the stacker for
an increased productivity.
FS-521
The stack assist guide motor (M24) drives the stack assist plate [1]. When being conveyed to the stacker sec-
tion, each sheet of paper is pressed at the position near the rear end of the paper [2] to be stacked at a speed
faster than a free fall.
The stack assist plate rotates by 65° from the home position in the staple mode and by 80° in the shift and
straight mode.
The stack assist home sensor (PS32) [3] detects the home position.
[2]
[3]
[1]
fs503to2014c
[1] Stack assist plate [3] Stack assist home sensor (PS32)
[2] Paper
Stack assist guide Forward

motor (M24)
Reverse
[1] [2] [3] fs503to2033c
[1] Start signal ON [3] Movement of the stack assist plate to the
[2] Paper pressure by the stack assist plate evacuation position
6.3.5 Rear stopper control

The rear stopper is a paper rear stopper when paper is exited in the non-staple (straight/sort) mode. It shortens
the conveyance distance to the main tray for an improved productivity.
The rear stopper motor (M26) drives and releases the rear stopper in the staple mode.
The set state in the non-staple mode (the position at which the rear stopper stops paper) is the home position of
the rear stopper, and the rear stopper home sensor (PS35) detects it.
25

A. Horizontal alignment
The horizontal alignment is made by the 2 alignment plates, that is, alignment plate /Fr and alignment plate /Rr.
FS-521
Each of the alignment motor /Fr (M22) and the alignment motor /Rr (M5) drive these 2 alignment plates indepen-
dently.
The alignment home sensor /Fr (PS31) detects the home position of the alignment plate /Fr, and the alignment
home sensor /Rr (PS8) detects the home position of the alignment plate /Rr .
(1) Straight mode

In the straight mode, each sheet of paper sent to the stacker is aligned by the alignment plate /Fr and the align-
ment plate /Rr before being exited to the straight position.
26
(2) Shift mode

In the shift mode, each time a sheet of paper is sent to the stacker, the alignment plate /Fr [1] and the alignment
plate /Rr [2] shift to the rear to convey the paper [3] to the shift position before exiting it.
FS-521
However, the alignment plates make only alignment operation and do not shift for the 1st page of 2nd and sub-
sequent copies when pages are overlapped in the shift mode. The paper exit alignment plate shifts after 2nd
page is conveyed to the stacker.
[3]
[2]
[1]
fs503to2015c
[1] Alignment plate /Fr [3] Paper

[2] Alignment plate /Rr
Stacker entrance sensor (PS5)
Alignment motor /Fr (M22)
Alignment motor /Rr (M5)
[1] [2] [3] [4] [5] [6]

fs503to2034c
[1] Start signal ON [4] Alignment operation for each sheet of paper
[2] Home position search [5] Move the paper to the shift position in the rear
[3] Move to the size position [6] Move the paper to the shift position in the front
27
(3) Staple mode

In the staple mode, the alignment operation is made by the alignment plates /Fr and /Rr for each sheet of paper
that has been sent to the stacker. After the last sheet of paper of the copy is conveyed to the stacker section,
FS-521
the alignment operation for the staple is made for stapling.
B. Vertical alignment
In the staple mode, for the vertical alignment of paper, the paper is pushed against the flat-stapling stopper by
the paddle driven by the paddle motor (M2).
The vertical alignment is assisted by the swing roller that is interlocked with the paddle by M2.
[2]
Paddle motor (M2)
Stapler motors /Fr (M31), /Rr (M30)

[1] [3] fs503to2035c
[1] Start button ON [3] Stapling

[2] Stapling of the 1st sheet of paper
6.3.7 Stacker paper exit

In the non-staple mode, the nip of the intermediate rollers /Up and /Lw eject the paper.
B. Staple control
In the staple mode, the paper exit arm that is driven by the paper exit arm motor (M23) eject the paper. The
paper exit arm home sensor (PS9) detects the home position of the paper exit arm.
[2]
Stapler motors /Fr (M31), /Rr (M30)
Paper exit arm motor (M23)
Paper exit arm home sensor (PS9)
[1] [3] [4] fs503to2036c
[1] Start signal ON [3] Movement to the paper exit arm standby position
[2] Stapling [4] Paper exit operation of paper bundle
28
Theory of Operation Ver.2.0 Jul. 2009 7. STAPLER SECTION
7. STAPLER SECTION
7.1 Configuration
FS-521
Stapler /Fr Stapler /Rr
Staple
scraps box fs503to2016c
29
7. STAPLER SECTION Theory of Operation Ver.2.0 Jul. 2009
7.2 Drive
7.2.1 Stapler movement/rotation
FS-521
[7] [8] [1]
[2]
[6]
[3]
[5] [4]
fs503to2017c
[1] Cam [5] Stapler /Fr

[2] Stapler rotation home sensor (PS14) [6] Stapler movement motor (M11)
[3] Stapler rotation motor (M4) [7] Stapler movement home sensor (PS11)
[4] Stapler /Rr [8] Belt
30
7.2.2 Stapler
FS-521
[1]
[5]
[2]
[4]
[3]
fs503to2018c
[1] Staple cut/bending arm [4] Stapling arm

[2] Stapler motors /Rr (M30), /Fr (M31) [5] Pressure plate
[3] Eccentric cam
31
7.3 Operation
7.3.1 Stapler movement control
FS-521
For stapler movements, there are 2 types, that is, the horizontal movement of the stapler intervals and the rota-
tion of the stapler /Rr. Movement is made according to the staple mode.
The stapler movement motor (M11) makes the horizontal movement of the stapler. The stapler /Rr and the sta-
pler /Fr are fixed on the upper side and the lower side of a belt that forms a loop and moved respectively in the
opposite direction by the motor M11.
The stapler movement home sensor (PS11) detects the home position of the horizontal movement.
The stapler rotation motor (M4) makes the 45° rotational movement of the stapler /Rr for the one-corner stapling
at rear.
The stapler rotation home sensor (PS14) detects the home position of the rotational movement.
A. 1 staple
(1) 1 staple/at front
When the start signal is turned ON, the stapler movement motor (M11) also turns ON to move the stapler to the
position according to the paper size.
(2) Size movement in 1 staple/one-corner stapling at rear

position according to the paper size. After a specified period of time, the stapler rotation motor (M4) also turns
ON to rotate the stapler /Rr and move it diagonally.
When a staple empty condition of the stapler /Rr is detected at the one-corner stapling at rear, M4 is driven to
replace the cartridge and the stapler is returned to its vertical position.
B. 2 staples
position according to the paper size.
32
7.3.2 Staple control

The staple control is made by the stapler motors /Rr (M30) and /Fr (M31) to drive the eccentric cam.
The inside [2] of the eccentric cam [1] has the cam groove [4] of the pressure arm [3] and the pin [6] of the staple
FS-521
cut/clinch arm [5]. The outside [7] of the eccentric cam also has the cam groove [9] of the stapling arm [8].
Each time when the eccentric cam makes a 1/4 turn, each of the following operations is made: 1. paper pres-
sure, 2. stapling, 3. staple cut/clinch, and 4. return to the home position. A series of the operations completes in
a full turn.
The stapler home sensors /Rr (PS40), /Fr (PS41) detects the home position.
[5] [1]
[9] [4]
[7] [2]
[6]
[8] [3] fs503to2019c
[1] Eccentric cam [6] Pin (for staple cut/clinch)

[2] Inside [7] Outside
[3] Pressure arm [8] Stapling arm
[4] Cam groove (for pressure arm) [9] Cam groove (for stapling arm)
[5] Staple cut/clinch arm
33
A. Paper pressure
When the eccentric cam rotates 90° from the home position, the cam groove [1] on the inside drives the pin [3]
provided on the pressure arm [2] in the arrow-marked direction. The pressure arm [2] drives the pressure plate
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[4] and presses the clinch side hard against the staple side [5] to press the paper [6].
At the same time, the pin [8] provided in the groove [7] on the outside of the cam drives the stapling arm [9]. The
pin [10] at the tip of the stapling arm moves along the groove [12] of the pressure claw [11], and drives the pres-
sure claw [11] with the lever to press the paper.
The following figure shows an inside cam on the left and an outside cam on the right.
[6] [6]
[4]
[5]
[3] [11]
[12]
[1]
[10]
[7]
[2]
[9]
[8]
fs503to2020c
[1] Cam groove [7] Cam groove (for stapling arm)

[2] Pressure arm [8] Pin
[3] Pin [9] Stapling arm
[4] Pressure plate [10] Pin
[5] Staple side [11] Pressure claw
[6] Paper [12] Groove
34
B. Staple control
When the eccentric cam rotates from 90° to 180° the cam groove [1] on the outside drives the pin [3] provided
on the stapling arm [2] in the arrow-marked direction. The pin at the tip [4] of the stapling arm pushes up the sta-
FS-521
pling blade [5] to push out the staple [6], punch out the paper [7] and staple it.
At the same time, to make preparation for the next stapling, the staple is bent at 90° by the staple bending blade
[8].
[7]
[6]
[5]
[5]
[4]
[1]
[2]
[8]
[3]
fs503to2021c
[1] Cam groove [5] Stapling blade

[2] Stapling arm [6] Staple
[3] Pin [7] Paper
[4] Pin at the tip [8] Staple bending blade
35
C. Staple cut/clinch control

When the eccentric cam rotates from 180° to 270° the pin [1] provided on the inside drives the staple cut/clinch
arm [2] in the arrow-marked direction.
FS-521
At the start of rotation, the lever operation of the staple cut/clinch arm [2] rotates the coupling metal fitting [3] to
pull the pin [4] in the arrow-marked direction and the staple [7] inserted into the round hole [6] of the staple cut
blade [5] is cut. Cut staple scraps drop into the duct to be collected in the staple scraps box.
With the further rotation of the eccentric cam, the tip of the presser metal fitting [8] that is interlocked with the
staple cut/clinch arm [2] pushes down the clinch metal fitting [9] to clinch the staple [7] that has been cut. When
the eccentric cam rotates up to 270° the clinch operation is completed.
After completion of clinching, the eccentric cam rotates to the home position to complete a series of operations.
[8]
[8]
[9] [3]
[9]
[7]
[5] [4]
[7]
[6]
[1]
[5]
[2]
fs503to2022c
[1] Pin [6] Round hole

[2] Staple cut/clinch arm [7] Staple
[3] Coupling metal fitting [8] Presser metal fitting
[4] Pin [9] Clincher plate
[5] Staple cut blade
36
D. Cartridge detection
The cartridge set sensors /Rr (PS42), /Fr (PS43) detect the presence of a cartridge or the incorrect setting of a
cartridge. When there is no cartridge or the cartridge is set incorrectly, an error message is displayed on the
FS-521
operation section.
E. Staple detection
When the staples run short, the staple empty sensors /Rr (PS44), /Fr (PS45) detect this condition and display an
error message on the operation section.
F. Staple tip detection

The staple ready sensors /Rr (PS46), /Fr (PS47) detect the tip of the staple.
While in the stapling operation, the staple ready sensors determine that the staples have been clogged when the
PS46 and PS47 do not turn ON within a specified period of time after the staple home sensors /Rr (PS 40), /Fr
(PS41) turn OFF, and rotate the stapler motors /Rr (M30), /Fr (M31) in the reverse direction up to the home posi-
tion.
G. Staple scraps box detection

The stapler scraps box set sensor (PS34) detects the presence of a staple scraps box or the incorrect setting of
a box. When there is no staple scraps box or it is set incorrectly, an error message is displayed on the operation
section.
37

8.1 Configuration
FS-521
Paper
exit opening unit
Main tray
paper exit roller
Thin paper
holding
material
Paper exit
alignment plate
Paper press
arm
Main tray
Lift wire
a0gyt2c025ca
1 38
8.2 Drive
8.2.1 Tray up/down drive
FS-521
[1]
[10] [11]
[9]
[8]
[7]
[6]
[5] [2]
[4]
[3]
a0gyt2c008ca
[1] Lift pulley /Up [7] Tray quarter position sensor (PS17)
[2] Tray up down motor (M3) [8] Counter reset sensor (PS15)
[3] Lift pulley /Lw [9] Paper empty sensor (PS39)/Paper empty
[4] Lift wire LED(LED2)
[5] Tray lower limit sensor (PS3) [10] Main tray
[6] Tray middle position sensor (PS6) [11] Tray upper limit sensor (PS16)/Tray upper
limit LED(LED1)
39
8.2.2 Main tray paper exit drive

FS-521
[5]
[1]
[4]
[3] [2]
a0gyt2c009ca
[1] Main tray exit motor (M7) [4] Main tray paper exit roller
[2] Coupling [5] Paper exit opening solenoid (SD9)
[3] Paper press arm
40
8.2.3 Paper exit opening drive
FS-521
[6]
[1]
[5]
[2]
[4]
[3]
fs503to2026c
[1] Cam [4] Main tray paper exit roller

[2] Paper exit opening motor (M8) [5] Paper exit opening unit
[3] Paper exit opening sensor (PS12) [6] Drive bar
41
8.2.4 Paper exit alignment plate drive

FS-521
[8]
[1]
[7] [2]
[6]
[5] [4] [3]
a0gyt2c010ca
[1] Paper exit alignment plate/Rr [5] Paper exit alignment motor /Fr (M15)
[2] Paper exit alignment plate home sensor /Rr [6] Front side direction
(PS19) [7] Paper exit alignment plate home sensor /Fr
[3] Paper exit alignment motor /Rr (M14) (PS18)
[4] Top side view [8] Paper exit alignment plate /Fr
42
8.2.5 Paper exit alignment plate retraction drive
FS-521
[1]
[3]
[2]
a0gyt2c011ca
[1] Paper exit alignment plate retraction home [3] Paper exit alignment plate
sensor (PS24)
[2] Paper exit alignment plate retraction motor
(M18)
43
8.3 Operation
8.3.1 Paper exit opening control
FS-521
When paper is too long and protruding, the paper exit opening is opened and closed for alignment.
There are 3 opening positions available according to the mode and the paper length.
For paper shorter than the following length, the paper exit opening is not opened in the non-staple mode or the
staple mode.
Mode Angle of the opening Paper length in the sub scan direction
Non-staple Approx. 27° 239mm or more
Staple Approx. 44° 400mm or more
Staple Approx. 55° Between 219mm and 400mm
For the open/close of the paper exit opening, the paper exit motor (M8) rotates and the deformed cam [1] lifts up
the entire paper exit opening unit [2] to open the paper exit opening. The paper exit opening home sensor
(PS12) [3] detects the open/close of the paper exit opening.
[7]
[6]
[6] [7]
[4]
[5] [5]
[1]
[4]
[2]
[3]
fs503to2027c
[1] Deformed cam [5] Position at 27°

[2] Paper exit opening unit [6] Position at 44°
[3] Paper exit opening sensor (PS12) [7] Position at 55°
[4] Position at 0°
When the paper length is less than 239mm, paper exit unit is not opened.
In the case that the paper length is 239mm or longer, paper exit unit is opened by 27° after the home position
search of M8 by the start signal ON. While in printing, after the alignment operation, the paper exit opening is
closed temporary to nip the paper to be exited.
44
B. Staple control
In the case that the paper length in the sub scan direction is less than 219mm, the paper exit opening closes
with the home position search of the paper exit opening motor (M8) by the start signal ON and then the paper is
FS-521
nipped and exited after the staple operation.
In the case that the paper length is 219mm or longer, paper exit unit is opened by 44° (paper length: 400mm or
more)/55° (paper length: 219mm to 399mm) after the home position search of M8 by the start signal ON. After
the staple operation, it closes the paper exit opening temporary to nip the paper and then exits paper.
8.3.2 Paper press arm control

Paper press arm control avoids exited pages misalignment.
Paper exit solenoid (SD9) drives paper press arm.
Subsequent pages cause a misalignment of pages already exited, so the paper press arm presses exited pages
to avoid that misalignment.
[3]
[2]
[1]
a0gyt2c012ca
[1] Paper [3] Paper exit opening solenoid (SD9)

[2] Paper press arm
45
A. Straight/Shift mode
After a specified period of time when the stacker empty sensor (PS20) detects the trailing edge of paper, the
paper exit opening solenoid (SD9) turns ON to press exited paper and stands by for subsequent exited paper.
FS-521
After a specified period of time when the stacker empty sensor (PS20) detects the trailing edge of the subse-
quent paper, SD9 turns OFF and paper press arm releases, right before the trailing edge of paper passes
through the paper exit roller, for the preparation to press paper which is passing through. It repeats the operation
for each paper exit.
[2]
Stacker empty sensor (PS20)
Paper exit opening sole-

noid (SD9)
[1] [3] [4]

a0gyt2c013ca
[1] Pressure for 1st paper [3] Pressure release

[2] 2nd paper exit [4] Pressure for 2nd paper
B. Subset staple mode

The paper press arm presses paper when the inserted paper exits, because the bundle of stapled sheets mis-
aligns paper which is inserted between the bundle of stapled sheets in the subset staple mode which the num-
ber of staple sheets is 10 or more.
After a specified period of time when the main tray paper exit sensor (PS10) detects the trailing edge of inserted
paper, the paper exit opening solenoid (SD9) turns ON and inserted paper is pressed. After a specified period of
time when PS10 detects the trailing edge of the bundle of stapled sheets, SD9 turns OFF and stands by for exit-
ing inserted paper.
[1] [3]
Main tray paper exit sensor (PS10)

Paper exit opening sole-
noid (SD9)
[2] [4] [5]

a0gyt2c014ca
[1] Trailing edge detection of insert paper [4] Pressure release

[2] Pressure [5] Insert paper
[3] Bundle of staple paper
46
8.3.3 Main tray up/down control

The driving force of the tray up down motor (M3) rotates the lift pulley by the belt and the gear to wind up the lift
wire. The main tray goes up or down according to the direction in which the up/down wire is wound up. When
FS-521
the lift pulley /Lw rotates clockwise as seen from the front, the main tray goes up and when it rotates counter-
clockwise, the tray goes down.
The tray upper limit LED (LED1) [1] and the tray upper limit sensor (PS16) [5] detect the upper surface of paper
(the main tray upper surface when no paper is exited) [3].
The paper empty LED (LED2) [4] and the paper empty sensor (PS39) [2] detect extraction of paper in continuous
operation.
[5]
[4] [1]
[2]
[3]
a0gyt2c015ca
[1] Tray upper limit LED (LED1) [4] Paper empty LED (LED2)
[2] Paper empty sensor (PS39) [5] Tray upper limit sensor (PS16)
[3] Upper surface of paper (Main tray upper surface
when no paper is exited)
With the start signal ON [1] from the main body, the tray up down motor (M3) turns ON to move down the main
tray [2], then the paper empty sensor (PS39) turns OFF, and then M3 turns reverse rotation ON to move up the
main tray. The tray upper limit sensor (PS16) turns ON to rerotate M3 in forward direction, and moves down the
main tray to the turning OFF position of PS16 from the paper exit opening.This operation maintains the distance
between the upper surface of the paper exited in the main tray (the surface of the main tray when no paper
exited) and the paper exit opening at a fixed distance to prevent the paper exited from having an uneven edge.
During the print operation, the exited paper turns PS16 ON, and M3 turns ON to move down the main tray to
the specified position.
47
[1]
FS-521
Tray upper limit sensor (PS16)
Tray up down motor Up

(M3)
Down
[2] [3] [4] [5]

a0gyt2c016ca
[1] Start signal ON [4] Main tray moving down to the specified position
[2] Main tray moving down [5] Main tray moving down to the specified position
[3] Main tray moving up
B. Staple control
(1) When the number of staple sheets is 20 or less.
It conducts same control as non-staple control.
(2) When the number of staple sheet is more than 20.

The stacker empty sensor (PS20) detects the trailing edge of paper, then the tray up down motor (M3) turns ON
to move down the main tray to the position according to the number of staple sheets, and then the motor turns
OFF.
When the paper empty sensor (PS39) turns OFF unexpectedly with the error caused by the staple sheets, M3
turns ON to move up the main tray to the position which the tray upper limit sensor (PS16) turns ON, then the
rotation is changed over to move down the main tray to the position which PS16 turns OFF, and then M3 turns
OFF.
C. Main tray paper detection control

The tray quarter position sensor (PS17), the tray middle position sensor (PS6), and the tray lower limit sensor
(PS3) detect the maximum number of loadable sheets on the main tray.
The stopping position of paper full detection varies according to the size of paper for each mode.
PS17 position : About 750 sheets (in the case of 80g/m2)
After it stops by detecting paper full, the paper full detection status is released when the tray up down motor
(M3) turns ON to turn the counter reset sensor (PS15) ON.
(1) Straight/Shift mode

It stops printing when each sensors turn ON and displays the message on the operation panel.
Z-Folding / center folding (weight:less than 130g/m2) stops at 50 main tray paper exit (switchable with DipSW)
by the software counter.
48
Weight (g/m2) Large-size paper Small-size Minimum-size
FS-521
(longer side: 320mm or more) (longer side: 250mm to 319mm) (longer side: 249mm or less)
64 to 300 PS6 PS3 (straight mode) PS17
PS6 (shift mode)
(2) Staple mode
Staple sheet Large-size Small-size (longer side: Minimum size (longer

(longer side: 320mm or more) 250mm to 319mm) side: 249mm or less)
2 to 5 PS17
6 to 9 PS6 PS6 PS17
10 to 100 PS3 PS6
D. Detection of paper removal in the continuous print mode

It turns OFF the paper empty sensor (PS39) and detects the removal if the exited paper is removed while in con-
tinuous printing.
Once it turns OFF PS39 while in continuous printing, it turns ON the tray up down motor (M3) and raises the
main tray until the tray upper limit sensor (PS16) turns ON, and then by switching the rotation it lowers the main
tray until PS16 turns OFF to turn OFF M3.
Tray upper limit sensor (PS16)
Tray up down Up
motor (M3)
Down
[1] [2]
a0gyt2c017ca
[1] Lift of the main tray by detecting the paper [2] Main tray moving down to the specified
removal position
E. Temporary stop button

Exiting paper to the main tray stops temporary by pressing the temporary stop button for more than 1second
while in the straight mode or the shift mode.
Press start key of the main body to restart.
49
8.3.4 Paper exit alignment control

Paper exit alignment motor /Fr (M15) [4] operates the alignment drive of the paper exit alignment plate /Fr [2]
and the paper exit alignment plate home sensor /Fr (PS18) [3] detects the home position. As well, the paper exit
FS-521
alignment motor /Rr (M14) [5] operates the alignment drive of the paper exit alignment plate /Rr [1] and the
paper exit alignment plate home sensor /Rr (PS19) [9] detects the home position.
When the paper exit alignment plate /Fr, /Rr moves to the paper size or returns to the home position, paper exit
alignment plate retraction motor (M18) projects the rack [7] and pushes up the bottom of the paper exit align-
ment plate [6] to conduct the retraction of the paper exit alignment plate. Once the rack is pulled back, the
paper exit alignment plate falls down to the alignment position with its weight. Paper exit alignment plate retrac-
tion home sensor (PS24) detects the home position in the retraction.
[9]
[8]
[1]
[2]
[3]
[7] [6] [5] [4]

a0gyt2c018ca
[1] Paper exit alignment plate/Rr [6] Bottom of the paper exit alignment plate
[2] Paper exit alignment plate /Fr [7] Rack
[3] Paper exit alignment plate home sensor /Fr (PS18) [8] Paper exit alignment plate retraction home
[4] Paper exit alignment motor /Fr (M15) sensor (PS24)
[5] Paper exit alignment motor /Rr (M14) [9] Paper exit alignment plate home sensor /Rr (PS19)
A. Straight mode
In the straight mode, it conducts the alignment operation at the center of the main tray if the paper is over
182mm in the main scan direction.
It turns ON the paper exit alignment motor /Fr (M15) and /Rr (M14) with the start signal ON, and the paper exit
alignment plate /Fr and /Rr move to the paper size standby position which is at the center of the main tray with
remaining in the retraction status (lift up), and then it turns OFF.
Once the movement to the paper size stand by position is completed, it turns ON the paper exit alignment plate
retraction motor (M18) and pulls down the paper exit alignment plate /Fr and /Rr.
After a specified period of time when the stacker empty sensor (PS20) detects the trailing paper edge, it con-
ducts the alignment operation on the paper exit alignment plate /Fr and /Rr by turning ON M15 and M14 for
each paper exit.
After a specified period of time when the last alignment operation is finished, it turns ON M18 to evacuate (lift up)
the paper exit alignment plate /Fr and /Rr and then turns OFF M18 by turning ON the paper exit alignment home
sensor (PS24).
50
At the same time, it turns ON M15 and M14 by turning ON PS24, moves the paper exit alignment plate /Fr and
/Rr to the home position, and turns OFF M15 and M14 by turning ON the paper exit alignment plate home sen-
sor /Fr (PS18) and /Rr (PS19).
FS-521
[2] [4] [7]
Paper exit align- Open

ment motor /Fr
(M15) Close
Paper exit alignment plate
home sensor /Fr (PS18)
ment motor /Rr
(M14) Close
home sensor /Rr (PS19)
Paper exit align- Down
ment plate retrac-
tion motor (M18) Up
retraction home sensor (PS24)
[1] [3] [5] [6]

a0gyt2c019ca
[1] Start signal ON [5] Alignment operation

[2] Move to paper size stand by position [6] Paper exit alignment plate retraction (up)
[3] Paper exit alignment plate retraction release [7] Returning to the home position of paper exit
(down) alignment plate
[4] Trailing edge of paper detected
B. Shift mode
In the shift mode, it conducts the alignment operation at the position 10mm away in front and rear from the cen-
ter of the main tray (Shift amount: 20mm) if the paper is over 210mm in the main scan direction.
If the paper is 210mm or less in the main scan direction, it does not conduct the paper exit alignment but con-
ducts the shift operation with the alignment plate of the stacker.
It conducts the paper exit alignment operation with one paper exit alignment plate while in fixing the other plate,
but the operation differs in small-size and large-size according to the length in the sub scan direction.
When shifting to the front side, in a case of small-size, it conducts the alignment operation with the paper exit
alignment plate /Fr while in fixing the paper exit alignment plate /Rr to the position of the paper edge which
exited from the stacker. When shifting to the back side, it conducts the alignment with the paper exit alignment
plate /Rr while in fixing the paper exit alignment plate /Fr.
When shifting to the front side, in a case of large-size, it conducts the alignment operation by fixing the paper
exit alignment plate /Fr while shifting the paper exit alignment plate /Rr to the front along with the exiting paper
from the stacker. When shifting to the back side as well, it conducts the alignment operation with the paper exit
alignment plate /Fr while in fixing the paper exit alignment plate /Rr.
51
(1) Small-size (sub-scanning direction length: shorter than 297mm)

It turns ON the paper exit alignment motors /Fr (M15) and /Rr (M14) with the start signal ON, and the paper exit
alignment plates /Fr and /Rr move to the paper size standby position which is 10mm front side from the center
FS-521
paper exit position of the main tray with remaining in the retraction status (lift up), and then it turns OFF.
After a specified period of time when the stacker empty sensor (PS20) detects the trailing paper edge, it con-
ducts the alignment operation with the paper exit alignment plate /Fr by turning ON M15 for each paper exit.
Once the last alignment operation of the 1st copy is finished, it turns ON M14 to keep the paper exit alignment
plate /Rr from the edge of paper at the same time as moving back to the paper size stand by position of M15
and then turns OFF at the specified position.
It turns ON M18 by turning OFF M15 and M14 to evacuate (lift up) the paper exit alignment plate /Fr and /Rr and
then turns OFF M18 by turning ON the paper exit alignment home sensor (PS24).
Once the evacuation (lift up) is finished by turning ON PS24, it turns ON M15 and M14, moves to the shift posi-
tion on the rear side, and turns OFF M15 and M14. It turns ON M18 by turning OFF M15 which moves longer to
pull down the paper exit alignment plate.
It conducts the alignment operation on the paper exit alignment plate /Rr for each paper exit after a specified
period of time when PS20 detects the trailing edge of paper.
After completion of the job, as well as the straight mode, once the last alignment operation is finished, it evacu-
ates (lifts up) the paper exit alignment plate and goes back to the home position.
[2] [4] [6] [9] [11]

ment motor /Fr
(M15) Close
Paper exit alignment plate home sensor /Fr (PS18)

ment motor /Rr
(M14) Close
Paper exit alignment plate home sensor /Rr (PS19)

ment plate retrac-
tion motor (M18) Up
Paper exit alignment plate retraction home
sensor (PS24)
[1] [3] [5] [7] [8] [10] [12]

a0gyt2c022ca
[1] Start signal ON [7] Move away from the edge of paper
[2] Movement to the paper size [8] Paper exit alignment plate retraction (up)
[3] Paper exit alignment plate retraction release (down) [9] Shift movement to the rear side
[4] Trailing edge of paper detected [10] Paper exit alignment plate retraction release (down)
[5] Alignment operation by the paper exit align- [11] Conveyance of 2 pages with the 1st and the
ment plate /Fr 2nd page of the 2nd copy
[6] Trailing edge of the last page detection of [12] Alignment operation by the paper exit align-
the 1st copy ment plate /Rr
52
(2) Large-size (sub-scanning direction length: 298mm or longer)

It turns ON the paper exit alignment motors /Fr (M15) and /Rr (M14) with the start signal ON, and the paper exit align-
ment plate /Fr moves to the paper size standby position which is 10mm front side from the center paper exit position
FS-521
of the main tray with remaining in the retraction status (lift up), and the paper exit alignment plate /Rr moves to the
center paper exit position of the main tray with remaining in the retraction status (lift up), and then it turns OFF.
It turns ON M14 with the paper trailing edge detection of FNS entrance sensor (PS4), assists the shift by moving the
paper exit alignment plate /Rr forward along with the timing of the stacker alignment plate shift, and turns OFF once,
then conducts the alignment operation on the paper exit alignment plate /Rr by turning ON M14 again after a specified
period of time when the stacker empty sensor (PS20) detects the trailing paper edge.
Once the last alignment operation of the 1st copy is finished, it turns ON M15 to keep the paper exit alignment plate /
Fr from the edge of paper at the same time as moving back to the paper size stand by position of M14 and then turns
OFF at the specified position.
It turns ON M18 by turning OFF M15 and M14 to evacuate (lift up) the paper exit alignment plate /Fr and /Rr and then
turns OFF M18 by turning ON the paper exit alignment home sensor (PS24).
Once the evacuation (lift up) is finished by turning ON PS24, it turns ON M15 and M14, moves to the shift position on
the rear side, and turns OFF M15 and M14. It turns ON M18 by turning OFF M14 which moves longer to pull down the
paper exit alignment plate.
It turns ON M15 by the PS4 detection of the trailing edge of paper, assists the shift to the rear side at the paper exit
alignment plate /Fr, and conducts the alignment operation at the paper exit alignment plate /Fr by turning ON M15
again after a specified period of time when PS20 detects the trailing edge of paper.
After completion of the job, as well as the straight mode, once the last alignment operation is finished, it evacuates
(lifts up) the paper exit alignment plate and goes back to the home position.
[2] [6] [8] [10]

ment motor /Fr
(M15) Close
Paper exit alignment plate home sensor /Fr (PS18)
Open
Paper exit align-
ment motor /Rr Close
(M14)
Paper exit alignment plate home sensor /Rr (PS19)

ment plate retrac-
tion motor (M18) Up
retraction home sensor (PS24)
[1] [3] [4][5] [7] [9] [11]

a0gyt2c020ca
[1] Start signal ON [7] Paper exit alignment plate retraction (up)
[2] Movement to the paper size [8] Shift movement to the rear side
[3] Paper exit alignment plate retraction release (down) [9] Paper exit alignment plate retraction release (down)
[4] Paper exit alignment plate/Rr shift assist operation [10] 1st page conveyance of the 2nd copy
[5] Alignment operation by the paper exit alignment plate /Rr [11] Paper exit alignment plate/Fr shift assist operation
[6] Move away from the edge of paper
53
C. Staple mode
Conduct the paper exit alignment only in the case of the staple mode with 20 sheets or less of minimum-size
(the main scan direction 182mm to 249mm). Control sequence is the same as the straight mode of nonstaple.
FS-521
The paper exit alignment does not work in the other staple modes.
54
MAINTENANCE
FS-521
CAUTION:

9.1.1 Lubrication to bypass roller /Lw pressure release cam
A. Periodic lubrication parts/cycle
• Bypass roller /Lw pressure release cam: Every 3,000,000 prints
B. Procedure
1. Lubricate to 2 bypass roller /Lw pressure release
cams [1]. (Molykote EM-30L)
Note
• Lubricate to the arc of the bypass roller /Lw
pressure release cam [1].
[1] a0gyt3c013ca
55
9.2 Stacker section

9.2.1 Replacing the intermediate roller release solenoid
FS-521

• Intermediate roller release solenoid : Every 5,200,000 prints *1
:Every 5,250,000 prints *2
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Procedure
1. Open the front door and pull out the stacker unit.
[3] [1]
2. Remove the screw [1] and 2 screws [2] and then
remove the cover[3].
[2] a0gyt3c001ca
3. Remove the connector [1] and 2 screws [2], and

[6] [5] [1]
then remove the intermediate roller release sole-
noid [3] to the allowed direction [4].
Note
• When installing it, insert the pin of the plunger
[5] to the groove [6] on the resin.
• When installing it, install with the screw [2] so
A that the stroke A of the plunger gets to the
standard value.
Standard value: A = 5.0mm to 6.0mm
[2] [3] [4] 4. Reinstall the above parts following the removal
a0gyt3c002ca
steps in reverse.
1 56
9.2.2 Lubrication to worm gear and cam

• Worm gear and cam: Every 3,000,000 prints
FS-521
B. Procedure
1. Pull out the stacker unit [1] and lubricate to the
[1]
cam [2] and all over around the worm gear [3].
(Molykote EM-30L)
[3] [2] a0gyt3c014ca
57
9.3 Stapler section

9.3.1 Replacing the stapler assy
FS-521

• Stapler assy /Fr : Every 3,000,000 prints (Actual replacement cycle: Every 500,000 staples) *1
: Every 5,000,000 prints (Actual replacement cycle: Every 500,000 staples) *2
• Stapler assy /Rr : Every 3,000,000 prints (Actual replacement cycle: Every 500,000 staples) *1
: Every 5,000,000 prints (Actual replacement cycle: Every 500,000 staples) *2
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Pre-arrangement for replacing the stapler assy
CAUTION:
• After moving the stapler, be sure to unplug the power plug from the power outlet.
Note
[3] [4]
• Be careful not to get your hand caught in the
opening [1] of the stapler assy.
• Pressing the staple side [2] and/or the clinch
[1] side [3] cause the opening [1] to close unex-
pectedly. It is very difficult to open the open-
ing by hand once it has closed. So, be careful
not to close it.
[2]
• When holding the stapler assy, be sure to hold
it at both ends of the cam shaft [4].
fs503fs2030c
1. Select 2 sheets A4 originals with 1-staple at the

[2] [1]
upper right corner, make a print and then move
the stapler to the stapling position.
2. Turn OFF the power switch (SW2) and the main
power switch (SW1) of the main body and unplug
the power plug from the power outlet.
4. Remove the screw [1] of the wire [2].
a0gyt3c015ca
1 58
5. Remove the stapler cartridges /Fr [1] and /Rr [2].

[3]
6. Remove the screws [3], 1 each, of the stoppers
provided in front and rear and pull further out the
FS-521
stacker unit.
steps in reverse.
[1] [2]
[3] fs503fs2005c
59
C. Stapler assy /Fr

1. Conduct "B. Pre-arrangement for replacing the
[2] [1]
stapler assy".
FS-521
2. Remove 2 screws [1] and then remove the stacker

entrance roller mounting plate /Fr [2].
[1] fs503fs2031c
3. Remove 2 screws [1] and then remove the ground

[2] [3]
[2] and the metal fitting [3].
[1]
fs503fs2032c
4. Disconnect 2 connectors [1] and remove the wire

[7] [6]
binding band [2].
5. Remove 1 screw [3] and raise the lower section of
the stapler assy mounting plate [4] a little to
remove it from the notch [5]. Slide the upper notch
[6] to the lower side to release it from the pin [7]
and then remove the stapler assy /Fr [8] together
with the mounting plate [4].
7. After replacing the parts, be sure to conduct the
counter reset of parts counter No.144.
[1]
[2]
[5] [4] [3] fs503fs2033c
1 60
D. Stapler assy /Rr

1. Conduct "B. Pre-arrangement for replacing the
[1] [2]
stapler assy".
FS-521
Note
• The following steps are the removal steps
using a short driver. When using a driver of a
regular length, removal of the stapler assy /Rr
is available only when the stapler assy /Fr has
been already removed. When using a regular
length driver, be sure to remove the stapler
assy /Fr in advance by following the steps
given in "C. Stapler assy /Fr".
[1] fs503fs2034c
2. Remove 2 screws [1] and then remove the stacker
entrance roller mounting plate /Rr [2].
3. Remove 2 screws [1] and then remove the ground

[2] [3]
[2] and the metal fitting [3].
[1]
fs503fs2035c
61
4. Disconnect 2 connectors [1] and remove 2 wire

[6]
binding bands [2].
5. In the same procedure as the step 5 of the stapler
FS-521
/Fr, remove the screw [3] and raise the lower por-
[2] tion of the stapler mounting plate [4] a little to
[1]
remove it from the notch [5]. Slide it to the lower
side and remove the stapler /Rr [6] together with
the mounting plate [4].
steps in reverse.
[4]
[3]
[5] 1050fs2036c
1 62
E. Replacing the stapler assy

1. Conduct the following operations.
[1]
• B. Pre-arrangement for replacing the stapler
FS-521
assy
• C. Stapler assy /Fr
• D. Stapler assy /Rr
2. Remove 3 screws [1] together with the stapler
assys /Fr and Rr, and then remove the cut staple
duct [2].
[2]
fs503fs2012c
3. Remove 4 screws [1] together with the stapler

[1] [3]
assys /Fr and Rr, and then remove the bracket [3]
from the stapler [2].
Note
• Take note that the brackets for the stapler
assys /Fr and /Rr are different in the position
[2]
where the wire binding band is attached.
fs503fs2013c
63
4. Remove 2 screws [1] and then remove the stapler

[2]
guide block [2].
FS-521
steps in reverse.
counter reset of parts counters No.144 and No.
145.
[1] fs503fs2063c
F. Checking of the stapler guide seal
Note
• The pasting of the stapler guide seal is limited only to the stapler assy /Rr.
1. Conduct the following operations.

[1]
• B. Pre-arrangement for replacing the stapler
assy
• D. Stapler assy /Rr
• E. Replacing the stapler assy
2. The stapler guide seal [2] must be pasted on the
clincher side [1] of the new stapler assy /Rr.
Note
• Be sure to align the end line [3] on the
clincher side [1] with the bend line of the sta-
pler guide seal [2] and paste it with no slip-
page (tolerance: 0.5mm).
• Be sure to check the guide seal to ensure it is
not damaged or soiled.
[3] [2] fs503fs2064c
1 64
9.3.2 Replacing the staples

• Staple cartridge: Every 5,000 staples
FS-521
B. Procedure
2. Pull the stapler cartridge knob [1] in the arrow-
marked direction to remove it.
[1] fs503fs2001c
3. Hold the knob [2] of the cover [1] and open it.
[2] [1]
4. Rotate and wind up carefully the remaining refill
staples [3] to the arrowed direction [4] and take it
out.
[3]
Note
• Be careful when handling the refill staples
[4] since they are apt to break away.
fs503fs2043c
65
5. With the refill staples [1] set as shown in the draw-

[2]
ing, place them gently in the pocket [2] of the sta-
pler cartridge.
FS-521
[1]
fs503fs2044c
6. Feed the refill staples [1] by hand to the arrow-

[4]
marked direction [2] and get the tip of the refill sta-
ples near to the stapling position [3]. New refill sta-
ples are attached with a lead sheet.
Note
[2] • The tip of the refill staples can be pulled up to
the stapling position by this lead sheet.
[1]
7. Close the cover [4].
steps in reverse.
[3] fs503fs2045c
9.3.3 Cleaning the cut staple box

A. Procedure
1. Open the front door.
2. Remove the screw [1] and pull out the cut staple
box [2].
steps in reverse.
[2]
fs503fs2037c
66
9.4 Main tray section

9.4.1 Replacing the paper exit roller
FS-521
• Paper exit roller /A (sponge roller) : Every 600,000 prints *1
:Every 750,000 prints *2
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
CAUTION:
• After having lowered the main tray, be sure to unplug the power plug from the power outlet.
Note
• When replacing the paper exit rollers /A (sponge roller), be sure to replace all 4 pairs of rollers (8
rollers in all).
B. Procedure
1. Turn on the power switch (SW2), lower the main
[2] tray [1] blocking the light of the tray upper limit
sensor (PS16) during up and down operation of
the main tray, and then turn OFF the main power
switch (SW1) and the power switch (SW2) of the
main body.
2. Unplug the power plug of the main body from the
power outlet.
[1]
a0gyt3c003ca
67 1
3. Insert a driver into the groove of the sponge roller

[1] [1] and remove the sponge roller [1] by prizing it
open.
FS-521
fs503fs2003c
4. With each of the depressions [1] of a new sponge

roller and the shaft brought together, press the
sponge roller until it clicks to fit it in securely.
[1]
[1]
fs503fs2004c
68
9.4.2 Replacing the paper exit opening solenoid assy

• Paper exit opening solenoid assy (SD9) : Every 5,200,000 prints *1
FS-521
: 5,250,000 prints *2
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Procedure
1. Remove the upper cover/1. (Refer to P.75)
[1] [3]
4. Remove the wiring harness from 6 wiring harness
guides [2] and slide the board mounting plate [3]
backward.
Note
• Be sure not to break the wiring harness when
moving the board mounting plate [3].
[2]
a0gyt3c004ca
69 1
5. Remove the connector [1].

[1] [6] [7] [5] 6. Remove the G ring [2] and then remove the arm
[3] from the pin [4].
FS-521
Note
• Be sure to install the G ring [2] to the position
about 2mm away from the arm [3] so that the
arm is free to move.
• Since the pin [4] does not have a groove, be
sure to check that the G ring is fixed securely
so that it does not come of from the pin.

exit opening solenoid assy (SD9) [6] together with
[4] [2] [3]

a0gyt3c005ca
Note
• Hold the paper exit opening solenoid (SD9)
temporally with screws and lower the mount-
ing plate of the paper exit opening solenoid
assy once, then slide it upward to tighten it
fully at the position where the paper press
arm [1] starts moving and protrudes for the
standard value from the paper stopper plate
[2].
Standard value A = -0.5mm to +0.5mm
[2] [1] a0gyt3c006ca
70

[3]
exit opening solenoid assy (SD9) [3] from the
mounting plate [2].
FS-521
A
Note
• Be sure to check that the stroke of the
plunger is the standard value A.
Standard value A = 5mm ± 0.5mm

steps in reverse.
[1] [2] a0gyt3c007ca
71

FS-521

1 Cover Front door P.73
2 Sub tray P.74
3 Upper cover /1 P.75
5 Left cover /Fr P.77
6 Rear cover P.78
7 Stacker section Stacker unit P.79
8 Main tray section Main tray P.83
9 Lift wire P.85
10 Tray up down motor P.90
11 Stapler section Handling of the clogged stapler 1 P.91
12 Handling of the clogged stapler 2 P.91
72
FS-521
CAUTION:
10.2.1 Front door

A. Procedure
1. Open the front door, remove the screw [1] and
[2] [1]
then remove the wire [2] of the door.
a0gyt3c015ca
2. Remove 2 screws [1] and then remove the door

support bracket [2] and the front door [3].
Note
• The front door is heavy. Support it securely
[1] when removing it.

steps in reverse.
[3] [2] fs503fs2046c
73
10.2.2 Sub tray

A. Procedure
1. Rotate the sub tray [1] in the arrowed direction [2]
FS-521
[7]
and remove the ball catch [3] from the ball [4].
2. Press the front and rear sections of the sub tray
[1] in the arrowed direction [5] to make it curve a
little, and detach the attaching hole [6] from the
pin [7] to remove the sub tray [1].
steps in reverse.
[6]
[5]
[1]
[4]
[2]
[3]
fs503fs2047c
74
10.2.3 Upper cover /1

A. Procedure
1. Remove the sub tray.
FS-521
2. Remove 6 screws [1] and the connector [2] and then
remove the upper cover /1 [3].
[2]
Note
• When the front door support section [4] is
[3] hard to remove, slide the upper cover /1 [3] a
[1] little to the front side and remove it while lift-
ing it up.

steps in reverse.
[4] [1] a0gyt3c008ca
75
10.2.4 Upper cover /2

A. Procedure
FS-521
main body.
power outlet.
[1]
a0gyt3c003ca
3. Remove each 2 screws [1] and then remove the

[1]
paper exit alignment plate /Fr [2], /Rr [3].
[3] [2] a0gyt3c009ca
76
4. Hold the installation section [1] of the paper exit

[1]
alignment plate and move inward.
FS-521
Note
• Do not hold the rack [2] to move.
5. Remove each 1 screw [3] and then remove each 1

cover [4].
[3] [4] [2] [4] [3] a0gyt3c010ca
6. Hold the installation section [1] of the paper exit

[2] [1] [1] [2] alignment plate and move outward to fit it to the
notch holes [2].
Note
• Do not hold the rack [3] to move.
7. Remove 4 screws [4] and then remove upper

[4] [3] [5] [4] cover /2 [5].
a0gyt3c011ca 8. Reinstall the above parts following the removal
steps in reverse.
10.2.5 Left cover /Fr

A. Procedure
1. Loosen 1 screw [1].
2. Remove 1 screw [2], slant the upper section of the
left cover /Fr [3] and remove it while lifting it up.
steps in reverse.
[2]
[3]
[1]
fs503fs2050c
77
10.2.6 Rear cover

A. Procedure
1. Remove 5 screws [1] and remove the rear cover
FS-521
[2].
Note
• When reinstalling it, be sure to hook the rear
cover to 2 catches [3] provided at the lower
section.

[2]
[3] [1]
fs503fs2051c
78
10.2.7 Stacker unit
FS-521
CAUTION:
• Be sure to conduct this operation with 2 people.
A. Procedure
[2] [1]
2. Open the front door, remove the screw [1] and
then remove the wire [2] of the door.
a0gyt3c015ca

4. Remove each cables from 4 wiring harness
guides [2].
5. Remove the E-ring [3] and the shaft [4], and cut
off the coupling arm [5].
[1]
[1]
[5]
[2]
[4] [3] a0gyt3c012ca
79
6. Remove the stopper screws [1], 1 each, provided

[1]
on the rails in front and rear, pull the stacker unit
further out.
FS-521
[1] fs503fs2061c
80
7. Remove the screws [1], 1 each, provided on the

rails in front and rear.
8. Lift up the stacker section [2] at the specified posi-
FS-521
tions [3], release the hook of the rail [4] from the
hole [6] and remove the stacker section [2].
[3]
CAUTION:
• Be careful of your posture when removing it
and be sure to conduct this operation with 2
[1] people so that you do not suffer backache.
Note
• When lifting up the stacker section, be sure to
hold it at the specified positions [3]. Holding
[6] other positions such as the roller shaft may
damage to these positions.
[5]
steps in reverse.
Note
• When reinstalling the stacker section to the
[3] rail [4], be sure to check that the hooks [5]
provided at 2 locations in front and rear, 4
locations in all, get into the attaching holes [6]
securely.
[1]
[2]
[6]
[5]
[4]
fs503fs2041c
81
Note
• When reinstalling it, be sure to pull out the rail
[1] fully and fasten it with the stopper screw
FS-521
[3]
[2] tentatively. Fix the rail in the rear with tape
[3] so that the rail does not move and con-
tract. It allows you to conduct the operation
smoothly.
[1] [2] fs503fs2042c
82
10.2.8 Main tray
FS-521
CAUTION:
• After having lowered the main tray, be sure to unplug the power plug from the power outlet.
A. Procedure
main body.
power outlet.
[1]
a0gyt3c003ca
83

[2]
4. Lift up the main tray [2] to unhook the up/down
stay [3], and remove the main tray [2].
FS-521

steps in reverse.
[3] [1] fs503fs2017c
84
10.2.9 Lift wire
Note
FS-521
• The following replacement procedure of the lift wire shows the steps taken on the rear side. The
figuration and the winding of wires on the front side are symmetrical to those on the rear side.
• The brackets of the lift wire are stamped with "F" on the front side and "R" on the rear side. Be
careful not to confuse one with the other.
A. Procedure
1. Bring the main tray down to the bottom.
(Refer to P.83)
[1] 2. Remove the following parts.
Main tray (Refer to P.83)
Rear cover (Refer to P.78)
[1] Left cover /Fr (Refer to P.77)
Front door (Refer to P.73)
3. Remove the screws [1], 2 each, and then remove
the tray stay covers /Fr [2] and /Rr [3].
[3] [2] fs503fs2038c
4. Disconnect the connector [1], remove 6 screws

[1] [2] and then remove the gear box [4] together with
the tray up down motor [3].
[3]
CAUTION:
• When the gear box is removed, the main tray
falls down. So, be sure to support the tray by
hand when removing the gear box.
[4]
[2] fs503fs2018c
85
5. Remove 2 screws [1] and then remove the wire

mounting plate [3] of the lift wire /Rr [2] from the lift
stay [4].
FS-521
[4]
[2]
[1]
[3]
fs503fs2019c
6. Loosen 2 screws [2] of the belt tensioner [1].
[1]
[2]
fs503fs2020c
86

[5] [2] and the lift pulley /Lw [3] to remove the lift wire
/Rr [4].
FS-521
Note
[3] • When removing the gear [2] and the lift pulley
/Lw [3], be careful that the pin [5] does not
come off and get lost.
[1] [2] [5]
[4]
fs503fs2021c
8. Tentatively fasten the wire mounting plate [2] of

[3]
the new lift wire /Rr [1] to the lift stay [3] with the 2
screws [4].
[4]
Note
• Be sure to install the lift wires placing the
[2] shorter one below the longer one.
9. Fasten the new lift wire /Rr [1] with the wire end [6]
of the lift pulley /Lw [5] and insert it into the shaft.
Rotate the lift pulley /Lw [5] and wind it 6 turns
clockwise from inside to outside around the lift
[1] pulley /Lw [5] with no slack, and then insert the lift
[5]
pulley /Lw [5] fully deep into the shaft so that it
coincides with the pin [7].
[7]
[6] fs503fs2022c
87
10. With the lift wire /Rr [1] hooked to the lift pulley /
Up [2], wind it 2 turns counterclockwise from
inside to outside around the lift pulley /Lw [3] with
FS-521
no slack and then fasten it with the wire end [4].
[2]
[1]
[4]
[3]
fs503fs2023c
11. Insert the pin [1] and the gear [2] into the shaft,
and fasten them with the E-ring [3].
[3]
[2]
[1]
[3]
[2]
fs503fs2024c
88
12. Use a tension gauge or a spring balance to pull

the belt tensioner [1] with a specified force A and
[1] tighten it up 2 screws [2].
FS-521
Standard value:A=2.5 ± 0.1kg
[2]
fs503fs2025c
13. Loosen 2 screws [2] of the wire mounting plate [1]

[4] [5] [3] [2] [1]
on the front side, press down the lift stay [3] to
bring it to a horizontal position, and tighten up 2
screws [5] of the wire mounting plate [4] on the
rear side and 2 screws [2] on the front side, that
is, 4 screws in all.
Note
• Check to see if the lift stay [3] is kept in a hor-
izontal position. If it is on the slant, an unnec-
essary load may be applied onto the gear,
thus damaging it.
[2]
[5] fs503fs2026c
steps in reverse.
Note
• When reinstalling the covers, be sure to rotate
the tray up/down motor counterclockwise as
seen from above to raise the lift stay about
12cm before installing each cover. Since the
lift stay comes down lower than the normal
operating range due to the lift gear box being
removed, it is inevitably necessary to raise
the lift stay to install it without the left cover /
Fr and the rear cover hitting against the up/
down stay.
89
10.2.10 Tray up down motor

A. Procedure
FS-521
[1] [3]
2. Disconnect the connector [1], remove 4 screws
[2] and then remove the tray up down motor [3].
Note
• When reinstalling it, make sure that the belt
[4] is set correctly to the gears [5] and [6].

steps in reverse.
[2]
[4]
[6] [5]
fs503fs2027c
90
10.2.11 Handling of the clogged stapler 1

A. Procedure
1. Remove the stapler cartridge.
FS-521
Note
[1] • When the stapler cartridge cannot be removed,
conduct the initial operation by turning ON and
OFF the power switch (SW2) of the main body.
[3]
• When removal of the stapler cartridge is not
[2] possible even after the initial operation, con-
duct "10.2.12 Handling of the clogged stapler
2".
fs503fs2052c
2. Press the release button [1] and open the staple

cover [2].
3. Remove the unnecessary staples [3].
4. Close the staple cover [2].
steps in reverse.
10.2.12 Handling of the clogged stapler 2

A. Procedure
[3] [4] CAUTION:

• Be careful not to get your hand caught in the
opening [1] of the stapler assy. Pressing the
staple side [2] and/or the clinch side [3] cause
[1] the opening [1] to close unexpectedly. It is
very difficult to open the opening by hand
once it has closed. So, be careful not to close
[2] it. When holding the stapler assy, be sure to
hold it at both ends of the cam shaft [4].
• When conducting the operation, be sure to
wear protective gloves.
• When conducting the operation, be careful
fs503fs2053c not to get the glove or your hand caught in
the gear.
91
1. Remove the stapler assy. (Refer to P.58)

[3] [2]
2. Remove 2 nuts [1] and then remove the clinch
protective plates /1 [2] and /2 [3].
FS-521
[1]
fs503fs2054c
3. Remove the clogged staples.

[3]
Note
• When reinstalling it, place the holes [2] of 2
clinch metal fittings [1] one upon the other so
[2] that the tip [3] of the clinch presser is
[4] engaged to the depression [4] of the clinch
metal fitting.
[1]
fs503fs2055c
4. When the clogged staples cannot be removed,

rotate the gear [1] of the stapler motor shaft and
the gear [2] that comes into contact the motor
gear to open the opening [5] until the pin [3] at the
tip of the stapling arm comes to the bottom of the
[5]
[6] slit [4].
[4]
CAUTION:
[3] • Considerable force is required to rotate the
gear. Be sure to wear gloves not to get
[2] [1] fs503fs2056c injured.
Note
• The gear can be rotated in the easier direction.
5. Remove the stapler cartridge [6]

Remove the unnecessary staples from the stapler
cartridge. (Refer to P.91)
steps in reverse.
92
10.2.13 Note for replacing the board

When the SD control board (SDCB) is replaced, be
FS-521
Remove the EEPROM (IC68) from the old control
board [1] and install it into the new control board [2].
Note
• Setting of the SW3 [3] has to be the same as
the setting of the old FNSCB. (Refer to Field
Service P.788)
[1]
[2] [3]
fd501fs2077c
Note
tion.
A
fd501fs2078c
93
FS-521
Blank page
94
FS-520/607
2009.07
Ver. 3.0
Revision history
Revision mark:
corresponding page.
NOTE
2009/07 3.0 2 Correction of an error in writing

CONTENTS
FS-520/607
FS-520/607
OUTLINE
3. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Non-sort/sort/group mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Sub tray mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Stapling mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Folding/saddle stitching mode (FS-607) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5 Tri-folding mode (FS-607) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CONFIGRATION/OPERATION
4. TRANSFER SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3.1 Punch registration control (available only when PK is installed) . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3.2 FS transfer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3.3 Gate drive control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3.4 Bypass gate control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.3.5 Shift control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.3.6 Paper exit roller control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.3.7 Paper exit opening solenoid control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.3.8 Paper exit opening control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3.9 Sub tray paper exit control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.3.1 Tray lift control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6. STACKER SECTION (FS-520) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.3.2 Stopper control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.3.3 Stacker entrance transfer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.3.4 Stacker paper exit control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7. STACKER SECTION (FS-607) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.3.1 Alignment /Up control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.3.2 Alignment /Lw control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.3.3 Stopper control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
i
7.3.4 Stacker entrance transfer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

7.3.5 Stacker paper exit control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
FS-520/607
8. STAPLER SECTION (FS-520) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

8.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.3.1 Stapler movement control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.3.2 Stapler control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9. STAPLER SECTION (FS-607) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
9.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
9.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9.3.1 Stapler movement control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9.3.2 Stapler control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
10. FOLDING/SADDLE STITCHING/TRI-FOLDING SECTION (FS-607) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
10.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10.3.1 Folding knife control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

10.3.2 Folding transfer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
10.3.3 Tri-folding gate control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
MAINTENANCE
11.1.1 Replacing the paper exit roller (sponge roller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
11.1.2 Replacing the intermediate transfer roller (sponge roller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
11.2 Stacker section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
11.2.1 Replacing the paper assist roller (sponge roller) (FS-520) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
11.2.2 Replacing the paper assist roller (FS-607). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
11.2.3 Replacing the cleaning plate assy (FS-520). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
11.3 Stapler section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
11.3.1 Removing/reinstalling the stapler unit cover (FS-607) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
11.3.2 Replacing the stapler unit (FS-607) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
11.3.3 Replacing the stapler unit (FS-520) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
12.2 List of parts to be disassembled and assembled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
12.3 Removal procedure of parts to be disassembled and assembled . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
12.3.1 Removing/reinstalling the upper cover /1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
12.3.2 Removing/reinstalling the upper cover /2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
12.3.3 Removing/reinstalling the front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
12.3.4 Removing and reinstalling the rear cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
12.3.5 Removing/reinstalling the left cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
12.3.6 Removing/reinstalling the main tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
12.3.7 Replacing the lift wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
12.3.8 Removing/reinstalling the stacker unit cover (FS-607) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
12.3.9 Removing/reinstalling the stacker unit (FS-520). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
12.3.10 Removing/reinstalling the stacker unit (FS-607). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
12.3.11 Removing/reinstalling the paper exit unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
ii
12.3.12 Note to keep in mind when replacing the board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
FS-520/607
iii
FS-520/607
Blank page
iv
OUTLINE
FS-520/607
A. Type
Type Stapling device (FS-520)

Multi folding multi stapling device (FS-607)
B. Functions
(1) Functions
Non-sort mode Exited to the main tray with no processing made.

Sort/group mode Exited to the main tray after being shifted for every copy.
Sub tray mode Exited to the sub tray with no processing made.
Stapling mode Exited to the main tray after being stapled.
Saddle stitching mode Exited to the booklet tray with the paper folded into two after being stitched and
folded at the center of the paper (FS-607 only).
Folding mode Exited to the booklet tray with the paper folded into two at its center (FS-607
only).
Tri-folding mode Exited to the booklet tray after being overlapped up to 3 sheets and being tri-
folded (FS-607 only).
1
(2) Stapling
Max. flat-stapling FS-520 50 sheets of 64 to 80 g/m2 (plain paper, high-quality paper, color paper)
FS-520/607
capacity 40 sheets of 81 to 105 g/m2 (plain paper), 30 sheets (high-quality paper,

color paper), 25 sheets (coated paper)
30 sheets of 106 to 135 g/m2 (plain paper, high-quality paper), 25 sheets
(color paper), 20 sheets (coated paper)
(color paper)
Up to 2 sheets of 200g/m2 can be added unless the total number of
sheets exceeds the above capacity.
staple position At coner Parallel or skew depending on
the paper size
At 2 places Symmetry at the center with
162 mm pitches
FS-607 50 sheets of 64 to 80 g/m2 (plain paper, high-quality paper), 30 sheets
(color paper)
(color paper, coated paper)
staple position Front parallel / back 45° 1 position diagonally, 2 posi-
tions at the center
Max. saddle stitching FS-607 20 sheets of 64 to 80 g/m2
capacity 16 sheets of 81 to 105 g/m2
staple position variable (128 to 168mm)
(3) Folding (FS-607)
Max.Folding 3 sheets of 64 to 105 g/m2 paper

Max.Tri-folding 3 sheets of 64 to 80 g/m2 paper
1 sheet of 81 to 105 g/m2 paper
2
(4) Max. paper capacity
Main tray FS-520 Non-sort 3000 sheets: A4, A4S, B5, B5S
FS-520/607
(Weighing 80g/ mode, sort/ 81/2 x 11, 81/2 x 11S
m2) group mode 16K, 16KS
1500 sheets: SRA3*1, A3, B4, SRA4*1, SRA4S
12 x 18, 11 x 17, 81/2 x 14,
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
8K
500 sheets: A5, A5S *1, B6S *1
51/2 x 81/2S *1
*3
Tab paper : A4, 81/2 x 11
Custom paper : Max. 314 x 458mm, Min.*2 182 x 148 mm
Stapling mode Max. 1000 sheets
No. of sheets per stapling Size in the sub The others
scan direction is
150 to 417 mm
2 to 9 100 copies 50 copies
FS-607 Non-sort 2500 sheets: A4, A4S, B5, B5S
mode, sort/ 81/2 x 11, 81/2 x 11S
group mode 16K, 16KS
1500 sheets: SRA3*1,A3, B4, SRA4*1, SRA4S,
12 x 18, 11 x 17, 81/2 x 14,
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
8K
500 sheets: A5, A5S *1, B6S *1
51/2 x 81/2S *1
Tab paper*3 : A4, 81/2 x 11
scan direction is
418mm or longer
3
Booklet tray Saddle stitch- Size in the sub scan direction is 299 mm or longer : 15 cop-
(Weighing 80g/m2) ing mode ies in 5 sheets of saddle stitching
FS-520/607
(FS-607 only) other than the above : 20 copies in 5 sheets of saddle stitching
Folding mode Size in the sub scan direction is 299 mm or longer : 25 cop-
ies in 3 sheets of folding
other than the above : 33 copies in 3 sheets of folding
Tri-folding 50 copies in 1 sheet of folding
mode
Sub tray 100 sheets : SRA3, A3, B4, SRA4, SRA4S, A4, A4S, B5, B5S, A5, A5S, B6S,
(Weighing 80g/ A6S
m2) 13 x 19, 12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
8K, 16K, 16KS
Tab paper*3 : A4, 81/2 x 11
Custom paper : Max. 330 x 487mm, Min. 100 x 148 mm
*1 Non-sort mode only

*2 Non-sort mode is 128 x 148 mm
*3 Operation of paper exit with tab area at the trail edge side is not assured.
C. Type of paper
(1) Stapling mode
Paper size A3, B4, SRA4S, A4, A4S, B5, B5S, A5

12 x 18*1, 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
8K, 16K, 16KS
Tab paper*2 (A4, 81/2 x 11)
Applicable paper Plain paper, high-quality paper, color paper, coated paper (same as the main
body)
Paper weight 60 to 209 g/m2 (FS-520)
64 to 105 g/m2 (FS-607)
*1 FS-607 only
(2) Saddle stitching mode (FS-607)
Paper size A3, B4, SRA4S, A4S

12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11S
8K
Applicable paper Plain paper, high-quality paper, color paper, coated paper
Paper weight 64 to 105 g/m2
4
(3) Folding mode (FS-607)
FS-520/607
12 x 18, 11 x 17, 81/2 x14, 81/2 x11S,
8K
(4) Tri-folding mode (FS-607)
Paper size A4S

81/2 x11S
D. Maintenance
E. Machine data
Power source 24/5VDC (supplied from the main body)

Maximum power consump- 80W or less
tion
Dimensions When the main tray is pulled out: 790.5 (W) x 656 (D) x 990 (H) mm
When the main tray is set in: 674.5 (W) x 656 (D) x 990 (H) mm
Weight Approx. 60 kg (FS-520)
Approx. 65 kg (FS-607)
Note
5 2
FS-520/607
For FS-520 and FS-607, the conveyance section and the main tray section are common but the stacker section
and the stapler section are different.
Transfer section
Stacker section
(FS-520)
Main tray section
Stapler section
(FS-607)
Stapler section
(FS-520)
Stacker section
Folding/saddle stitching/tri-folding section (FS-607) (FS-607)
a04dt1c001cb
6
3. PAPER PATH
FS-520/607
3.1 Non-sort/sort/group mode
[6]
[5]
[1]
[2]
[4]
[3]
FS-607 only
a04dt1c002cb
[1] Paper path from PI (PI-502 installed) [4] Main tray

[2] Paper path from the main body [5] Paper exit unit
[3] Gate [6] Shift unit (sort/group mode only)
7
3.2 Sub tray mode

FS-520/607
[1]
[4]
[2]
[3]
FS-607 only
a04dt1c003cb
[1] Paper path from PI (PI-502 installed) [3] Gate

[2] Paper path from the main body [4] Sub tray
8
3.3 Stapling mode
FS-520/607
[8]
[1]
[7] [2]
[3]
[4]
[5]
[6]
FS-607 only
a04dt1c004cb
[1] Paper path from PI (PI-502 installed) [5] Flat-stapling stopper

[2] Paper path from the main body [6] Stapler *
[3] Gate [7] Main tray
[4] Clincher * [8] Paper exit unit
* Illustrations of the clincher and the stapler are same as those of FS-607.
9
3.4 Folding/saddle stitching mode (FS-607)

FS-520/607
[1]
[2]
[3]
[4]
[8]
[5]
[6]
[7]
15jmt1c001na
[1] Paper path from PI (PI-502 installed) [5] Folding knife

[2] Paper path from the main body [6] Saddle stitching stopper
[3] Gate [7] Booklet tray
[4] Clincher [8] Stapler
10
3.5 Tri-folding mode (FS-607)
FS-520/607
[1]
[2]
[3]
[4]
[7]
[5]
[6]
15jmt1c002na
[1] Paper path from PI (PI-502 installed) [5] Saddle stitching stopper
[2] Paper path from the main body [6] Booklet tray
[3] Gate [7] Tri-folding stopper
[4] Folding knife
11
FS-520/607
Blank page
12
Theory of Operation Ver.3.0 Jul. 2009 4. TRANSFER SECTION
CONFIGRATION/OPERATION
FS-520/607
4. TRANSFER SECTION
4.1 Composition
Sub tray paper full sensor

Shift unit (PS19)
Sub tray paper exit sensor

(PS1)
Shift roller
Gate
Paper exit unit

PI transfer roller
Main tray exit paper
sensor (PS6)
Entrance roller
FNS entrance sensor

(PS4)
Transfer roller /A
Transfer roller /B
Main tray exit roller Intermediate transfer roller
Bypass gate
a04dt2c005ca
13
4. TRANSFER SECTION Theory of Operation Ver.3.0 Jul. 2009
4.2 Drive
FS-520/607
[15] [16] [17] [18] [19] [20] [21] [1]
[2]
[14]
[3]
[13]
[4]
[12]
[11]
[5]
[10]
[6]
[9] [8] [7]
a04dt2c001ca
[1] FNS transfer motor (M1) [12] Shift roller

[2] PI transfer roller [13] Main tray exit roller
[3] Entrance roller [14] Paper exit opening solenoid (SD4)
[4] Transfer roller /A [15] Paper exit roller motor (M7)
[5] Transfer roller /B [16] Sub tray paper exit motor (M21)
[6] Bypass gate [17] Sub tray paper exit roller
[7] Intermediate transfer roller [18] Paper exit motor (M8)
[8] Bypass gate solenoid (SD5) [19] Shift roller motor (M2)
[9] Paper exit belt [20] Sub tray transfer roller
[10] Paper exit arm [21] Gate motor (M12)
[11] Gate
14
4.3 Operation
FS-520/607
4.3.1 Punch registration control (available only when PK is installed)
The FNS conveyance motor (M1) turns OFF temporarily to stop conveyance of paper when the specified time
has passed since paper exit sensor (PS37) detected the leading edge of the paper. Thus the paper is pressed
against the entrance roller forming a loop to correct the bend. When the specified time has passed, M1 turns
ON to restart conveying the paper.The above operation is not performed when conveying a large paper (220
mm and longer in the sub scan direction) and in the non-punchingmode.
When punching the paper conveyed from PI, the loop is formed on the PI's side. For details, refer to PI-502 ser-
vice manual.
[4]
[1]
[2]
[3]
a04dt2c002ca
[1] Main body [3] Loop

[2] Entrance roller [4] PK (option)
15
4.3.2 FS transfer control

The FS transfer is conducted by the 24V DC motor controlled by the FNS control board (FNSCB).
FS-520/607
A. Door switch control

The FS transfer drive control is started when transmitting the start signal from the main body. However, en error
message is transmitted to the main body PRCB and the control is not started if the door switch (MS1) turns OFF.
B. FS transfer control
The FNS transfer motor (M1) rotates in high speed when pressing the start button. In the mode the paper is
exited from the main body in slow speed, M1 rotates in slow speed when the main body paper exit sensor
(PS37) turns ON. Then it rotates in high speed after a specified period of time since the FNS entrance sensor
(PS4) turns ON.
When exiting to the main tray, M1 rotates in middle speed to in sync with the FS paper exit line speed after a
specified period of time since PS4 detects the trailing edge of the paper. Then after a specified period of time,
M1 returns to rotate in high speed and waits for the subsequent paper.
16
4.3.3 Gate drive control

The gate switches among the paper transfer path to the main tray, the one to the sub tray, and the one to the
FS-520/607
stacker.
A. Gate operation
The gate motor (M12) drives the gate cam [2], and then 2 cams /UP [3] and /Lw [4] of the gate cum drive the 2
gates /UP [5] and /Lw [6] respectively. The gate home sensor (PS16) [7] detects the home position.
[1]
[7]
[2]
[3]
[4]
[5]
[6]
15jkt2c004na
[1] Gate motor (M12) [5] Gate /Up

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

[2] Stacker
17
4.3.4 Bypass gate control

The bypass gate is located in the paper path to the stacker section. The bypass gate is the gate to transfer the
FS-520/607
subsequent paper during the stapling operation for eliminating the time loss and increasing the productivity.
A. Bypass gate operation

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

[2] Bypass gate solenoid (SD5) [4] Regular route
18
B. Bypass gate control

The bypass gate only operates for the small size paper (A4, B5, and 81/2 x 11) in the stapling mode. The FNS
FS-520/607
control board (FNSCB) controls the bypass gate solenoid (SD5).
When stapling 2 sheets of paper for 3 copies, SD5 operates as follows.

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

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

The bypass gate (SD5) turns ON and draws the 1st paper of the 3rd copy to the bypass after a specified period
of time since the FNS entrance sensor (PS4) detects the trailing edge of the last paper of the 2nd copy [7]. SD5
turns OFF after a specified period of time since PS4 detects the trailing edge of the paper [8].
[1] [2] [3]
FNS transfer motor (M1)
Bypass gate solenoid (SD5)
Stapler movement motor (M11)
[4] [5][6] [7] [8] 15jkt2c007na
[1] The 1st copy [5] Drawing the 1st paper of the 2nd copy to
[2] The 2nd copy the bypass
[3] The 3rd copy [6] Trailing edge of the 1st paper of the 2nd copy
[4] Stapling operation for the 1st copy started [7] Trailing edge of the last paper of the 2nd copy
[8] Trailing edge of the 1st paper of the 3rd copy
19
4.3.5 Shift control

The FNS transfer motor (M1) drives the shift roller. The shift roller moves itself backward to shift the paper while
FS-520/607
transferring the paper to the main tray.
A. Shift operation
During conveying the paper to the main tray [1], the crank mechanism [3] shifts the shift movable section [5]
including the shift roller [4] approximately 30 mm backward [6] to shift and exit the paper when shift roller motor
(M2) [2] rotates.
The shift roller home sensor (PS18) [7] detects the shift position.
[7] [2]
[4]
[5]
[1] [3]
[3]
[2]
[5] [4]
[6]
[7] 15jkt2c008na
[1] To the main tray [5] Shift movable section

[2] Shift roller motor (M2) [6] Rear
[3] Crank mechanism [7] Shift roller home sensor (PS18)
[4] Shift roller
20
B. Shift control
In the sort/group mode, the shift roller motor (M2) turns ON [2] and shifts the shift movable section after a spec-
FS-520/607
ified period of time since the FNS entrance sensor (PS4) detects the trailing edge of the paper [1]. The FNS
transfer motor (M1) drives the shift roller. It shifts the paper while transferring it.
M2 stops when the shift roller completes the shift operation and the shift roller home sensor (PS18) turns ON [3].
Then, M2 turns ON [4] again after a specified period of time since it stops. It stops when PS18 turns OFF [5].
This operation replaces the shift movable section to its original position, and then it stands by for the subsequent
paper to be shifted.
These operations are repeated for every paper to offset it.
[1]
930 mm/s
FNS transfer motor
(M1) 400 mm/s
Shift roller motor (M2)
Shift roller home sensor (PS18)
[2] [3] [4] [5] 15jkt2c009na
[1] Trailing edge of the paper detected [4] Moving to the home position started
[2] Shift started [5] Moving to the home position completed
[3] Shift completed
21
4.3.6 Paper exit roller control

The paper exit roller motor (M7) controlled by the FNS control board (FNSCB) drives the main tray paper exit
FS-520/607
roller and the paper exit belt.
A. Non-sort/sort/group mode
The paper exit roller motor (M7) rotates in high speed when the FNS entrance sensor (PS4) detects the leading
edge of the paper [1]. M7 rotate in low speed [2] and exits the paper after a specified period of time since PS4
detects the trailing edge of the paper.
To transfer the subsequent paper, M7 rotate in high speed again after a specified period of time since the main
tray paper exit sensor (PS6) detects the trailing edge of the paper [3].
M7 stops after a specified period of time since PS6 detects the last paper.
Paper exit roller 400 mm/s

motor (M7)
253 mm/s
[1] [2] [3] 15jkt2c010na
[1] Leading edge of the paper detected [3] Preparing to transfer the subsequent paper
[2] Paper exit started
B. Stapling mode (when the paper length is B5S or longer in the sub scan direction)
Transmitting the FNS signal [1] from the main body, the paper exit roller motor (M7) rotates to drive the paper exit
belt in the stacker section. M7 stops and the paper exit arm moves to the home position for the stapling mode
when the paper exit belt home sensor (PS9) turns ON [3].
The paper exit opening is open if the paper length is longer than B5S in the sub scan direction. The paper exit
motor (M8) closes the paper exit opening when the stapling operation is completed. M7 rotates to drive the
paper exit arm when the paper exit home sensor (PS12) detects the opening is closed [6]. The paper exit arm
lifts up the paper to the paper exit roller, and then the paper exit roller exits the paper to the main tray.
M7 stops when PS9 turns ON [7].
Paper exit roller motor (M7)
Paper exit belt home sensor (PS9)
Paper exit home sensor (PS12)
[1] [2] [3] [4] [5] [6] [7] 15jkt2c030na
[1] FNS signal turned ON [5] Closing the paper exit opening
[2] Opening the paper exit opening [6] Paper exit opening closed
[3] Paper exit arm home position [7] Paper exit arm home position
[4] Stapling operation completed
22
4.3.7 Paper exit opening solenoid control

The paper exit roller is usually releasing the nip except when exiting the paper because its rotation is slower than
FS-520/607
the transfer roller. However, the nip movable section moves to nip the paper when the paper reaches to the
paper exit opening.
A. Paper exit opening solenoid operation

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

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

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

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

In all modes, the paper exit opening solenoid (SD4) turns OFF after a specified period of time since the main tray
paper exit sensor (PS6) detects the paper.
23
4.3.8 Paper exit opening control

In the stapling mode (when the paper length is B5S or longer in the sub scan direction) and the folding/saddle
FS-520/607
stitching/tri-folding mode, the paper exit opening is opened from the beginning of the printing operation to the
end of the stapling operation because the paper protrudes.
A. Paper exit opening/closing operation

The paper exit opening unit [3] opens/closes by the crank mechanism [2] when the paper exit motor (M8) [1]
rotates. The paper exit home sensor (PS12) [4] detects the opening/closing of the paper exit opening.
[3] [2] [3]
[2]
[1]
[1]
[4]
[4] a04dt2c003ca
[1] Paper exit motor (M8) [3] Paper exit unit

[2] Crank mechanism [4] Paper exit home sensor (PS12)
24
B. Paper exit opening/closing control

(1) Stapling mode (when the paper length is B5S or longer in the sub scan direction)
FS-520/607
Transmitting the FNS signal [1] from the main body, the paper exit motor (M8) rotates [2] to open the paper exit
opening.
When the stapling operation completes, M8 turns ON [3] again to close the paper exit opening. It stops when
the paper exit home sensor (PS12) detects the paper exit opening is closed.
These operations are repeated for every stapled bundle.
[5]
Stapler motor /Fr (M14)

Clincher motor /Fr (M15)
Stapler motor /Rr (M9)
Clincher motor /Rr (M10)
Paper exit opening solenoid (SD4)
[1] [2] [3] [4] 15jkt2c013na
[1] FNS start signal turned ON [4] Paper exit opening closed
[2] Opening the paper exit opening [5] Paper nipped by the paper exit opening
[3] Closing the paper exit opening solenoid (SD4)
(2) Folding/saddle stitching/tri-folding mode (FS-607 only)

Transmitting the start signal [1] from the main body, the paper exit motor (M8) rotates [2] to open the paper exit
opening.
M8 turns ON [3] again to close the paper exit opening after a specified period of time since the folding paper exit
sensor (PS25) or the folding full sensor (PS29) detects the trailing edge of the last page. It stops when the paper
exit home sensor (PS12) detects the paper exit opening is closed [4].
Folding paper exit sensor (PS25)
[1] [2] [3] [4] 15jkt2c014na
[1] FNS start signal turned ON [3] Closing the paper exit opening
[2] Opening the paper exit opening [4] Paper exit opening closed
25
4.3.9 Sub tray paper exit control

The sub tray paper exit motor (M21) controlled by the FNS control board (FNSCB) drives the sub tray paper exit
FS-520/607
roller.
A. Sub tray paper exit motor (M21) control

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

When the exited paper on the sub tray reached to a specified thickness, the sub tray full sensor (PS19) turns ON
and the sub tray full information is sent to the main body. Then, the main body displays the message on its dis-
play panel.
26
FS-520/607
5.1 Composition
Paper exit unit

Main tray exit roller
Main tray
Lift wire
a04dt2c004ca
27
5.2 Drive
FS-520/607
[5] [1]
[2]
[4]
[3]
15jkt2c015na
[1] Lift pulley /Up [4] Lift pulley /Lw

[2] Lift wire [5] Main tray
[3] Main tray lift motor (M3)
28
5.3 Operation
FS-520/607
5.3.1 Tray lift control
A. Tray lift operation
The worm gear installed in the shaft of the main tray lift motor (M3) [6] winds up the lift wire.
It lifts up or down the main tray [9] depending on the winding direction. Rotating the lift pulley /Lw clockwise and
counterclockwise in view of front, the main tray is lifted up and down respectively.
[1]
[9]
[2]
[3]
[8]
[4]
[5]
[7] [6]
15jkt2c016na
[1] Stapler paper exit upper limit sensor (PS7) [6] Main tray lift motor (M3)
[2] Main tray upper limit sensor (PS2) [7] Lift pulley /Lw
[3] Counter reset sensor (PS15) [8] Lift pulley /Up
[4] Main tray lower limit sensor (PS3) [9] Main tray
[5] Timing belt
B. Paper detection
The main tray upper limit sensor (PS2) [2] and the stapler paper exit upper limit sensor (PS7) [1] keep the speci-
fied distance between the upper surface of the paper exited to the main tray (the upper surface of the main tray
if there is no exited paper) and the paper exit opening to eliminate the misalignment of the exited paper.
During the consecutive printing operation, FS counts the number of exited paper and stops the printing when it
reaches the maximum capacity.
If the exited paper is ejected during the printing operation, the tray moves up and the counter reset sensor
(PS15) [3] turns ON and resets the counter. It makes possible to exit paper with no limitation.
The main tray lower limit sensor (PS3) [4] detects the lower limit of the tray. During the intermittent printing oper-
ation, PS3 controls the capacity of the paper exit because the counter does not integrate the total number of
exited paper.
29
C. Tray lift control

The main tray lift motor (M3) lifts up and down the main tray by rotating in the forward and reverse direction
FS-520/607
respectively. The FNS control board (FNSCB) controls M3.
(1) Non-sort/sort/group mode

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

Transmitting the FNS signal from the main body, the tray lift motor (M3) lifts up the tray until the stapler paper exit
upper limit sensor (PS2) turns ON.
The tray lift motor (M3) lifts down the main tray after a specified period of time since the paper exit roller motor
(M7) turns ON. After a specified period of time, M3 rotates in the reverse direction to lift up the main tray, and
then stops when the stapler paper exit upper limit sensor (PS7) turns OFF.
[2]
400 mm/s
Paper exit roller
motor (M7) 253 mm/s
Reverse
Stapler paper exit upper limit sensor (PS7)
Tray lift motor (M3) UP
DOWN
[1] [3] [4] 15jkt2c018na
[1] FNS start signal turned ON [3] Main tray lifted down
[2] Paper bundle exited to the main tray [4] Main tray lifted up
30
Theory of Operation Ver.3.0 Jul. 2009 6. STACKER SECTION (FS-520)
6. STACKER SECTION (FS-520)
FS-520/607
6.1 Composition
Alignment home sensor (PS8)

Alignment plate /Up
Paper exit belt home sensor

(PS9)
Paper exit arm Stacker entrance motor (M13)
Paper exit belt Alignment motor /Up (M5)
Stacker empty sensor Stacker entrance roller
(PS20)
Stacker entrance sensor

(PS5)
Swing belt
a0drt2c001ca
31
6. STACKER SECTION (FS-520) Theory of Operation Ver.3.0 Jul. 2009
6.2 Drive
FS-520/607
[12]
[1]
[2]
[11] [3]
[2] [4]
[4] [5]
[10] [9] [6]

[6]
[8]
[7]
a0drt2c001cb
[1] Coupling (from M7) [7] Paper assist roller

[2] Alignment motor /Up (M5) [8] Paper exit belt
[3] Paper assist motor (M51) [9] Swing belt /Lw
[4] Stacker entrance motor (M13) [10] Swing belt /Up
[5] Paper assist solenoid (SD51) [11] Paper exit arm
[6] Stacker entrance roller [12] Alignment plate /Up
32
6.3 Operation
FS-520/607
The alignment motor /Up (M5) rotates in the forward/reverse direction to open/close the alignment plate /Up to
perform the alignment of the paper transferred to the stacker in the main scan direction.
[3]
[2]
[1]
FRONT
15jkt2c031na
[1] Alignment motor (M5) [3] Alignment plate /Up

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

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

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

[2] Standing by for the paper at the paper size
33
6.3.2 Stopper control

The secured 5 stoppers determine the position where the paper transferred to the stacker stops. When stapling
FS-520/607
at the corner, the 3 stoppers excluding the 2 outside stoppers secured to the stapler unit determine the position
because the stapler moves to the front and rear sides.
15jkt2c021na
34
6.3.3 Stacker entrance transfer control

The stacker entrance motor (M13) drives the stacker entrance roller, swing belt /Up, and the swing belt /Lw to
FS-520/607
transfer the paper to the stacker, align the trailing edge of the paper, and adjust the staple wait timing.
A. Stacker entrance operation

The downsizing of the device is achieved by adopting the stack method whose incline angle is approximately
70°. The corrugation roller is adopted for the stacker entrance roller [5] to assist the paper exit to the stacker.
After the paper falls to the stacker, the swing belts /Up [7], /Lw [6] and the paper guide (FS-505 only) align the
paper with its trailing edge.
To assist in aligning the curled paper with the trailing edge according to the number of sheets stacked and the
paper size, the paper assist solenoid (SD51) [3] pressurizes the paper while the paper assist motor (M51) [1]
drives the paper assist roller [2].
[1]
[2]
[3]
[4]
[7] [5]
[6]
a0drt2c002cb
[1] Paper assist motor (M51) [5] Stacker entrance roller

[2] Paper assist roller [6] Swing belt /Lw
[3] Paper assist solenoid (SD51) [7] Swing belt /Up
[4] Stacker entrance sensor (PS5)
35
B. Stacker entrance transfer control

(1) Stapling mode (the paper size is not A4, B5, or 81/2 x 11, without the bypassing operation)
FS-520/607
Transmitting the FNS signal from the main body [1], the stacker entrance motor (M13) turns ON and rotates in
high speed.
M13 rotates in low speed to transfer the paper in low speed [3] when the stacker entrance sensor (PS5) detects
the trailing edge of the paper. When the paper assist roller is driven, the paper assist motor (M51) and the paper
assist solenoid (SD51) operate to assist the stacking operation. M13 rotates in high speed and stands by for the
subsequent paper after a specified period of time since it rotates in low speed.
After the last paper of the copy passes, M13 stops when the stapling operation is started.
M13 turns ON and rotates in high speed to stand by for the subsequent paper when the paper exit motor (M8)
completes the closing operation.
[2] [4] [7]
Stacker entrance High speed

motor (M13)
Low speed
Paper assist motor (M51)
Paper assist solenoid (SD51)
Stapler motors (M9 and M14)
[6]
[1] [3] [5] 15jkt2c023na
[1] FNS start signal turned ON [5] Stapling operation

[2] 1st to 9th paper [6] Closing the paper exit opening
[3] Paper transferred to the stacker in low speed [7] Standing by for the paper of the subsequent
[4] Paper assist roller in operation copy
36
(2) Stapling mode (the paper size is A4, B5, or 8 /2 x 11, with the bypassing operation)
1
The 1st copy is transferred by the same operation for the paper whose size is other than A4, B5, or 81/2 x 11.
FS-520/607
When transferring the 1st and 2nd paper of the 2nd and following copies, the stacker entrance motor (M13)
stops after a specified period of time since the stacker entrance sensor (PS5) detects the trailing edge of the last
paper of the 1st copy [3]. To prevent the paper of the 2nd copy is transferred to the stacker before the stapling
operation for the 1st copy is completed, the 1st paper for the 2nd copy stands by in the bypass path.
The stacker entrance motor (M13) turns ON and rotates in high speed after a specified period of time since the
FNS entrance sensor (PS4) detects the trailing edge of the 2nd paper. Then the 1st and 2nd paper are over-
lapped and transferred to the stacker.
[3] [4] [5]

High speed
Stacker entrance
motor (M13) Low speed
[1] [2] [6] 15jkt2c024na
[1] FNS start signal turned ON [4] 1st paper of the 2nd copy
[2] Paper transferred to the stacker in low speed [5] 2nd paper of the 2nd copy
[3] Trailing edge of the last paper of the 1st [6] 1st and 2nd paper of the 2nd copy trans-
copy detected ferred simultaneously
When transferring the 3rd and following paper of the 2nd and following copies, the paper is transferred to the
stacker by the same operation for the paper of the 1st copy.
37
6.3.4 Stacker paper exit control

The paper exit roller motor (M7) controlled by the FNS control board (FNSCB) drives the paper exit belt of the
FS-520/607
stacker via the coupling gear.
A. Paper exit belt operation

The paper exit arm [2] mounted on the paper exit belt [1] exits the paper to the main tray in the stapling mode.
The paper exit roller motor (M7) [4] drives the paper exit belt [1] via the coupling pin [3].
The paper exit belt home sensor (PS9) [5] detects the home position of the paper exit arm.
[4]
[3]
[2]
[5]
[1]
a0drt2c003cb
[1] Paper exit belt [4] Paper exit roller motor (M7)
[2] Paper exit arm [5] Paper exit belt home sensor (PS9)
[3] Coupling pin
38
B. Paper exit arm control

(1) Stapling mode (when the paper length is shorter than B5S in the paper feed direction)
FS-520/607
Completing the stapling operation, the paper exit roller motor (M7) rotates to drive the paper exit belt in the
stacker section. The paper exit arm lifts up the paper to the paper exit roller, and then the paper exit roller exits
the paper to the main tray. M7 stops when the paper exit belt home sensor (PS9) turns ON.
(2) Stapling mode (when the paper length is B5R or longer in the paper feed direction)
Completing the stapling operation, the paper exit motor (M8) rotates. When the paper exit home sensor (PS12)
detects the paper exit opening is closed, the paper exit roller motor (M7) rotates to drive the paper exit arm in
the stacker section. The paper exit arm lifts up the paper to the paper exit roller, and then the paper exit roller
exits the paper to the main tray.
M7 stops when the paper exit belt home sensor (PS9) turns ON.
39
7. STACKER SECTION (FS-607)

FS-520/607
7.1 Composition

Alignment plate /Up
Paper exit belt home sensor (PS9)
Paper exit arm

Stacker entrance motor (M13)
Paper exit belt Alignment motor /Up (M5)
Stacker empty sensor Stacker entrance roller

(PS20)
Saddle stitching
Stacker entrance sensor
stopper motor (M18)
(PS5)
Swing belt Alignment home

sensor/Lw (PS24)
Flat-stapling stopper
Alignment motor /Lw

(M16)
Saddle stitching stopper
home sensor (PS23)
Saddle stitching stopper

Alignment plate /Lw
a04dt2c006ca
40
7.2 Drive
FS-520/607
[11] [12] [13] [14] [15]
[1]
[2]
[3]
[4]
[10] [5]
[6]
[7]
[9] [8] 15jmt2c001na
[1] Coupling (from M7) [9] Alignment plate /Lw

[2] Alignment motor /Up (M5) [10] Flat-stapling stopper release solenoid /Fr (SD8),
[3] Stacker entrance motor (M13) Flat-stapling stopper release solenoid /Rr (SD7)
[4] Stacker entrance roller [11] Paper assist roller
[5] Flat-stapling stopper /Fr, Flat-stapling stopper /Rr [12] Paper assist solenoid (SD51)
[6] Alignment motor /Lw (M16) [13] Paper exit arm
[7] Saddle stitching stopper [14] Paper assist motor (M51)
[8] Saddle stitching stopper motor (M18) [15] Alignment plate /Up
41
7.3 Operation
FS-520/607
7.3.1 Alignment /Up control

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

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

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

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

/Up (M5)
OPEN
[1] [2] [3] 15jmt2c002na
[1] Closing the alignment plate /Up (FNS signal) [3] Alignment operation for every paper
[2] Standby position of the alignment plate /Up
42
7.3.2 Alignment /Lw control

In the saddle stitching/folding/tri-folding mode, the alignment plate /Up and the alignment plate /Lw move back
FS-520/607
and forth to align the paper in the main scan direction.
The alignment motor /Lw (M16) performs the alignment operation by rotating in the forward and reverse direc-
tion to move the alignment plate back and forth.
[1]
[2]
[3]
FRONT
15jmf5c024na
[1] Alignment plate home sensor /Lw (PS24) [3] Alignment plate /Lw
[2] Alignment motor /Lw (M16)
A. Alignment /Lw operation

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

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

/Lw (M16)
OPEN
[1][2] [3] 15jmt2c003na
[1] Closing the alignment plate /Lw (FNS signal) [3] Alignment operation for every paper
[2] Standby position of the alignment plate /Lw
43
7.3.3 Stopper control

The stopping position in vertical direction of paper conveyed to the stacker is different among the stapling mode,
FS-520/607
the saddle stitching mode, and the folding mode.

2 stoppers (the saddle stitching stopper and the flat-stapling stopper) control the stopping position of paper.
A. Stopper operation
In the stapling mode, the flat-stapling stopper [1] is set on the paper path by the pushing pressure by the spring
[2]. The flat-stapling stopper [1] determines the position of the leading edge of the fallen paper.
In the saddle stitching/folding/tri-folding mode, the flat-stapling release solenoids (SD7 and SD8) turn ON and
evacuate the flat-stapling stopper from the paper path. Then, the paper falls down to the saddle stitching stop-
per [3] without contacting with the flat-stapling stopper.
The saddle stitching stopper motor (M18) [5] moves the saddle stitching stopper up and down in accordance
with the paper size. The saddle stitching stopper home sensor (PS23) [6] detects the home position.
[1]
[1]
[2]
[4]
[5]
[6]
[3]
[3] 15jmt2c004na
[1] Flat-stapling stopper [4] Flat-stapling stopper release solenoids (SD7 and SD8)
[2] Spring [5] Saddle stitching stopper motor (M18)
[3] Saddle stitching stopper [6] Saddle stitching stopper home sensor (PS23)
44
B. Stopper control
(1) Folding mode
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Transmitting the FNS signal from the main body [1], the saddle stitching stopper motor (M18) rotates [2] to move
down the saddle stitching stopper to the stopping position in accordance with the paper size.
After completing the alignment operation of the last paper [3], M18 rotates [4] to move down the saddle stitching
stopper to the folding position.
After completing the folding operation, when the folding paper exit sensor (PS25) detects the trailing edge of the
paper bundle, M18 rotates [5] to move up the saddle stitching stopper to the alignment position in accordance
with the paper size and stand by for the paper of the subsequent copy.
[3]
Alignment motor /Up (M5)
Alignment motor /Lw (M16)
Saddle stitching stopper home sensor (PS23)
Saddle stitching UP
stopper motor (M18)
DOWN
[1] [2] [4] [5] 15jmt2c005na
[1] FNS start signal turned ON [4] Moving to the folding position for the paper size
[2] Moving to the alignment position for the [5] Moving to the alignment position for the
paper size subsequent copy
[3] Last paper of the copy aligned
45
(2) Saddle stitching mode

FS-520/607
After completing the stapling operation [3], the alignment motors /Up (M5) and /Lw (M16) open the alignment
plate and M18 rotates [4] to move down the saddle stitching stopper to the folding position.
paper bundle, M18 rotates [5] to move up the saddle stitching stopper to the saddle stitching position in accor-
dance with the paper size and stand by for the paper of the subsequent copy.
[3]

Clincher motor /Fr (M15)

Saddle stitching stop- UP

per motor (M18)
DOWN
[1] [2] [4] [5] 15jmt2c006na
[1] FNS start signal turned ON [4] Moving to the folding position for the paper size
[2] Moving to the saddle stitching position for [5] Moving to the saddle stitching position for
the paper size the subsequent copy
[3] Stapling operation
46
(3) Tri-folding mode

FS-520/607
After completing the alignment operation of the last paper [3], M18 rotates [4] to move down the saddle stitching
stopper to the 1st folding position in the tri-folding.
paper bundle, M18 rotates [5] to move up the saddle stitching stopper to the alignment position in accordance
with the paper size and stand by for the paper of the subsequent copy.
[3]
Saddle stitching stop- UP

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

The saddle stitching stopper motor (M18) does not operate in the flat-stapling mode.
47
7.3.4 Stacker entrance transfer control

The stacker entrance motor (M13) drives the stacker entrance roller, swing belt to transfer the paper to the
FS-520/607
stacker, align the trailing edge of the paper, and adjust the staple wait timing.
A. Stacker entrance operation

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

[2] Paper assist roller [6] Swing belt
[3] Paper assist motor (M51) [7] Stacker empty sensor (PS20)
[4] Stacker entrance sensor (PS5)
48
B. Stacker entrance transfer control

(1) Stapling mode (the paper size is not A4, B5, or 81/2 x 11, without the bypassing operation)
FS-520/607
high speed.
M13 rotates in low speed [3] when the stacker entrance sensor (PS5) detects the trailing edge of the paper and
then the paper assist roller starts to rotate to transfer the paper to the stacker in low speed. When the paper
assist roller is driven, the paper assist motor (M51) and the paper assist solenoid (SD51) operate to assist the
stacking operation. M13 rotates in high speed and stands by for the subsequent paper after a specified period
of time since it rotates in low speed.
After the last paper of the copy passes, M13 stops when the stapling operation is started [5].
M13 turns ON [6] and rotates in high speed to stand by for the subsequent paper when the paper exit motor
(M8) completes the closing operation.
[2] [4] [7]
High speed
Stacker entrance
Paper assist motor (M51)
Paper assist solenoid (SD51)
Stapler motors (M9 and M14)
[1] [3] [5] [6] 15jmt2c009na

[2] 1st to 9th paper [6] Closing the paper exit opening
[3] Paper transferred to the stacker in low [7] Standing by for the paper of the subsequent
speed copy
[4] Paper assist roller in operation
49
(2) Stapling mode (the paper size is A4, B5, or 8 /2 x 11, with the bypassing operation)
1
The 1st copy is transferred by the same operation for the paper whose size is other than A4, B5, or 81/2 x 11.
FS-520/607
When transferring the 1st and 2nd paper of the 2nd and following copies, the stacker entrance motor (M13)
stops after a specified period of time since the stacker entrance sensor (PS5) detects the trailing edge of the last
paper of the 1st copy [3]. To prevent the paper of the 2nd copy is transferred to the stacker before the stapling
operation for the 1st copy is completed, the 1st paper for the 2nd copy stands by in the bypass path.
The stacker entrance motor (M13) turns ON and rotates in high speed after a specified period of time since the
FNS entrance sensor (PS4) detects the trailing edge of the 2nd paper [5]. Then the 1st and 2nd paper are over-
lapped and transferred to the stacker [6].
[3] [4] [5]
High speed
Stacker entrance
motor (M13)
Low speed
[1] [2] [6] 15jmt2c010na
[1] FNS start signal turned ON [4] 1st paper of the 2nd copy
[2] Paper transferred to the stacker in low speed [5] 2nd paper of the 2nd copy
[3] Trailing edge of the last paper of the 1st [6] 1st and 2nd paper of the 2nd copy trans-
copy detected ferred simultaneously
When transferring the 3rd and following paper of the 2nd and following copies, the paper is transferred to the
stacker by the same operation for the paper of the 1st copy.
50
(3) Folding/saddle stitching mode

FS-520/607
high speed.
M13 rotates in low speed [2] to transfer the paper in low speed when the stacker entrance sensor (PS5) detects
the trailing edge of the paper. M13 rotates in high speed and stands by for the subsequent paper after a speci-
fied period of time since it rotates in low speed.
M13 stops after completing the alignment operation [4] of the last paper of the copy [3].
M13 turns ON and rotates in high speed to stand by for the subsequent paper when the folding paper exit sen-
sor (PS25) detects the trailing edge of the paper bundle [5].
[3] [6]
Stacker entrance High speed

motor (M13)
Low speed
Alignment motors /Up (M5) and /Lw (M16)
[1] [2] [4] [5] 15jmt2c011na
[1] FNS start signal turned ON [4] Last paper of the copy aligned
[2] Paper transferred to the stacker in low speed [5] Folding paper exit operation
[3] Last paper of the copy [6] Standing by for the paper of the subsequent
copy
51

FS-520/607
high speed.
M13 rotates in low speed [2] to transfer the paper in low speed when the stacker entrance sensor (PS5) detects
the trailing edge of the paper. M13 rotates in high speed and stands by for the subsequent paper after a speci-
fied period of time since it rotates in low speed.
M13 stops after completing the alignment operation of the last paper of the copy [3] and the movement of the
saddle stitching stopper to the tri-folding position [4].
M13 turns ON and rotates in high speed to stand by for the subsequent paper when the folding paper exit sen-
sor (PS25) detects the trailing edge of the paper bundle [5].
[3] [6]
High speed
Stacker entrance
DOWN
Saddle stitching stop-
per motor (M18)
UP
[1] [2] [4] [5] 15jmt2c012na
[1] FNS start signal turned ON [4] Saddle stitching stopper moving to the tri-fold-
[2] Paper transferred to the stacker in low speed ing position
[3] Last paper of the copy [5] Tri-folding paper exit operation
[6] Standing by for the paper of the subsequent
copy
52
7.3.5 Stacker paper exit control

The paper exit roller motor (M7) controlled by the FNS control board (FNSCB) drives the paper exit belt of the
FS-520/607
stacker via the coupling gear.
A. Paper exit belt operation

The paper exit arm [2] mounted on the paper exit belt [1] exits the paper to the main tray in the stapling mode.
The paper exit roller motor (M7) [4] drives the paper exit belt via the coupling pin [3].
The paper exit belt home sensor (PS9) [5] detects the home position of the paper exit arm.
[4]
[3]
[2]
[5]
[1]
15jmt2c013na
[1] Paper exit belt [4] Paper exit roller motor (M7)
[2] Paper exit arm [5] Paper exit belt home sensor (PS9)
[3] Coupling pin
53
B. Paper exit arm control

(1) Stapling mode (when the paper length is shorter than B5S in the sub scan direction)
FS-520/607
Completing the stapling operation, the paper exit roller motor (M7) rotates to drive the paper exit belt in the
stacker section. The paper exit arm lifts up the paper to the paper exit roller, and then the paper exit roller exits
the paper to the main tray. M7 stops when the paper exit belt home sensor (PS9) turns ON.
(2) Stapling mode (when the paper length is B5S or longer in the paper feed direction)
Completing the stapling operation, the paper exit motor (M8) rotates. When the paper exit home sensor (PS12)
detects the paper exit opening is closed, the paper exit roller motor (M7) rotates to drive the paper exit arm in
the stacker section. The paper exit arm lifts up the paper to the paper exit roller, and then the paper exit roller
exits the paper to the main tray.
M7 stops when the paper exit belt home sensor (PS9) turns ON.
(3) Folding/saddle stitching mode

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

The paper exit roller motor (M7) rotates in the reverse direction to assist in transferring the paper to the tri-folding
position after completing the paper alignment operation. M7 stops when the paper exit belt home sensor (PS9)
turns ON.
54
Theory of Operation Ver.3.0 Jul. 2009 8. STAPLER SECTION (FS-520)
8. STAPLER SECTION (FS-520)
FS-520/607
8.1 Composition
Stapler /Fr Stapler /Rr
Stapler movement home sensor (PS11) Stapler movement motor (M11)
a0drt2c002ca
55
8. STAPLER SECTION (FS-520) Theory of Operation Ver.3.0 Jul. 2009
8.2 Drive
FS-520/607
[11] [12] [13] [14] [1] [2] [3]
[4]
[5]
[10] [9] [8] [7]
[6]
15jkt2c026na
[1] Stapler /Rr [8] Stapler movement motor (M11)

[2] Stapler rotation shaft /Rr [9] Stapler movement home sensor (PS11)
[3] Rack mounting platform [10] Stapler drive rack /Fr
[4] Stapler spring /Rr [11] Stapler spring /Fr
[5] Parallel stapling position [12] Stapler rotation shaft /Fr
[6] One-corner stapling position [13] Stapler /Fr
[7] Stapler drive rack /Rr [14] Pinion gear
56
8.3 Operation
FS-520/607
A. Stapler movement operation
Since the stapler /Fr [11] and the stapler /Rr [1] operate symmetrically, the explanation is given of the stapler /Rr
[1].
The stapler movement motor (M11) [9] moves the stapler. When M11 rotates as shown in [10], it drives the sta-
pler drive rack [8] backward with the stapler via the pinion gear [12].
The stapler spring [6] always applies a rotational force to [7] on the stapler. However, the stapler does not rotate
because the height of the stapler guide roller [3] is restricted to the same height as the stapler rotational shaft by
the rack mounting platform [4].
When the stapler moves backward, the guide roller is pressed into the flute [5] on the rack mounting platform
and the stapler rotates as much as the difference to the stapler rotation shaft [2] so that the stapler moves to the
one-corner stapling position.
[11] [12] [1] [2] [3] [4]

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

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

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

(1) Size movement in 1 staple
Transmitting the FNS signal from the main body, the stapler movement motor (M11) turns ON to widen the dis-
tance between the staplers. It stops when they are positioned at the specified positions.
(2) 2 staples
The staplers do not move because the stapling operation is performed at the home position.
57
8.3.2 Stapler control

The stapling operation is performed by the stapler motors /Rr (M9) and /Fr (M14).
FS-520/607
A. Stapling operation
In the stapling operation, the stapler motors /Rr (M9) and /Fr (M14) [3] in the staplers /Rr and /Fr drive the
clincher side [2] to press the paper [1]. Then, the staple is pushed out from the stapler side [4] and bent at the
clincher side.
[1]
[4]
[2]
[3] 15jkt2c027na
[1] Paper [3] Stapler motors /Rr (M9) and /Fr (M14)
[2] Stapler (clincher side) [4] Stapler (stapler side)
58
B. Staple control
(1) Stapling
FS-520/607
After completing the alignment operation of the alignment plate, the stapler motors /Rr (M9) and /Fr (M14) per-
form the stapling operation.
The stapling operation is completed when the stapler motor home sensors /Rr (PS30) and /Fr (PS31) in the sta-
plers /Rr and /Fr detect the home position and turn ON.
(2) Clogged staple detection

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

The cartridge set switches /Rr (SW1) and /Fr (SW3) detect the presence of a cartridge or the incorrect setting of
a cartridge.
When no cartridge is set or it is set incorrectly, the main body displays the error message on its display panel.
(4) Staple detection control
When the staples run out, the staple empty switches /Rr (SW2) and /Fr (SW4) turn ON and the main body dis-
plays the error message on its display panel.
59
9. STAPLER SECTION (FS-607)

FS-520/607
9.1 Composition
Stapler rotation motor (M6)

Stapler /Rr
Stapler movement motor

Stapler movement (M11)
home sensor (PS11)
Stapler /Fr
Clincher rotation motor

(M4)
Stapler rotation home sensor
(PS13)
Clincher /Rr
Clincher rotation home sensor (PS14)

Clincher /Fr
a04dt2c007ca
60
9.2 Drive
FS-520/607
[9] [10]
[2] [10] [11]

[9]
[8]
[7]
[6]
[1]
[2]
[5] [4] [3]
[6]
[4] [3]
15jmt2c014na
[1] Stapler movement motor (M11) [7] Stapler /Fr

[2] Upper side of the timing belt [8] Stapler movement home sensor (PS11)
[3] Clincher rotation motor (M4) [9] Stapler /Rr
[4] Clincher /Rr [10] Stapler rotation motor (M6)
[5] Clincher /Fr [11] Timing belt
[6] Lower side of the timing belt
61
9.3 Operation
FS-520/607

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

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

[2] Upper side of the timing belt [7] Stapler movement home sensor (PS11)
[3] Clincher /Rr [8] Stapler /Rr
[4] Clincher /Fr [9] Timing belt
[5] Lower side of the timing belt
62
B. Rotational movement operation

The stapler /Rr and the clincher /Rr rotate 45° for performing 1 staple/one-corner stapling at rear.
FS-520/607
The stapler rotation motor (M6) [10] rotates the stapler /Rr [9] and the clincher rotation motor (M4) [5] rotates the
clincher /Rr [7].
The ball rock mechanism that consists of the ball [1] and the spring [2] securely locks the stapler and the clincher
at 0° or 45°.
The illustrations [3] and [4] show the mechanism locked and unlocked respectively.
[10]
[9]
[5]
[8] [1] [2]
[7]
[6]
[3] [4] 15jmt2c016na
[1] Ball [6] Clincher rotation home sensor (PS14)

[2] Spring [7] Clincher /Rr
[3] Locked [8] Stapler rotation home sensor (PS13)
[4] Unlocked [9] Stapler /Rr
[5] Clincher rotation motor (M4) [10] Stapler rotation motor (M6)
63
C. Stapler movement control

(1) Size movement in 1 staple/front and 2 staples
FS-520/607
Transmitting the FNS signal from the main body, the stapler movement motor (M11) turns ON to widen the dis-
tance between stapler and clincher. It stops when they are positioned at the specified positions.
M11 turns ON after a specified period of time since the main tray paper exit sensor (PS6) detects the last paper.
M11 stops when the stapler movement home sensor (PS11) turns ON.
(2) Size movement in 1 staple/one-corner stapling at rear

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

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

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

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

[2] Stapler /Rr and clincher /Rr moving horizon- [5] Stapler /Rr and clincher /Rr moving to the
tally home position rotational
[3] Stapler /Rr and clincher /Rr rotating 45° [6] Stapler /Rr and clincher /Rr moving to the
home position horizontally
64

The stapling operation is performed by the stapler motors /Rr (M9) and /Fr (M14) and the clincher motors /Rr
FS-520/607
(M10) and /Fr (M15).
A. Stapling operation
In the stapling operation, the stapler motors /Rr (M9) and /Fr (M14) in the staplers /Rr and /Fr [6] push out the
paper press section [4] to the clinchers [2] by the cam mechanism [5] to hold the paper [1] and punch out the
staples [3]. Then, the clincher motors /Rr (M10) and /Fr (M15) in the staplers /Rr and /Fr bend the staples.
[6] [1]
[2]
[3]
[5]
[4]
[2]
[3] [6]
15jmt2c018na
[1] Paper [4] Paper press section

[2] Clincher [5] Cam mechanism
[3] Staple [6] Staplers /Rr and /Fr
65
B. Staple control
(1) Stapling
FS-520/607
After completing the alignment operation of the alignment plate, the stapler motors /Rr (M9) and /Fr (M14) per-
form the stapling operation. After a specified period of time, the clincher motors /Rr (M10) and /Fr (M15) bend
the staples.
The stapling operation is completed when the clincher motor home sensors /Rr (PS32) and /Fr (PS33) and the
stapler motor home sensors /Rr (PS30) and /Fr (PS31) detect the home position and turn ON.
(2) Clogged staple detection

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

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

When the staples run out, the staple empty switches /Rr (SW2) and /Fr (SW4) turn ON and the main body dis-
plays the error message on its display panel.
66
Theory of Operation Ver.3.0 Jul. 2009 10. FOLDING/SADDLE STITCHING/TRI-FOLDING SECTION (FS-607)
10. FOLDING/SADDLE STITCHING/TRI-FOLDING SECTION (FS-607)
FS-520/607
10.1 Composition
Tri-folding gate solenoid (SD6)
Folding paper exit sensor

(PS25)
Folding knife home sensor (PS22)
Tri-folding gate
Folding transfer motor

(M20)
Folding full sensor
(PS29)
Tri-folding stopper
Folding knifeg
Folding roller
Folding full LED Folding knife motor

Tri-folding roller (PS29) (M19)
Folding pass-through
sensor (PS26) Saddle stitching
stopper
a04dt2c008ca
67
10. FOLDING/SADDLE STITCHING/TRI-FOLDING SECTION (FS-607) Theory of Operation Ver.3.0 Jul. 2009
10.2 Drive
FS-520/607
[6] [7]
[1]
[5]
[4]
[2]
[3]
15jmt2c019na
[1] Folding knife [5] Tri-folding gate solenoid (SD6)

[2] Folding knife motor (M19) [6] Tri-folding gate
[3] Folding transfer motor (M20) [7] Folding roller
[4] Tri-folding roller
68
10.3 Operation
FS-520/607
10.3.1 Folding knife control
The folding knife motor drives the folding knife. The folding knife is used in the folding/saddle stitching/tri-folding
mode. In the tri-folding mode, it is used at the 1st folding.
A. Folding knife operation

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

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

The folding knife motor (M19) turns ON and sticks out the folding knife to the paper after a specified period of
time since the folding pass-through sensor (PS26) [3] detects the paper and the saddle stitching stopper stops
at the folding position.
M19 stops when the folding knife reciprocates and the folding knife home sensor (PS22) [1] turns OFF.
69
10.3.2 Folding transfer control

The folding transfer motor (M20) drives the folding roller. Then, the folding roller drives the tri-folding roller.
FS-520/607
A. Folding transfer control

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

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

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

The folding full sensor (PS29) that consists of the LED light emitting section and the light receiving section
detects the booklet tray paper full.
It determines the booklet tray is full if the exited paper shields the folding full sensor for the specified period of
time.
70
10.3.3 Tri-folding gate control

The tri-folding gate switches between the folding/saddle stitching path and the tri-folding path. The tri-folding
FS-520/607
gate solenoid (SD6) drives the tri-folding gate.
A. Tri-folding 2nd folding operation

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

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

After the saddle stitching stopper stops at the tri-folding position, the tri-folding gate solenoid (SD6) [5] turns ON
and drive the tri-folding gate [6] to switch the paper path to the tri-folding stopper.
SD6 turns OFF after a specified period of time since the folding paper exit sensor (PS25) [9] detects the trailing
edge of the paper bundle.
71
FS-520/607
Blank page
72
MAINTENANCE
FS-520/607
Caution:
• Be sure to unplug the power cord of the main body from the power outlet.

11.1.1 Replacing the paper exit roller (sponge roller)
• Paper exit roller (sponge roller) : Every 200,000 prints *1
*1 PRO C6501 /C6501P/C65hc

*2 PRO C5501
Note
• When replacing the paper exit rollers /A (sponge rollers), be sure to replace all 5 pairs of rollers
(10 rollers in all).
73 1
B. Procedure
1. Turn ON the main power switch (SW1) and the
FS-520/607
power switch (SW2) of the main body.

2. Push up the actuator [1] of the main tray upper
limit sensor (PS2) with your finger, and then lower
the main tray [2].
3. Turn OFF the SW1 and the SW2 of the main body,
and then unplug the power cord of the main body
from the power outlet.
[1] [2]
15vlf2c001na
74

[1] and remove the sponge roller by prizing it
[1]
FS-520/607
open.
15jkf2c002na

[1]
15jkf2c003na
75
11.1.2 Replacing the intermediate transfer roller (sponge roller)

FS-520/607
• Intermediate transfer roller (sponge roller) : Every 200,000 prints *1

*1 PRO C6501 /C6501P/C65hc

*2 PRO C5501
Note
• When replacing the intermediate transfer rollers (sponge rollers), be sure to replace all 2 pairs of
rollers (4 rollers in all).
B. Procedure
2. Remove 2 screws [1] and the bearing [2], and
then remove the shaft of the intermediate transfer
roller [3].
[2]
[1]
[3]
15jkf2c004na

[1]
[1] and remove the sponge roller by prizing it
open.
15jkf2c005na
1 76

FS-520/607
Note
[1]
• When installing the intermediate transfer
roller, be sure to insert the pin at the rear of
the shaft of the intermediate transfer roller
into the groove.
15jkf2c006na
77
11.2 Stacker section

FS-520/607
11.2.1 Replacing the paper assist roller (sponge roller) (FS-520)

• Paper assist roller (sponge roller) : Every 400,000 prints *1
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
[2] [1]
2. Pull out the stacker unit.
3. Remove the C-clip [2], and then remove paper
assist roller [1].
steps in reverse.
15jkf2c007na
11.2.2 Replacing the paper assist roller (FS-607)

• Paper assist roller (sponge roller) : Every 400,000 prints *1
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
3. Open the paper assist section [1], and then lift up
the paper assist roller [2].
4. Remove the C-clip [3], and then remove the paper
assist roller [2].
steps in reverse.
[1]
[3] [2] 15jmf2c001na
1 78
11.2.3 Replacing the cleaning plate assy (FS-520)

FS-520/607
• Cleaning plate assy : Every 400,000 prints *1
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
[1] 2. Pull out the stacker unit.
cleaning plate assy [2].
steps in reverse.
[2]
a0drf2c001ca
79 1
11.3 Stapler section

FS-520/607
11.3.1 Removing/reinstalling the stapler unit cover (FS-607)
Caution:
• Be careful not to let FS fall down when removing FS from the main body and pulling out the
stacker unit from FS. It may cause the injury.
A. Procedure

2. Pull out the stacker unit [1].
[1] 15jmf2c002na
3. Remove 2 screws [1] from the rail stopper, and

[1] then pull out the stacker unit [2] further.
Note
• Be sure to place a support [3] under the
stacker unit to prevent FS from falling down.
[1]
[2]
[3] 15jmf2c003na
80
4. Remove 5 screws [1], and then remove the stapler

unit cover [2].
FS-520/607
steps in reverse.
[1]
[2]
15jmf2c004na
11.3.2 Replacing the stapler unit (FS-607)
Note
• The stapler unit consists of the clincher section and the stapler section.
• Never move the clincher section and the stapler section in the horizontal direction manually.
Otherwise, it may cause the timing belt skipping.
• After the reinstallation, be sure to adjust the stapler position in the vertical direction.

• Stapler unit : Every 1,000,000 prints (actual replacement cycle : every 200,000 staples) *1
: Every 900,000 prints (actual replacement cycle : every 200,000 staples) *2
*1 PRO C6501/C6501P/C65hc
*2 PRO C5501
B. Procedure
1. Enter the service mode and select [State Confir-
[2] [1] [3]
mation]- [I/O Check Mode]. Perform the output
code 72-32 : Stapler movement motor (M11) (A4,
1-stapling position). Then turn OFF the main body.
3. Pull out the stacker unit, and then remove the sta-
pler unit cover.
(Refer to P.80)
4. Disconnect the connector [1] and remove the
screw [2], and then remove the flat-stapling stop-
per release unit /Fr [3].
5. Enter the service mode and select [State Confir-
mation]- [Output check]. Perform the output code
15jmf2c005na
72-31. Then turn OFF the main body.
81 1
6. Remove the screw [1], the ground [2], and the

[5]
clamp [3].
FS-520/607

clincher /Fr [5] and disconnect the connector [6].
[6] [4]
[1]
[3] [2]
15jmf2c006na
8. Remove the screw [1] and then remove the flat-

[2] [1]
stapling stopper release unit /Rr [2].
9. Disconnect the connector [3] on the back of the
flat-stapling stopper release unit /Rr [2], and the
remove the wiring harness from the clamp [4].
[3] [4]
15jmf2c007na
82
10. Remove 4 screws [2] from the clincher /Rr [1], and
[2]
then remove the ground [3].
FS-520/607
[1] [3] 15jmf2c008na
11. Remove 2 screws [1] and the ball bearing mount-

[3]
ing plate [2], and then rotate and remove the
clincher /Rr [3] and disconnect the connector [4].
Note
• Be careful not to lose the ball bearing stopper
spring [5] and the ball.
[4]
[5] [1]
[2] 15jmf2c009na
12. Remove the cartridge from the stapler.

[2]
13. Remove 4 screws [2] from the stapler /Fr [1] and
the screw [3] from the ground, and then remove
[1]
the stapler /Fr [1] and disconnect the connector
[4].
[2]
[3] [4] 15jmf2c010na
83

mounting plate [3] from the stapler /Fr [2].
FS-520/607
[1] [3] [2] 15jmf2c011na
15. Remove 2 screws [3] from the sensor cover [2] of

[1]
the stapler /Rr [1], and then remove the screw [4]
from the ground and disconnect the connector
[5].
[2] Note
• When installing the sensor cover [2], be sure
to keep the wiring harness out of the stapler
rotation home sensor (PS13) [7] and be care-
ful not to let the gear bite it.
[5]
[3] [4] [6]

15jmf2c012na
16. Remove 4 screws [1], and then remove the stapler

[1]
/Rr [2] and disconnect the connector [3].
[2]
Note
• When removing the stapler /Rr [2], be sure not
to damage PS13 [4].
[1]
[4] [3]
15jmf2c013na
84

mounting plate [3] from the stapler /Rr [2].
FS-520/607
steps in reverse.
[3] [1] [2] 15jmf2c014na
11.3.3 Replacing the stapler unit (FS-520)

• Stapler unit : Every 500,000 staples
NOTE
• Be sure not to move the stapler unit in the horizontal direction by hand.
Otherwise, it may cause the timing belt skipping.
B. Procedure
[3] [4] [1]
3. Remove the cartridge from the stapler.
4. Remove 2 screws [2] from the stapler platform /Fr
[1], and then remove the stapler platform /Fr [1].
NOTE
• When reinstalling the stapler platform, you
can use the screw holes [3] if the screw holes
[2] are loose.
• When reinstalling it, be sure not to damage
the pet [4].
[2] 15jkf2c008na
85
5. Remove the connector cover [1], and then dis-

connect 2 connectors [2].
FS-520/607
6. Remove the screw [3], and then remove the

ground wire [4].
[4] [3] [2] [1] 15jkf2c009nb
7. Remove 2 screws [1] from the stapler platform /Fr

[2] [1]
[2], and then remove the stapler /Fr [3] from the
stapler platform /Fr [2].
[3] 15jkf2c010na
8. Remove the stapler /Rr [1] by repeating the proce-

[1]
dure from steps 4 to 7 .
steps in reverse.
15jkf2c011na
86
FS-520/607
A. The screw not allowed to be removed in the folding stopper
There is a screw in the folding stopper, that is not allowed to be removed.
[1]
15jmf2c017na
[1] The screw not allowed to be removed in the folding stopper
Note
• For ease of understand, the position of the folding stopper is shown lower than the actual position
in the illustration.
(2) Reason
The tilt adjustment of the folding stopper should be made at the slide shaft of the folding stopper. (Refer to Field
Service P.497) Never loosen the screw not allowed to be removed in the folding stopper because the tilt of the
folding stopper may be changed and the adjustment reference in the slide shaft may be misaligned if the screw
is loosen.
87
12.2 List of parts to be disassembled and assembled

No. Section Part name Page referred to
FS-520/607
1 Cover Upper cover /1 P.89

3 Front door P.90
4 Rear cover P.90
5 Left cover P.91
6 Main tray section Main tray P.92
7 Lift wire P.93
8 Stacker section Stacker unit cover P.99
9 Stacker unit P.102
10 Transfer section Paper exit unit P.104
88
12.3 Removal procedure of parts to be disassembled and assembled
FS-520/607
12.3.1 Removing/reinstalling the upper cover /1
A. Procedure
1. Remove 2 caps [1].
[1]
2. Open the front door [2] and remove the 5 screws
[3] [3], and then remove the upper cover /1 [4].
steps in reverse.
[2]
[3] 15jkf2c012na
12.3.2 Removing/reinstalling the upper cover /2
Note
• Remove optional PI if it is installed.
A. Procedure
1. Remove the upper cover /1. (Refer to P.89)
[3] 2. Open the front door [1].
[4]
3. Remove 2 screws [2] and pull out the sub tray [3],
and then remove the upper cover /2 [4].
[1]
steps in reverse.
[2] 15jkf2c013na
89
12.3.3 Removing/reinstalling the front door

A. Procedure
FS-520/607

[3] 2. Remove 2 screws [3] from the lower hinge plate
[1] [2], and then remove the front door [1].
steps in reverse.
[2]
15jkf2c034na
12.3.4 Removing and reinstalling the rear cover

A. Procedure
1. Remove 6 screws [1], and then remove the rear
cover [2].
steps in reverse.
[1]
Note
[1] • When reinstalling the rear cover, be sure to
[3] [4] hook the notch [3] of the rear cover on the
prong [4] of the frame.
[2]
15jkf2c035nb
90
12.3.5 Removing/reinstalling the left cover

A. Procedure
FS-520/607
[1]
2. Remove 3 screws [1], and then remove the left
cover [2].
steps in reverse.
[2] 15jkf2c036na
91
12.3.6 Removing/reinstalling the main tray

FS-520/607
Caution:
• After opening the main tray, be sure to unplug the power cord of the main body from the power
outlet.
A. Procedure
1. Push up the actuator [1] of the main tray upper

limit sensor (PS2) with your finger, and then open
[1]
the main tray [2].
2. Turn OFF the main power switch (SW1) and the
sub power switch (SW2) of the main body, and
then unplug the power cord of the main body from
the power outlet.
[2]
15jkf2c014na
3. Remove 2 screws [1] from the main tray.

[2]
4. Lift up the main tray [2] and unhook the main tray
from the lift stay [3], and then remove the main
tray [2].
steps in reverse.
[1]
[3]
15jkf2c015na
92
12.3.7 Replacing the lift wire
FS-520/607
Caution:
• When the main tray lift motor is removed, the main tray may fall down. When removing the main
tray lift motor, be sure to support the main tray with your hand.
Note
• The following procedure for replacing the lift wire shows the examples on the rear side. The con-
figuration and winding of the wires on the front side are symmetrical to the rear side.
• The front and rear lift wires are marked as "F" and "R" on their mounting plates respectively. Be
sure to check it when reinstalling the lift wires.
A. Procedure
For FS-520
[3] [4]
• Front cover (Refer to P.90)
• Main tray (Refer to P.92)
2. Remove 5 screws [1] to remove the reinforcing
metal [2], and then remove the wiring harness
from 3 clamps [3] and disconnect the connector
[4].
Note
• In FS-520 and FS-607, the lift motor is
installed up side down so that the position of
the connector and the positions of the mount-
[2] [1] ing holes of the reinforcing metal are differ-
15jkf2c016na
ent.
For FS-607
[3] [4]
[2] [1] 15jmf2c015na
93
3. Remove 5 screws [1], and then remove the lift

[2] [1]
motor unit [2].
FS-520/607
Caution:
• When the lift motor assy [2] is removed, the
main tray may fall down. When removing the
lift motor assy, be sure to support the main
tray with your hand.
15jkf2c017na
4. Remove 2 screws [1], and then remove the wire

mounting plate [3] of the rear lift wire [2] from the
lift stay [4].
[2]
[1]
[3]
[4]
15jkf2c018na
94
5. Loosen 2 screws [2] on the belt tensioner [1].
FS-520/607
[2]
[1]
15jkf2c019na
6. Remove the E-ring [1], the gear [2], and the lift
pulley /Lw [3], and then remove the lift wire [4].
[5]
[3]
Note
• When removing the lift pulley /Lw, be sure not
to let 2 pins [5] fall down.
[4]
[1] [2]
15jkf2c020na
95
7. Tighten the wire mounting plate [1] of the new lift

wire [4] on the lift stay [2] with 2 screws [3] tempo-
FS-520/607
rarily.
Note
• The lift wire [4] should be placed with the
short side [5] to the bottom and the long side
[6] to the top.
[6]
[2]
[4]
[1]
[5] [3]
15jkf2c021na
8. Fasten the wire end of the lift wire with the inner
wire end hole of the lift pulley /Lw [1]. Then, draw
the lift wire through the notch [2] and wind it a little
less than 5 turns from inside to outside around the
lift pulley with no slack, and then insert the lift pul-
ley /Lw [1] into the shaft so that it coincides with
[3] the pin [3].
[1]
[2]
15jkf2c022na
96
9. Insert the up/down pulley [1] wound around with

[2] [1] [4] [3]
the wire into the shaft so that the pin [3] that has
FS-520/607
been inserted into the shaft [2] in advance is set to
the groove [4] of the pulley.
15vlf2c009na
10. Hook the lift wire on the lift pulley /Up [1]. Then,
wind the lift wire 2 turns from inside to outside
[1] around the lift pulley Lw [2] with no slack, draw the
lift wire through the notch and fasten it with the
wire end hole [3].
[3] Note
• Be sure to wind the lift wire on the lift pulley /
UP without the short side (the side wound in
advance) and the long side (the side wound
subsequently) are overlapped.
[2]
15jkf2c023na
11. Insert the pin [1] and the gear [2], and then fasten
it with E-ring [3].
[1]
[2]
[3] 15jkf2c024na
97
12. Use a tension gauge or spring balance to pull up

the belt tensioner [1] with a standard force "A" [3]
FS-520/607
and fasten it with the 2 screws [2].

Standard value [3]: A = 2.5 ± 0.25 kg
[3]
[2]
[1]
15jkf2c025na
13. Loosen the 2 screws [2] on the wire mounting

[2] plate [1] at the front to push down the lift stay [3]
to the horizontal position, and then remove 4
screws [2] and [5] from both the front and the rear.
Note
• Be sure to check the lift stay [3] is in the hori-
[1]
zontal position. If it is in the tilt position, the
main tray lift motor (M3) or the gear may be
damaged due to the excessive force.

[3]
[4] [5] steps in reverse.
15jkf2c026na
98
12.3.8 Removing/reinstalling the stacker unit cover (FS-607)

A. Procedure
FS-520/607
[2]
stacker unit cover [2].
steps in reverse.
[1] 15jmf2c016na
99
12.3.9 Removing/reinstalling the stacker unit (FS-520)

FS-520/607
Caution
• Be sure to conduct this operation with 2 personnel.
A. Procedure
[2] • Booklet tray
2. Remove FS from the main body.
4. Disconnect 2 connectors [2] (CN22, CN23) from
the relay board (RB) [1] on the back of the stacker
unit.
5. Remove the wiring harness from the 3 clamps [3].
[3] [1] a0drf2c002ca
6. Remove the C-clip [1] and the shaft [2], and then
[2] [1] separate the coupling arm [3].
[3] a0drf2c003ca
100
7. Remove the 2 screws [1] from the rail stopper,

[1]
and then pull out the stacker unit [2] further.
FS-520/607
Note
• In order to prevent the FS from falling down,
be sure to place a support [3] beneath the
stacker unit that has been pulled out.
[2] [3] [1] 15vlf2c012na
8. Remove 2 screws [1], and then lift up the stacker

[4] unit [2] and remove it from the guide rails [3].
[3]
Note
• When removing the stacker unit, be careful of
[5]
your posture not to suffer a crick in the back.
[1]
steps in reverse.
Note
• When installing the stacker unit [2] to the
guide rail [3], be sure to check to see if the
hooks [4] are set securely into the installation
holes [5].
[2] [1]
[3] [5]
[4]
15vlf2c013na
101
12.3.10 Removing/reinstalling the stacker unit (FS-607)

FS-520/607
Caution:
• Be sure to conduct this operation with 2 personnel.
A. Procedure
[1] [2]
• Booklet tray
2. Remove FS from the main body.
4. Disconnect 3 connectors [1] (CN22, CN23, CN24)
from the relay board (RB) [2] on the back of the
stacker unit.
5. Remove the wiring harness from the 4 clamps [3].
[3]
a04df2c001ca
6. Remove the C-clip [1] and the shaft [2], and then
[2] [1]
separate the coupling arm [3].
[3] 15jkf2c028na
102

then pull out the stacker unit [2] further.
FS-520/607
Note
[1] • Be sure to place a support [3] under the
[2]
[1]
[3] 15jkf2c029na
8. Remove 2 screws [1], and then lift up the stacker

[4] unit [2] and remove it from the guide rails [3].
[3]
Note
• Be careful of your posture in order not to
[5]
throw out your back when removing it.
[1]
steps in reverse.
Note
[2]
• When reinstalling the stacker unit [2] to the
guide rails [3], be sure to check that the
hooks [4] are inserted into the mounting holes
[5] [5] securely.
[3]
[4] [1]
15jkf2c030na
103
12.3.11 Removing/reinstalling the paper exit unit

A. Procedure
FS-520/607

[2] • Remove the upper cover /1 or optional PI
(Refer to P.89)
• Upper cover /2 (Refer to P.89)
• Main tray (Refer to P.92)
2. Remove 4 screws [1], and then remove the main
paper exit cover [2].
[1]
15vlf2c014na
3. Remove the screw [3] from the paper exit open/

close link [2] of the paper exit unit [1].
[2]
[3]
[1]
15jkf2c031na
4. Remove the clamp [1], the screw [2] securing the

[4] [1] [2]
ground wire, 2 connectors [3] and 3 screws [4]
from the clamp.
[3] 15jkf2c032na
104
5. Remove the E-rings [1], 1 each, and the bearings,

[1] [2]
1 each, from both the front and the rear, and then
FS-520/607
remove the paper exit unit [3].
steps in reverse.
[2] [1]
[3]
15jkf2c033na
105

When the FNS control board (FNSCB) is replaced, be
FS-520/607
sure to remove the EEPROM (IC10) from the old con-

trol board [1] and install it into the new control board
[2].
[1]
[2]
a04df2e001ca
Note
tion.
A
fd501fs2078c
106
PI-502
2008.07
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
PI-502
PI-502
OUTLINE
3. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Auto sheet feeding (online operation). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Manual sheet feeding (offline operation). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPOSITION/OPERATION
4.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2.1 Paper feed drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2.2 Tray lift drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3.1 Tray lift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3.2 Pick-up mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3.3 Separation mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.3.4 Registration control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
MAINTENANCE
5.1 Paper feed section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.1.1 Replacing the pick-up roller /Up and the paper feed roller /Up . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.1.2 Replacing the pick-up roller /Lw and the paper feed roller /Lw . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.1.3 Replacing the separation roller /Up and the torque limiter /Up . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.1.4 Replacing the separation roller /Lw and the torque limiter /Lw . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.2.1 Removing/reinstalling the top cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2.2 Removing/reinstalling the rear cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2.3 Removing/reinstalling the operation panel cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
i
PI-502
Blank page
ii
OUTLINE
PI-502
A. Type
Type Torque limiter separation type seat feeding device
B. Functions
Auto sheet feeding (online Feeds the sheet to FS automatically under the instruction from the main body.
operation)
Manual sheet feeding Feeds the sheet to FS under the instruction from the operation panel of PI.
(offline operation) You can select the following 5 post processing modes:
• 1 staple/back mode
• 2 staples (flat-stapling) mode
• Punch mode (when PK-512/513 is installed on FS)
• Saddle stitching mode
• Tri-folding mode
Note
• The tray /Lw only supports the manual sheet feeding.
C. Type of paper
Paper size Tray /Up A4, A4S, B5, B5S, A5

81/2 x 11, 81/2 x 11S, 51/2 x 81/2
16K, 16KS
Custom paper (Max.216 x 297 mm, MIn. 182 x 139 mm)
Tray /Lw A3, B4, SRA4S, A4, A4S, B5, B5S, A5
12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
8K, 16K, 16KS
Paper type Plain paper, recycle paper, color paper, special paper, coated paper, high-quality paper
Capacity Tray /Up, /Lw 200 sheets (80 g/m2) or 30 mm or less in height
Paper curling
[1]
a
15jft1c001na
a Curling: 10 mm or less
[1] 5 papers
1
D. Maintenance

PI-502
E. Machine data

tion
Weight Approx. 10.5 kg
Note
2

Tray /Up section Pick-up /Up section
PI-502
Separation /Up section
Conveyance
section
Tray /Lw section
Pick-up /Lw section

Separation /Lw section 15jft2c001na
3
3. PAPER PATH
3.1 Auto sheet feeding (online operation)
PI-502
[1]
[2] 15jft1c002na
[1] Paper path from the tray /Up [2] Paper path from the tray /Lw
3.2 Manual sheet feeding (offline operation)
[1]
15jft1c003na
[1] Paper path from the tray /Lw
4
PI-502
4.1 Composition
Tray /Up Pick-up roller /Up

Paper feed roller /Up
Separation
roller /Up
Conveyance
roller /Up
Paper feed
roller /Lw
Tray /Lw Conveyance

roller /Lw
Pick-up roller /Lw

Separation roller /Lw a04ht2c001ca
5
4.2 Drive
PI-502
[1] [2] [3] [4]

[5]
[6]
[7]
[8]
[9]
[10]
[14]
[13] [11]
[12]
[18]
[17] [15]
[16]
15jft2c002nb
[1] Pick-up roller /Lw [10] Paper feed roller /Lw

[2] Pick-up roller /Up [11] Conveyance roller /Lw
[3] Pick-up solenoid /Up (SD201) [12] Separation roller /Lw
[4] Paper feed roller /Up [13] Pick-up solenoid /Lw (SD202)
[5] Transfer clutch (MC201) [14] Transfer motor (M203)
[6] Separation roller /Up [15] Pick-up solenoid /Up (SD201), /Lw (SD202)
[7] Transfer clutch /Lw (MC202) [16] Front
[8] Conveyance roller /Up [17] Pick-up roller /Up and /Lw
[9] Registration clutch (MC203) [18] Paper feed roller /Up and /Lw
6
PI-502
[3]
[1]
[2] 15jft2c003nb
[1] Front [3] Tray lift motor /Up (M201)
[2] Tray lift motor /Lw (M202)
7
4.3 Operation
4.3.1 Tray lift mechanism
PI-502
The tray lift motors /Up (M201) [2] and /Lw (M202) [7] move up and down the trays /Up and /Lw by rotating in
the forward and reverse direction to drive the lift arms /Up [10] and /Lw [4] and move up and down the lift plates
/Up [8] and /Lw [6], respectively.
At the upper limit positions, the tray upper limit sensors /Up (PS205) [1] and /Lw (PS209) [3] detect the actuators
lifted up by the lift plates.
At the lower position of the tray, the tray lower limit sensors /Up (PS204) [9] and /Lw (PS210) [5] detect the actu-
ators coupled with the lift arms /Up and /Lw.
[9] [10]
[8]
[1]
[7]
[2]
[3]
[6]
[5] [4]
15jft2c004na
[1] Tray upper limit sensor /Up (PS205) [6] Tray lift plate /Lw
[2] Tray lift motor /Up (M201) [7] Tray lift motor /Lw (M202)
[3] Tray upper limit sensor /Lw (PS209) [8] Tray lift plate /Up
[4] Lift arm /Lw [9] Tray lower limit sensor /Up (PS204)
[5] Tray lower limit sensor /Lw (PS210) [10] Lift arm /Up
8

The pick-up solenoids /Up (SD201) [2] and /Lw (SD202) turn ON to pick up the paper. The release arm [5] held
upward by the spring [1] lifts up the pick-up roller mounting plate [4] to release the pick-up roller [3]. When
PI-502
SD201 and SD202 turn ON, the release arm moves backward, and then the pick-up roller mounting plate and
the pick-up roller fall down by their own weight. The pick-up roller driven by the transfer motor (M203) presses
the paper and picks it up to transfer it to the separation section.
[4] [5]
[1]
[3] [2] 15jft2c005nb
[1] Spring [4] Pick-up roller mounting plate

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

The separation roller [4] is driven to rotate in the opposite direction from the paper transfer direction [2]. When
transferring no or 1 sheet of paper, the separation roller rotates in the paper transfer direction to transfer the
PI-502
paper to the paper transfer section because the frictional force between the paper feed roller [1] or the paper
and the separation roller [4] is stronger than the frictional force of the torque limiter [3].
When transferring 2 or more sheets of paper, the separation roller rotates in the reverse direction to prevent the
bottom sheet from being transferred because the frictional force between the sheets is stronger than the fric-
tional force of the torque limiter [3].
[7]
[6] [1]
[2]
[5]
[3]
[4]
15jft2c006na
[1] Paper feed roller [5] 2nd sheet

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

Transmitting the FS start signal [1], the transfer motor (M203) rotates in low speed and the pick-up solenoids /
UP (SD201) and /Lw (SD202) turn ON. At the time, the tray lift motors /Up (M201) and /Lw (M202) rotate in the
PI-502
forward direction to lift up the trays /Up and /Lw.
M201 and M202 stop when the tray upper limit sensors /Up (PS205) and /Lw (PS209) turn ON [2], and after a
specified period of time, the transfer clutch /Up (MC201) and /Lw (MC202) turn ON and the paper is picked up
from the tray. Only 1 sheet of paper is transferred by the transfer roller because of the separation roller.
M203 rotates in high speed when the paper reaches the paper passage sensors /Up (PS201) and /Lw (PS206)
[3]. At the time, the paper is pressed against the transfer roller and forms a loop because the registration clutch
(MC203) is OFF. After a specified period of time, MC203 turns ON [4] and M203 drives the paper to FS.
M203 switches to rotate in low speed to feed the subsequent paper since the paper passed PS201/PS206 [5],
and then MC203 turns OFF after a specified period of time.
Transfer motor Low speed

(M203)
HIgh speed
Transfer clutch /Lw (MC202)
Tray lift motor /Lw (M202)
Tray upper limit sensor /Lw (PS209)
Pick-up solenoid /Lw (SD202)
Paper passage sensor /Lw (PS206)
[1] [2] [3] [4] [5] 15jft2c007na
[1] FS start signal turned ON [4] Registration clutch (MC203) turned ON

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

The paper size VRs /Up (VR201) [1] and /Lw (VR202) [3] coupled with the side guide [2] detects the paper size in
the main scan direction.
PI-502
The paper set sensors /Up (PS203) [5] and /Lw (PS212) [4] and the L size sensor /Lw (PS208) [6] detects the
paper size in the sub scan direction.
[1]
[6] [2]
[5] [4] [3]

15jft2c008na
[1] Paper size VR /Up (VR201) [4] Paper set sensor /Lw (PS212)
[2] Side guide plate [5] Paper set sensor /Up (PS203)
[3] Paper size VR /Lw (VR202) [6] L size sensor (PS208)
12
MAINTENANCE
PI-502
5.1 Paper feed section
Caution:
5.1.1 Replacing the pick-up roller /Up and the paper feed roller /Up
• Pick-up roller /Up: Every 1,000,000 prints (actual replacement cycle: every 200,000 prints)
• Paper feed roller /Up: Every 600,000 prints (actual replacement cycle: every 100,000 prints)
B. Procedure
1. Remove the top cover (Refer to P.19)
[2]
[1] 2. Remove 2 C-clips [1], and then slide the bearings
[1]
[2] at the both sides and remove the paper feed
roller assy /Up [3].
[2]
[3]
15jff2c001na
13
3. Remove the bearing [1] and then remove the

actuator [2].
PI-502
[1]
[2]
a04hf2c001ca
4. Remove 2 C-rings [1], and remove 2 bearings [2].
[2]
[1]
a04hf2c002ca

[2] [3]
6. Slide 2 roller shafts [2] to the arrow-marked direc-

tion to remove the pick-up roller /Up [3] and the
paper feed roller /Up [4].
Note
• Reinstalling the pick-up roller and the paper
feed roller with the blue faces of the one-way
clutches of the pick-up roller and the paper
feed roller face to the front.
[4] [1] a04hf2c003ca
14
7. Remove the pick-up roller [1] and the paper feed

[2] [5] [1]
roller [2] from the one-way clutches [3] and [4].
PI-502
Note
• When reinstalling the pick-up roller [1], be
sure to insert its cutout [5] over the protrusion
[6] of the one-way clutch [3].
[7] • When reinstalling the paper feed roller [2], be
sure to insert its cutout [7] over the protrusion
[4] [3]
[8] of the one-way clutch [4].
[8] [6] a04hf2c004ca

steps in reverse.
15
5.1.2 Replacing the pick-up roller /Lw and the paper feed roller /Lw
• Pick-up roller /Lw: Every 1,000,000 prints (actual replacement cycle: every 200,000 prints)
PI-502
• Paper feed roller /Lw: Every 600,000 prints (actual replacement cycle: every 100,000 prints)
B. Procedure
1. Pull the release lever [1] and open the top door [2].
[1] [2] 2. Perform the steps 2 to 7 in "5.1.1 Replacing the
pick-up roller /Up and the paper feed roller /Up."
steps in reverse.
15jff2c004na
5.1.3 Replacing the separation roller /Up and the torque limiter /Up
• Separation roller /Up: Every 600,000 prints (actual replacement cycle: every 100,000 prints)
• Torque limiter /Up: Every 3,000,000 prints (actual replacement cycle: every 600,000 prints)
B. Procedure
[2]
[1] 2. Remove 2 C-clips [1], and then slide the bearings
[1]
[2] at the both sides and remove the paper feed
roller assy /Up [3].
[2]
[3]
15jff2c005na
16
3. Release hooks [1] at the both sides, and then lift

[2]
up and remove the separation roller assy /Up [2].
PI-502
[1] 15jff2c006na
4. Remove the C-clip [1] from the separation roller

[1] [2]
assy /Up, and then remove the separation roller /
Up [2] and the torque limiter /Up [3].
[3]
steps in reverse.
Note
[4]
• Install the separation roller with 2 notches [4]
[5] face to the front and be aligned with the
15jff2c007na
prong [5].
5.1.4 Replacing the separation roller /Lw and the torque limiter /Lw
• Separation roller /Lw: Every 600,000 prints (actual replacement cycle: every 100,000 prints)
• Torque limiter /Lw: Every 3,000,000 prints (actual replacement cycle: every 600,000 prints)
B. Procedure
1. Pull the release lever [1] and open the top door [2].
[1] [2] 2. Perform the steps 2, 3, and 4 in "5.1.3 Replacing
the separation roller /Up and the torque limiter /
Up."
steps in reverse.
15jff2c008na
17
6. OTHER PROCEDURES
PI-502

1 Cover Top cover P.19
2 Rear cover P.19
3 Operation panel cover P.20
18
PI-502
Caution:
6.2.1 Removing/reinstalling the top cover

A. Procedure
1. Remove the cap [2] of the top cover [1].
[3]
2. Remove 4 screws [3], and then remove the top
[2]
cover [1].
15jff2c009na
6.2.2 Removing/reinstalling the rear cover

A. Procedure
[3]
2. Remove the screw [1], and then remove the con-
[4] nector cover [2].
[1] cover [4].
steps in reverse.
[2]
[3]
15jff2c010na
19
6.2.3 Removing/reinstalling the operation panel cover

A. Procedure
PI-502
[2] [1]
2. Remove 2 screws [1] and disconnect the connec-
tor [2], and then remove the operation panel
assembly [3].
steps in reverse.
[3] 15jff2c011na
20
PK-512/513
2008.07
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
PK-512/513
PK-512/513
OUTLINE
2. UNIT COMPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. PUNCH SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2.1 Punch shift drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2.2 Punch drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.3.1 Punch standby position movement control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.3.2 Punch position correction control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3.3 Punch control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5. PUNCH SCRAPS BOX SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.3.1 Punch scraps box control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
MAINTENANCE
6.3.1 Removing/reinstalling the punch unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
i
PK-512/513
Blank page
ii
OUTLINE
PK-512/513
A. Type
Type FS-integrated type punching operation device
B. Functions
Punching method Stops and punches every paper

No. of holes PK-512: 2 holes/3 holes (inch) or 2 holes/4 holes (metric)
PK-513: 4 holes
Hole diameter φ 6.5 mm (2 holes/4 holes), φ 8.0 mm (3 holes)
Hole pitch PK-512: 80 mm (2 holes/4 holes), 108 mm (3 holes)
PK-513: 21, 70, 21 mm
Supported mode Punch mode, straight mode
Applicable post processing Sort, group, staple
mode
C. Type of paper
Paper size PK-512 (2 holes): A3, B4, SRA4S, A4, A4S, B5, B5S, A5, A5S
11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
8K, 16K, 16KS
PK-512 (3 holes/4 holes): A3, B4, A4, B5
11 x 17, 81/2 x 11
8K, 16K
PK-513: A3, B4, A4, B5
Applicable paper Plain paper, high quality paper, color paper, coated paper (same as the main
body)
Punch prohibited paper Label paper, tab paper, transparency film, 2nd base paper, holed paper, and the
other paper that may interfere with the operation of the punch unit or the punch
blade.
Paper curling
a [1]
15knt1c001na
a Curling (10 mm or less)

[1] 5 sheets of paper
1
D. Maintenance

PK-512/513
E. Machine data
Power source 24/5V DC (supply from the main body)

Maximum power 40 W or less
consumption
Weight Approx. 3 kg
NOTE
2
Theory of Operation Ver.1.0 Jul. 2008 2. UNIT COMPOSITION
2. UNIT COMPOSITION
PK-512/513
Punch section
Punch scraps box

section
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3
3. PAPER PATH
PK-512/513
[1]
[2]
[3]
[4]
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[1] Paper path from PI [3] Paper path from the main body
[2] Punch unit [4] Punch scraps box
4
PK-512/513
4. PUNCH SECTION
4.1 Composition
Punch blade Paper size sensor (PS305)

Punch unit
Punch blade
Entrance roller
a04et2e001ca
5
4.2 Drive
PK-512/513
4.2.1 Punch shift drive
[6] [7] [1]
[5] [3] [2]

[4]
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[1] Punch unit [5] Punch shift motor (M302)

[2] Guide shaft [6] Rack
[3] Belt [7] Punch shift home sensor (PS303)
[4] Front
6
4.2.2 Punch drive

A. PK-512 (2 to 3 holes)
PK-512/513
[3] [1]
[1]
[12] [13] [2]
[2]
[3]
[10] [11]
[9]
[3]
[8]
[7] [4]
[6] [5]
[10] [11]
[9] [3]
[8]
[7] [4]
[5] [6]
15kjt2e007nb
[1] Punch motor (M301) [8] Groove of the switching cam

[2] Eccentric cam [9] Projection of the punch blade
[3] Slide link [10] Projection of the switching cam
[4] Switching cam [11] Punch blade
[5] When the punch blade is driven [12] Punch blade of the 3-hole punch
[6] When the punch blade is not driven [13] Punch blade of the 2-hole punch
[7] Switching cam shaft
7
B. PK-512 (2 to 4 holes)
PK-512/513
[3] [1]
[1]
[12] [13] [2]
[2]
[3]
[10] [11]
[9]
[3]
[8]
[7] [4]
[6] [5]
[10] [11]
[9]
[3]
[8]
[7] [4]
[5] [5]
a04et2f002ca
[1] Punch motor (M301) [8] Groove of the switching cam

[2] Eccentric cam [9] Projection of the punch blade
[3] Slide link [10] Projection of the switching cam
[4] Switching cam [11] Punch blade
[5] When the punch blade is driven [12] Punch blade of the 4-hole punch
[6] When the punch blade is not driven [13] Punch blade of the 2-hole and 4 hole punch
[7] Switching cam shaft
8
C. PK-513
PK-512/513
[4]
[1]
[2]
[3]
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[1] Eccentric cam [3] Punch blade

[2] Drive arm [4] Punch motor (M301)
9
4.3 Operation
PK-512/513
4.3.1 Punch standby position movement control

Turning ON the device, the punch shift motor (M302) rotates to move the punch unit [6] to the home position
until the punch shift home sensor (PS303) turns ON.
Selecting the punch mode, M302 rotates to move the punch unit [6] so that the paper size sensor (PS305) [1] of
the punch unit [6] is positioned 5 mm inward [2] from the side edge of the paper.
PS305 consists of 5 sensors. Each sensor detects the following paper.
Sensor Paper size
1 A5S, 51/2 x 81/2S
2 B5S, 16KS
3 A4S, A5, 81/2 x 11S, 81/2 x 14S, 51/2 x 81/2, 81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
4 B4, B5, 8K, 16K
5 A3, A4, 11 x 17, 81/2 x 11
* The sensors are numbered 1 to 5 from the front side
And, when the stand-by position is 5 mm for B5 and B4 paper sizes, the corner of the paper passes through
below the punch hole and the stand-by position is changed to 1.5 mm to prevent the hitching of the paper.
The punch unit returns to the home position at the end of the job.
[5] [6] [1]

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

[2] Moving distance from the paper edge [5] Punch blade
[3] Paper transfer direction [6] Punch unit
Note
• In the model PK-512, the paper size sensor (PS305) is positioned on the front side and its opera-
tion is contrary to that in the above illustration on the right and left sides.
10
4.3.2 Punch position correction control

For the punch unit positioned from the side edge of the paper to the inside (Refer to "4.3.1 Punch standby posi-
PK-512/513
tion movement control"), the punch position is adjusted in the following procedure so that punching is made
symmetrically to the center of paper at all times. The punch position correction is operated by moving the punch
unit back and forth while conveying the paper.
• When the FNS entrance sensor (PS4) detects the leading edge of the paper, the punch unit [11] is moved to
the rear side until the paper size sensor (PS305) [2] detects the side edge of the paper. If you conduct the
punch operation on the paper conveyed from PI, it is started when the paper entrance sensor /Up (PS201)
or /Lw (PS206) detects the leading edge of the paper.
• Then, the punch unit [11] is moved to the front side until PS305 [2] detects the side edge of the paper (the
side edge reference position detection).
• Once it detects the side edge reference position [3], the punch unit is moved further [11] so that the center
of the punch blade [1] is positioned to the center of the paper [5]. The moving distance and its direction are
depending on the paper size. It is stopped temporarily at the side edge reference position if it is moved to
the rear side.
[10] [11] [1] [2]
[3]
[9] [8]
[7]
[6]
[5] [4]
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[1] Center of the punch blade [7] Punch unit moving direction
[2] Paper size sensor (PS305) [8] Rear side
[3] Side edge reference position [9] Front side
[4] Paper [10] Punch blade
[5] Center of the paper [11] Punch unit
[6] Paper transfer direction
Note
• In the model PK-512, the paper size sensor (PS305) is positioned on the front side and its opera-
tion is contrary to that in the above illustration on the right and left sides.
11
4.3.3 Punch control

A. Registration loop control
PK-512/513
The FNS conveyance motor (M1) turns OFF temporarily to stop conveyance of paper when the specified time
has passed since paper exit sensor (PS13) detected the leading edge of the paper. Thus the paper is pressed
against the entrance roller forming a loop to correct the bend. When the specified time has passed, M1 turns
ON to restart conveying the paper.
The above operation is not performed when conveying a large paper (220 mm and longer in the sub scan direc-
tion) and in the non-punching mode.
When punching the paper conveyed from PI, the loop is formed on the PI's side. For details, refer to PI-502
SHB.
[4] [2]
[1]
[3]
[2]
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[1] Main body [3] Loop

[2] Entrance roller [4] PK
12
B. Punch control (PK-512)

The FNS transfer motor (M1) is driven by the main body start signal.
PK-512/513
In the punching mode, the motor M1 stops temporarily after the FNS entrance sensor (PS4) detects the rear edge of paper.
At the same time, the punch motor (M301) [3] rotates in the direction according to the number of punched
holes. Number of punched holes of PK-512 is switched between 2 to 4 and 2 to 3 holes depending on the
country. The motor M301 drives the slide link in the main scanning direction through the eccentric cam. As a
result, the projection of the switching cam is pushed in the slide link moving direction and the switching cam is
rotated around its axis. And then the punching blade [7] lowers to punch a hole. The projection of the punch
blade is fitted into the groove of the switching cam.
Moving distance of the slide link [5] is controlled by detecting the eccentric cam actuator [4] with the punch
home sensor (PS301) [1]. When the actuator rotates 180 degrees, first punching is completed. In the second
punching, M301 is reversed. When the actuator reverses 180 degrees, punching is completed. Forward and
reverse rotations are repeated alternately.
The rotating speed of M301 is controlled by detecting the rotation of the punch encoder plate [6] fixed to the
axis of M301 with the punch encoder sensor (PS306) [2].
Then, M301 reverses and the punch home sensor (PS301) [1] returns to ON and the M301 stops finally.
When a specified time elapsed after M1 stops temporarily, M1 resumes rotating and paper is transferred.
[1]
[2]
[7] [6]
[3]
[4] [1]
[5]
[8]
[1]
[9]
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[1] Punch home sensor (PS301) [7] Punching blade

[2] Punch encoder sensor (PS306) [8] Operation of 3-hole punching in the 2 to 3 hole
[3] Punch motor (M301) mode and 4-hole punching in the 2 to 4 hole mode
[4] Actuator [9] Operation of 2-hole punching in the 2 to 3 hole
[5] Slide link mode and 2-hole punching in the 2 to 4 hole mode
[6] Punch encoder plate
13
(1) 2 to 3 holes mode

In the 2 to 3 punched hole mode, the groove of the switching cam of the 3-hole punching blade is shaped so
PK-512/513
that the rear side is concentric with the rotating axis and the front side is curved toward the rotating axis. For this
reason, when the switching cam is rotated clockwise, the punching blade is driven downward and when the
cam is rotated counterclockwise, the punching blade is not driven. The shape of the groove of the punching
blade for 2 holes is contrary to it on the right and left sides. When the switching cam is rotated counterclock-
wise, the punching blade is driven.
(2) 2 to 4 holes mode

In the 2 to 4 holes mode, the 2 punching blades at both ends are driven only when the switching cam is rotated
clockwise in the same way as in the 2 to 3 hole mode. As the 2 punching blades at the center should be driven
in both cases of 2 or 4 hole punching, shape of the groove of the switching cam is symmetrical on the right and
left sides and both the front and rear sides are curved in the rotating axis direction.
14
C. Punch control (PK-513)

Transmitting the start signal from the main body, the FNS conveyance motor (M1) rotates.
PK-512/513
In the punch mode, M1 stops temporarily a specified period of time after the FNS entrance sensor (PS4) detects
the trailing edge of the paper.
At the same time, the punch motor (M301) [9] drives the shaft [10] to rotate a full circle. The eccentric cams [2]
rotate in sync with the shaft to move down the punch blade [1] to conduct the punch operation. M301 stops
and the punch operation is completed when the punch home sensor (PS301) [3] turns ON.
M1 rotates again to convey the paper a specified period of time after it stops temporarily.
[2]
[10]
[1]
[2]
[9]
[8]
[3]
[7] [4]
[2]
[5]
[1]
[6]
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[1] Punch blade [6] Paper

[2] Eccentric cam [7] Punch blade at the upper position
[3] Punch home sensor (PS301) [8] Front side
[4] Punch blade at the lower position [9] Punch motor (M301)
[5] Drive arm [10] Shaft
15
5. PUNCH SCRAPS BOX SECTION Theory of Operation Ver.1.0 Jul. 2008
5. PUNCH SCRAPS BOX SECTION

PK-512/513
5.1 Composition
Punch scraps box full sensor

(PS302)
Punch scraps box set
sensor (PS304)
Punch scraps box
Front side
15kjt2e009nb
5.2 Drive
The punch scraps box section comprises no moving parts.
5.3 Operation
5.3.1 Punch scraps box control
A. Punch scraps box full detection
The punch scraps generated by the punch operation falls in the punch scraps box [3]. The punch scraps box full
sensor (PS302) [1] turns ON and transmits the "no punch scraps box" information to the main body when the
punch scraps box becomes full of punch scraps.
B. Punch scraps box detection

The punch scraps box set sensor (PS304) detects whether the punch scraps box is set or not. PS304 turns
OFF and transmits the "no punch scraps box" information to the main body if the punch scraps box is not set.
16
MAINTENANCE
PK-512/513
6. OTHER PROCEDURES
A. Screws not allowed to be removed
Never loosen the following screws.
[1]
[2]
15kjf2c001na
[1] Punch unit [2] Screw not allowed to be removed
(2) Reason
The specified performance cannot be retained if the screw is loosen.
17

PK-512/513

1 Punch unit Punch unit P.19
18
PK-512/513
Caution:
6.3.1 Removing/reinstalling the punch unit

A. Procedure
1. Remove the punch scraps box [1].
[1]
15kjf2c002na
2. Remove the screw [2], and then remove the

[1] punch drive board cover [1].
[2]
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19
3. Remove the 2 clamps [1].

[3] [4]
4. Disconnect 2 connectors [3] and the relay con-
PK-512/513
nector [4] from the punch drive board (PDB) [2].
[1]
[2]
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5. Remove 3 screws [2], and then remove the punch

[1] unit cover [1].
[2]
15kjf2c005na

[3] [2] 7. Remove 4 screws [1], and then remove the punch
unit [3] from FS.
[1]
8. Reinstall the above parts by following the removal
steps in reverse.
[1] [2]
15kjf2c006na
20
Note
• When reinstalling the punch drive board
PK-512/513
(PDB), attach the board supports of the punch
[1]
drive board (PDB) at 4 positions [1] in the fig-
ure.
15kjf2c007na
21
PK-512/513
Blank page
22
SD-506
2009.07
Ver. 2.0
Revision history
Revision mark:
corresponding page.
NOTE

2009/07 2.0 1 bizhub PRO 1200/1200P/1051.
CONTENTS
SD-506
SD-506
OUTLINE
3. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4. HORIZONTAL CONVEYANCE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2.1 Entrance conveyance drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2.2 Horizontal conveyance drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2.3 Gate drive/subtray pressure release drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3.1 Conveyance path switching control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3.2 Conveyance line speed switch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3.3 Subtray paper exit control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3.4 Subtray paper full detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5. RIGHT ANGLE CONVEYANCE SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2.1 Right angle conveyance drive/alignment drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2.2 Overlap drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.3.1 Paper overlap control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.3.3 Right angle conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6. FOLDING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.2.1 Folding entrance drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.2.2 Folding conveyance drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2.3 Folding blade drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.2.4 Folding main scan alignment drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2.5 Folding sub scan alignment/center folding exit drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.2.6 Guide shaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.3.1 Folding entrance conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.3.2 Folding main scan alignment control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.3.3 Folding control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.3.4 Folding sub scan alignment control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.3.5 Guide shaft control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7. SADDLE STITCHING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
i
7.2.1 Saddle stitching alignment drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

7.2.2 Saddle stitching hold drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.2.3 Clincher up down drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
SD-506
7.2.4 Stapler/clincher movement drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

7.2.5 Stapler/clincher drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.2.6 Bundle arm rotation drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.2.7 Bundle arm movement drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.2.8 Bundle arm assist drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.2.9 Bundle clip drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.3.1 Saddle stitching alignment control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.3.2 Stapler/clincher movement control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.3.3 Saddle stitching hold control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.3.4 Clincher up down control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.3.5 Stapler control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.3.6 Bundle arm control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.3.7 Bundle arm assist control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.3.8 Bundle clip control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8. BUNDLE PROCESSING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

8.1 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.2.1 Bundle press stage lift drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.2.2 Bundle press movement drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
8.2.3 Bundle registration drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
8.2.4 Bundle press drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
8.2.5 Bundle exit drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
8.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8.3.1 Bundle press stage up down control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8.3.2 Bundle press movement control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.3.3 Bundle press control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
8.3.4 Bundle registration control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
8.3.5 Bundle exit control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9. TRIMMER SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
9.1 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
9.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
9.2.1 Trimmer press drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
9.2.2 Trimmer blade drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
9.2.3 Trimmer board drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
9.2.4 Paddle drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
9.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
9.3.1 Trimmer press control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
9.3.2 Trimmer blade control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
9.3.3 Trimmer board control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
9.3.4 Trimmer paddle control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
MAINTENANCE
10.1 Saddle stitching section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
10.1.1 Replacing the stapler assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
10.1.2 Remove the slope unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
ii
10.1.3 Pull out the saddle stitching unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

10.1.4 Removing/installing the saddle stitching unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
10.2 Trimmer section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
SD-506
10.2.1 Removing/installing the trimmer paddle assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
10.2.2 Replacing the trimmer blade kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
10.2.3 Replacing the trimmer board assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
10.2.4 Replacing the trimmer press motor (M32). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
10.2.5 Lubrication to the trimmer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
10.3 Bundle processing section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
10.3.1 Replacing the bundle press stage gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
11.1 Items not allowed to be disassembled and adjusted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
11.1.1 Trimmer section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
11.2 List of disassembling and assembling parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
11.3 Removing procedure of disassembling and assembling parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
11.3.1 Rear cover /Lt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
11.3.2 Rear cover /Rt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
11.3.3 Left cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
11.3.4 Upper cover /Fr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
11.3.5 Upper cover /Rr3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
11.3.6 Subtray cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
11.3.7 Front door /Lt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
11.3.8 Front door /Rt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
11.3.9 Roller release solenoid /1 (SD5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
11.3.10 Roller release solenoid /2 (SD6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
11.3.11 Right angle conveyance gate solenoid (SD2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
11.3.12 Roller release solenoid/3 (SD7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
11.3.13 Folding unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
11.3.14 Bundle press stage unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
11.3.15 Trimmer blade motor (M31) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
11.3.16 Trimmer unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
iii
SD-506
Blank page
iv
OUTLINE
SD-506
A. Type
Type Saddle stitching unit with fore-edge trimming and multi-folding function
B. Functions
(1) Functions
Subtray paper exit mode Exit paper to the subtray without any process.
Coupling paper exit mode Convey paper to the succeeding device without any process.
Saddle stitching mode Exit paper to the bundle exit tray after the center folding/saddle stitching operation.
Saddle stitching trimming Exit paper to the bundle exit tray after the center folding/saddle stitching/trim-
mode ming operation.
Multi center folding mode Exit paper to the bundle exit tray after the center folding on 1 or more sheets of paper.
Multi center folding trim- Exit paper to the bundle exit tray after the center folding and the trimming oper-
ming mode ation on 1 or more sheets of paper.
Overlap tri-folding mode Exit paper to the tri-folding tray after the letter folding operation on 1 or more
sheets of paper.
Sub tray 200 sheets

(Weighing 80g/m2) Z-Folding 20 sheets
Center folding 40 sheets
Bundle exit tray Center stitching/ Stitching sheets Set
trimming mode 2 - 10 50 or more
11 - 20 30 or more
21 - 40 20 or more
41 - 50 15 or more
Multi center fold- 30 sets
ing mode
Tri-folding paper exit tray Overlap tri-folding 20 sets
mode
1
C. Paper
(1) Straight/subtray mode

SD-506
B5S, A5, A5S*4, B6S*4, A6S*4
13 x 19*4, 12 x 18, 11 x 17, 9 x 11, 81/2 x 14, 81/2 x 11, 81/2 x 11S,
51/2 x 81/2*3, 51/2 x 81/2S*4, 81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13, 8K*4*5, 16K*4*5,
16KS*4*5
Custom size paper (Max. 324mm x 463mm, Min. 95 x 139mm*3,
Min. 100mm x 148mm*4)
Tab paper*6 (A3, B4, A4, A4S, B5, B5S,
11 x 17, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2, Max. 324mm x 463mm)
Weight 40g/m2 - 350g/m2 *3 *7, 64g/m2 - 300g/m2 *4

*3 1200/1200P/1051 only
*4 C6501/C6501P/C65hc only
1 2
Paper size SRA3, A3, JISB4*1, ISOB4*2*3, SRA4S, A4S, B5S
SD-506
12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11S, 81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13,
8K*4*5, 16KS*4*5
Custom size paper (Max. 324mm x 463mm, Min. 182mm x 257mm)
Weight 50g/m2 - 244g/m2 *3 , 64g/m2 - 244g/m2 *5
Maximum saddle stitching Plain, Coat Weight Sheet
sheets Plain Coat*5
50g/m2 - 81g/m2 50*6 30*6
82g/m2 - 91g/m2 30*6 15*6
92g/m2 - 130g/m2 20*6 10*6
131g/m2 - 161g/m2 15*6 5*6
162g/m2 - 209g/m2 10 -
210g/m2 - 244g/m2 5 -
Fine Paper brand 55kg (64g/m2) 70kg (81.4g/m2)
Kinmari 50 sheets 50 sheets
High quality
Kanabishi
OK prince -
new NPi 50 sheets 30 sheets
POD prince high
quality
shiraoi

*3 1200/1200P/1051 only
*5 C6501/C6501P/C65hc only
*6 1 sheet can be switched to a thick paper (200g/m2)
Staple position Can be automatically changed (90mm - 165mm) in accordance with paper size.
[1]
[2]
15ant1c006na
[1] = [Paper size] /2 ± 2mm

3 1
Folding height
[1]
SD-506
15ant1c011na
Stitching [1] Folding height

sheets A3 B4 A4S B5S
12 x 18 81/2 x 14 81/2 x 11S (260mm or
11 x 17 (301mm to (261mm to less)
(401mm or 400mm) 300mm)
more)
2-5 35mm or less 40mm or less 45mm or less Not defined
6 - 15 45mm or less 50mm or less Not defined
16 - 30 50mm or less 55mm or less
(The above information is applied when paper weight is 64g/m2 and no thick
cover is not used.)
(3) Trimming mode

12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11S, 81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13,
8K*4*5, 16KS*4*5
Wide Paper*3 (A3W, B4W, A4SW, B5SW, 12 x 18W, 11 x 17W, 81/2 x 11SW,
Max. 324mm x 463mm)
Weight 50g/m2 - 244g/m2 *3 , 64g/m2 - 244g/m2 *5
Maximum trimming sheets 50 sheets (80g/m2) or 49 sheets (80g/m2) + 1 sheet (200g/m2)
(The above is the number of the printed paper before folding. The number of
fore-edge (after folding) is double.)

*3 1200/1200P/1051 only
*5 C6501/C6501P/C65hc only
1 4
(4) Multi center folding mode
SD-506
12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11S, 81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13,
8K*4*5, 16KS*4*5
Max. 324mm x 463mm)
Weight 50g/m2 - 244g/m2 *3 , 64g/m2 - 244g/m2 *5
Maximum overlap folding Weight Sheet
sheets 50g/m2 - 81g/m2 5 sheets
82g/m2 - 130g/m2 3 sheets
131g/m2 - 244g/m2 2 sheets
Folding precision (for 1
sheet)
[1]
15ant1c009na
[1] = [Paper size] /2 ± 1.5mm
[1] 15ant1c008na
[1] = 1.5mm or less

*3 1200/1200P/1051 only
*5 C6501/C6501P/C65hc only
5 1
(5) Overlap tri-folding mode
Paper size A4S, 8 1/2 x 11S

50g/m2 - 91g/m2 *1, 64g/m2 - 91g/m2 *2
SD-506
Weight
Weight Sheet
Maximum overlap folding 50g/m2 - 81g/m2 5 sheets
sheets
Folding precision (for 1 sheet) Paper size [1] [2] [3]
A4S 97.5 ± 4mm 102.0 ± 4mm 1.5mm or less
81/2 x 11S 91.6 ± 4mm 96.1 ± 4mm
[3]
[3]
[1]
[2]
15ant1c010na
*1 1200/1200P/1051 only
*2 C6501/C6501P/C65hc only
D. Maintenance
E. Machine data
Maximum power consumption 270W
Dimension When the bundle exit tray is stored: 1,170 (W) x 775 (D) x 1,020 (H) mm
When the bundle exit tray is pulled out: 1,170 (W) x 1,441 (D) x 1,020 (H) mm

Note
1 6
SD-506
[1]
[2]
[7]
[3]
[6]
[5]
[4]
15ant1c001na
[1] Folding section [5] Trimmer section

[2] Right angle conveyance section [6] Saddle stitching section
[3] Bundle processing section [7] Horizontal conveyance section
[4] Left-side view
7
3. PAPER PATH
A. Coupling exit/subtray exit mode
SD-506
[3] [2] [1]
15ant1c002na
[1] Horizontal conveyance [3] Coupling exit

[2] Subtray exit
8
B. Overlap tri-folding mode
SD-506
[1]
[4] [5] [7] [6] [8]
[3]
[2]
[10] [9]
15ant1c003na
[1] Stack to the angle conveyance section [6] Paper exit

[2] Right angle conveyance [7] Stack movement of the paper exit
[3] Conveyance to the folding section [8] Front side view
[4] 1st folding [9] Top side view
[5] 2nd folding [10] Right-side view
9
C. Center folding/saddle stitching mode

(1) From the paper exit from the main body to the center folding
SD-506
[1]
[4] [5] [6]
[3]
[2]
[8] [7]
15ant1c004na
[1] Stack to the angle conveyance section [5] Release from the folding roller
[2] Right angle conveyance [6] Front side view
[3] Conveyance to the folding section [7] Top side view
[4] Center folding (1st folding) [8] Right-side view
10
(2) From the center folding to the paper exit
SD-506
[1]
[7]
[2]
[3]
[4] [5] [6] [8]

15ant1c005na
[1] Conveyance from the folding section to the [5] Paper exit
saddle stitching section [6] Stack movement of the paper exit
[2] Movement by the bundle arm [7] Front side view
[3] Movement by the clip [8] Left-side view
[4] Conveyance to the trimmer section (only for
saddle stitching mode)
11
SD-506
Blank page
12
Theory of Operation Ver.2.0 Jul. 2009 4. HORIZONTAL CONVEYANCE SECTION
SD-506
4. HORIZONTAL CONVEYANCE SECTION
4.1 Configuration
Sub tray Subtray paper full sensor (PS12) Horizontal conveyance Horizontal convey- Entrance con-
gate ance veyance
Entrance gate 15ant2c001nb
13
4. HORIZONTAL CONVEYANCE SECTION Theory of Operation Ver.2.0 Jul. 2009
4.2 Drive
4.2.1 Entrance conveyance drive
SD-506
[1]
[2]
[5] [4] [3] 15ant2c002nb
[1] Entrance roller [4] Front side view

[2] Entrance conveyance motor (M1) [5] Conveyance roller
[3] Overlap assist roller
4.2.2 Horizontal conveyance drive
[2] [3] [4] [5] [3]
[1] 15ant2c003na
[1] Front side view [4] Horizontal conveyance motor (M2)

[2] Exit roller [5] Subtray exit roller
14
4.2.3 Gate drive/subtray pressure release drive
[1] [2] [3] [4] [5] [6]
SD-506
15ant2c004na
[1] Subtray exit roller [4] Horizontal conveyance gate

[2] Roller release solenoid /4 (SD4) [5] Entrance gate solenoid (SD1)
[3] Horizontal conveyance gate solenoid (SD3) [6] Entrance gate
15
4. HORIZONTAL CONVEYANCE SECTION Theory of Operation Ver.2.0 Jul. 2009
4.3 Operation
4.3.1 Conveyance path switching control
SD-506
A. Entrance gate solenoid control

The entrance gate switches the path to the horizontal conveyance section and one to the right angle convey-
ance section. The entrance gate solenoid (SD1) switches them. The right angle conveyance path is selected
when SD1 turns OFF and the horizontal conveyance path is selected when it turns ON.
In the coupling exit mode and the subtray exit mode, SD1 turns ON and sets the entrance gate to the horizontal
conveyance section when the main body print signal turns ON. SD1 turns OFF after the paper exit.
B. Horizontal conveyance gate control

The horizontal conveyance gate switches the path to the subtray section and the coupling conveyance path to
the succeeding device. The horizontal conveyance gate solenoid (SD3) switches them. The coupling convey-
ance path is selected when SD3 turns OFF and the subtray path is selected when it turns ON.
4.3.2 Conveyance line speed switch control

The entrance conveyance motor (M1) and the horizontal conveyance motor (M2) convey them.
M1 and M2 turn ON when the main body start signal [1] turns ON. M1 switches its rotational speed in accor-
dance with the main body line speed [3] when the main body paper exit sensor turns ON [2]. Then it switches its
rotational speed to high speed [4] to convey the paper when it receives the paper trailing edge signal (when the
paper trailing edge passes through the fusing).
[2]
Paper exit sensor

Entrance con- High speed
veyance motor
(M1) Low speed
Horizontal conveyance motor (M2)
[1] [3] [4] 15ant2c005na
[1] Main body print signal [3] M1 switching to low speed

[2] Main body exit sensor ON [4] Main body paper trailing edge signal
16
4.3.3 Subtray paper exit control

When exiting the paper to the subtray, the paper misalignment is prevented by releasing the nipping of the
subtray exit roller by the roller release solenoid /4 (SD4) to nip the paper only at the trailing edge and slowing
SD-506
down the paper by the subtray exit roller that is rotating in low speed for every paper. The horizontal conveyance
sensor /1 (PS2) [1] and the subtray exit sensor (PS11) [2] detect the paper exited to the subtray.
[4] [3] [2] [1]
15ant2c006na
[1] Horizontal conveyance sensor /1 (PS2) [3] Roller release solenoid (SD4)
[2] Subtray exit sensor (PS11) [4] Subtray exit roller
The roller release solenoid /4 (SD4) turns ON [2] to release the nipping of the subtray exit roller [3] after a speci-
fied period of time since the horizontal conveyance sensor /1 (PS2) detects the leading edge of paper [1]. SD4
turns OFF [5] and the subtray exit roller nips at the trailing edge of paper [6] after a specified period of time since
PS2 detects the trailing edge of paper [4]. This control is conducted for every paper exited to the subtray.
[4]
Horizontal conveyance sensor /1 (PS2)
Subtray exit sensor (PS11)
Roller release solenoid /4 (SD4)
[1] [2] [3] [5] [6] 15ant2c007na
[1] Detection of the leading edge of paper [4] Detection of the trailing edge of paper
[2] SD4 ON [5] SD4 OFF
[3] Releasing nip [6] Nipping at the trailing edge of paper
4.3.4 Subtray paper full detection control

The subtray paper full sensor (PS12) detects the subtray paper full via the actuator.
PS12 turns ON under normal circumstances. The subtray paper full condition is detected and the subtray paper
full signal is transmitted to the main body when stacked paper presses the actuator and PS12 turns OFF. Then,
the main body displays the message on its operation panel.
17
5. RIGHT ANGLE CONVEYANCE SECTION Theory of Operation Ver.2.0 Jul. 2009
5. RIGHT ANGLE CONVEYANCE SECTION

5.1 Configuration
SD-506
Right angle convey- Alignment claws

ance gate
Alignment Right angle convey-

section ance roller /1
Right angle convey-

ance roller /2
Overlap sec-
tion
Overlap stopper
Right angle conveyance roller /1 (Driven) Right angle conveyance roller /3 (Driven)
15ant2c008nb
18
Theory of Operation Ver.2.0 Jul. 2009 5. RIGHT ANGLE CONVEYANCE SECTION
5.2 Drive
5.2.1 Right angle conveyance drive/alignment drive
SD-506
[1]
[2]
[3]
[11]
[10]
[9]
[6] [7]
[8]
[4]
[5] 15ant2c009na
[1] Alignment claws [7] Right angle conveyance roller /4

[2] Torque limiter [8] Right angle conveyance roller /3
[3] Roller release solenoid /1 (SD5) [9] Right angle conveyance roller /2
[4] Front side direction [10] Right angle conveyance motor (M6)
[5] Top side view [11] Right angle conveyance roller /1
[6] Roller release solenoid /2 (SD6)
19
5.2.2 Overlap drive

SD-506
[7] [8]
[6]
[1]
[2]
[5] [4] [3] 15ant2c010nb
[1] Overlap stopper [5] Front side view

[2] Overlap motor (M13) [6] Right angle conveyance gate
[3] Right-side view [7] Right angle conveyance gate solenoid (SD2)
[4] Overlap home sensor (PS17) [8] Overlap assist roller
20
5.3 Operation
5.3.1 Paper overlap control
SD-506
A. Overlap mechanism
When the folding operation is conducted for more than 1 sheet of paper, they are overlapped in the right angle
conveyance section, and then conveyed to the folding section.
The overlap mechanism is the mechanism to overlap the paper in adequate paper conveyance order. The right
angle conveyance gate [1] driven by the right angle conveyance gate solenoid (SD2) [7] and the overlap stopper
[5] driven by the overlap motor (M13) [3] conduct the operation. The overlap home sensor (PS17) [4] detects the
home position of the overlap stopper.
The overlap stopper [5] is positioned at the position where the trailing edge of paper [2] is positioned 20mm under
from the right angle conveyance gate [1] in accordance with the paper size when it stands by for the paper.
When the SD2 is turned off, the paper from the main body is conveyed into between the right-angle conveyance
gate [1] and the overlap assist roller [8]. Then the paper is conveyed further by the overlap assist roller [8] driven
by the entrance conveyance motor (M1) and stopped by the overlap stopper.
[1]
[2]
[7]
[8]
[3]
[4]
[6] [5] 15ant2c011nb
[1] Right angle conveyance gate [5] Overlap stopper

[2] Position of the trailing edge of paper [6] Front side view
[3] Overlap motor (M13) [7] Right angle conveyance gate solenoid (SD2)
[4] Overlap home sensor (PS17) [8] Overlap assist roller
21
The first stacked sheet of paper [5] is conveyed while the overlap stopper is located at the standby position [4].
Before conveying the second paper, right angle conveyance gate solenoid (SD2) turns ON to move the right
angle conveyance gate [6] to the right [7]. At the time, overlap motor (M13) moves the overlap stopper 30mm
SD-506
upward [3]. It transfers the stacked paper to the left-side of the right angle conveyance gate. The right angle
conveyance gate is replaced [9] to clear the conveyance path. The subsequent paper [8] passes the right-side of
the right angle conveyance gate and the paper is overlapped in adequate order. Then, M13 moves the overlap
stopper downward [1].
The same as the second sheet is conducted until all of sheets are stacked.
[7] [8] [9]
[6]
[5]
[1]
[4] [3] [2] 15ant2c012nb
[1] Overlap stopper descending 30mm down [6] Right angle conveyance gate
[2] Front side view [7] Movement of the right angle conveyance gate
[3] Overlap stopper moving 30mm upward [8] 2nd paper
[4] Standby position of the overlap stopper [9] Replacement of the right angle conveyance gate
[5] 1st paper
22
B. Overlap control
(1) Overlap tri-folding mode control
In the overlap tri-folding mode, up to 5 sheets are stacked in the right angle conveyance section and conveyed
SD-506
to the folding section. The overlap tri-folding is available only with paper of 50g/m2 to 91g/m2 in weight and is
unavailable with others.
The overlap motor (M13) turns ON when the main body start signal [1] turns ON and moves the overlap stopper
upward to its standby position.
Turning ON the right angle conveyance gate solenoid (SD2) [3] after a specified period of time since the entrance
sensor (PS1) detects the trailing edge of the paper, the right angle conveyance gate is switched, M13 moves the
paper upward [4], and isolate the paper from the conveyance gate by transferring it to the left-side of the right
angle conveyance gate. Turning OFF SD2 [5], the conveyance gate opens and waits for the subsequent paper.
Conveying the subsequent paper through the right-side of the right angle conveyance gate [6] and detecting the
trailing edge of paper by the entrance sensor (PS1) [7], M13 descends the overlap stopper down [8]. When the
trailing edge of paper passes under the right angle conveyance gate, SD2 turns ON [9] to switch the right angle
conveyance gate and M13 moves up the overlap stopper [10] to send the conveyed sheets of paper to the left-
side of the right angle conveyance gate. Then, SD2 turns OFF [11] and stands by for the subsequent paper.
The overlap stopper moves down to the standby position and stands by for the 1st paper of the subsequent set
[12] after a specified period of time since PS1 detects the trailing edge of last paper of the set.
[4] [7] [10]
Overlap motor Up
(M13)
Down
Right angle conveyance gate solenoid (SD2)
[12]
[1] [2] [3] [5] [6] [8] [9] [11] 15ant2c074na
[1] Main body start signal [7] Trailing edge of the subsequent paper detected
[2] Movement to the standby position [8] Descent of paper
[3] Switching the right conveyance gate [9] Switching the right conveyance gate
[4] Separating paper [10] Separating paper
[5] Securing conveyance path [11] Securing conveyance path
[6] Conveyance of the subsequent paper [12] Movement to the standby position
23
(2) Center folding/saddle stitching mode control

In the center folding/saddle stitching mode, 1, 2, or 3 sheets of paper are stacked and conveyed to the folding
section. The number of the stacked sheets is different depending on its paper weight and the conveyance pat-
SD-506
tern.
Normal paper (less than 131g/m2): up to 3 sheets are stacked and conveyed to the folding section.
Thick paper (131g/m2or more): due to the limit of the folding performance, up to 2 sheets are stacked and con-
veyed to the folding section.
• Normal paper
For the 1st set, 2 sheets of paper are stacked and conveyed to the folding section at first. Similarly, 2 sheets of
paper are stacked and conveyed to the folding section for the subsequent sheets. At the final conveyance, 2
sheets are conveyed (if the total number of the paper is even) or 1 sheet is conveyed (if the number is odd). The
reason why it does not convey 3 sheets at a time for the odd case is because the timing to transmit the informa-
tion such as the page count, the paper type, and so on is too late in printing from PC.
For the 2nd and following set, 3 sheets of paper are stacked and conveyed to the folding section at first to take
adequate time to conduct the folding operation for the preceding set. At the final conveyance, 2 sheets are con-
veyed (if the total number of the paper is odd) or 3 sheets are conveyed (if the number is even).
• Thick paper
Up to 2 sheets of paper can be stacked for the thick paper.
For every set, 2 sheets of paper are stacked and conveyed to the folding section at first. Similarly, 2 sheets of
paper are stacked and conveyed to the folding section for the subsequent sheets. At the final conveyance, 2
sheets are conveyed (if the total number of the paper is even) or 1 sheet is conveyed (if the number is odd).
• Using PI function
The same as the thick paper control is conducted because the paper type information cannot be obtained in the
print job using PI.
24

A. Alignment mechanism
The alignment is conducted by driving the alignment claws [2] by the right angle conveyance motor (M6) [5]
SD-506
through the belt [3] and the torque limiter [4].
The alignment claws move to the rear of the shelter direction [7] and stops at the mechanical stoppers [1]
through the torque limiter when M6 is rotating toward the paper conveyance direction. Rotating M6 in the
reverse direction, the alignment claws push the edge of paper to conduct the alignment [6].
[4] [5] [6] [7]
[1]
[3] [2]
15ant2c013na
[1] Mechanical stoppers [5] Right angle conveyance motor (M6)

[2] Alignment claws [6] Aligning direction
[3] Belt [7] Shelter direction
[4] Torque limiter
25
B. Alignment control
The right angle conveyance motor (M6) rotates in the reverse direction when the main body start signal [1] turns
ON and the alignment claws move to the standby position [2] in accordance with the paper size.
SD-506
No alignment operation is conducted for the 1st paper. M6 rotates in the reverse direction to align paper with the
alignment claws [3] after a specified period of time since the entrance sensor (PS1) detects the trailing edge of
2nd paper. Then, M6 rotates in the forward direction to replace the alignment claws to the standby position [4].
M6 rotates to convey the paper to the folding section [6] and evacuate the alignment claws to the home position
after a specified period of time after the alignment operation [5] for the last paper of the set. After a specified period
of time after the right angle conveyance sensor /2 (PS6) detects the leading edge of paper, M6 rotates in the
reverse direction to move the alignment claws to the standby position [7] for the subsequent copy.
[7]
Right angle con- Forward

veyance motor
(M6) Reverse
Right angle conveyance sensor /2 (PS6)
[1] [2] [3] [4] [5] [6] 15ant2c075na
[1] Main body start signal [5] Alignment operation

[2] Standby position movement [6] Paper conveyance to the folding section
[3] Alignment operation [7] Return to the standby position
[4] Return to the standby position
26
5.3.3 Right angle conveyance control

A. Right angle conveyance mechanism
In the right angle conveyance, the right angle conveyance motor (M6) and the roller release solenoids /1 (SD5)
SD-506
[5] and /2 (SD6) [10] convey the paper.
When conveying the paper to the overlap section, the paper falls vertically [6] to the overlap stopper [7] by its
own weight after conveyed by the overlap assist roller. At the time, the press by the right angle conveyance roller
/1 [3] is released by default since the conveyance direction is not the rotational direction of the right angle con-
veyance roller /1 [3] but the axial direction of the right angle conveyance roller /1.
After stacking and aligning the specified number of papers, the roller release solenoid /1 (SD5) [5] turns ON to
nip the paper and convey the paper to the position rotated 90° from the right side to the front side [8]. The roller
release solenoid /3 (SD7) [14] is OFF to release the pressure of the folding entrance roller by default since the
upper edge of the paper [1] passes over the folding entrance roller [13].
When conveying the paper from the right angle conveyance section to the folding section [12], the roller release
solenoid /2 (SD6) [10] turns ON to release the pressure of the right angle conveyance roller /4 [9] and convey the
paper to the folding section by nipping the paper with the folding entrance roller [13].
[14] [1]
[2]
[13] [3]
[12]
[4]
[11]
[10] [5]
[9] [6]
[8]
[7]
15ant2c014na
[1] Upper edge of the paper path [8] Right angle conveyance
[2] Entrance sensor (PS1) [9] Right angle conveyance roller /4
[3] Right angle conveyance roller /1 [10] Roller release solenoid /2 (SD6)
[4] Right angle conveyance sensor /1 (PS5) [11] Right angle conveyance sensor /2 (PS6)
[5] Roller release solenoid /1 (SD5) [12] Paper conveyance to the folding section
[6] Paper conveyance to the overlap section [13] Folding entrance roller
[7] Overlap stopper [14] Roller release solenoid /3 (SD7)
27
B. Conveyance control
The roller release solenoid /1 (SD5) turns ON to press the right angle conveyance roller /1 [2] after a specified
period of time since the entrance sensor (PS1) detects the trailing edge of last paper of the set [1]. After the
SD-506
alignment operation [3], the right angle conveyance motor (M6) rotates in the forward direction to convey the
paper to the front side [4] by rotating 90°. At this time, the roller release solenoid (SD7) turns OFF a specified
period of time after the entrance sensor (PS1) detects the trailing edge of paper and releases the pressure of the
folding entrance roller /1 [5].
A specified period of time after the right angle conveyance sensor /2 (PS6) detects the leading edge of paper,
SD7 turns ON to pressure the folding entrance roller /1 and nip [6] the upper section of paper that has been
conveyed to the front side. Also, a specified period of time after that, when the roller release solenoid /2 (SD6)
turns ON [7] to release the right angle conveyance roller /4 and convey the paper to the folding section.
[1] [3] [4]
Right angle con- Forward

veyance motor
(M6) Reverse
Right angle conveyance sensor /2 (PS6)
[2] [5] [6] [7] 15ant2c076na
[1] Trailing edge of the last paper of the set detected [5] Folding entrance roller pressure release
[2] Right angle conveyance roller /1 pressure [6] Folding entrance roller pressure
[3] Paper alignment [7] Right angle conveyance roller /4 pressure release
[4] Paper conveyance
28
Theory of Operation Ver.2.0 Jul. 2009 6. FOLDING SECTION
6. FOLDING SECTION
6.1 Configuration
SD-506
Alignment Conveyance belt (tri-folding) 2nd folding blade Folding roller /3
claws /Fr
(main scan)
2nd folding stopper
Folding roller /2
Alignment stopper
Rr (main scan)
Folding roller /1 Guide shaft Folding exit claws Folding alignment 1st folding blade
(Center folding (same as for sub stoppers /Rt (sub scan)
exit) scan alignment) 15ant2c015nc
29
6. FOLDING SECTION Theory of Operation Ver.2.0 Jul. 2009
6.2 Drive
6.2.1 Folding entrance drive
SD-506
[4]
[3] [2] [1]

15ant2c016na
[1] Folding entrance motor (M3) [3] Folding entrance roller /1

[2] Right-side view [4] Roller release solenoid /3 (SD7)
30
6.2.2 Folding conveyance drive
SD-506
[7] [8] [9] [1]
[2]
[3]
[6] [5] [4] 15ant2c017na
[1] One-way clutch [6] Right-side view

[2] Oscillation connecting gear [7] Paper exit belt
[3] Folding conveyance motor (M4) [8] Folding roller /3
[4] Folding roller /2 [9] Tri-folding exit clutch (CL1)
[5] Folding roller /1
31
6.2.3 Folding blade drive

SD-506
[8] [9] [10] [11] [12] [13] [14]

[1]
[7] [6] [5] [4] [3] [2] 15ant2c018na
[1] 1st folding blade motor (M18) [8] 2nd folding blade motor (M19)
[2] Folding roller /2 [9] 2nd folding blade home sensor /2 (PS23)
[3] 1st folding blade home sensor /2 (PS21) [10] 2nd folding blade home sensor /1 (PS22)
[4] 1st folding blade home sensor /1 (PS20) [11] 2nd folding blade
[5] 1st folding blade [12] Folding roller /3
[6] Folding roller /1 [13] Spring (press the folding roller /2 and /3)
[7] Right-side view [14] Spring (press the folding roller /1 and /2)
32
6.2.4 Folding main scan alignment drive
[1]
SD-506
[8]
[2]
[6] [7]
[5] [4] [3] 15ant2c019na
[1] Folding main scan alignment home sensor /Rr (PS19) [5] Folding main scan alignment motor /Fr (M7)
[2] Alignment stopper /Rr [6] Folding main scan alignment home sensor /Fr1 (PS18)
[3] Right-side view [7] Folding main scan alignment home sensor /Fr2 (PS49)
[4] Alignment claws /Fr [8] Folding main scan alignment motor /Rr (M14)
33
6.2.5 Folding sub scan alignment/center folding exit drive

SD-506
[1] Folding alignment stoppers /Rt [6] Front side direction

[2] Home position stoppers /Rt [7] Folding sub scan alignment home sensor (PS56)
[3] Folding exit home sensor (PS24) [8] Folding exit claws
[4] Torque limiter [9] Alignment stoppers /Lt
[5] Folding sub scan alignment exit motor (M8)
34
6.2.6 Guide shaft drive
SD-506
[4]
[3] [2] [1] 15ant2c021na
[1] Guide shaft home sensor (PS46) [3] Front side view
[2] Guide shaft motor (M25) [4] Guide shaft
35
6.3 Operation
6.3.1 Folding entrance conveyance control
SD-506
A. Mechanism
The folding entrance motor (M3) and the roller release solenoid /3 (SD7) [5] conduct the folding entrance con-
veyance operation.
The paper [1] conveyed from the right angle conveyance section is conveyed to the folding entrance with the
pressure of the folding entrance roller /1 [7] released. Once the right angle conveyance is completed, SD7 [5]
turns ON to pressure the nipping of the folding entrance roller /1 and the roller release solenoid /2 (SD6) [3] turns
ON to release the right angle conveyance roller /4, M3 convey the paper to the folding section.
The folding entrance sensor (PS60) [6] detects the paper at the folding entrance.
[5] [6] [7]

[4]
[3] [2] [1] 15ant2c022na
[1] Paper [5] Roller release solenoid /3 (SD7)

[2] Right angle conveyance roller /4 [6] Folding entrance sensor (PS60)
[3] Roller release solenoid /2 (SD6) [7] Folding entrance roller /1
[4] Right angle conveyance sensor /2 (PS6)
36
B. Control
The roller release solenoid /3 (SD7) turns ON to nip the paper with the folding entrance roller [2] after a specified
period of time since the right angle conveyance sensor /2 (PS6) detects the leading edge of paper [1], and then
SD-506
the roller release solenoid /2 (SD6) turns ON to release the nip of the right angle conveyance roller /4 after a
specified period of time. Then the folding entrance motor (M3) turns ON and conveys the paper to the folding
section [4].
At the time, the folding conveyance motor (M4) rotates in the reverse direction [5] to prevent the paper from
being caught between the folding rollers /1 and /2.
SD7 turns OFF to release the pressure of the folding entrance roller [7] after a specified period of time since the
entrance sensor (PS1) detects the trailing edge of last paper of the subsequent set [6] and it stands by for the
paper of the subsequent set being conveyed to the front side of the right angle conveyance section.
[1] [4] [6]

Right angle conveyance
sensor /2 (PS6)
Folding entrance motor (M3)
Forward
Folding convey-
ance motor (M4) Reverse
[2][3] [5] [7] 15ant2c078na
[1] Last paper of the 1st set [5] Caught-protection to the folding section
[2] Folding entrance roller nipped [6] Last paper of the subsequent set
[3] Nip of the right angle conveyance roller /4 released [7] Nip of the folding entrance roller released
[4] Folding entrance conveyance
37
6.3.2 Folding main scan alignment control

A. Mechanism
In the folding main scan alignment, the alignment stoppers /Rr [5] driven by the folding main scan alignment
SD-506
motor /Rr (M14) stop at the appropriate position in accordance with the paper size, and then the alignment
claws /Fr [2] driven by the folding main scan alignment motor /Fr (M7) conduct the alignment operation. The
folding main scan alignment home sensors /Fr1 (PS18) [8] and /Fr2 (PS49) [7] detect the home position of the
alignment claws /Fr and the folding main scan alignment home sensor /Rr (PS19) [4] detects the home position
of the alignment stopper /Rr.
The alignment claws /Fr [2] convey [6] the paper by pushing its trailing edge once the paper passes through the
folding entrance roller /3 [3] and until the leading edge of paper contacts with the alignment stopper /Rr because
there is no conveyance roller between the folding entrance conveyance roller /3 [3] and the alignment stopper /
Rr [5].
[5] [6] [7] [8]

[1]
[4]
[2]
[3] 15ant2c023na
[1] Front side direction [5] Alignment stopper /Rr

[2] Alignment claws /Fr [6] Paper conveyance
[3] Folding entrance roller /3 [7] Folding main scan alignment home sensor /Fr2 (PS49)
[4] Folding main scan alignment home sensor /Rr (PS19) [8] Folding main scan alignment home sensor /Fr1 (PS18)
38
B. Control
The folding main scan alignment motor /Rr (M14) drives the alignment stopper /Rr to the appropriate position in
accordance with the paper size [2] when the main body start signal [1] turns ON.
SD-506
The folding main scan alignment motor /Fr (M7) rotates in the forward direction [3] to let the alignment claws /Fr
push the trailing edge of paper for conveyance after a specified period of time since the folding entrance sensor
(PS60) detects the trailing edge of paper, and then M7 stops after a specified period of time [4]. The alignment
stoppers /Rr push the leading edge of paper to conduct the alignment. M7 rotates in the reverse direction [5],
and after a specified period of time it rotates in the forward direction to conduct the alignment again [6].
M7 rotates in the reverse direction to replace the alignment claws to the home position [7] when the 1st folding
blade home sensor /1 (PS20) detects the completion of the folding operation. M7 starts rotating to replace the
alignment claws to the home position for subsequent set when PS21 detects the completion of the folding oper-
ation since the 1st folding blade conducts the reciprocal operation in which the 1st folding blade home sensor /
1 (PS20) and the 1st folding blade home sensor /2 (PS21) counter changes their positions at each folding oper-
ation. M7 stops rotating when the folding main scan alignment home sensor /Fr1 (PS18) detects the home posi-
tion of the alignment claws.
Transmitting the print termination signal from SD, M14 rotates to move the alignment stoppers to the home posi-
tion [8]. It stops rotating when the folding main scan alignment home sensor /Rr (PS19) detects the home posi-
tion of the alignment stoppers.
[2] [3] [4] [5] [6] [7] [8]
Folding main scan Forward

alignment motor /
Fr (M7) Reverse
alignment motor /
Rr (M14) Reverse
Folding entrance
sensor (PS60)
Folding main scan alignment
home sensor /Fr1 (PS18)
home sensor /Fr2 (PS49)
home sensor /Rr (PS19)
1st folding blade home sensor /1 (PS20)
[1] 15ant2c079na
[1] Main body print signal [5] Alignment claws /Fr shelter operation
[2] Alignment stopper /Rr moved for appropriate paper size [6] Realignment operation
[3] Paper conveyance of the alignment claws /Fr [7] Alignment claws /Fr home position movement
[4] Alignment [8] Alignment stoppers /Rr moved to the home position
39
6.3.3 Folding control

A. Mechanism
Folding has the 1st folding and 2nd folding.
SD-506
The 1st folding is conducted in the overlap tri-folding mode, the overlap tri-folding mode, and the saddle stitch-
ing mode.
In the 1st folding operation, the 1st folding blade [7] pushes and inserts the paper between the folding rollers /1
[8] and /2 [3].
The folding rollers /1 and /2 are pressured each other by the spring [2]. The 1st blade motor (M18) [4] drives the
1st folding blade via the crank mechanism [5].
In the 2nd folding operation, as well, the 2nd folding blade [14] pushes and inserts the paper between the fold-
ing rollers /2 [3] and /3 [15]. The 2nd folding operation has an adjustable stopper [12] which defines the fold from
the 1st folding and accurizes the 2nd folding position.
The folding rollers /2 and /3 are pressured each other by the spring [16]. The 2nd blade motor (M19) [10] drives
the 2nd folding blade via the crank mechanism [11].
The folding sensors /2 (PS44) [9], /1 (PS7) [1], and the folding passage sensor (PS8) [13] detect paper.
[10] [11] [12] [13] [14] [15] [16]

[1]
[2]
[9] [8] [7] [6] [5] [4] [3] 15ant2c024nb
[1] Folding sensor /1 (PS7) [9] Folding sensor /2 (PS44)

[2] Spring (press the folding roller /1 and /2) [10] 2nd folding blade motor (M19)
[3] Folding roller /2 [11] Crank mechanism
[4] 1st folding blade motor (M18) [12] 2nd folding stopper
[5] Crank mechanism [13] Folding passage sensor (PS8)
[6] Right-side view [14] 2nd folding blade
[7] 1st folding blade [15] Folding roller /3
[8] Folding roller /1 [16] Spring (press the folding roller /2 and /3)
40
B. Tri-folding control
(1) Operation
After the initial operation, the 1st folding blade [8] is at the standby position /1 [5]. In the actuator [7], the 1st fold-
SD-506
ing blade home sensor /2 (PS21) [3] is ON and the 1st folding blade home sensor /1 (PS20) [6] is OFF. When
paper [9] is conveyed to the folding section and the 1st folding blade motor (M18) is rotated [2], the crank [4]
rotates 90° to project the 1st folding blade to the paper and push the paper [12] between the folding roller /1
[10] and /2 [11] with its edge. At the time, the actuator also rotates 90° so that PS21 [3] turns OFF and PS20 [6]
turns ON.
M18 keeps rotating in the same direction [13], and then the crank [4] stops when it reaches at the standby posi-
tion /2 [1] (PS20 turns OFF) where is 180° opposite from the standby position /1. In the 1st folding operation for
the subsequent set, M18 rotates in the reverse direction [14] and the crank [4] also rotates 180° in the reverse
direction to conduct the 1st folding operation.
The 2nd folding operation is operated as in the 1st folding operation.
[11] [12]
[10]
[9]
[8]
[7] [14]
[13]
[5] [2] [1]

[6] [4] [3] 15ant2c025na
[1] Standby position /2 [8] 1st folding blade

[2] Projecting position [9] Paper
[3] 1st folding blade home sensor /2 (PS21) [10] Folding roller /1
[4] Crank [11] Folding roller /2
[5] Standby position /1 [12] Insert paper
[6] 1st folding blade home sensor /1 (PS20) [13] Rotational direction to the standby position /2
[7] Actuator [14] 1st folding for the subsequent set
41
(2) Control
When the folding main scan alignment motor /Fr (M7) stops rotating at the completion of the paper alignment
operation, the 1st folding blade motor (M18) turns ON and starts rotating in the reverse direction. The 1st folding
SD-506
blade folds and inserts the paper between the folding rollers /1 and /2. When the 1st folding blade home sensor
/1 (PS20) turns ON, the folding conveyance motor (M4) turns ON to conduct the 1st folding [2]. M18 stops when
PS20 turns OFF [3]. Then, M4 turns OFF and the 1st folding operation is completed [4] after a specified period
of time since the folding passage sensor (PS8) detects the leading edge of paper.
After a specified period of time since PS8 turns ON, the 2nd folding blade motor (M19) turns ON and rotates in
the reverse direction to start the 2nd folding operation. When the 2nd folding blade home sensor /1 (PS22) turns
ON, M4 rotates in high speed to perform the 2nd folding, and then the tri-folded paper is conveyed to the tri-
folding exit. M19 stops when PS22 turns OFF.
The 1st folding operation for the subsequent set, M18 rotates in the forward direction to conduct the 1st folding
[7] and stops rotating when the 1st folding blade home sensor /2 (PS21) turns ON. In the 2nd folding operation,
M19 rotates in the forward direction to conduct the 2nd folding [9] and stops rotating when the 2nd folding
blade home sensor /2 (PS23) turns ON [10].
[1] [2] [4] [5] [7] [9]

High speed
Folding convey-
ance motor (M4) Low speed
Reverse
Folding main Forward

scan alignment
motor /Fr (M7) Reverse
Forward
1st folding blade
motor (M18)
Reverse
2nd folding blade Forward

motor (M19)
Reverse
2nd folding blade home sensor /1 (PS22)
2nd folding blade home sensor /2 (PS23)
Folding passage sensor (PS8)
[10]
[3] [6] [8] 15ant2c080na
[1] Paper alignment operation completed [6] 2nd folding blade motor (M19) stopped
[2] 1st folding [7] 1st folding by M18 rotating the forward direction
[3] 1st folding blade motor (M18) stopped [8] M18 stopped
[4] 1st folding completed [9] 2nd folding by M19 rotating the forward direction
[5] 2nd folding [10] M19 stopped
42
C. Tri-folding exit control

(1) Operation
In the multi letter folding exit, the driving force of the folding conveyance motor (M4) is transmitted via the tri-fold-
SD-506
ing exit clutch (CL1).
CL1 turns ON and the exit belt [4] is driven approximately 7mm to convey the paper to the front side for every
paper exit.
The tri-folding paper full sensor (PS10) [3] detects the paper when it is reached at the front, and then the main
body displays the message on the operation panel.
[3] [4]
[1]
[2] 15ant2c081na
[1] Tri-folding exit sensor (PS9) [3] Tri-folding paper full sensor (PS10)
[2] Right-side view [4] Paper exit belt
(2) Control
The tri-folding exit clutch (CL1) turns ON and drives the exit belt [1] and stops it [2] after a specified period of
time when the tri-folding exit sensor (PS9) detects the leading edge of paper.
The folding conveyance motor (M4) stops [3] after a specified period of time since PS9 detects the trailing edge
of paper.
Folding conveyance motor (M4)
Tri-folding exit clutch (CL1)
Tri-folding exit sensor (PS9)
[1] [2] [3] 15ant2c082na
[1] Exit belt drive [3] Folding conveyance motor (M4) stopped
[2] Exit belt stop
43
D. Center folding control

When the folding main scan alignment motor /Fr (M7) stops at the completion of the paper alignment operation,
the 1st folding blade motor (M18) turns ON and rotates in the reverse direction [2] to let the 1st folding blade
SD-506
insert the paper between the folding rollers /1 and /2. When the 1st folding blade home sensor /1 (PS20) turns
ON, the folding conveyance motor (M4) rotates in the reverse direction to rotate the folding rollers /1 and /2 in
the reverse direction to release the paper. When PS20 turns OFF, M18 and M4 stop rotating [3].
In the folding operation for the subsequent set, M18 rotates in the forward direction [4] and it stops when the 1st
folding blade home sensor /2 (PS21) turns ON [5].
[1] [2] [4]
Forward
Folding convey-
ance motor (M4) Reverse

alignment motor /
Fr (M7) Reverse
Forward
1st folding blade
motor (M18) Reverse
[3] [5] 15ant2c083na
[1] 1st folding blade is projected with the paper [4] M18 rotating the forward direction
[2] Folding conveyance motor (M18) rotating the [5] M18 stopped
reverse direction
[3] M18 and M4 stopped
44
6.3.4 Folding sub scan alignment control

A. Mechanism
The folding sub scan alignment operation is conducted in the multi letter folding mode and is conducted with the
SD-506
folding exit claws [13] and the folding alignment stoppers /Rt [3] driven by the folding sub scan alignment exit
motor (M8) [8].
The folding exit claws move to the right [14] and the folding alignment stoppers /Rt move to the left [2] when M8
rotates in the reverse direction [9]. The folding alignment stoppers /Rt are contacted with the alignment stopper
[1] and stopped by the torque limiter [7]. The folding exit claws move to the positions for the paper width of A4S
or 8 1/2 x 11S and conduct the folding sub scan alignment operation, and then the folding is conducted.
In the multi center folding mode and the saddle stitching mode, M8 rotates in the forward direction to move the
folding exit claws to the left [11] after the folding operation. Once the folding exit claws make a round, they con-
duct the paper exit operation to the saddle stitching section. At the time, the folding alignment stoppers /Rt
moving to the right [4] are contacted with the alignment stopper [5] and stopped by the torque limiter [7].
The folding sub scan alignment home sensor (PS56) [12] detects the home position of the folding exit claws in
the alignment operation. The folding exit home sensor (PS24) [6] detects the initial position and the center fold-
ing exit operation.
[1] Alignment stopper [8] Folding sub scan alignment exit motor (M8)
[2] Direction at the alignment operation (to the left) [9] M8 rotated in the reverse direction
[3] Folding alignment stoppers /Rt [10] Folding sensor /2 (PS44)
[4] Movement in the center folding exit operation (Right) [11] Direction at the center folding exit operation
[5] Home position stopper [12] Folding sub scan alignment home sensor (PS56)
[6] Folding exit home sensor (PS24) [13] Folding exit claws
[7] Torque limiter [14] Direction at the alignment operation (to the right)
45
B. Folding sub scan alignment control

The folding sub scan alignment exit motor (M8) rotates in the reverse direction to conduct the alignment opera-
tion in the sub scan direction [2] after a specified period of time since the right angle conveyance sensor /2 (PS6)
SD-506
detects the trailing edge of paper and the alignment operation in the main scan direction is conducted [1]. When
the folding sub scan alignment home sensor (PS56) detects the folding exit claws, M8 conducts the alignment
by pressing the side of the paper, and then it stops [3].
The M8 conducts the shelter operation and stops [4] after a specified period of time since PS6 detects the trail-
ing edge of paper.
[1]
Right angle conveyance

sensor /2 (PS6)
alignment motor /
Reverse
Fr (M7)
Folding sub scan Forward

alignment exit
Reverse
motor (M8)
Folding sub scan alignment

home sensor (PS56)
[2] [3] [4] 15ant2c084na
[1] Alignment operation in the main scan direction [3] M8 stopped

[2] Alignment operation in the sub scan direction [4] Shelter operation
C. Center folding exit operation

The folding sub scan alignment exit motor (M8) does not conduct the alignment operation in the sub scan direc-
tion in the multi center folding/saddle stitching mode.
M8 drives the folding exit claws to conduct the paper exit operation [2] to the saddle stitching section after a
specified period of time since the folding main scan alignment motor /Fr (M7) completes the realignment opera-
tion in the main scan direction [1] (after the center folding operation). After a specified period of time since the
folding sensor /2 (PS44) detects the trailing edge of paper, M8 rotates in low speed [3] and conduct the home
position search operation, and then it stops [4] when the folding exit home sensor (PS24) turns ON.
[1] [2] [3] [4]
Folding main Forward

scan alignment
motor /Fr (M7) Reverse
High speed
Folding sub scan
alignment exit Low speed
motor (M8)
Reverse
Folding exit home sensor (PS24)

Folding sensor /2 (PS44)
15ant2c085na
[1] Realignment operation in the main scan direction [3] Switched to the low speed
[2] Paper exit operation started [4] Stopped at home position
46
6.3.5 Guide shaft control

A. Mechanism
The guide shaft [2] holds the fold line [4] from the bottom and makes certain of the stack [3] in the saddle stitch-
SD-506
ing section when the folding exit claws [7] exit the folded paper [1] to the saddle stitching section.
The guide shaft is projected [5] in sync with the paper exit only when the first folded paper for each set is exited
and put away immediately to the folding section [6]. In the subsequent paper exit, the guide shaft does not oper-
ate because the paper [3] stacked in the saddle stitching section works as the guide.
[4] [5] [6] [7] [1]
[3] [2] 15ant2c027na
[1] Folded paper [5] Projection direction of the guide shaft

[2] Guide shaft [6] Storage direction of the guide shaft
[3] Stacked paper [7] Folding exit claws
[4] Fold line
47
B. Guide shaft control

The guide shaft motor (M25) turns ON [2] and the guide shaft is projected after a specified period of time since
the folding main scan alignment motor /Fr (M7) completes the realignment operation in the main scan direction
SD-506
[1] (after the center folding operation). The guide shaft conducting the back and forth operation by the belt rota-
tion stops when the guide shaft home sensor (PS46) turns ON [3].
[1] [2] [3]

alignment motor /
Fr (M7) Reverse
Guide shaft motor (M25)
Guide shaft home sensor (PS46)
15ant2c086na
[1] Realignment operation in the main scan direction [3] Guide shaft motor (M25) stopped
[2] Guide shaft projecting started
C. Folding unit lock control

During the print operation, the folding unit lock solenoid (SD8) locks the folding unit to prevent the guide shaft or
the folding exit claws from damage due to pulling out the folding unit by mistake.
When the paper gets jammed, the positions of the guide shaft and the folding exit claws are monitored. SD8
turns OFF and releases the lock only when both the folding exit home sensor (PS24) and the guide shaft home
sensor (PS46) detect the home position.
48
Theory of Operation Ver.2.0 Jul. 2009 7. SADDLE STITCHING SECTION
7. SADDLE STITCHING SECTION

7.1 Configuration
SD-506
Saddle stitching align-
Stapler Saddle stitching hold /Up Saddle stitching hold /
Lw ment plate
Clip
Bundle arm
Bundle arm
Assist plate
Clincher
15ant2c028nb
49
7. SADDLE STITCHING SECTION Theory of Operation Ver.2.0 Jul. 2009
7.2 Drive
7.2.1 Saddle stitching alignment drive
SD-506
[6] [7] [8] [1]

[2]
[5] [4] [3] 15ant2c029na
[1] Saddle stitching alignment motor /Rt (M9) [5] Saddle stitching alignment home sensor /Lt (PS29)
[2] Folding sensor /2 (PS44) [6] Saddle stitching alignment motor /Lt (M16)
[3] Saddle stitching alignment home sensor /Rt (PS28) [7] Saddle stitching alignment plate /Lt
[4] Front side view [8] Saddle stitching alignment plate /Rt
7.2.2 Saddle stitching hold drive
[8]
[7]
[1]
[6] [5] [4] [2]
[3] 15ant2c030na
[1] Saddle stitching hold /Up [5] Eccentric cam

[2] Arm [6] Saddle stitching press home sensor (PS27)
[3] Left-side view [7] Saddle stitching press motor (M21)
[4] Spring [8] Stapler
50
7.2.3 Clincher up down drive
SD-506
[8]
[7]
[6]
[1]
[2]
[5] [4] [3] 15ant2c031na
[1] Left-side view [5] Clincher up down motor (M20)

[2] Roller [6] Spring
[3] Eccentric cam [7] Clinchers /Rt, /Lt
[4] Clincher up down home sensor (PS26) [8] Saddle stitching hold /Lw
51
7.2.4 Stapler/clincher movement drive

SD-506
[1]
[8] [2]
[4]
[7] [3]
[5]
[6]
[1]
15ant2c032na
[1] Top side view [5] Stapler movement home sensor (PS25)
[2] Stapler /Rt [6] Stapler movement motor (M15)
[3] Clincher /Rt [7] Clincher /Lt
[4] Front side view [8] Stapler /Lt
52
7.2.5 Stapler/clincher drive
SD-506
[8]
[1]
[2]
[3]
[7] [5]
[4]
[6]
15ant2c077na
[1] Stapling arm [5] Staple

[2] Staple bending arm [6] Left-side view
[3] Clincher plate [7] Eccentric cam
[4] Clincher solenoids /Rt (SD9), /Lt (SD10) [8] Stapler motors /Rt (M29), /Lt (M30)
53
7.2.6 Bundle arm rotation drive
[1]
SD-506
[7]
[2]
[3]
[6] [5]
[4]
15ant2c033na
[1] Bundle arm [5] Guide shaft

[2] Slide guide [6] Fulcrum shaft
[3] Left-side view [7] Bundle arm rotation home sensor (PS31)
[4] Bundle arm rotation motor (M22)
54
7.2.7 Bundle arm movement drive
SD-506
[1]
[3]
[2]
[4]
[6] [5] 15ant2c034na
[1] Bundle arm [4] Bundle arm motor (M10)

[2] Guide shaft [5] Bundle arm home sensor (PS32)
[3] Folding sensor /2 (PS44) [6] Fulcrum shaft
55
7.2.8 Bundle arm assist drive

SD-506
[5] [1]
[3]
[2]
[4] 15ant2c035na
[1] Bundle arm assist upper limit sensor (PS39) [4] Bundle arm assist home sensor (PS38)
[2] Left-side view [5] Bundle arm assist motor (M26)
[3] Bundle arm assist plate
56
7.2.9 Bundle clip drive
SD-506
[9] [10]
[1]
[8]
[7]
[6] [5]
[2]
[4] [3] 15ant2c036nb
[1] Bundle clip upper limit sensor (PS33) [6] Release roller
[2] Bundle clip motor (M11) [7] Wire
[3] Left-side view [8] Spring
[4] Bundle clip lower limit sensor (PS30) [9] Release plate /Up
[5] Release plate /Lw [10] Clip
57
7.3 Operation
7.3.1 Saddle stitching alignment control
SD-506
A. Mechanism
In the saddle stitching alignment, the saddle stitching alignment plates /Lt [2] and /Rt [8] align the center folded
paper [5] in the sub scan direction.
The saddle stitching alignment motor /Lt (M16) [3] drives the saddle stitching alignment plate /Lt [2] in the sub
scan direction via the belt by rotating in the forward and reverse directions. The saddle stitching alignment plate
/Lt moves to the position for the appropriate paper size when the main body start signal turns ON, and it does
not move during the print operation. It return to the position at the saddle stitching alignment home sensor /Lt
(PS29) [4] after the print operation.
The saddle stitching alignment motor /Rt (M9) [7] drives the saddle stitching alignment plate /Rt [8] in the sub
scan direction via the belt by rotating in the forward and reverse directions. The alignment operation is con-
ducted by M9 by rotating in the forward/reverse directions every time the center folded paper is conveyed. It
return to the position at the saddle stitching alignment home sensor /Rt (PS28) [6] after the print operation.
[7] [8]
[1]
[2]
[6]
[3]
[5]
[4] 15ant2c037na
[1] Front side direction [5] Paper

[2] Saddle stitching alignment plate /Lt [6] Saddle stitching alignment home sensor /Rt (PS28)
[3] Saddle stitching alignment motor /Lt (M16) [7] Saddle stitching alignment motor /Rt (M9)
[4] Saddle stitching alignment home sensor /Lt (PS29) [8] Saddle stitching alignment plate /Rt
58
B. Control
The saddle stitching alignment motor /Lt (M16) rotates in the reverse direction when the main body start signal
[1] turns ON and the saddle stitching alignment plate /Lt moves to the position for the appropriate paper size [2].
SD-506
The saddle stitching alignment motor /Rt (M9) rotates in the forward direction and the saddle stitching alignment
plate /Rt conducts the preliminary alignment operation [4] when the folding sensor /2 (PS44) at the exit of the
folding section detects the trailing edge of the paper [3]. Then, M9 rotates in the forward direction to conduct the
alignment operation [5] when the paper is stacked at the stapler position. After a specified period of time, M9
rotates in the reverse direction to go back the saddle stitching alignment plate to its home position and stands
by for the subsequent set [6].
For the last paper of the set [7], M9 rotates in the reverse direction to go back the saddle stitching alignment
plate to its home position when the saddle stitching press motor (M21) is completed with holding the paper [8].
[7]

Saddle stitching Forward
alignment motor /Rt
(M9) Reverse
alignment motor /Lt
(M16) Reverse
Saddle stitching press motor (M21)
[9]
[1] [2] [3] [4] [5] [6] [8] 15ant2c087na
[1] Main body print signal [6] Moved to the home position
[2] Moved for appropriate paper size [7] Last paper of the set
[3] Detected the trailing edge of paper [8] Held the paper with the saddle stitching hold
[4] Preliminary alignment operation [9] Moved to the home position
[5] Alignment operation
59
7.3.2 Stapler/clincher movement control

A. Mechanism
The staplers/clinchers move to the stapling position in accordance with the paper size.
SD-506
The stapling position is different for every paper size to make the stapling distance half of the paper size.
The staplers /Rt [10] and /Lt [8] are fixed to the belt /Up [9] and the clinchers /Rt [2] and /Lt [4] to the belt /Lw [1].
The stapler movement motor (M15) [5] moves them in the sub scan direction via the connecting shaft [6].
To prevent the tooth skipping of the belts /Up and /Lw at the maintenance, the gear-shaped rotating knob [7] is
provided on the connecting shaft [6]. By rotating the knob manually, the staplers /Rt and /Lt and the clinchers /
Rt and /Lt move simultaneously.
[7] [8] [9] [10]

[6]
[5] [4] [3] [2] [1] 15ant2c038na
[1] Belt /Lw [6] Connecting shaft

[2] Clincher /Rt [7] Rotating knob
[3] Stapler movement home sensor (PS25) [8] Stapler /Lt
[4] Clincher /Lt [9] Belt /Up
[5] Stapler movement motor (M15) [10] Stapler /Rt
B. Control
The stapler movement motor (M15) rotates in the forward direction when the main body start signal turns ON
and moves the staplers and the clinchers to the position for the appropriate paper size.
They go back to their home position at the end of the printing operation.
60
7.3.3 Saddle stitching hold control

A. Mechanism
The saddle stitching hold is the mechanism to prevent the paper misalignment at stapling. The saddle stitching
SD-506
hold /Up [1] moves down to the saddle stitching hold /Lw [2] at its lower position and hold the center folded
paper [3] at the fold line from both up and down.
The eccentric cam [5] moves the saddle stitching hold /Up [1] up and down via the arm [6].
[1] Saddle stitching hold /Up [4] Left-side view
[2] Saddle stitching hold /Lw [5] Eccentric cam
[3] Center folded paper [6] Arm
61
The spring [3] enforces the saddle stitching hold /Up [6] toward the saddle stitching hold /Lw [5]. When the sad-
dle stitching press motor (M21) rotates the eccentric cam [2] via the gear [1], the arm [4] moves along with the
shape of the eccentric cam and the spring [3] lowers the saddle stitching hold /Up.
SD-506
The saddle stitching hold /Up [6] holding the center folded paper at its lower position is pushed up to its upper
position by the saddle stitching hold /Lw [5] during the stapling operation. This allows the paper to be moved
from the lower position to the upper position without any misalignment.
The saddle stitching press home sensor (PS27) [8] detects the home position of the eccentric cam.
[8]
[6] [7]
[1]
[5]
[4] [3] [2] 15ant2c040na
[1] Gear [5] Saddle stitching hold /Lw

[2] Eccentric cam [6] Saddle stitching hold /Up
[3] Spring [7] Front side direction
[4] Arm [8] Saddle stitching press home sensor (PS27)
62
B. Control
At the end of the paper alignment operation [1], the saddle stitching press motor (M21) rotates to move the sad-
SD-506
dle stitching hold /Up downward [2] and hold the paper between the saddle stitching holds /Up and /Lw. Then,
the clincher up down motor (M20) starts rotating and the saddle stitching hold /Up is pushed up by the saddle
stitching hold /Lw while holding the paper [3]. M20 rotates in the reverse direction and lowers the saddle stitch-
ing hold /Lw [5] when the clinching operation [4] is started. Also the spring lowers The saddle stitching hold /Up.
M21 turns ON and go back the saddle stitching hold /Up to its standby position [6] after a specified period of
time since the clinching operation is started.
[1] [5]
Forward
Saddle stitching
alignment motor /Rt
Reverse
Clincher up down Forward

motor (M20)
Reverse
Clincher solenoids /Rt (SD9), /Lt (SD10)
Saddle stitching press home sensor (PS27)
[2] [3] [4] [6] 15ant2c088na
[1] Alignment operation [4] Clinching operation

[2] Saddle stitching hold /Up moved down [5] Saddle stitching hold /Lw moved down
[3] Saddle stitching hold /Lw moved up [6] Saddle stitching hold /Up moved up

At the end of the paper alignment operation [1], the saddle stitching press motor (M21) rotates to move the sad-
dle stitching hold /Up downward [2] and stack the paper securely. Then, M21 keeps rotating to move the saddle
stitching hold /Up upward to its standby position [3].
[1]

alignment motor /Rt
Reverse
(M9)
Saddle stitching press home sensor (PS27)
[2] [3] 15ant2c089na
[1] Alignment operation [3] Saddle stitching hold /Up moved up

[2] Saddle stitching hold /Up moved down
63
7.3.4 Clincher up down control

A. Mechanism
The clincher shelters at the lower position to obtain space between the stapler and the clincher when the paper
SD-506
is conveyed between them.

After the alignment operation, the saddle stitching hold /Up [7] moves down and holds the center folded paper
[6]. Then the eccentric cam [5] drives the saddle stitching hold /Lw [2] and the clincher [3] to push up the saddle
stitching hold /Up [7] to the position where the stapler [1] is positioned while holding the center folded paper.
[1] Stapler [5] Left-side view

[2] Saddle stitching hold /Lw [6] Center folded paper
[3] Clincher [7] Saddle stitching hold /Up
[4] Eccentric cam
64
The clincher [7] moves down to the lower position by its own weight and moves upward by the clincher up down
motor (M20).
The roller [2] attached to the arm [5] is pushed up and the clincher is contacted with the stapler when M20
SD-506
rotates the eccentric cam [3]. The paper between the clincher and the stapler is held securely by the spring [6].
Once the stapling operation is completed, M20 rotates in the reverse direction to go back the eccentric cam,
and then the clincher moves down by its own weight.
[8]
[3] [4]
[7]
[6]
[1]
[9]
[5] [2] [5] [4] [3] [2] 15ant2c042na
[1] Left-side view [6] Spring

[2] Roller [7] Clinchers /Rt, /Lt
[3] Eccentric cam [8] Saddle stitching hold /Lw
[4] Clincher up down home sensor (PS26) [9] Front side direction
[5] Arm
65
B. Control
The clincher moves up or down only in the saddle stitching mode.
Once the saddle stitching press motor (M21) moves down the saddle stitching hold /Up [1], the clincher up
SD-506
down motor (M20) rotates in the forward direction to move up the clinchers /Rt and /Lt and the saddle stitching
hold /Lw [2]. M20 is stopped when the clincher up down home sensor (PS26) turns ON.
M20 rotates in the reverse direction to move down the clinchers /Rt and /Lt and the saddle stitching hold /Lw
when the clincher solenoids /Rt (SD9) and /Lt (SD10) starts the clinching operation [4]. They are stopped at the
lower position [5] when PS26 turns OFF.
[2] [3] [5]
Clincher up Forward
down motor Reverse
(M20)
Clincher up down home sensor (PS26)

[1] [4] 15ant2c090na
[1] Saddle stitching hold /Up moving down [4] Clinching operation
stopped
[2] Clinchers /Rt and /Lt moved up [5] Clinchers /Rt and /Lt stopped at lower posi-
tion
[3] Clinchers /Rt and /Lt stopped at the upper
position
66

A. Mechanism
The stapler motors /Rt (M29) and /Lt (M30) [10] and the clincher solenoids /Rt (SD9) and /Lt (SD10) [5] operate
SD-506
the stapler operation.
The stapler home sensors /Rt (HS1) and /Lt (HS3) [8] and the clincher start sensors /Rt (HS2) and /Lt (HS4) [11]
detect the stapler operation. HS1, HS2, HS3, and HS4 are hall element sensors and control the position of the
magnet [12] of the rotating eccentric cam [9].
M29 and M30 [10] drive the staple bending arm [3] and the stapling arm [2] via the eccentric cam [9]. The staple
bending arm bends the rolled staple [6] into the U-shape and the stapling arm staples it toward the clincher.
Then the clinchers solenoids /Rt (SD9) and /Lt (SD10) bend the staple by driving the clincher plate [4]. The sta-
pling operation is completed with these operations.
The staple empty switches /Rt (SW1) and /Lt (SW2) [7] detect whether the staple or cartridge is set or not.
[11] [12]
[10] [1]
[2]
[3]
[4]
[9] [8] [7] [6]
[5]
15ant2c091na
[1] Front side direction [8] Stapler home sensors /Rt (HS1) and
[2] Stapling arm /Lt (HS3)
[3] Staple bending arm [9] Eccentric cam
[4] Clincher plate [10] Stapler motors /Rt (M29), /Lt (M30)
[5] Clincher solenoids /Rt (SD9), /Lt (SD10) [11] Clincher start sensor /Rt (HS2) and
[6] Staple /Lt (HS4)
[7] Stapler empty switches /Rt (SW1) and /Lt [12] Magnet
(SW2)
67
B. Control
(1) Staple control
The stapler motors /Rt (M29) and /Lt (30) start the stapling operation [2] when the clincher up down home sen-
SD-506
sor (PS26) detects that the clinchers /Rt and /Lt are contacted with the stapler assy [1].
The clincher solenoids /Rt (SD9) and /Lt (SD10) bend the staple and the stapling operation is completed when
the clincher start sensors /Rt (HS1) and /Lt (HS3) in the stapler assy turn ON [3]. M29 and M30 stop and return
to the home position [4] when the stapler home sensors /Rt (HS1) and /Lt (HS3) detects the home position.
[1]
Stapler motors /Rt (M29), /Lt (M30)
Stapler home sensors /Rt (HS1) and /Lt (HS3)
Clincher start sensor /Rt (HS2) and /Lt (HS4)

[2] [3] [4] 15ant2c092na
[1] Clincher contacted [3] Clinching operation

[2] Stapling operation [4] Returning to the home position
(2) Staple and cartridge detection

When the remaining amount of the staple becomes 20 or the cartridge is not set, the staple empty switches /Rt
(SW1) and /Lt (SW2) turn ON and the main body displays the message on its operation panel.
68
7.3.6 Bundle arm control

The bundle arm [4] rotates and moves in the sub scan direction.
It rotates to convey the paper from the stapling section to the bundle clip section and moves in the sub scan
SD-506
direction to catch/release the paper.
In the multi center folding mode, the bundle arm rotates to the stapling position after the last paper of the set is
conveyed. In the saddle stitching mode, it rotates after the stapling operation.
By moving the bundle arm, the tip of the bundle arm is inserted under the fold line of the paper and the paper is
caught [1].
The caught paper is conveyed to the bundle clip section [2] by the rotation of the bundle arm. The bundle arm
moves in the outside of the sub scan direction and releases the paper [3] when the bundle clip holds the paper
at the folding side.
[1]
[4]
[2]
[3]
15ant2c043na
[1] Paper caught [3] Paper released

[2] Conveyance [4] Bundle arm
69
A. Bundle arm movement mechanism

The bundle arm motor (M10) [6] drives the bundle arm [5] to catch/release the paper [4] in the sub scan direc-
tion via the belt.
SD-506
The bundle arm home sensor (PS32) [1] detects the home position of the bundle arm.
[4] [5] [6]
[1]
[2]
[3] 15ant2c044na
[1] Bundle arm home sensor (PS32) [4] Paper

[2] Front side direction [5] Bundle arm
[3] Guide shaft [6] Bundle arm motor (M10)
70
B. Bundle arm rotation mechanism

The bundle arm rotation motor (M22) [2] drives the bundle arm [8] via the belt, slide guide [5], and guide shaft [6].
When M22 drives the slide guide [5] in the main scan direction, the guide shaft [6] passing through the long hole
SD-506
of the slide guide is rotated, and then the bundle arm [8] is rotated around the fulcrum. When it is driven to the
paper [3] side, M22 stops where the ring [7] is contacted with the guide plate [4].
The bundle arm rotation home sensor (PS31) [9] detects the home position of the bundle arm.
[9]
[6]
[5]
[1]
[2]
[3]
[8]
[1]
[4]
[7] [6] [5] 15ant2c045na
[1] Front side direction [6] Guide shaft

[2] Bundle arm rotation motor (M22) [7] Ring
[3] Paper [8] Bundle arm
[4] Guide plate [9] Bundle arm rotation home sensor (PS31)
[5] Slide guide
71
In the rotation drive of the bundle arm [8], the slide guide [5] has to be overrun to be sure to make the ring [7] of
the bundle arm contact with the guide plate [6]. To prevent any parts from damage due to the overrun, the guide
shaft [3] is movable with the shock absorbing guide [4] and the spring [2].
SD-506
[8]
[1]
[7]
[2]
[6]
[5]
[3]
[4]
15ant2c046na
[1] Front side direction [5] Slide guide

[2] Spring [6] Guide plate
[3] Guide shaft [7] Ring
[4] Shock absorbing guide [8] Bundle arm
72
C. Bundle arm control

The bundle arm motor (M10) rotates in the reverse direction when the main body start signal [1] turns ON and
moves the bundle arm to the appropriate position in accordance with the paper size.
SD-506
The bundle arm rotation motor (M22) rotates in the forward direction to rotate the bundle arm to the stapling section
[3] after a specified period of time since the folding sensor /2 (PS44) detects the trailing edge of paper of the last set.
It stops the bundle arm in an upright position [4] when the bundle arm rotation home sensor (PS31) turns OFF.
Then, M22 rotates again [5] to drive the bundle arm until it is contacted with the guide plate on the stapling section [6]. The
timing for M22 to restart the rotation [5] is different between in the multi center folding mode and in the saddle stitching mode.
• Multi center folding mode: When the saddle stitching press home sensor (PS27) detects the saddle stitch-
ing hold /Up has been moved to its upper position.
• Saddle stitching mode: After a specified period of time since the clincher up down home sensor (PS26)
detects that the clinchers are contacted with the staplers.
M10 inserts the tip of the bundle arm under the fold line of the paper [7] when the bundle arm assist motor (M26) starts the
assisting operation by pushing up the trailing edge of paper at the back side and M10 stops after a specified period of time [8].
M22 rotates in the reverse direction to convey the paper to the bundle clip section when M10 stops [8]. It stops
after a specified period of time since PS31 turns ON.
M10 rotates in the forward direction to pull out the bundle arm from the paper and take shelter it from the con-
veyance path [11] after a specified period of time since the bundle clip starts to catch the paper [10]. M10 stops
when the bundle arm home sensor (PS32) turns ON [12].
M10 rotates in the reverse direction to go back the bundle arm to its standby position [13] for the subsequent
set after a specified period of time since it stops.
[14] [9] [11] [12][13]
Bundle arm assist motor (M26)
Bundle arm Forward

motor (M10)
Reverse
Bundle arm Forward
rotation motor
(M22) Reverse
Bundle arm rotation home sensor (PS31)
Bundle arm home sensor (PS32)

Bundle clip Forward
motor (M11)
Reverse
[1][2] [3] [4] [5] [6][7] [8] [10] 15ant2c093na
[1] Main body start signal [8] Insertion completed and conveyance started
[2] Moved for appropriate paper size [9] Conveyance completed
[3] Bundle arm started to rotate [10] Paper clip caught paper
[4] Bundle arm stopped in an upright position [11] Bundle arm shelter operation
[5] Bundle arm restarted to rotate [12] Shelter completed
[6] Bundle arm contacted with the guide plate [13] Bundle arm moved for the subsequent set
[7] Bundle arm inserted under the fold line [14] Time chart of the saddle stitching mode
73
7.3.7 Bundle arm assist control

A. Mechanism
The bundle arm assist mechanism is the mechanism to assist the paper conveyance of the bundle arm rotation
SD-506
drive to be conducted without fault. It pushes up the fore edge side of the paper [6] with the bundle arm assist
plate [4] to tilt it to the front.
The bundle arm assist motor (M26) [2] drives the bundle arm plate [4] via the belt.
The bundle arm assist upper limit sensor (PS39) [1] detects the upper home position and the bundle arm assist
home sensor (PS38) [3] detects the lower home position.
The bundle arm assist plate [4] waits at the position5mm below the fore edge side of the paper during standby.
To keep the error to a minimum, the small-size paper (less than 314mm) and the large-size paper (314mm or
more) are moved to the standby position from the position of PS39 and PS38 respectively since the driving time
of M26 (DC brush motor) positions the standby position for the paper.
In the bundle arm assist operation, the fore edge side of the paper is pushed up 35mm (or until PS39 turns ON).
[6]
[1]
[2]
[5]
[4]
[3]
15ant2c065na
[1] Bundle arm assist upper limit sensor (PS39) [4] Bundle arm assist plate
[2] Bundle arm assist motor (M26) [5] Front side direction
[3] Bundle arm assist home sensor (PS38) [6] Paper
74
B. Control
(1) Small-size paper (less than 314mm)
For the small-size paper, the bundle arm assist motor (M26) rotates in the forward direction when the main body
SD-506
start signal [1] turns ON to drive the bundle arm assist plate at the home position to the position at the bundle
arm assist upper limit sensor (PS39) [2]. After a specified period of time, M26 rotates in the reverse direction to
drive the bundle arm assist plate from the upper limit position to the standby position in accordance with the
paper size [3] and stands by for the paper.
Then, M26 rotates in the forward direction to push up the fore edge side of the paper [6] for assisting the bundle
arm to be inserted under the fold line of the paper. The operation timing [6] of M26 is different between in the
multi center folding mode and in the saddle stitching mode.
• Multi center folding mode: When the bundle arm is contacted with the guide plate of the stapler section [4]
by the bundle arm rotation motor (M22).
• Saddle stitching mode: When the clincher moves downward [5] at the end of the stapling operation.
M26 rotates in the forward direction to assist the bundle arm to convey the paper [7] after a specified period.
Then the bundle arm assist plate goes back to the standby position and stands by for the subsequent set [8].
[2] [3] [6] [7] [8]

[9]
Bundle arm assist Forward
motor (M26)
Reverse
Bundle arm assist home sensor (PS38)
Bundle arm assist upper limit sensor (PS39)
Clincher up Forward
down motor
(M20) Reverse
Bundle arm Forward

rotation motor
(M22) Reverse
[1] [4] [5] 15ant2c095na
[1] Main body start signal [6] Assist of the insertion of the bundle arm
[2] Movement to the upper limit [7] Assist of the bundle arm conveyance
[3] Moved for appropriate paper size [8] Moved for appropriate paper size
[4] Bundle arm contacted with the guide plate [9] Time chart of the saddle stitching mode
[5] Clincher moved down
75
(2) Large-size paper (314mm or more)

For the large-size paper, the bundle arm assist motor (M26) rotates in the forward direction when the main body
start signal [1] turns ON to drive the bundle arm assist plate to the standby position in accordance with the
SD-506
paper size [2] and stands by for the paper.

The subsequent operation is conducted in the same manner as for the small-size paper.
[2] [5] [6] [7]

[8]
Bundle arm assist Forward

motor (M26)
Reverse
Bundle arm assist home sensor (PS38)
Bundle arm assist upper limit sensor (PS39)
Clincher up Forward
down motor
(M20) Reverse
Bundle arm Forward

rotation motor
(M22) Reverse
[1] [3] [4] 15ant2c096na
[1] Main body start signal [5] Assist of the insertion of the bundle arm
[2] Moved for appropriate paper size [6] Assist of the bundle arm conveyance
[3] Bundle arm contacted with the guide plate [7] Moved for appropriate paper size
[4] Clincher moved down [8] Time chart of the saddle stitching mode
76
7.3.8 Bundle clip control

A. Mechanism
The bundle clip is the mechanism to hold the paper that the bundle arm conveyed to the slope and convey the
SD-506
paper to the bundle press stage with its fore edge side to the trimmer section.
The bundle clip catches, releases, and conveys the paper. It catches the paper at the upper limit position [1],
conveys it [2], and then release it at the lower limit position [3].
[1]
[2]
[3]
15ant2c047na
[1] Catching [3] Releasing

[2] Conveyance
77
The bundle clip motor (M11) [5] drives the bundle clip [1] up [8] and down [7] via the gear and belt.
The spring [9] provides the bundle clip the force to catch the paper, and the wire [2] and the winding shaft [3]
open the bundle clip to release the paper.
SD-506
The bundle clip upper limit sensor (PS33) [4] detects the upper limit of the bundle clip and the bundle clip lower
limit sensor (PS30) [6] detects the lower limit.
[9] [1]
[2]
[3]
[8]
[7] [4]
[6] [5] 15ant2c048na
[1] Clip [6] Bundle clip lower limit sensor (PS30)

[2] Wire [7] Down
[3] Winding shaft [8] Up
[4] Bundle clip upper limit sensor (PS33) [9] Spring
[5] Bundle clip motor (M11)
78
The bundle clip is closed all the time except when it is located at the upper and lower limit position. When the
bundle clip moves up [1], the release roller /Up [6] gets onto [7] the release plate /Up [8]. Then the wire winding
shaft [4] rotates [3] and takes up the wire [5] to open the bundle clip.
SD-506
In the same way, when the bundle clip moves down [2], the release roller /Lw [10] gets onto [12] the release
plate /Lw [11] and then the wire winding shaft [4] rotates [9] and takes up the wire [5] to open the bundle clip.
[5] [6] [7] [8]
[1] [10] [4] [3]
[2] [1]
[5]
[12] [11] [10] [4] [9] 15ant2c049na
[1] Up [7] Getting over at up

[2] Down [8] Release plate /Up
[3] Wire winding rotation [9] Wire winding rotation
[4] Wire winding shaft [10] Release roller /Lw
[5] Wire [11] Release plate /Lw
[6] Release roller /Up [12] Getting over at down
79
B. Control
The bundle clip motor (M11) rotates in the forward direction to move up the bundle clip until the bundle clip
upper limit sensor (PS33) turns ON [2] after a specified period of time since the bundle assist motor (M26) starts
SD-506
the assisting operation [1]. Then, the bundle clip stops with its clip opened.
The bundle arm conveys the paper from the stapling section to the bundle clip section, and then the bundle arm
rotation motor (M22) stops [3]. After a specified period of time, M11 rotates in the reverse direction to move
down the bundle clip and close the bundle clip to catch the paper, and then M11 stops after a specified period
of time [4]
When the bundle arm motor (M10) completes the shelter operation [5], M11 rotates in the reverse direction to
move down the bundle clip [6]. The bundle clip opens the clip to release the paper [7] and M11 stops when the
bundle clip lower limit sensor (PS30) turns ON.
M11 rotates in the forward direction to move up the bundle clip after a specified period of time since M11 stops.
Then, M11 stops to move the bundle clip at the standby position for the subsequent set after a specified period
of time since PS30 turns OFF [8].
[3] [5] [8]

Forward
Bundle arm
motor (M10) Reverse
Bundle arm Forward

rotation motor
(M22) Reverse
Bundle arm assist motor (M26)

Bundle clip Forward
motor (M11)
Reverse
Bundle clip upper limit sensor (PS33)
Bundle clip lower limit sensor (PS30)
[1] [2] [4] [6] [7] 15ant2c099na
[1] Assisting operation by the bundle arm [5] Bundle arm shelter operation
[2] Bundle clip opened [6] Conveyed by the bundle clip
[3] Paper conveyance by the bundle arm completed [7] Paper released
[4] Paper caught [8] Returned to the standby position
80
Theory of Operation Ver.2.0 Jul. 2009 8. BUNDLE PROCESSING SECTION
8. BUNDLE PROCESSING SECTION

8.1 Configuration
SD-506
Trimmer scraps removal Lift wire Bundle press stage Bundle press plate Exit claws
fan (FM1)
Bundle tray paper
Bundle registration plate
full sensor (PS61)
Shutter Registration
claws
Trimmer scraps press Trimmer scraps full sensor Scraps box Bundle exit convey- Bundle exit tray
plate (PS41) ance belt
15ant2c050nb
81
8. BUNDLE PROCESSING SECTION Theory of Operation Ver.2.0 Jul. 2009
8.2 Drive
8.2.1 Bundle press stage lift drive
SD-506
[1] Bundle registration plate [8] Bundle press stage up down home sensor (PS35)
[2] Bundle registration plate wire [9] Bundle press stage up down limit sensor (PS45)
[3] Lift wire [10] Bundle press stage up down motor (M24)
[4] Bundle press stage [11] Over-winding-prevention stopper
[5] Front side direction [12] Wire winding shaft
[6] Bundle exit auxiliary roller [13] Bundle registration plate home sensor (PS16)
[7] Knob
82
8.2.2 Bundle press movement drive
[1]
SD-506
[5] [4] [3] [2] 15ant2c052na
[1] Bundle press [4] Left-side view

[2] Bundle press movement home sensor (PS36) [5] Bundle press movement motor (M17)
[3] Bundle press stage
8.2.3 Bundle registration drive
[1]
[6]
[5]
[4] [3] [2] 15ant2c053na
[1] Exit claws [4] Registration claws

[2] Left-side view [5] Bundle registration home sensor (PS34)
[3] Bundle press stage [6] Bundle registration motor (M12)
83
8.2.4 Bundle press drive

SD-506
[1] Press plate [6] Front side direction

[2] Release wire /Rt [7] Bundle press lower limit sensor (PS47)
[3] Wire winding shaft [8] Bundle press home sensor (PS37)
[4] Bundle press motor (M23) [9] Spring
[5] Release wire /Lt
84
8.2.5 Bundle exit drive
SD-506
[13]
[1]
[12]
[11]
[10]
[9]
[8] [2]
[7] [6] [5] [4] [3] 15ant2c055nb
[1] Bundle exit conveyance belt [8] Trimmer scraps press plate
[2] Left-side view [9] Scraps press home sensor (PS48)
[3] Bundle exit drive belt [10] Trimmer scraps press claws
[4] Actuator [11] Pin
[5] Belt [12] Shutter
[6] Bundle exit motor (M5) [13] One-way clutch (for pressing the trimmer scraps)
[7] One-way clutch (for the bundle exit convey-
ance belt)
85
8.3 Operation
8.3.1 Bundle press stage up down control
SD-506
The bundle press stage conducts the up and down operation to convey and exit the paper by the switch back method.
The bundle press stage is moved up [7] to decrease the angle difference when receiving the paper [8] conveyed by the bundle clip
from the slope [1]. The bundle press stage exits the paper [5] to the bundle exit tray at the horizontal position [4] at the paper exit.
The bundle registration plate [6] and the bundle exit auxiliary roller [3] move up and down together with the up
and down operation of the bundle press stage.
[7] [8]
[1]
[2]
[3]
[6] [5] [4] 15ant2c057na
[1] Slope [5] Paper path at the paper exit

[2] Front side direction [6] Bundle registration plate
[3] Bundle exit auxiliary roller [7] Bundle press stage (upper position)
[4] Bundle press stage (horizontal position) [8] Paper path to the bundle press stage
The registration claws [3] push in the paper to make sure that the paper is conveyed to the bundle press stage
when the bundle press stage [4] receives the paper from the bundle clip [6].
[5] [6]
[1]
[2]
[4] [3] 15ant2c061na
[1] Slope [4] Bundle press stage

[2] Front side direction [5] Paper conveyance
[3] Registration claws [6] Bundle clip
86
A. Mechanism
The bundle press stage up down motor (M24) [12] rotates the wire winding shaft [14] and winds up the lift wire
[3]. During the initial phase, the wire is tightened and the wire arm [4] comes to the horizontal position but the
SD-506
bundle press stage [5] does not move up. At the time, as the wire arm comes horizontal, the bundle registration
plate wire [2] is loosened and the bundle registration plate [1] moves down and works as the stopper against the
registration operation.
Then, the bundle press stage moves up as the wire winding shaft [14] rotates and winds up the up down wire [3]
and it stops when the bundle press stage up down limit sensor (PS45) [11] turns ON.
The bundle registration plate home sensor (PS16) [15] detects the home positions (shelter position) for the bun-
dle registration plate, and the bundle press stage up down home sensor (PS35) [10] detects the home position
of the bundle press stage.
The over-winding-prevention stopper [13] prevents the over winding since you can move up and down the bun-
dle press stage manually by rotating the knob [9].
[1] Bundle registration plate [9] Jam clearing knob

[2] Bundle registration plate wire [10] Bundle press stage up down home sensor
[3] Lift wire (PS35)
[4] Wire arm [11] Bundle press stage up down limit sensor (PS45)
[5] Bundle press stage [12] Bundle press stage up down motor (M24)
[6] Bundle exit auxiliary roller arm [13] Over-winding-prevention stopper
[7] Front side direction [14] Wire winding shaft
[8] Bundle exit auxiliary roller [15] Bundle registration plate home sensor (PS16)
87
B. Control
(1) Trimming mode
The bundle press stage up down motor (M24) rotates in the forward direction to move up the bundle press
SD-506
stage [2] when the main body start signal [1] turns ON. M24 stops while holding the bundle press stage in slant-
ing position when the bundle press stage up down limit sensor (PS45) turns ON [3].
M24 rotates in the reverse direction to move down the bundle press stage [5] after the bundle clip releases the
paper, the bundle registration motor (M12) assists the paper conveyance operation, and the bundle press move-
ment motor (M17) conveys the paper to the paper conveyance position [4]. M24 stops when the bundle press
stage up down home sensor (PS35) turns ON [6].
M24 starts to rotate in the forward direction and moves up the bundle registration plate [8] to open the paper
path to the trimmer section when the bundle press motor (M23) completes the paper press operation after the
registration operation.
M24 moves up the bundle press stage [10] for the subsequent set when M12 completes the paper exit [9].
[7] [9]
Bundle press Forward *

movement
motor (M17) Reverse
Bundle press Forward

motor (M23)
Reverse
Bundle registra- Forward

tion motor
(M12) Reverse
Bundle press stage Forward
up down motor
(M24) Reverse
Bundle press stage up down home sensor (PS35)

Bundle press stage up down limit sensor (PS45)
Bundle registration plate home sensor (PS16)
[1] [2] [3] [4][5][6] [8] [10] 15ant2c100na
[1] Main body start signal [7] Paper press operation completed
[2] Bundle press stage moved up [8] Bundle registration plate moved up
[3] Stopped at the upper limit [9] Paper exit completed
[4] Paper conveyance assisting operation com- [10] Bundle press stage moved up
pleted
[5] Bundle press stage moved down
[6] Returning to the home position * Only for paper of 297mm or more (before folding)
88
(2) No trimming mode

The bundle press stage up down motor (M24) rotates in the forward direction to move up the bundle press
stage [2] when the main body start signal [1] turns ON. M24 stops while holding the bundle press stage in slant-
SD-506
ing position when the bundle press stage up down limit sensor (PS45) turns ON [3].
M24 rotates in the reverse direction to move down the bundle press stage [5] after the bundle clip releases the
paper, the bundle registration motor (M12) assists the paper conveyance operation, and the bundle press move-
ment motor (M17) conveys the paper to the paper conveyance position [4]. M24 stops when the bundle press
stage up down home sensor (PS35) turns ON [6].
M24 moves up the bundle press stage [8] for the subsequent set when M12 completes the paper exit [7].
[7]

movement
motor (M17) Reverse

motor (M23)
Reverse
tion motor
(M12) Reverse
Bundle press stage Forward

up down motor
(M24) Reverse

Bundle press stage up down limit sensor (PS45)
Bundle registration plate home sensor (PS16)
[1] [2] [3] [4][5][6] [8]

15ant2c101na
[1] Main body start signal [6] Returning to the home position
[2] Bundle press stage moved up [7] Paper exit completed
[3] Stopped at the upper limit [8] Bundle press stage moved up
[4] Paper conveyance assisting operation completed
[5] Bundle press stage moved down * Only for paper of 297mm or more (before folding)
89
8.3.2 Bundle press movement control

The bundle press movement is the mechanism to convey the paper to the trimmer section by pressing the
paper with the press section to prevent the trimming skew at the trimmer operation after the paper registration
SD-506
operation.
A. Mechanism
The bundle press movement motor (M17) drives the bundle press section [9] in the main scan direction.
When receiving the paper with the bundle press stage [2], the bundle press section [9] moves 100mm backward
from the home position to obtain the paper conveyance path.
When conducting the bundle registration operation, the bundle press section moves to the appropriate position
in accordance with the paper size.
The bundle press movement home sensor (PS36) [3] detects the home position of the bundle press section.
When the bundle press section moves to the home position, the metal plate [7] gets down the actuator [6] for
the trimmer registration sensor (PS55) [8] and obtains the paper conveyance path.
The bundle sensor /4 (PS54) [10] is for the paper jam detection.
[9] [8] [10] [1]

[8]
[6]
[5]
[7]
[2]
[6] [4] [3] 15ant2c058na
[1] Actuator [6] Actuator

[2] Bundle press stage [7] Metal plate
[3] Bundle press movement home sensor (PS36) [8] Trimmer registration sensor (PS55)
[4] Actuator [9] Bundle press section
[5] Front side direction [10] Bundle sensor /4 (PS54)
90
B. Control
(1) Trimming mode
The bundle press movement motor (M17) rotates in the reverse direction to move the bundle press section to
SD-506
the paper conveyance position [2] after specified period of time since the bundle clip motor (M11) starts convey-
ing the paper [1]. Then M17 rotates in the forward direction to move the bundle press section to the appropriate
press standby position in accordance with the paper size [3].
M17 rotates in the reverse direction and searches for the press position [6] for the paper when the bundle press
stage up down home sensor (PS35) detects that the bundle press stage has been moved down [5]. M17 stops
the bundle press section at the appropriate position in accordance with the paper size [7] after a specified period
of time since the trimmer registration sensor (PS55) turns OFF.
M17 searches the home position [8] and then moves the bundle press section to the paper trimming position [9]
after a specified period of time since the bundle press motor (M23) completes the paper press operation.
The bundle press section is returned to the home position [10] after a specified period of time since the trimming
operation is completed.
[1] [2] [3] [4][6] [7] [8] [9] [10]
Bundle clip Forward
motor (M11)
Reverse

movement
motor (M17) Reverse

motor (M23)
Reverse
Bundle press movement home sensor (PS36)
Trimmer registration sensor (PS55)
Trimmer blade motor (M31)
[5] 15ant2c102na
[1] Conveyed by the bundle clip [7] Press position stop

[2] Moved to the paper conveyance position [8] Home position search
[3] Moved to the press standby position [9] Moved to the trimming position
[4] Home position detected [10] Returning to the home position
[5] Bundle press stage moving down completed
[6] Searching the press position * Only for paper of 297mm or more (before folding)
91
(2) No trimming mode

The bundle press movement motor (M17) rotates in the reverse direction to move the bundle press section to
the paper conveyance position [2] after a specified period of time since the bundle clip motor (M11) starts con-
SD-506
veying the paper [1]. Then M17 rotates in the forward direction to move the bundle press section to the appro-
priate press position in accordance with the paper size [3].
M17 rotates in the forward direction to return the bundle press section to the home position [5] when the bundle
press stage up down home sensor (PS35) detects that the bundle press stage has been moved down [4].
[1] [2] [3] [5]
Bundle clip Forward

motor (M11)
Reverse
movement
motor (M17) Reverse
Bundle press movement home sensor (PS36)

[4] 15ant2c103na
[1] Conveyed by the bundle clip [4] Bundle press stage up down home position
[2] Moved to the shelter position [5] Returning operation to the home position
[3] Moved to the press position * Only for paper of 297mm or more (before folding)
92
8.3.3 Bundle press control

The bundle press is the mechanism to hold the paper during trim operation to prevent the trimming skew after
the paper registration operation.
SD-506
A. Mechanism
The bundle press plates /Up [1] and /Lw [15] hold the paper. The bundle press plate /Up is pulled to the bundle press plate
/Lw [15] (to the direction to hold and press the paper) by the spring [13] via the press wires /Rt [2] and /Lt [12]. The bundle
press plate /UP [1] moves down with the force of the spring [13] when the bundle press motor (M23) [5] rotates the wire
winding shaft [4] and releases the release wires /Rt [3] and /Lt [6]. The force of the spring presses the paper.
When M23 keeps rotating, the press wire /Lt [6] is loosened and the bundle press lower limit sensor (PS47) [8]
turns OFF by the actuator [9] due to the spring [10], and then the paper press position is detected.
The wire winding shaft [4] winds the release wires /Rt [3] and /Lt [6] to move up the bundle press plate /Up [1] for
releasing the press the paper [16] when M23 rotates in reverse.
The bundle press home sensor (PS37) [11] detects the home position of the bundle press plate /Up [1].
[1] Bundle press plate /Up [9] Actuator

[2] Press wire /Rt [10] Spring
[3] Release wire /Rt [11] Bundle press home sensor (PS37)
[4] Wire winding shaft [12] Press wire /Lt
[5] Bundle press motor (M23) [13] Spring
[6] Release wire /Lt [14] Bundle press plate /Up (down)
[7] Front side direction [15] Bundle press plate /Lw
[8] Bundle press lower limit sensor (PS47) [16] Bundle press plate /Up (up)
93
B. Control
The bundle press motor (M23) rotates in the forward direction to conduct the paper press operation [2] to press
the paper properly when the bundle press movement motor (M17) completes the press position search [1]. M23
SD-506
rotates in the reverse direction to move up the bundle press plate /Up slightly to prevent the paper from becom-
ing loose [4] when the bundle press lower limit sensor (PS47) detects the lower limit [3] and turns OFF.
M23 rotates in the forward direction to press the paper [5] after a specified period of time since the trimmer reg-
istration sensor (PS55) detects the completion of the registration operation.
M23 rotates in the reverse direction to return the bundle press plate /Up to the home position [7] when the trim-
mer blade motor (M31) completes the paper trimming operation [6].
[1][2] [5] [7]

movement
motor (M17) Reverse
Forward
Bundle press
motor (M23) Reverse
Bundle press home sensor (PS37)
Bundle press lower limit sensor (PS47)
[3][4] [6] 15ant2c105na
[1] Searching the press position completed [5] Press

[2] Press operation [6] Trimming completed
[3] Lower limit detected [7] Returning to the home position
[4] Press release
94
8.3.4 Bundle registration control

The paper registration operation reforms the skew at trimming.
SD-506
A. Mechanism
The bundle registration motor (M12) drives the registration claws [4].
2 registration claws [4] conduct the registration by making the paper [14] contact [3] with the bundle registration
plate [13] from the gutter side.
In the registration operation, the bundle press section [7] conducts the pressing by moving to the appropriate
position in accordance with the paper size. To conduct the bundle registration, the registration claws [4] press
the paper until the actuator [2] on the bundle press section comes in the upright position and the trimmer regis-
tration sensor (PS55) [1] turns ON.
The bundle exit claws [9] are located at the 180° opposite to the registration claws on the belt. M12 rotates in
the reverse direction [10] to exit the paper at the paper exit.
The home position of the registration claws [4] is detected when the registration claws push the actuator [11]
and turns ON the bundle registration home sensor (PS34) [12].
[14] [1] [2]
[13]
[3]
[4]
[12]
[11]
[5]
[10] [9] [8] [7] [6] 15ant2c060na
[1] Trimmer registration sensor (PS55) [8] Bundle sensor /4 (PS54)

[2] Actuator [9] Bundle exit claws
[3] Registration direction [10] Drive direction of the bundle exit tabs
[4] Registration claws [11] Actuator
[5] Left-side view [12] Bundle registration home sensor (PS34)
[6] Bundle sensor /2 (PS15) [13] Bundle registration plate
[7] Bundle Press Section [14] Paper
95
B. Control
The bundle registration motor (M12) rotates in the reverse direction when the main body start signal turns ON
and the registration claws move to the standby position in accordance with the paper size [2].
SD-506
The bundle registration motor (M12) rotates in the reverse direction to conduct the paper conveyance assisting
operation [4] and the pre-registration operation [5] after a specified period of time since the bundle clip motor
(M11) starts conveying the paper [3]. Then M12 stops when the registration claws reach at the specified posi-
tion.
M12 rotates in the reverse direction and conducts the registration operation [7] with the registration claws when
the bundle press motor (M23) completes the press releasing operation [6]. The registration claws stop when the
trimmer registration sensor (PS55) turns ON [8].
M12 rotates in the forward direction to move the registration claws to the specified shelter position [10] when
M23 completes the press operation [9].
M12 rotates in the forward direction to let the bundle exit claws push the paper to conduct the paper exit oper-
ation [12] after a specified period of time since the trimmer blade motor (M31) completes the trimming operation
[11]. M12 stops when the bundle registration home sensor (PS34) turns ON [13]. M12 rotates in the reverse
direction to move the bundle exit claws to the standby position [14] after a specified period of time. Then it
stands by for the subsequent set.
[2] [3] [4] [5] [6] [9][10] [12] [14]
Bundle clip Forward

motor (M11)
Reverse

motor (M23)
Reverse

tion motor
(M12) Reverse
Bundle registration home sensor (PS34)
[13]
[1] [7] [8] [11] 15ant2c106 na
[1] Main body start signal [8] Registration operation completed

[2] Standby position movement [9] Paper press operation completed
[3] Conveyance by the bundle clip started [10] Shelter operation
[4] Paper conveyance assisted [11] Trimming completed
[5] Pre-registration [12] Paper exit operation
[6] Press release [13] Home position detected
[7] Registration [14] Standby position movement
96
8.3.5 Bundle exit control

A. Mechanism
(1) Bundle exit mechanism
SD-506
The paper is exited to the bundle exit tray [12].
The paper exited to the bundle exit tray is conveyed to the front by the bundle exit conveyance belt [1] and
stacked.
The bundle exit motor (M5) [5] drives the bundle exit conveyance belt [1] via the bundle exit drive belt [4] and the
bundle exit belt drive shaft [3].
M5 drives the bundle exit conveyance belt for a specified period of time to convey the paper to the front [13] for
every paper exit. The bundle exit tray is expandable.
The bundle tray set sensor (PS58) [9] detects whether the bundle exit tray is stored or not.
M5 also drives the scrap press plate [11]. In each drive path from M5 to the bundle exit drive belt and the scraps
press plate, there is a one-way clutch respectively that switches the rotational direction of M5. Therefore, the
bundle exit drive and the scraps press plate are not driven simultaneously.
[12] [13]
[1]
[2]
[11]
[3]
[10]
[4]
[9]
[5]
[8]
[6]
[7] 15ant2c062na
[1] Bundle exit conveyance belt [8] Scraps press claws

[2] Bundle exit auxiliary roller [9] Bundle tray set sensor (PS58)
[3] Bundle exit belt drive shaft [10] Trimmer scraps full sensor (PS41)
[4] Bundle exit drive belt [11] Scraps press plate
[5] Bundle exit motor (M5) [12] Bundle exit tray
[6] Scraps press home sensor (PS48) [13] Front side direction
[7] Scraps box set sensor (PS40)
97
(2) Bundle exit tray expanding mechanism

The bundle exit tray is expandable. The folded bundle exit conveyance belt [6] is also expanded [1] when the
bundle exit tray is expanded. At the time, it also moves the bundle exit conveyance belt drive shaft [5] for the
SD-506
bundle exit conveyance belt [1] and [6].
[5]
[6]
[4]
[3]
[1]
[2]
15ant2c063na
[1] Bundle exit conveyance belt (expanded) [4] Bundle exit drive belt
[2] Folding stand [5] Bundle exit conveyance belt drive shaft
[3] Drive shaft [6] Bundle exit conveyance belt (folded)
98
(3) Trimmer scraps press mechanism

Trimmer scraps press is executed by driving the bundle exit motor (M5). The M5 motor drives the pins [10] via
the scraps press claws [4] on the belt [5] to move the scraps press plate [2] forward, then the plate presses the
SD-506
trimmer scraps. The spring [11] pushes the scraps press plate to put it back.
The trimmer scraps press is carried out when the actuator [8] turns on the scraps press home sensor (PS48) [9]
with the press position of the scraps press plate is at the home position
The maximum displacement of the scraps press plate is 200mm.
The trimmer scraps press is carried out when the trim is performed 5 times or when the total trimmed number of
sheets becomes 60 sheets (30 sheets before folding) or more.
[10] [11]
[9]
[1]
[8]
[7] [6] [5] [4] [3] [2]

15ant2c064nb
[1] Front side direction [7] Backmost position

[2] Scraps press plate [8] Actuator
[3] Press position [9] Scraps press home sensor (PS48)
[4] Scraps press claws [10] Pin
[5] Belt [11] Spring
[6] Scraps press plate home position (trimming position)
99
(4) Shutter mechanism

When the spring [10] pushes the scraps press plate [2] to its backmost position, the shutter arm [6] is pushed up
and the shutter [9] is opened. On the other hand, the shutter is closed when the scraps press plate is moved for-
SD-506
ward from the back most position to the position [3] by the spring of the shutter arm.
Opening the shutter allows the guide sheet [7], which is attached to the shutter, to be straightened [8] due to the
tension. Closing the shutter allows slack in the guide sheet to widen the dropping path of scraps.
Before trimming, the scraps press plate moves 50mm [3] from the backmost position and stops to be ready for
trimming.
The shutter repeats opening/closing operation by shuttling the scraps press plate 50mm back and forth in each
trimming operation. This shutter operation creates vibration with the guide sheet to shake off the trimmer scraps.
[8] [9] [10]
[7]
[6]
[1]
[5]
[4] [3] [2]

15ant2c117na
[1] Front side direction [6] Shutter arm

[2] Scraps press plate [7] Guide sheet
[3] Shutter closing position [8] Guide sheet (straightened)
[4] Shutter opening position [9] Shutter
[5] Scraps press claws [10] Spring
100
B. Trimmer scraps removal control

The scraps removal fan motor (FM1) [3] blows air [4] to make sure to put the trimmer scraps to the scraps box.
SD-506
[5] [6]
[4] [3] [2] [1] 15ant2c115na
[1] Left-side view [4] Air
[2] Bundle clip lower limit sensor (PS30) [5] Bundle press
[3] Scraps removal fan motor (FM1) [6] Bundle clip
The scraps removal fan motor (FM1) operates only in the trimmer mode.
When the main body start signal [1] turns ON, FM1 is rotated and the bundle clip releases [2] the paper, FM1
stops for a time to prevent the paper from having the uneven edge. When the bundle press motor (M23) com-
pletes the paper press [3], FM1 is rotated again to send air so that sheet trimming scraps get in the scraps box
without fail.

motor (M23)
Reverse
Scraps removal fan motor (FM1)

Bundle clip lower limit sensor (PS30)
[1] [2] [3] 15ant2c116na
[1] Main body start signal [3] Paper press operation completed
[2] Bundle clip released the paper
101
C. Bundle exit control

The bundle exit motor (M5) rotates in the forward direction and the bundle exit conveyance belt conveys the exit
paper [2] after a specified period of time since the trimmer blade motor (M31) completes the trimming [1]. M5
SD-506
stops after a specified period of time since the bundle exit sensor /2 (PS57) detects the trailing edge of paper [3].
[2]
Bundle exit Forward

motor (M5)
Reverse
Bundle exit sensor /2 (PS57)
[1] [3] 15ant2c107na
[1] Trimming completed [3] Trailing edge of paper detected

[2] Bundle exit conveyance
[1] 15ant2c114na
[1] Bundle exit sensor /2 (PS57)
102
D. Shutter / trimmer scraps press control

When the trimming is executed with the shutter closed, the bundle exit motor (M5) starts rotating forward to exit
paper [1]. Then the scraps press plate moves backward to drop the trimmer scraps with the shutter opened [2].
SD-506
After a specified period of time since the paper exit is finished [3], the M5 motor rotates in reverse to move the
scraps press plate frontward 50mm and stops [4] with the shutter closed. Then the next trimming is excused in
this condition.
After a specified period of time from paper exit when the trimming is performed 5 times or when the total
trimmed number of sheets becomes 60 sheets (30 sheets before folding) or more after the previous scraps
press operation [5], the M5 motor starts rotating in reverse to start the press operation [6]. When the press oper-
ation is started, the shutter opened by the paper exit operation is closed again [7]. When the scraps press home
sensor (PS48) detects that the scraps press plate is at the home position, the M5 motor stops [8] and next oper-
ation of the trimming and paper exit [9] is performed.
[1] [2] [3] [4] [5][6][7] [9]
Forward
Bundle exit
motor (M5)
Reverse
Scraps press home sen-

sor (PS48)
[8]
15ant2c118na
[1] Start of paper exit [6] Start of press operation

[2] Shutter is opened [7] Shutter is closed
[3] Finish of paper ejection [8] Press position stop
[4] Shutter is closed [9] Paper exit
[5] Finish of paper ejection
103
E. Bundle exit paper full control

The bundle tray paper full sensor (PS61) [1] detects the bundle exit paper full. The main body displays the mes-
sage on its operation panel when the paper full is detected.
SD-506
[1] 15ant2c109na
[1] Bundle tray paper full sensor (PS61)

F. Trimmer scraps full control

The trimmer scraps full sensor (PS41) detects the paper scraps full of the scraps box. When the PS 41 is turned
on for 3 seconds after the paper exit operation driven by the bundle exit motor (M5) is finished, the scraps are
detected as full. The main body displays the message on its operation panel when the scraps full is detected.
G. Trimmer scraps tray set detection

The scraps box set sensor (PS40) detects whether the scraps box is set or not. The main body displays the
message on its operation panel when the scraps box is not set.
104
Theory of Operation Ver.2.0 Jul. 2009 9. TRIMMER SECTION
9. TRIMMER SECTION
9.1 Configuration
SD-506
Trimmer press plate
Trimmer paddle Trimmer blade Trimmer board
a0h2t2c001ca
105 1
9. TRIMMER SECTION Theory of Operation Ver.2.0 Jul. 2009
9.2 Drive
9.2.1 Trimmer press drive
SD-506
[1] Trimmer brake [7] Trimmer press motor (M32)

[2] Planetary gear [8] Trimmer press home sensor (PS53)
[3] Slide guide shaft [9] Trimmer press upper limit sensor (PS52)
[4] Nut [10] Brake solenoid (SD12)
[5] Press drive screw [11] Planetary gear
[6] Trimmer press plate
1 106
9.2.2 Trimmer blade drive
SD-506
[1] Trimmer completion sensor (PS62) [10] Wire slack prevention sensor (PS66)
[2] Trimmer blade [11] Front side direction
[3] Guide shaft [12] Wire
[4] Guide hole [13] Torque limiter
[5] Trimmer blade retaining plate [14] Trimmer blade motor (M31)
[6] Spring [15] Planetary gear
[7] Trimmer blade home sensor (PS50) [16] Winding pulley
[8] Trimmer blade upper limit sensor (PS51) [17] Planetary gear
[9] Movable pulley
107 1
9.2.3 Trimmer board drive

SD-506
[1] Front side direction [5] Trimmer board

[2] One-way clutch [6] Trimmer board solenoid (SD11)
[3] Pinion [7] Actuator
[4] Feed rack [8] Trimmer board replacement sensor (PS59)
1 108
9.2.4 Paddle drive
SD-506
[1] Trimmer paddle motor (M33) [3] Front side direction
[2] Trimmer paddle
109 1
9.3 Operation
9.3.1 Trimmer press control
SD-506
A. Mechanism
The trimmer press is the mechanism to hold the paper at its fore-edge side to prevent the trimming misalign-
ment.
It opens about 6mm at the home position and drives the planetary gears [2] and [11] by the driving of the trim-
mer press motor (M32) [7]. The output shaft of the planetary gear rotates the press drive screw (trapezoidal
screw) [5] and drives the nut [4] up and down. By this operation, the trapezoidal nut drives the trimmer press
retaining plate [6] along the shaft [3] and presses paper. M32 detects the completion of the paper press via over-
current.
M32 rotates in the reverse direction to widen the opening to approximately 20mm before conveying the paper to
the trimmer section, in case the number of the print paper is 16 or more (32 or more for the saddle stitched
paper).
The trimmer press home sensor (PS53) [8] and the trimmer press home sensor (PS52) [9] detect the home posi-
tion and 20mm of opening respectively.
The brake solenoid (SD12) [10] drives the trimmer brake [1]. It presses the timing belt from M32 with ON to pre-
vent the inverse rotation caused by the pushing of the trimmer blade.
[1] Trimmer brake [7] Trimmer press motor (M32)

[2] Planetary gear [8] Trimmer press home sensor (PS53)
[3] Slide guide shaft [9] Trimmer press upper limit sensor (PS52)
[4] Nut [10] Brake solenoid (SD12)
[5] Press drive screw (trapezoidal screw) [11] Planetary gear
[6] Trimmer press plate
1 110
When changing the trimming position of the trimmer board or replacing the trimmer board via the I/O check
mode, M32 rotates in the reverse direction to move up the trimmer press section higher than the position of the
trimmer press upper limit sensor (PS52) and release the trimmer board [3] by pushing the shaft [1] of the trimmer
SD-506
board fixing plate [2] to the upper plate. At the time, the opening is approximately 23mm. The position is
detected via overcurrent.
[1] Shaft [3] Trimmer board
[2] Trimmer board fixing plate
111 1
B. Control
(1) The number of the print paper is 16 or more (32 or more for the saddle stitched paper)
The trimmer press motor (M32) rotates in the reverse direction [2] when the bundle clip motor starts conveying
SD-506
the paper [1]. When the trimmer press upper limit sensor (PS52) [3] detects upper limit position of the trimmer
board, M32 is stopped and waits for the paper.
At this time, the opening is approximately 20mm. M32 rotates in the forward direction to press the paper when
the paper is conveyed to the opening by the bundle press movement motor (M17) [4]. The brake solenoid
(SD12) turns ON when M32 stops, and keeps the belt to prevent the trimmer press board from being pushed up
by the trimmer blade.
When the trimmer blade motor (M31) completes trimming [6], SD12 turns OFF and M32 rotates in the reverse
direction to start opening. When the print is completed, the returning operation to the home position [9] of M32
stops by PS5 ON.
[1] [2] [4] [5] [8]
Bundle clip motor (M11)


movement
motor (M17) Reverse
Forward
Trimmer press
motor (M32) Reverse
Trimmer blade Forward

motor (M31) Reverse
Brake solenoid (SD12)
Trimmer press upper

limit sensor (PS52)
Trimmer press
home sensor (PS53)
[3] [6] [7] [9]
a0h2t2c008ca
[1] Conveyance by the bundle clip started [6] Trimming completed

[2] Opening operation [7] Brake release
[3] Stopped when the opening is approx. 20mm [8] Opening operation started
[4] Conveyance of the trimmed paper completed [9] Returning operation to the home position
[5] Trimmer press completed
(2) The number of the print paper is 15 or less (30 for the saddle stitched paper)
The trimmer press motor (M32) rotates in the forward direction to press the paper without widening the opening
when the paper is conveyed to the opening.
1 112
9.3.2 Trimmer blade control

A. Mechanism
The trimmer blade driven by the trimmer blade motor (M31) [15] conducts the trimming while trimmer press presses the paper.
SD-506
When the trimmer blade [3] goes up, M31 drives the winding pulley [18] in the direction of winding [17] to wind
up the wire [13]. The planetary gears [16] and [19] are between M31 and the winding pulley [18] and it enables
the high output by high gear ratio.
Once the wire [13] is winded up, the trimmer blade retaining plate [6] goes up in a slanting direction since the
movable pulley is pulled and the guide hole [5] is controlled by the guide shaft [4]. It trims the paper with the trim-
mer blade [3] attached on the trimmer blade retaining plate [6].
The completion of the trimming is detected when the upper surface of the trimmer blade retaining plate [5]
pushes up the actuator and the trimmer completion sensor (PS62) [1] turns ON. When PS62 cannot detect it,
the overcurrent of M31 detects the completion of the trimming.
If the overcurrent of M31 is not detected even if the trimmer blade keeps moving up, the trimmer blade upper
limit sensor (PS51) [9] detects the upper limit.
For moving down the trimmer blade, M31 rotates in the reverse direction to loosen the wire and the spring [7]
lowers the trimmer blade retaining plate [6]. The trimmer blade home sensor (PS50) [8] detects the lower limit.
The torque limiter is equipped to prevent the wire from being slacking inertially when moving down. Wire slack
prevention sensor (PS66) [11] detects the slack of the wire.
[1] Trimmer completion sensor (PS62) [11] Wire slack prevention sensor (PS66)
[2] Actuator [12] Front side direction
[3] Trimmer blade [13] Wire
[4] Guide shaft [14] Torque limiter
[5] Guide hole [15] Trimmer blade motor (M31)
[6] Trimmer blade retaining plate [16] Planetary gear
[7] Spring [17] Winding direction
[8] Trimmer blade home sensor (PS50) [18] Winding pulley
[9] Trimmer blade upper limit sensor (PS51) [19] Planetary gear
[10] Movable pulley
113 1
B. Control
The trimmer blade motor (M31) starts the trimming when the trimmer press motor (M32) completes the press
and stops [1].
SD-506
M31 stops when the trimming completes with the trimmer completion sensor (PS62) ON.
M31 starts the returning operation to the home position [4] when the bundle press motor (M17) starts releasing
the press [3]. M31 stops when the trimmer blade home sensor (PS50) turns ON [5].
[1] [3]

movement motor
(M17) Reverse
Trimmer press Forward
motor (M32)
Reverse
motor (M31)
Reverse
Trimmer completion
sensor (PS62)
Trimmer blade
home sensor (PS50)
[2] [4] [5]

a0h2t2c010ca
[1] Trimmer press completed [4] Returning operation to the home position
[2] Trimming completed [5] Home position detected
[3] Paper exit operation start
1 114
9.3.3 Trimmer board control

A. Mechanism
If the trimmer board gets the trimmer blade to the same position many times, the trimmer operation is carried
SD-506
out improperly due to the damage on the board. For this reason, the trimmer board is slid 1mm backward for
sheet cutting each time a job of 700 times trimming is completed.
The trimmer board solenoid (SD11) [6] slides the trimmer board [5] to backward with its fixing released by the
trimmer press motor (M32).
The pinion [3] pushes the feed rack [4] 0.5mm every time SD11 turns ON. The rotation of the pinion [3] is trans-
mitted to the rack by the one-way clutch [2] and pushes the trimmer board when SD2 turns ON. The pinion [3]
does not rotate and push the trimmer board when SD11 turns OFF by the one-way clutch.
Each time a job of 700 times trimming is completed, SD11 is turned on twice to move the trimmer board 1mm.
The trimmer board can be slid up to approximately 26mm. The main body displays the message on its operation
panel when the trimmer board replacement sensor (PS59) [8] is turned ON by the actuator [7]. The trimmer
operation is prohibited when the trimming is conducted 700 times since PS59 turns ON.
Note
• The operation timing of the trimmer board solenoid can be selected among 500/300/700 (700 by
default), and the travel distance can be selected among 1.0/1.5/2.0mm (1.0 by default) from "Fin-
isher Adjustment" in service mode.
• If the DIPSW22-5 setting in service mode is changed to 1, the operation timing of the trimmer
board solenoid becomes selectable among 700/500/300 (700 by default) on the adjustment screen
in the user mode.
• The burr occurs on the trimmed edge of the paper before the movement cycle of the trimmer
board and that depends on the paper type.
[1] Front side direction [5] Trimmer board

[2] One-way clutch [6] Trimmer board solenoid (SD11)
[3] Pinion [7] Actuator
[4] Feed rack [8] Trimmer board replacement sensor (PS59)
115 1
B. Control
The trimmer press motor (M32) starts the returning operation [2] to the home position when the 700th trimmer
operation [1] is completed. M32 does not stop by defection of the trimmer press home sensor (PS53) [3]. The
SD-506
opening keeps widening until the overcurrent of M32 is detected [4]. When M32 stops, the trimmer board sole-
noid (SD11) turns ON and OFF twice [5] to move the trimmer board 1mm. Then, M32 starts the returning oper-
ation to the home position [6].
[4] [5] [6]
Trimmer board solenoid (SD11)

Trimmer press Forward
motor (M32)
Reverse

motor (M31)
Reverse
Trimmer press upper limit sensor (PS52)

Trimmer press home sensor (PS53)
[1] [2] [3] 15ant2c113na
[1] 700th trimmer operation [4] Overcurrent of M32 detected

[2] Opening operation of the trimmer press [5] Trimmer board moved 1mm
[3] Home position detected [6] Returning operation to the home position
116
9.3.4 Trimmer paddle control

A. Mechanism
The trimmer paddle [2] is provided to prevent the saddle-stitched paper from creating trails with scraps by get-
SD-506
ting into the paper during the press operation, and to drop the scraps forcibly. The trimmer paddle motor (M33)
drives the trimmer paddle.
Trimming amount is 15mm or less: M33 rotates forward [1] to drop [3] the trimming scraps with the trimming
paddle. Trimming amount is more than 15mm: The M33 motor rotates in the reverse direction [5] to rake and to
drop the scraps to the wider dropping path [4].
[5]
[1]
[4]
[2]
[3]
a0h2t2c012ca
[1] Trimmer paddle motor (M33) forward direc- [4] Dropping path (Trimming amount is more
tion than 15mm)
[2] Trimmer paddle [5] Trimmer paddle motor (M33) reverse direction
[3] Dropping path (Trimming amount is 15mm or less)
117 1
B. Control
In trimming mode, the trimmer paddle motor (M33) starts forward/reverse rotation after the bundle clip motor
(M11) operates paper clipping, and then the M33 motor stops when the trimming JOB is finished.
SD-506
If the trimming amount value is specified by the "Trimming adjustment" in service mode, the forward/reverse
rotation of motor is controlled by the trimming amount that adds the adjusted value. (Edges of standard-sized
paper are trimmed by 2mm even when the adjustment value is specified to 0.)
118
MAINTENANCE
SD-506
CAUTION:
10.1 Saddle stitching section

10.1.1 Replacing the stapler assy
A. Periodically replaced parts/Spotted replaced parts/Cycle
• Stapler assy : Every 20,250,000 prints *1 (Actual replacement cycle: Every 1,000,000 staples *2)
*1 The periodical replacement is only for 1200/1200P/1051.
*2 Actual replacement cycle of 1200/1200P/1051/C6501/C6501P/C65hc
B. Procedure
1. Remove the front door /Lt. (Refer to P.154)
[1] 2. Remove the rear cover /Lt. (Refer to P.150)
3. Disconnect 2 connectors [1] from the back side of
the stapler, and release the wires on the stapler
side from the clamps.
15anf2c034na
4. Pull out the saddle stitching unit. (Refer to P.126)

[3] [2]
5. Tilt the bundle arm [1] to the front.
6. Remove the staple cartridges [2] to the front.
Note
• When moving the stapler assy, be sure to
move them by rotating the rotating knob [3] to
prevent the belt tooth from skipping. Other-
wise, it causes the belt tooth skipping.
[1] 15anf2c035na
119 1
7. Remove 2 screws [1] on each stapler.

[4] 8. Move the staplers /Lt [2] and /Rt [3] forward, and
then remove the pins [4], 2 for each, from each 2
SD-506
[5] holes [5] on each stapler. Then remove the sta-

[1] [1]
plers /Lt [4] and /Rt [5] downward.
[2] [3]
a0h2t3c047ca
Note
• When removing/reinstalling the stapler /Lt, be
sure not to bend the guide sheet [6].
[6]
a0h2t3c048ca

[1] [2]
cover [2].
15anf2c038na
120

[3]
Note
SD-506
• When reinstalling the saddle stitching unit, be
careful not to let the connector [1] make con-
tact with the main body.
11. Remove 3 screws [2], and then remove the saddle

stitching guide plate [3].
[1]
[2] 15anf2c039na
12. Remove 2 screws [1] each and then remove 2

[3] [4]
connector covers [2].
Note
• When removing the connector covers, while
lifting up the clinchers /Lt [3] and /Rt [4].
[1]
[1] [2] 15anf2c040na
13. Remove each 1 screws [1] and then remove the

[5] [4] [6]
ground [2].
Note
• When installing the grounds, fasten it with
screws letting the wiring harness on the lower
side.
14. Remove each of 1 connectors [3].

15. Remove each of 2 screws [4], and then remove
the clinchers /Lt [5] and /Rt [6].
Note
• When installing the clinchers, slide them
down as far as they go, and secure them with
screws.
[3] [1]
[1] [3] [2] 15anf2c041na
121
16. Remove the connector [1] and then remove the

wiring harness [3] from the clincher [2].
SD-506
[3] [1] [2] 15anf2c042na
Note
[4] [5]
• When reinstalling the wiring harness [4], be
sure to wire the wiring harness to the guide
(white) side [5] of the clincher.
Do not route the wiring harness to the rear
side as shown in the figure [7], or the wiring
harness may break at the clincher operation.

steps in reverse.
18. Adjust the mounting position of the staplers and
the clinchers. (Refer to P.123)
[6]
[7] 15anf2c043na
122
C. Procedure for adjusting the mounting position

1. Rotate the screw [1] clockwise until clicked to
[7] [7]
make the clinchers [2] contact with the staplers [3]
SD-506
and lock the clinchers [2], and then check the
step edges [4] of the staplers are aligned with the
edges [5] of the clincher in the sub scan direction
[6].
Standard value: 0 ± 0.5mm
2. When the value is not within the standard value,
loosen 2 screws [7] each and move the staplers in
the sub scan direction for adjustment while rotat-
ing the screw [1] counterclockwise to make the
clinchers [2] and the stapler [3] closer, and then
[11] [11] tighten the screws [7].
3. Tighten the screw [1] clockwise until it clicks to
[4] [6] [10]
make the clinchers [2] contact with the stapler [3]
and lock it. Make sure that the standard surface of
A [8]
the stapler [8] is located in rear side in main scan
direction [10] compared to the inside plate inner
surface [9] of the clincher.
[9] Standard value 'a': 0.2mm to 0.3mm
a 4. When the value is not within the standard value,
loosen 2 screws [11] each and move the staplers
in the main scan direction for adjustment while
rotating the screw [1] counterclockwise to make
the clinchers [2] and the stapler [3] closer, and
then tighten the screws [11].
A [5]
Section A Note
[3] • After the reinstallation, perform the saddle
stitching and check that the stapling is per-
formed without problem.
• After the adjustment, be sure to perform the
adjustment between the fold line position and
the staple position, and tilt/gap adjustment of
[2]
[1] the clincher.
(Refer to: Field Service P.506), (Refer to: Field
Service P.509)
15anf2c063nc
123 1
10.1.2 Remove the slope unit

A. Procedure
1. Remove 3 screws [1], and then remove the motor
SD-506
[2]
cover [2].
[1] 15anf2c018na
2. Remove 2 connectors [1].

[1]
15anf2c019na
3. Holding the bundle arms [1] on both sides in the

[2]
vicinity of the fulcrum shaft [2], push them to the
rear simultaneously and move the bundle arms [1]
approximately 30mm.
Note
• When rotating the bundle arm [1] manually, be
sure to rotate it gently with both hands
because the bundle arm is driven simulta-
neously by the belts on both sides. Otherwise,
it causes the belt tooth skipping.
• Never rotate the bundle arm [1] by holding its
[1] 15anf2c020na tip. Be sure to rotate it by holding the bundle
arm [1] in the vicinity of the fulcrum shaft [2].
It causes the deformation.
124
4. Remove 2 screws [2] and 2 screws [3] for the

[2] [4]
slope unit [1] from the bottom and top respec-
tively, and then remove the slope unit [1].
SD-506
Note
• When reinstalling the slope, be sure to align 2
positioning projections [4].

steps in reverse.
[2] [1]
[3] 15anf2c022na
125
10.1.3 Pull out the saddle stitching unit

A. Procedure
1. Remove the front door /Lt. (Refer to P.154)
SD-506
2. Remove the slope unit. (Refer to P.124)

3. Remove the wire [1] from the screw [2].
Note
• When remove the 2nd wire [1], support the
horizontal conveyance guide plate /Lt [3] with
your hand so that it does not fall down.
[2] [1]
[3] 15anf2c014na
4. Slide 2 pins [1] to the arrow-marked direction and

[1] [2] [1]
hook into the notches [2] to release the horizontal
conveyance guide plate /Lt [3], and then remove
the guide plate.
Note
• When reinstalling the horizontal conveyance
guide plate /Lt [3], align the positions of the
shafts [4], and then displace the pins [1] from
the notches.
[4] [3] [4] 15anf2c015na
126
5. Remove the screw [1], move the wiring harness

cover [4] to the rear, unplug the pin [2] from the
hole [3], and remove the wiring harness cover [4].
SD-506
[3]
[2]
[1] [4]
15anf2c016na
6. Remove 6 connectors [1].

[1]
15anf2c017na
127

SD-506
[1]
15anf2c069na
128
[1] [6] [1] 8. Holding the bundle arms [1] on both sides in the
vicinity of the fulcrum shaft [2], gently move them
to the inside [3], and then remove the guide shaft
SD-506
[4] from the hole of the shock absorbing guide [5].
Note
• When narrowing the space between the bun-
dle arms [1], be sure to move them gently and
simultaneously.
• When reinstalling them, be sure to check that
the guide shaft [4] has been inserted into the
shock absorbing hole [5].
[1]
9. Rotate the bundle arms [1] to the guide plate [6]
on the stapler side.
[3]
[2]
[4] [5]
[3]
[5] [4] [2] [1] 15anf2c021na
10. Remove the 6 screws (with 1 washer each) [1],

[1] [2] [1]
and then hold the shafts [2] to pull out the saddle
stitching unit [3].
Note
• When pull out the saddle stitching unit, be
sure not to snap the wiring harness of the
removed connector contact with SD.

steps in reverse.
[1]
[1] [2] [3] 15anf2c024nb
129
10.1.4 Removing/installing the saddle stitching unit

SD-506
CAUTION:
• Be sure to perform this operation with 2 people because the saddle stitching unit is heavy.
A. Procedure
1. Pull out the saddle stitching unit. (Refer to P.126)
[3] [4] [5]
2. Remove 6 screws [1], 1 screw [2], and remove the
saddle stitching unit [5] with 2 people by holding
the shafts [3] and [4] while lift up the shaft [3]
slightly and shift the saddle stitching unit to the
front side.
Note
• Be sure to hold the saddle stitching unit at the
shafts [3] and [4].
• When reinstalling the saddle stitching unit,
check that the unit is surely placed on the
rails [6] before releasing the unit.

[6]
[1] 15anf2c025na
130
10.2 Trimmer section

10.2.1 Removing/installing the trimmer paddle assy
SD-506
A. Procedure
[1] • Rear cover /Lt (Refer to P.150)
2. Store the trimmer scraps box completely in the
SD.
3. Remove 2 screws [1], and remove the trimmer
scraps guide [2].
Note
• When installing the trimmer scraps guide, be
sure that the trimmer scraps box is stored
completely in the SD, and the trimmer scraps
guide [2] is fully stretched. If you stretch the
trimmer scraps guide with the trimmer scraps
[2] a0h2t3c009ca box has not stored completely, the trimmer
scraps guide gets broken during operation.
4. Remove 4 screws [1] and remove the trimmer

[1] paddle assy [2].
steps in reverse.
[2] a0h2t3c010ca
131 1
10.2.2 Replacing the trimmer blade kit

SD-506
DANGER:
[2]
• Pay extra caution when holding the trimmer
blade [1]. Never touch the edge [2] of the
blade. You get injured.
• Remove the blade cover only at the replace-
ment. Otherwise, never remove the cover. You
get injured.
CAUTION:
• Dispose the used trimmer blade as specified
by the local authority.
[1] a0h2t3c011ca
1 132

• Trimmer blade kit : Every 1,400,000 prints (Actual replacement cycle: Every 37,500 cuts) *1
: Every 1,500,000 prints (Actual replacement cycle: Every 37,500 cuts) *2
SD-506
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Procedure
1. Move the trimmer board to the release position.
[3] [2] [1]
Note
• Move the trimmer board to the trimmer press
upper limit sensor (PS52) by the output check
code "71-56" in the I/O check mode in the ser-
vice mode.

then unplug the power plug from the power outlet.
3. Remove the rear cover /Lt. (Refer to P.150)
4. Remove the trimmer paddle assy. (Refer to P.131)
[6] 5. Remove the screw [1].
6. Loosen the screws [2] and [3].
[7]
[4]
DANGER:
• Do not loosen the screws [2] and [3] too
much, or the trimmer blade drops during the
operation. Keep the loosening amount of the
[5]
a0h2t3c012ca
screws [2] and [3] to a minimum requirement
for removing the trimmer blade [4].
7. Hold the screws [2] and [3] and slightly lift the
screw [3] side. Then move the trimmer blade [4] in
the arrow-marked direction [6] to pull out from the
hole [5], and remove it.
8. Put the trimmer blade [4] at a safe place with no
fear of falling down.
DANGER:
• Pay extra caution when handling the trimmer
blade [1]. Never touch the edge [7] of the
blade. You get injured.
133 1
9. Insert the #2.5 hex wrench [2] onto the mounting

[1] [2] slit [1] of the trimmer blade, and then slide it from
right [3] to left [4] (viewed from the operator) to
SD-506
clean the trimmer scraps.
Note
• Conduct the cleaning with the #2.5 hex
wrench which is one-step thinner than the
hex wrench #3 used for the installation
screws of the trimmer blade. Using #3 causes
[5]
the deformation of the mounting slit.
• To change the direction of the hex wrench,
remove the wrench once and reinsert it again.
• The bottom of the slit of the left side [4]
(viewed from the operator) is curved in the
same manner as the blade [5]. Be sure to
[4] [3] scrape the trimmer scraps.
a0h2t3c013ca
10. Clean the mounting slit [1] of the trimmer blade

with the blower brush.
11. Put a new trimmer blade [1] on the floor and insert
[4] 2 new screws about half and a bit length of them
[3] into the marked side [2].
DANGER:
• Be sure to insert the screws [3] enough to
hold the trimmer blade, otherwise the trimmer
blade falls down during the operation.
[3] [1] [2]
a0h2t3c014ca
Note
• Install the brand-new screws [3] that are
shipped with the trimmer blade kit.
12. Remove the blade cover [4] of the new trimmer

blade kit and put that cover on the old trimmer
blade.
1 134
13. Insert the trimmer blade to the hole [3] by holding

2 screws [2]. Then insert 2 screws [2] to the screw
grooves [4].
SD-506
[3]
[2]
[1] [4]
[2]
[4]
a0h2t3c015ca
135 1
14. Tighten the new screw [1] temporarily. Then press

[1][2] [4] [6] 2 screws [1] and [2] downward [3] until the trim-
mer blade contacts the bottom, and then press it
SD-506
to the right side [5] (viewed from the operator).

15. Tighten 2 screws [1] and [2] with the #3 hex
wrench [6].
[7]
CAUTION:
[8] • When tightening 2 screws [1] and [2], tighten
them temporarily with the torque that bends
the tip of the #3 hex wrench [6] approximately
5° [7], and then fully tighten them with the
strong torque that bends it approximately 15°
[3] [5] [8].
Note
• Be sure to check and clear the foreign object
that obstacles the operation of the trimmer
blade.
[2] [1] 16. Reinstall the above parts following the removal
a0h2t3c016ca
steps in reverse.
Note
• After replacing the trimmer blade, perform
the saddle stitch with trimming and check
that the trimming is performed without prob-
lem.
1 136
10.2.3 Replacing the trimmer board assy

• Trimmer board assy : Every 600,000 prints (Actual replacement cycle: Every 18,900 cuts) *1
SD-506
: Every 750,000 prints (Actual replacement cycle: Every 18,900 cuts) *2
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Procedure
1. Move the trimmer board to the release position.
[7] [1]
Note
• By the output check code "71-97" in the I/O
check mode in the service mode, move the
trimmer press board to the position where the
trimmer board is released.

then unplug the power plug from the power outlet.
4. Remove the trimmer paddle assy. (Refer to P.131)
[4] 5. Remove the trimmer board assy [1] by pulling it
[3] horizontally to the back side.
[5]
Note
• When reinstalling it, aligning the slit [2] of the
trimmer board assy [1] with the pin [3] and
[6] insert it between the trimmer press plate [4]
and the hold plate [5].
• When inserting it, be careful not to bend the
guide sheet [6].
• When pushing it into the machine, be sure to
insert it horizontally by pushing the move-
[2] ment arm receiver [7].
a0h2t3c017ca
6. Clean the bottom surface of the actuator [1] and

[1] the top surface [2] of the trimmer blade retaining
plate which contacts to the bottom surface.
Note
• When the trimmer scraps remain or the clean-
ing is not conducted properly, the trimmer
completion timing differs and a trimming fault
occurs.
[2] a0h2t3c067ca
137 1

steps in reverse.
8. Reset the trimmer board solenoid operation
SD-506
counter.
Note
• Reset the trimmer board solenoid operation
counter by the output check code "71-95" of the
I/O check mode of the service mode.
• If the counter is not reset, the trimmer board
solenoid (SD11) operating timing after the
trimmer board is replaced becomes faster
than specified timing (700/500/300 times of
trimming). (In the first operation only)
• After replacing the trimmer board, perform
the saddle stitch with trimming and check
that the trimming is performed without prob-
lem.
138
10.2.4 Replacing the trimmer press motor (M32)

A. Periodically replaced parts/Spotted replaced parts/cycle
• Trimmer press motor (M32) : Every 20,250,000 prints *1 (Actual replacement cycle: Every 500,000 cuts) *2
SD-506
*2 Actual replacement cycle of 1200/1200P/1051/C6501/C6501P/C65hc.
B. Procedure
1. Pull out the trimmer unit. (Refer to P.181)
[2] [3] [6] [4] [2] 2. Disconnect the connector [1].
Note
• When reinstalling it, be sure to tighten 4
screws [2] after making the tension of the
spring [3] over the mounting plate [4].
4. Remove 4 screws [6] with keeping the trimmer

press motor (M32) [5], and then remove it from the
belt [7].
[7] [8] [6] Note

• When reinstalling it, be sure to put the trim-
mer press motor (M32) [5] into the round hole
[8].
[5] [1]
a0h2t3c022ca
5. Loosen the screw [1] and then remove the gear [2]
[1] [2] from the trimmer press motor (M32) [3].
steps in reverse.
[3] a0h2t3c023ca
139 1
10.2.5 Lubrication to the trimmer unit

SD-506
• Paper holding screw : Every 1,400,000 prints (Actual lubricating cycle: Every 37,500 cuts)*1
: Every 1,500,000 prints (Actual lubricating cycle: Every 37,500 cuts)*2
• Drive gears /3, /4 : Every 20,250,000 prints (Actual lubrication cycle: Every 500,000 cuts)*2
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Procedure
[3] [2]
2. Lubricate Molykote EM-30L to the paper holding
screw [1].
3. Lubricate Molykote EM-30L to the drive gears /3
[2] and /4 [3].
steps in reverse.
Note
• When applying the grease, be careful not to
spill the grease to other parts.
[1]
[3] [2]
[1]
a0h2t3c060ca
1 140
10.3 Bundle processing section

10.3.1 Replacing the bundle press stage gear
SD-506
A. Periodically replaced parts/Spotted replaced parts/Cycle
• Bundle press stage gear : Every 20,250,000 prints *1 (Actual replacement cycle: Every 500,000 set (num-
ber of set of sheets exited to the bundle tray) *2)
*2 Spotted replaced cycle of 1200/1200P/1051/C6501/C6501P/C65hc
B. Procedure

2. Rotate the jam cleaning knob [1] in the arrow-
marked direction until it stops.
Note
• When the jam cleaning knob [1] stops, be
sure to check that the bundle registration
plate [2] comes to the upper position [3] after
the bundle press stage goes down and the
tension of the wire [4] is released.
• Be sure not to rotate the jam cleaning knob
too much.
[8] [7] [3]
3. Remove the E-ring [5] and move the gear [8] to

the back side after moving the bearings [6] and
[7].
[4] [1]
[6]
[5]
a0h2t3c028ca
141 1

[2] [3] [1] 5. Remove 2 screws [2] and then remove the bundle
press stage up down motor (M24).
SD-506
Note
• Be careful not to lose the pin [3] as it drops off
when removing the gear [2].
a0h2t3c029ca
6. Remove the E-ring [2], and then remove the bun-

dle press stage gear [2] and 2 bearings [3] on both
sides of the gear.
Note
• After replacing the bundle press stage gear
[2], be sure to apply plas guard No.2 to the
gear.

steps in reverse.
[1] [2] [3] a0h2t3c030ca
1 142

SD-506
11.1.1 Trimmer section
A. Trimmer blade home sensor (PS50), Trimmer blade upper limit sensor (PS51)
(1) Positions from which removing the screws is prohibited
• 1 fixing screw of the mounting plate on each the trimmer blade home sensor (PS50) and the trimmer blade
upper limit sensor (PS51)
[1] [2] [3] [4] [5] [6]
a0h2t3c061ca
[1] Screw not allowed to be adjusted/removed [4] Screw not allowed to be adjusted/removed
[2] Mounting plate [5] Mounting plate
[3] Trimmer blade upper limit sensor (PS51) [6] Trimmer blade home sensor (PS50)
(2) Reason of prohibition

• Trimmer blade home sensor (PS50) detects the home position of the trimmer blade. Once the home posi-
tion is out of alignment, the trimmer blade gets out from the trimmer press plate. It prevents paper from
entering to the trimmer section and causes the trimming error or damages the trimmer blade retaining plate.
Therefore, be sure not to change the installation position of PS50.
• The trimmer blade upper limit sensor (PS51) detects the upper limit of the trimmer blade after the comple-
tion of the trimming. Once the upper limit detection is out of alignment, the paper fails to be trimmed
because the trimmer blade stops before the completion or the trimmer blade and the trimmer board get
damaged because the trimmer blade cuts in the trimmer board deeply. Therefore, be sure not to change
the installation position of PS51.
143 1
B. Trimmer completion sensor (PS62)

• 1 fixing screw of the trimmer completion sensor (PS62) mounting plate
SD-506
[3] [2] [1]
a0h2t3c062ca
[1] Mounting plate [3] Trimmer completion sensor (PS62)

[2] Screw not allowed to be adjusted/removed

• The trimmer completion sensor (PS62) detects the completion of the trimming. Once the trimmer comple-
tion timing is out of alignment, the paper fails to be trimmed or the trimmer blade and the trimmer board get
damaged because the trimmer blade cuts in the trimmer board deeply. Therefore, be sure not to change
the installation position of PS50.
1 144
C. Wire slack prevention sensor (PS66)

• 1 fixing screw of the wire slack prevention sensor (PS66) mounting plate
SD-506
[3] [2] [1]
a0h2t3c063ca
[1] Mounting plate [3] Wire slack prevention sensor (PS66)

[2] Screw not allowed to be adjusted/removed

• The wire slack prevention sensor (PS66) detects the slack of the winding wire on the trimmer blade. Once
the detection position is out of alignment, the wire is removed from the winding pulley and damages the
trimmer unit. Therefore, be sure not to change the installation position of PS66.
145 1
D. Trimmer press upper limit sensor (PS52), Trimmer press home sensor (PS53)
• 1 fixing screw of the trimmer press upper limit sensor (PS52) mounting plate
SD-506
• 1 fixing screw of the trimmer press home sensor (PS53) actuator
[4] [5] [6]
[3] [2] [1] a0h2t3c064ca
[1] Screw not allowed to be adjusted/removed [4] Trimmer press upper limit sensor (PS52)
[2] Actuator [5] Screw not allowed to be adjusted/removed
[3] Trimmer press home sensor (PS53) [6] Mounting plate

• The trimmer press home sensor (PS53) detects the home position of the trimmer press plate. Once the
home position is out of alignment, the opening is not opened enough for the paper. It causes the trimming
error by preventing paper from entering to the trimming section. Therefore, be sure not to change the posi-
tion of the actuator of PS53.
• The trimmer press upper limit sensor (PS52) detects the upper limit of the trimmer press. Once the upper
limit position is out of alignment, the opening is not opened enough for the paper. It causes the trimming
error by preventing paper from entering to the trimming section, or the opening is not enough for replacing
the trimmer blade. Therefore, be sure not to change the installation position of PS52.
1 146
E. Trimmer press brake

• 1 gap adjusting screw of the trimmer press brake
SD-506
[2] [1] a0h2t3c065ca
[1] Trimmer press brake [2] Screw not allowed to be adjusted/removed

• The trimmer press brake pushes the timing belt and prevents the trimmer press motor (M32) from rotating
too much which caused by the inertia of the trimmer press board. Once the gap between the trimmer press
brake and the timing belt changes, it damages the timing belt or disables the brake. Therefore, be sure not
to adjust the gap adjusting screw of the trimmer press brake.
147 1
F. Fixing screw of the trimmer press timing belt

• All screws which fix the driving system of the trimmer press
SD-506
[1] [2]
a0h2t3c066ca
[1] Screw not allowed to be adjusted/removed [2] Screws allowed to be removed

(all screws shown in the picture)

• The paper holding screw on right and left drives the trimmer press plate through the timing belt. Once the
part such as gear of the driving system is removed, the parallelism of the trimmer press plate is not guaran-
teed because of the belt tooth skipping. Therefore, be sure not to remove the attaching screw of the cover
which fixes the driving system and the bearing fixing screw.
1 148

SD-506
1 Cover Rear cover /Lt P.150
2 Rear cover /Rt P.150
3 Left cover P.151
6 Subtray cover P.153
7 Front door /Lt P.154
8 Front door /Rt P.155
9 Right angle convey- Roller release solenoid /1 (SD5) P.156
10 ance section Roller release solenoid /2 (SD6) P.158
11 Right angle conveyance gate solenoid (SD2) P.159
12 Roller release solenoid/3 (SD7) P.165
13 Folding section Folding unit P.166
14 Bundle processing Bundle press stage unit P.170
section
15 Trimmer section Trimmer blade motor (M31) P.179
16 Trimmer unit P.181
149 1

SD-506
CAUTION:
11.3.1 Rear cover /Lt

A. Procedure
[1] 1. Remove 8 screws [1], and then remove the rear

cover /Lt [2].
steps in reverse.
[1] [2] 15anf2c002na
11.3.2 Rear cover /Rt

A. Procedure
[1]
cover /Rt [2].
steps in reverse.
[2] [1] 15anf2c003na
150
11.3.3 Left cover

A. Procedure
1. Remove 7 screws [1], slide the bottom of the left
SD-506
[1]
cover [2] to the outside, and remove it to the bot-
tom.
steps in reverse.
[2] [1] 15anf2c004na
11.3.4 Upper cover /Fr

A. Procedure
1. Open the front doors /Rt and /Lt.
[3] [2]
2. Remove the 5 screws [1] on the front, 2 screws
[2], 1 screw [3] on the left, and 3 screws [4] under
the cover.
3. Loosen a screw [5].
4. Lift up and remove the upper cover /Fr [6].
[1]
Note
• When removing the upper cover /Fr [6], pull
the screw [5] to the front to so that the tip of
the screw does not catch the top cover /Fr
[6].
[6]

steps in reverse.
[4] [5] 15anf2c005nb
151
11.3.5 Upper cover /Rr3

A. Procedure
SD-506
[1] [2]
2. Remove 2 screw caps [1] and then remove 2
screws [2].
4. Loosen the screw [4] and then remove the upper
cover /Rr3 [5].
Note
• When removing the upper cover /Rr3 [5], pull
the screw [4] to the front so that the tip of the
screw does not catch the upper cover /Rr3
[5].
[5]
steps in reverse.
[3] [3] [3]
[4] 15anf2c006na
152
11.3.6 Subtray cover

A. Procedure
1. Remove the upper cover /Fr. (Refer to P.151)
SD-506
[2] [3] [2]
2. Remove the upper cover /Rr3. (Refer to P.152)
3. Remove 2 screws [1] and 4 screws [2], and then
remove the subtray cover [3].
steps in reverse.
Note
• When reinstalling the subtray cover [3], pull
the screw [4] to the outside.
[3] [1] [4] [1]
15anf2c007na
153
11.3.7 Front door /Lt

A. Procedure
1. Open the front door /Lt [1].
SD-506
[6] [5] [4] 2. Remove the screw [2], and then remove the front
door stopper /Lt [3].
3. Remove 2 screws [4] and remove the fulcrum [6]
by sliding the hinge [5] upward, and then remove
the front door /Lt [1].
Note
• Support the front door /Lt [1] with your hand
so that it does not fall down when removing
the screw [4].

steps in reverse.
[3] [2]
[1]
15anf2c008na
154
11.3.8 Front door /Rt

A. Procedure
1. Open the front door /Rt [1].
SD-506
[5] [4] [6]
2. Remove the screw [2], and then remove the front
door stopper /Rt [3].
3. Remove 2 screws [4] and remove the fulcrum [6]
by sliding the hinge [5] upward, and then remove
the front door /Rt [1].
Note
• Support the front door /Rt [1] with your hand
so that it does not fall down when removing
the screw [4].
[2] [3] 4. Reinstall the above parts following the removal

steps in reverse.
[1] 15anf2c009na
155
11.3.9 Roller release solenoid /1 (SD5)

A. Procedure
1. Remove SD from the main body.
SD-506
2. Remove 3 screws [1] and remove the cover [2].
[2] [1]
15anf2c028na

[4] [5] [3] [6]
4. Remove 2 screws [2] and remove the roller
release solenoid/1 (SD5) [3].
Note
• When installing the solenoid, make sure that
the pin [5] is hitched to the plunger [4].
• Install it with the wiring harness [6] located on
the guide plate side.
[2] [1]
15anf2c029na
1 156
5. With the plunger [1] pulled, temporarily hold the

[2] new roller release solenoid /1 and adjust the posi-
tion so that the clearance "a" between the roller
SD-506
[3] and the guide plate [2] is at a standard value,
a and then fully tighten the screws.
Standard value "a": 0mm to 0.5mm
[3]
steps in reverse.
[1]
15anf2c030nb
157 1
11.3.10 Roller release solenoid /2 (SD6)

• Roller release solenoid /2 : Every 20,250,000 prints (Actual replacement cycle: Every 5,000,000
SD-506
operations)*1
*1 1200/1200P/1051
B. Procedure
1. Open the front door /Rt.
[1] [2]
15anf2c031na

release solenoid /2 (SD6) [3].
Note
• When reinstalling it, be sure to check that the
pin [5] has been inserted into the hole on the
plunger [4].
[1] [6] [2] [3] [4] [5]
15anf2c032na
5. With the plunger [1] pulled, temporarily hold the

[2] new roller release solenoid /2 and adjust the posi-
tion so that the clearance "a" between the roller
a [3] and the guide plate [2] is at a standard value,
and then fully tighten the screws.
[3] Standard value "a": 0mm to 0.5mm
steps in reverse.
[1]
15anf2c033nb
1 158
11.3.11 Right angle conveyance gate solenoid (SD2)

A. Procedure
1. Open the front door /Rt and then remove the
SD-506
[1]
screw [1].
2. Remove the rear cover /Rt. (Refer to P.150)
3. Remove the hex wrench (short, #2.5) from the
trimmer section. (Refer to P.133)
15anf2c057na
4. Remove the E-ring [1] and the pulley [2] and then
[3] [2] [1]
remove the belt [3].
[4]
15anf2c058na
159 1
6. Remove the screw [1] and then remove the stop-

per [2].
SD-506
[2] [1]
15anf2c059nb
7. Remove the screw [1] and then remove the stop-

[4] [8] [3] per [2].
8. Pull the spring [3] in the arrow-marked direction [4]
and release it, and then open the right angle con-
veyance guide plate [5].
Note
• When reinstalling the spring [3], hook the long
arm [6] on the position between the frame
and the E-ring [7] of the jam release handle
shaft and insert the tip of the short arm [3]
into the hole [8].
[1] [2] [6] [7] [5]

15anf2c130ca
1 160

[1] [3] [3] [1]
entrance conveyance unit [2].
SD-506
Note
• When reinstalling, press it against 2 position-
ing pins [3] and then tighten the screw [1].
[1]
[2] 15anf2c060na
Note
[1] [2] • As the positioning pin [1] has anti-drop
grooves, be sure to insert it fully before tight-
ening the screw.
a0h2t3c043ca
161 1

[3] [2] [1] 11. Remove 2 screws [2] and then remove the
entrance gate solenoid [3] and the plunger [4].
SD-506
[4] a0h2t3c044ca
Note
[4] • When reinstalling, be sure to set in the follow-
ing conditions before tightening the screw [4];
[2] [1]
with the plunger of the entrance gate solenoid
not pulled, the gap between the entrance gate
[1] and the guide plate [2] is at a standard
value "a", and with the plunger of the
a entrance gate solenoid pulled, the gap
between the entrance gate [1] and the guide
plate [3] is at a standard value "b".
b Standard value
a: 2.0mm ± 0.3mm
b: 5.0mm ± 0.5mm
[3]
a0h2t3c051ca
1 162

[6] [5] [2] [4] [3]
14. Remove 2 screws [3] and pull out the arm [4] from
SD-506
the shaft [5] in the arrow-marked direction [6].
Then remove the right angle conveyance gate
solenoid assy [7].
Note
• When reinstalling, press the arm [4] against
the D-cut of the shaft [5] and then tighten the
screws [2].
[1] [7]
a0h2t3c045ca
Note
• With the plunger [1] pulled, adjust the position
[1] so that the clearance "a" between the right
angle conveyance gate [3] and the guide plate
[2] is at a standard value "a", and then fully
tighten the screws [4].
Standard value a: 4.8mm ± 0.5mm
[4]
[3]
[2]
a0h2t3c052ca
163 1
15. Remove 2 screws [1], mounting plate [2], arm [3],

[7] [2] [4] [3] plunger [4], and the right angle conveyance gate
solenoid (SD2) [5].
SD-506
Note
• When installing the right angle conveyance
gate solenoid, make sure that the wires [6]
are located on the other side of the hole [7] in

steps in reverse.
[1] [5] [6]

a0h2t3c046ca
1 164
11.3.12 Roller release solenoid/3 (SD7)

A. Procedure
1. Open the front doors /Rt and /Lt.
SD-506
[1] [2]
15anf2c157ca

[2] [6] [3] [1]
release solenoid /3 (SD7) [3].
Note
• When installing the solenoid, make sure that
the pin [5] is hitched to the plunger [4].
[4] [5]
15anf2c158ca
5. Slightly tighten the new roller release solenoid/3

with the plunger [1] pulled, adjust the position so
that the gap between the paper feed surface [2] of
the guide plate and the roller surface [3] falls within
the standard value, and secure the roller release
solenoid/3.
[1] Standard value "a": 1.3mm to 1.8mm
steps in reverse.
[3]
[2] a
15anf2c159ca
165 1
11.3.13 Folding unit
CAUTION:
SD-506
• Be sure to perform this operation with 2 people because the folding unit is heavy.
A. Procedure
1. Remove the front door /Rt. (Refer to P.155)
[5] [4] [2]
2. Remove the rear cover /Rt. (Refer to P.150)
3. Remove 2 screws [1] and 2 clamps [2] from the
rear of the folding unit.
Note
• Be sure not to let the clamps [2] fall down.
4. Remove the screw [3] and the ground [4].

6. Remove the clamp and fall drop the wiring har-
ness [7] from the hole [6] on the wiring harness
guide.
[3] [1] [6] [7] [1]
15anf2c010na
166
7. Pull out the folding unit.

8. Pull out the folding unit. Remove 2 screws [1],
separate the notch [2] from the hole [3] and
SD-506
remove the lower cover /2 [4].
9. Loosen the screw [5], remove the 2 screws [6]
and remove the lower cover /1 [7].
10. Remove 2 screws [8], separate the notch [10]
from the shaft [9] and remove the lower cover /3
[8] [11] [1] [4] [6] [7] [11].
[2] [9] [10] [3] [5]
15anf2c011na
Note
• Install the lower cover /3 [11] between 2 pins
[2] of the shaft [1]. If it is installed at an
improper position, other parts are damaged in
storing the folding unit.
[1] [2] 15anf2c071na
167
11. Remove 4 screws [1], and then lift up and remove

[1]
the folding unit [2] upward with 2 people.
SD-506
Note
• When reinstalling it, be sure to align the posi-
tioning pin [3] with the hole.
[3] [2]
[3]
[1] 15anf2c012na
168
Note
[5] [7] [6]
• When holding the folding unit, be sure to hold
the shafts [4] at front and rear or the upper
SD-506
top of the side plate [5]. Never hold the jam
release lever [6] or the handle [7]. They get
damaged.
• When placing the folding unit, place it on the
table to avoid the guide plate [8] on the front
being contacted with the floor because it is
projected from the bottom of the unit.

steps in reverse.
[8] [4]
15anf2c013na
169
11.3.14 Bundle press stage unit

• Bundle press stage unit : Actual replacement cycle: Every 2,500,000 copies (bundle tray paper exit)
SD-506
B. Procedure

• Rear cover /Rt (Refer to P.150)
• Trimmer unit (Refer to P.181)
2. Rotate the jam cleaning knob [1] in the arrow-
marked direction until it stops.
Note
• When the jam cleaning knob [1] stops, be
sure to check that the bundle registration
plate [2] comes to the upper position [3] after
the bundle press stage goes down and the
tension of the wire [4] is released.
[3]
• Be sure not to rotate the jam cleaning knob
too much.
[4] [1] a0h2t3c031ca
1 170

4. Remove the wiring harness [2] from the clamp [3],
[1] and then pull it out from the hole [4] by following
SD-506
the arrow.
[2]
[5] [4] [3]
Note
• When reinstalling it, be careful not to nip the
wiring harness [2] with the trimmer unit plate
[5].
a0h2t3c032ca
5. Remove 1 each of the screws at 2 places and

[1] [2] [4] remove 1 each of the up-down wire [2], and then
take it out to the front side of the machine from
the trimmer unit plate [3] by following the arrow.
Note
• When reinstalling it, be sure to lubricate
Molykote EM-30L to each 2 shafts [4].
6. Remove 8 screws [5] and then remove the trim-

mer unit plate [3].
Note
[7] [3] • Be careful not to damage the trimmer scraps
guide [6].
• When reinstalling it, be sure to align the pro-
jection [7].
[5][6][5]
a0h2t3c033ca
171 1
7. Disconnect the connector [1] and remove the wir-

[3] [1] ing harness [2] from clamp [3], and then take it out
from the hole [4] of the metal plate to the arrow-
SD-506
marked direction.
bracket [6].
9. Remove 2 screws [7] and then remove the guide
plate [8].
[5] [6] [2] [4]
[7] [8]
a0h2t3c034ca
1 172

[1] [3] [2] 11. Remove 3 screws [2] and then remove the bundle
registration motor (M12) [3].
SD-506
13. Remove 4 screws [5] and then remove the bundle
press movement motor (M17) [6].
[6] [5]
[4]
a0h2t3c035ca
173 1
[1] [2] [3] [2] and the pin [3].
SD-506
[5] and the pin [6].
[4] [5] [6] a0h2t3c036ca
1 174

[2] [6] [3] [4] 17. Cut the wire binding bands [2] and [3] and remove
the wiring harness [4].
SD-506
Note
• Be sure to let the wire binding bands [2] and
[3] into the shaft hole [5] and install the wire
retaining band [6] on the [2] side between the
bands [2] and [3].
[5]
[1]
a0h2t3c037ca
175 1
18. Pull out the bundle paper exit tray [1].

[7] [5][10] [6] [2] [3] [4] 19. Remove 2 screws [2] and then remove the wire
mounting plate /Lt [3].
SD-506
Note
• Since the wire /Lt [4] has the tension of the
spring, be sure to remove 2 screws [2] with
keeping the wire mounting plate /Lt [3] and lift
it up until the tension is released, and then
[8]
take it off gently.
20. Loosen the screws [5] and pull the wire mounting
plate /Rt [6] downward to move it to the opposite
side of the shaft [7], and then remove it to the
space between the side plate [8] and the timing
belt [9].
Note
[9] [1] • Since the wire /Rt [10] has the tension of the
a0h2t3c038ca
spring, be sure to lift up the wire mounting
plate /Rt [6] until the tension is released, and
then take it off gently.
Note
• When reinstalling it, be sure to put the wire [1]
on 2 pulleys [2].
[1] [2] a0h2t3c039ca
1 176
21. Push the bundle paper exit tray [1] fully to the
back.
[6]
22. Remove 2 E-rings [2] and then remove 2 bearings
SD-506
[3] and the drive shaft [4].
[5]
23. Remove 2 E-rings [5] and then remove the bear-
ings [6].
[3]
[2]
[4] [1]
a0h2t3c040ca
24. While keep holding the bundle paper exit assist

[3] [2] [1] roller [1] horizontally, push the bundle press stage
unit [3] to the back with holding the shaft [2] to
release the roller pin [4] of the bundle paper exit
assist roller arm from the regulation bracket [5].
After the release, put down the bundle paper exit
assist roller [1] gently.
Note
• Once the roller pin [4] of the bundle paper exit
assist roller arm is removed from the regula-
tion bracket [5], the bundle paper exit assist
roller drops off. Therefore, be sure to hold
[5] with hands.
• When reinstalling, be sure to put the roller pin
[4] [4] under the regulation bracket [5].
a0h2t3c041ca
177 1
25. Pull out the bundle paper exit tray [1] to about
[4] half.
SD-506
Note
• If the bundle paper exit tray [1] is pulled out
too much, the bundle press stage unit [2]
drops off from the tray.
26. Pull out the bundle press stage unit [2] to the posi-
tion in the picture with holding the bundle press
section [3]. Then, pull it out more to the back with
paying attention to the contacting places [5], [6],
and [7] on the right side, and remove the arm [8].
[2] [3] [8] [1] 27. Reinstall the above parts following the removal
steps in reverse.
[5]
Note
• After the installation, be sure to check that
the bundle press stage unit goes up and down
horizontally by rotating the jam cleaning
[6] knob.
[7]
a0h2t3c042ca
1 178
11.3.15 Trimmer blade motor (M31)

A. Procedure
1. Remove the trimmer unit. (Refer to P.181)
SD-506
[1] a0h2t3c024ca
3. Remove 3 screws [1] and then remove the trim-

[1] [2] [1] mer blade motor (M31) [2].
Note
• When reinstalling it, be sure to set so that the
wiring harness [3] comes in the position as
shown in the picture.
[3] a0h2t3c025ca
Note
[2] [1] • When reinstalling it, be sure to insert the D-
cut [1] of the shaft on the trimmer blade
motor (M31) into the D-cut hole [2] of the
planetary gear.
a0h2t3c026ca
179 1
4. Remove 4 screws [1] and then remove the mount-

[2] [4] [3] [5] [1] ing bracket [3] from the trimmer blade motor
(M31) [2].
SD-506
Note
• When reinstalling it, be sure that the label [4]
is in the same direction as the slotted hole [5]
on the mounting bracket [3].

steps in reverse.
[1] a0h2t3c027ca
1 180
11.3.16 Trimmer unit
SD-506
CAUTION:
• Be sure to perform this operation with 2 people because the trimmer unit is heavy.
A. Procedure for pulling out the trimmer unit

[2] [2] • Rear cover /Lt (Refer to P.150)
• Rear cover /Rt (Refer to P.150)
• Trimmer paddle assy (Refer to P.131)
2. Remove each 4 of the screws at 2 places, and
[1]
[1] then remove 2 fixing plates [2].
a0h2t3c018ca
181 1

[2] [1] [2]
Note
SD-506
• When reinstalling it, be careful not to nip the

wiring harness with the metal plate.

5. Pull out the trimmer unit to the back side until the
stoppers [4] and [5] touch to the anti-drop brack-
ets [6] and [7] by holding the configuration parts
[3] of the trimmer unit.
[5] [7] [6] [4] steps in reverse.
[3]
a0h2t3c019ca
B. Removing/installing the trimmer unit

1. Conduct by the step 4 of the procedure for pulling
[1] out the trimmer unit
(Refer to A.Procedure for pulling out the trimmer
unit)
DANGER:
• Be sure not to pull out the trimmer unit to the
back side until the stopper is removed. If the
stopper is removed while the trimmer unit is
pulled out to the back side, the trimmer unit
drops.

wiring harness from the wiring harness clamp.
[1] a0h2t3c020ca
1 182
3. Remove each 2 of the screws [1] at 2 places, and

[1] [3] [2] [1] then remove the stoppers /1 [2] and /2 [3].
4. Pull out the trimmer unit [4] to the back side by
SD-506
holding the configuration parts [5].
Note
• Remove or reinstall the trimmer unit [4] by lift-
ing it slightly to avoid the projection for pre-
venting falling off [6] on the trimmer unit
plate.
• Be sure not to hold the position that is easily
damaged like the electrical parts.
CAUTION:
• Be sure to perform this operation with 2 peo-
ple because the trimmer unit is heavy.
[5] [4] [5]

steps in reverse.
[6]
a0h2t3c021ca
183 1
SD-506
Blank page
184
PB-501/502
2009.07
Ver. 2.0
Revision history
Revision mark:
corresponding page.
NOTE

2009/07 2.0 1 bizhub PRO 1200/1200P/1051.
CONTENTS
PB-501/502
PB-501/502
OUTLINE
3. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Subtray exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Perfect binding mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.3.1 Gate control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.3.2 Entrance conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3.3 Intermediate conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3.4 Cover paper conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3.5 Sub tray paper exit release control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3.6 Sub tray full-status detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.3.7 Cover paper multi feed detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5. SUB COMPILE (SC) SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.3.1 SC section operation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.3.2 SC entrance conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3.3 SC switchback conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.3.4 SC main scan alignment control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.3.5 Sub scan alignment control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3.6 SC paper bundle conveyance control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3.7 Clamp entrance movement control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3.8 SC stopper control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.3.9 SC pressure arm control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6. CLAMP SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.3.1 Clamp alignment control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.3.2 Clamp control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.3.3 Clamp rotation control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.3.4 Book thickness detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7. PELLET SUPPLY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
i
7.3.1 Pellet supply operation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

7.3.2 Pellet supply arm control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
PB-501/502
7.3.3 Pellet supply control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

7.3.4 Pellet supply amount control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.3.5 Pellet remaining amount detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.3.6 Pellet supply door opening/closing detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.3.7 Stirring stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
8. GLUE TANK SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.1 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.3.1 Glue tank unit movement control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.3.2 Glue apply roller control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.3.3 Glue tank lifting control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.3.4 Cover paper glue control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8.3.5 Glue temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
9. COVER PAPER SUPPLY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
9.1 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
9.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9.2.1 Cover paper tray lift drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9.2.2 Paper feed drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
9.2.3 Pick-up drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
9.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9.3.1 Up/down control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9.3.3 Separation mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
9.3.4 Paper feed mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
9.3.5 Air assist mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
9.3.6 Cover paper empty detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
9.3.7 Paper feed assist plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10. COVER PAPER TABLE SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10.1 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
10.3.1 Cover paper table section operation overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
10.3.2 Cover paper conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
10.3.3 Cover paper cutting control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
10.3.4 Cover paper alignment drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
10.3.5 Cover paper table up down control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
10.3.6 Cover paper folding plate control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
10.3.7 Cover paper conveyance arm control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
10.3.8 Cover paper lifting (supporting) control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
10.3.9 Book paper exit control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
10.3.10 Waste paper control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
11. BOOK STOCK SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
11.1 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
11.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
11.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
11.3.1 Book stock section operation overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
11.3.2 Book conveyance and movement control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
ii
11.3.3 Book conveyance belt control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

11.3.4 Book conveyance up down control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
PB-501/502
11.3.5 Book movement control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
11.3.6 Book stopper control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
11.3.7 Book full status detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
12. OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
12.1 Fan control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
12.2 Door opening/closing control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
MAINTENANCE
13.1 Sub compile (SC) section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
13.1.1 Replacing the switchback roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
13.1.2 Lubrication to the sub scan alignment plate shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
13.2 Cover paper table section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
13.2.1 Cleaning the cover paper folding plate and the book spine backing plate . . . . . . . . . . . . . . . . 140
13.2.2 Lubrication to the cover paper alignment plate shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
13.3 Cover paper supply section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
13.3.1 Removing/reinstalling the pick-up roller assy and the separation roller assy . . . . . . . . . . . . . . 142
13.3.2 Replacing the pick-up roller and the paper feed roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
13.3.3 Replacing the separation roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
13.3.4 Replacing the paper feed clutch (MC71) and the cover paper separation clutch (MC72). . . . . 151
13.4 Framework section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
13.4.1 Replacing filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
13.5 Glue tank section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
13.5.1 Replacing the cover paper glue roller drive gear bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
13.5.2 Lubrication to the glue apply roller motor drive connecting gear . . . . . . . . . . . . . . . . . . . . . . . 156
13.5.3 Replacing the pellet supply cooling fan (M4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
13.6 Clamp section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
13.6.1 Lubrication to the clamp pressing board shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
13.7 Book stock section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
13.7.1 Lubrication to the guide shafts /Rt and /Lt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
14.1 List of disassembling and assembling parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
14.2 Removing procedure for disassembly/reassembly parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
14.2.1 Front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
14.2.2 Upper cover /Fr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
14.2.3 Upper cover /Rr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
14.2.4 Upper cover / Lt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
14.2.5 Rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
14.2.6 Left cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
14.2.7 Pellet supply cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
14.2.8 SC cover /Fr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
14.2.9 SC cover /Lt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
14.2.10 SC cover /Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
14.2.11 Book stock cover /Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
14.2.12 Book stock cover /Fr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
14.2.13 Book stock cover /Rr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
14.2.14 Pellet supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
14.2.15 Glue tank unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
iii
14.2.16 SC unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

14.2.17 SC switchback release motor (M13) and the one-way clutches /A and /B . . . . . . . . . . . . . . . 180
PB-501/502
14.2.18 SC pressure arm solenoid (SD13). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

14.2.19 FD alignment solenoid (SD11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
14.2.20 Clamp unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
14.2.21 Book stock unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
14.2.22 Book lift wire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
14.2.23 Conveyance unit /Lw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
14.2.24 Sub tray exit solenoid (SD4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
14.2.25 Cover paper tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
14.2.26 Cover paper lift wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
14.2.27 Roller cutter blade assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
14.2.28 Binding mode procedure with manual operating function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
14.2.29 Multi feed detection boards /1 (MFDTB71) and /2 (MFDTB72) . . . . . . . . . . . . . . . . . . . . . . . . 214
iv
OUTLINE
PB-501/502
A. Type
Type Simplified perfect binding machine (Consoled hot-melt type)
B. Functions
(1) Functions
Perfect binding mode Automatically binds and stocks in a book stock section.
Subtray mode Exits paper to the subtray without any process.
(2) Binding sheets
Binding sheets Min. thickness 10 sheets

Max. thickness Plain paper :300 sheets or 30mm
Fine, color paper, Coat: 150 sheets or 15mm
Binding sheets with Z-Fold Single-sided print
Number of Z-Fold Max. number of unfold Total
sheets*1
sheets sheets
1 sheet 200 sheets 201 sheets
2 sheets 150 sheets 152 sheets
Double-sided -

print
sheets sheets
1 sheet 200 sheets 201sheets
Simplex/duplex When 1 or more unfold sheets is single-sided, the specifi-

mixed print cation is the same as the simplex print.
(printer function) When the z-folded sheet is single-sided, the specification is
the same as the duplex print.
*1 The limit of the total number of sheets can be released by switching DIPSW37-2 from 0 (default) to 1.
1 1

Book stock section Max. 11 books *2 x 2 rows *3 (book thickness: 30mm)
PB-501/502
10 to 30 sheets 10 to 30 sheets book: 50 books

book
31 to 150 sheets 35 books or until the upper limit is detected.
book
151 to 300 Until the upper limit is detected
sheets book
PB cover paper tray*3 1000 sheets (82g/m2)
500 sheets (161g/m2)
Sub tray 200 sheets (80g/m2)
*1 The available number of books may decrease due to curls of papers.

*2 When books have been stacked up to the limit at the first row, the first stack is automatically moved to the
second row, and piling books at the first row continues.
*3 Cover paper supply is selectable from PB cover paper tray, main body tray, PI or PI-PFU (1200/1200P/
1051only).
(4) Others
Warm-up time Approx. 20 minutes
Cover trimming Selectable from Trim/Not trim.
1 2
C. Type of paper
(1) Paper size
PB-501/502
Perfect binding mode Inside paper : A4, B5, ISOB5*1, A5, A5S*2, 81/2 x 11, 51/2 x 81/2*1, 51/2 x 81/2S*2, 16K*3
Custom size paper (Max. 307 (W) x 221 (L) mm)
Only for Z-Fold: 11 x 17, A3, B4, ISOB4*1, A4S, 81/2 x 11S, 8K*3
Cover paper : Max. 307 (W) x 472 (L) mm Vertical (main scan direction)
Same as the inside paper size.
Horizontal (sub scan direction) Wide size L
L = book size in the sub scan direction x 2 + book thickness +
3mm (for trimming)
Sub tray mode SRA3, A3, JISB4*4, ISOB4*1*5, SRA4, SRA4S, A4, A4S, JISB5*4, ISOB5*1*5,
B5S, A5, A5S*2, B6S*2
13 x 19, 12 x 18, 11 x 17, 9 x 11, 81/2 x 14, 81/2 x 11, 81/2 x11S, 8 1/4 x 13,
81/8 x 131/4, 8 x 13, 71/4 x 101/2, 51/2 x 81/2*1, 51/2 x 81/2 S*2, 81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
Wide paper*1 (A3W, B4W, A4W, A4SW, B5W, B5SW, A5W, 12 x 18W,
11 x 17W, 81/2 x 11W, 81/2 x 11SW, 51/2 x 81/2W, Max. 324mm x 463m)
Custom size paper (Max. 324 x 463mm, Min. 100 x 139mm)
11 x 17, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2, Max. 324mm x 463m)
(2) Paper weight
Perfect binding mode Inside paper : 64g/m2 - 91g/m2 *1, 64g/m2 -105g/m2 *2
Cover paper : 82g/m2 - 161g/m2 *1, 82g/m2 -161g/m2 *2
Sub tray mode 50g/m2 - 300g/m2 *1, 64g/m2 - 300g/m2 *2
*1 1200/1200P/1051 only
*2 C6501/C6501P/C65hc only
D. Maintenance
E. Machine data
Power source Common to AC100V 50/60Hz

DC5V (supplied from the main body)
Power consumption 1000W or less
Dimensions 1,303 (W) x 1,223 (H) x 775 (D) mm
Binding section 740 (W) x 1,223 (H) x 775 (D) mm
Book stock section : 563 (W) x 740 (H) x 685 (D) mm

Note
3 1
PB-501/502
[6] [7] [8] [1]
[5]
[4]
[2]
[3]
a075t1c001ca
[1] Conveyance section [5] Glue tank section

[2] Cover paper table section [6] Pellet supply section
[3] Cover paper supply section [7] Sub compile (SC) section
[4] Book stock section [8] Clamp section
4
3. PAPER PATH
PB-501/502
3.1 Subtray exit
[1]
[2]
a075t1c002ca
[1] Subtray exit [2] Exit from the FD sub tray
5
3.2 Perfect binding mode

PB-501/502
A. Conveyance of inside papers to the clamp section and conveyance of cover paper
[4]
[1]
[2]
[3]
a075t1c003ca
[1] Conveyance of inside papers [3] Conveyance of cover paper from the PB tray
[2] Conveyance of cover paper from the main body [4] Switchback conveyance
6
B. Clamping and glue application
PB-501/502
[2]
[1]
a075t1c004ca
[1] Switchback conveyance [2] Bypass conveyance
7
C. Glue application to cover paper and cover paper folding operation

PB-501/502
[1]
a075t1c005ca
[1] Cover paper folding operation
8
D. Book stock
PB-501/502
[2]
[1] a075t1c006ca
[1] Moving to the second row [2] Paper exit of the book
9
PB-501/502
Blank page
10
PB-501/502
4.1 Configuration
SC entrance sensor (PS2)
Sub tray full sensor (PS5)

Bypass gate
Sub tray
Sub tray exit sensor (PS4)
Sub tray conveyance

roller
Sub tray gate
Entrance sensor
(PS1)
Intermediate
conveyance roller
Entrance conveyance Entrance gate
roller
Cover paper Cover paper entrance sensor

conveyance roller (PS3)
Cover paper conveyance
sensor /4 (PS78)
Multi feed detection board /1

(MFDTB71)
Multi feed detection board /2

(MFDTB72)
Cover paper feed
roller Cover paper conveyance sen-
sor /5 (PS79)
a075t2c001ca
11
4.2 Drive
PB-501/502
A. Entrance conveyance drive/Intermediate conveyance drive/Cover paper conveyance drive
[5]
[1]
[2]
[4] [3]
a075t2c002ca
[1] Entrance conveyance motor (M1) [4] Cover paper feed motor (M74)
[2] Registration roller (to the cover paper supply section) [5] Intermediate conveyance motor (M2)
[3] Paper feed roller (to the cover paper supply section)
12
B. Entrance gate drive/Bypass gate drive/Sub tray gate drive/Sub tray exit and separation drive
PB-501/502
[6] [7] [8] [1]
[2]
[3]
[4]
[5]
a075t2c003ca
[1] Sub tray paper exit solenoid (SD4) [5] Entrance gate
[2] Sub tray gate solenoid (SD3) [6] Bypass gate solenoid (SD2)
[3] Sub tray gate [7] Bypass gate
[4] Entrance gate solenoid (SD1) [8] Paper exit driven roller
13
4.3 Operation
PB-501/502
4.3.1 Gate control

A. Entrance gate control
• The entrance gate switches the paper path for the cover paper used for perfect binding so that the paper
conveyed from the main body, PI-PFU or the PI of FD is conveyed to the cover paper table section.
• The entrance gate solenoid (SD1) activates the gate. When the SD1 turns OFF, the gate is opened to con-
vey the cover paper toward the sub tray gate, and when the SD1 turns ON, the gate is changed to make a
paper path toward the cover paper table section.
• The SD1 turns OFF while the inside papers for perfect binding are conveyed, or while they are exit on the
sub tray. It turns ON while cover paper is conveyed from the main body, PI-PFU or PI of FD.
(1) When cover paper being conveyed from the main body
1. When a print job is received, the entrance gate solenoid (SD1) turns OFF [1] to open the entrance gate
toward the sub tray gate.
2. Cover paper is conveyed through the entrance gate [2].
3. When the paper exit sensor (PS3) of the main body detects the leading edge of the cover paper, the SD1
turns ON to switch the entrance gate direction toward the cover table section [4].
4. Once a prescribed time period has elapsed after the cover paper entrance sensor (PS3) detects the trailing
edge of cover paper [4], the SD1 turns OFF to switch the entrance gate direction toward the sub tray gate.
[1] [2] [3]
Paper exit sensor (main body PS30)
Entrance gate solenoid (SD1)
Cover paper entrance sensor (PS3)
[4] a075t2c004ca
[1] Print start signal ON [3] Cover paper leading edge detection
[2] Paper conveyance [4] Cover paper trailing edge detection
B. Sub tray gate control

• The sub tray gate switches the paper path for inside papers used for perfect binding between toward the
SC section and toward the sub tray to be exit.
• The sub tray gate solenoid (SD3) activates the sub tray gate. When the SD3 is OFF, the gate is opened
toward the SC section, and when the SD3 becomes ON, the gate direction is switched toward the sub tray
to exit inside papers.
• While inside papers are exit on the sub tray, the SD3 turns ON upon receiving a print job, and turns OFF
when the job is finished.
1 14
C. Bypass gate control

• The SC section is designed to stack a certain number of inside papers (n) of the subsequent book while the
PB-501/502
pages of previous book is glued at the clamp section. The bypass gate [3] operates to lay next 2 sheets of
inside paper ("n+1"th and "n+2"th) one on top of another and keep them until the stacked "n"th sheet of
inside paper at the SC section is conveyed to the clamp section [1]. It saves time for conveying the inside
paper and increases productivity.
• The bypass gate solenoid (SD2) activates the bypass gate.
[2] [3] [4]
[1]
a075t2c005ca
[1] Paper bundle from the first page to the "n"th [3] Bypass gate
page of the 2nd and subsequent copies [4] "n+2"th paper of subsequent book
[2] "n+1"th paper of subsequent book
(1) Control
1. The bypass gate solenoid (SD2) turns ON when a specified period of time has elapsed after the SC entrance
sensor (PS2) detects the trailing edge [1] of the "n+1"th inside paper of subsequent book.
2. The solenoid turns OFF when a prescribed time period has elapsed after the "n+2"th inside paper is laid over
the "n+1"th inside paper, and the SC entrance sensor (PS2) detects the trailing edge of the "n+2"th inside
paper [2].
[1] [2]

Bypass gate solenoid (SD2)
a075t2c006ca
[1] Detection of trailing edge of "n+1"th paper [2] Detection of trailing edge of "n+2"th paper
of subsequent book
15
4.3.2 Entrance conveyance control

• The entrance conveyance motor (M1) drives the entrance conveyance roller, sub tray conveyance roller,
PB-501/502
main body cover paper conveyance roller, and the cover paper conveyance roller. The drive force is trans-
mitted via the gear and the timing belt.
A. Perfect binding mode

(1) When feeding cover paper from the PB cover paper tray
• When detecting that the print start signal turns ON, the entrance conveyance motor (M1) turns ON (starts to
turn at high speed).
• The M1 stops when the JOB is finished.
(2) When feeding cover paper from the main body

1. When detecting that the print start signal turns ON, the entrance conveyance motor (M1) turns ON (starts to
turn at high speed).
2. When the main body paper exit sensor (PS3) is turned ON [4] by the leading edge of the cover paper, the M1
starts to turn at the same speed as the main unit.
3. Upon detection of the trailing edge of the cover paper by the PS3, the M1 starts to turn at high speed [5] to
convey the paper.
[1] [2] [4] [5]
Cover paper entrance sensor (PS3)
High speed
Entrance conveyance
motor (M1) Main body
speed
[3] a075t2c007ca
[1] Print start signal ON [4] Change to the same speed as the main unit
[2] Paper [5] Change to high speed rotation
[3] Change of main body process speed
16
B. Sub tray exit motor

(1) Large-size double-sided mode, single-sided main body straight mode (320mm or longer in the
PB-501/502
sub scan direction)
1. The entrance conveyance motor (M1) starts to turn at high speed [1] upon receiving a print job, and starts to
decelerate [2] in accordance with the main body process speed when the entrance sensor (PS1) detects the
leading edge of paper.
2. After the specified time period from the entrance sensor (PS1), the M1 starts to turn at high speed again.
[1] [2]
Fusing paper exit sensor
(main body PS22)
High speed
Entrance conveyance
motor (M1) Main body
speed
a075t2c008ca
[1] Print start signal ON [2] Change to the main body process speed
(2) Small-size all modes, large-size main body reverse paper exit mode (320mm or shorter in the sub
scan direction)
• The entrance conveyance motor (M1) starts to turn at high speed upon receiving a print job.
4.3.3 Intermediate conveyance control

• The intermediate conveyance roller is driven by the drive force of the intermediate conveyance motor (M2)
transmitted via the gear and the timing belt.
A. Perfect binding mode

• The intermediate conveyance motor (M2) starts to rotate when a print job is received.
B. Sub tray exit motor

• The intermediate conveyance motor (M2) does not work.
4.3.4 Cover paper conveyance control

• The cover paper conveyance section and the cover paper conveyance roller are driven by the drive force of
the cover paper feed motor (M74) transmitted via the gear, timing belt, and the coupling.
• The M74 stops when a prescribed time period has elapsed after the cover paper conveyance sensor/4
(PS78) detects the trailing edge of the cover paper.
• For more information on the feeding operation, refer to 9. COVER PAPER SUPPLY SECTION. (Refer to
P.81)
4.3.5 Sub tray paper exit release control

• The sub tray release operation is performed to align edges of papers exit onto the sub tray.
• The sub tray exit solenoid (SD4) activates the operation. The sub tray exit roller separates from the spring
when the SD4 becomes ON, and the roller moves to push the spring when the SD4 turns OFF.
17
(1) Large-size (320mm or longer in the sub scan direction)

1. When a prescribed time period has elapsed after the entrance sensor (PS1) detects the leading edge of
PB-501/502
paper [1], the sub tray exit solenoid (SD4) turns ON to release the sub tray exit roller from the spring [2].
2. The SD4 turns OFF to make the roller push the spring [3] when a prescribed time period has elapsed after
the PS1 detects the trailing edge of the paper.
[1] [3]
Sub tray paper exit solenoid (SD4)
[2] a075t2c009ca
[1] Paper leading edge detection [3] The sub tray exit roller pushes against the
[2] The sub tray exit roller separates from the spring
spring
(2) Small-size (320mm or shorter in the sub scan direction)

1. After the entrance sensor (PS1) detects the trailing edge of paper, the sub tray exit solenoid (SD4) turns ON
to make the sub tray exit roller separate from the spring [1].
2. The SD4 turns OFF to make the roller push the spring [2] when a prescribed time period has elapsed after
the PS1 detects the trailing edge of the paper.
[1] [2]
Sub tray paper exit solenoid (SD4)
a075t2c010ca
[1] The sub tray exit roller separates from the [2] The sub tray exit roller pushes against the
spring spring
4.3.6 Sub tray full-status detection control

• When the sub tray becomes full, the sub tray full sensor (PS5) detects the full-status.
18
4.3.7 Cover paper multi feed detection control

• When multiple papers are conveyed from the PB cover paper tray at a time, the supersonic sensors; multi
PB-501/502
feed detection board /1 (MFDTB71) [2] and /2 (MFDTB72) [1] detect the error. The MFDTB71 transmits a
supersonic wave and the MFDTB72 receives it.
[1] [2]
a075t2c011ca
[1] Multi feed detection board /2 (MFDTB72) [2] Multi feed detection board /1 (MFDTB71)
19
5. SUB COMPILE (SC) SECTION Theory of Operation Ver.2.0 Jul. 2009
5. SUB COMPILE (SC) SECTION

PB-501/502
5.1 Configuration
Switchback roller
Straight gate
SC alignment plate
SC entrance roller
Pressure arm
Clamp entrance roller

Straight gate
FD alignment plate
Switchback roller
SC entrance roller
SC paper detection sensor

SC alignment plate (PS16)
SC roller Pressure arm
Clamp entrance roller
SC stopper FD alignment plate

a075t2c021ca
20
Theory of Operation Ver.2.0 Jul. 2009 5. SUB COMPILE (SC) SECTION
5.2 Drive
PB-501/502
A. SC entrance conveyance drive/Switchback conveyance drive/Paper bundle conveyance drive
[1] [2] [3]
[4]
[5]
[7]
[6]
a075t2c022ca
[1] SC switchback conveyance motor (M12) [5] SC roller

[2] SC switchback roller [6] Clamp entrance roller
[3] SC entrance conveyance motor (M11) [7] SC bundle conveyance motor (M17)
[4] SC entrance roller
21
B. Switchback release drive

PB-501/502
[12] [13] [1]
[11]
[2]
[10]
[9]
[3]
[4]
[8] [5]
[7]
[6]
a075t2c023ca
[1] SC switchback release motor (M13) [8] Pressure plate

[2] SC switchback arm pressure detection sensor (PS12) [9] Switchback spring
[3] One-way clutch [10] Switchback cam
[4] Press cam [11] Switchback arm
[5] SC switchback roller [12] One-way clutch
[6] Pressure bracket [13] SC switchback spring pressure sensor
[7] Pressure spring (PS13)
22
C. SC roller release drive/Clamp entrance release drive
PB-501/502
[1] [2] [3]
[4]
[6] [5] a075t2c024ca
[1] SC roller cam [4] Clamp entrance roller release motor (M20)
[2] SC roller release motor (M18) [5] Clamp entrance driven roller
[3] Clamp entrance roller cam [6] SC driven roller
23
D. Clamp entrance movement drive

PB-501/502
[1]
[2]
[3]
[5]
[4]
a075t2c025ca
[1] Clamp entrance movement motor (M19) [4] FD alignment plate

[2] SC roller [5] Clamp entrance movement HP sensor
[3] Clamp entrance roller (PS18)
24
E. SC main scan alignment drive
PB-501/502
[3] [4] [1]
[2]
a075t2c026ca
[1] SC alignment HP sensor (PS14) [3] SC alignment plate /Fr

[2] SC alignment motor (M15) [4] SC alignment plate /Rr
F. Sub scan alignment drive
[1]
[2]
a075t2c027ca
[1] FD alignment plate [2] FD alignment solenoid (SD11)
25
G. SC stopper drive/SC pressure arm drive/Straight gate drive

PB-501/502
[5]
[1]
[4]
[3]
[2]
a075t2c028ca
[1] SC pressure arm solenoid (SD13) [4] SC stopper solenoid (SD12)

[2] SC pressure arm [5] Straight gate solenoid (SD91)
[3] SC stopper
26
5.3 Operation
PB-501/502
5.3.1 SC section operation overview
• The SC section is provided to stack a certain number of papers for subsequent book while papers for the
previous book being glued at the clamp section and the glue tank section.
• The number of papers stacked in the SC section varies depending on the print mode and paper size.
A. Operation overview
1. A page [2] for the first book [3] goes to the SC section and then goes to the clamp section. Once the page
[2] is set in the SC section, the SC stopper [6] is released, and the page is conveyed to the clamp section by
the SC switchback roller [1], SC roller [5] and the clamp entrance roller [4]. All inside papers for the first book
are conveyed to the clamp section in this manner one by one.
[1]
[2]
[6]
[5]
[3]
[4]
a075t2c029cb
[1] Switchback roller [4] Clamp entrance roller

[2] Paper [5] SC roller
[3] Page for the first book [6] SC stopper
27 1
2. When the last page of the first book reaches the clamp section, the SC stopper [5] moves back to its original
position, and the SC driven roller [2] and the clamp entrance driven roller [3] move away from their paper-
PB-501/502
feed position. A certain number of papers (n) for the next book are stacked in the SC section by the SC
switchback roller [1].
[1]
[2]
[3]
[6]
[5]
[4]
a075t2c029cb
[1] Switchback roller [4] All inside papers for the first book
[2] SC driven roller [5] SC stopper
[3] Clamp entrance driven roller [6] Page for the next book
1 28
3. When binding of the first book is finished, the clamp unit inclines from its upright position to receive paper for
the next book. At the same time, the SC stopper [7] moves to open the path and conveys the bundle of
PB-501/502
paper (n) [6] pressed by the SC driven roller [1] and the clamp entrance driven roller [5]. During the above
operation, the next 2 papers ("n+1"th [4] and "n+2"th [2]) are set in the bypass gate [3].
4. The 2 sheets of paper are conveyed to the clamp section at a time.
5. The rest of the papers for the book are conveyed to the clamp section one by one in the same manner as for
the first book.
[1]
[2]
[7]
[3]
[6]
[4]
[5]
a075t2c030ca
[1] SC driven roller [5] Clamp entrance driven roller

[2] "n+2"th page [6] Bundle of paper (n)
[3] Bypass gate [7] SC stopper
[4] "n+1"th page
29 1
5.3.2 SC entrance conveyance control

• The SC entrance roller is driven by the drive force of the SC entrance conveyance motor (M11) transmitted
PB-501/502
via the belt.
A. Control
1. The SC entrance conveyance motor (M11) starts to turn at low speed [1] upon receiving a print job.
2. The M11 speed changes to high speed when the SC entrance sensor (PS2) detects the trailing edge of
paper [2].
3. When a prescribed time has elapsed after the M11 acceleration, the M11 returns to low speed [3] before the
paper goes through the SC entrance roller.
4. The above conveyance operation is carried out for the last paper of the first book [4] and the first page [5] to
the "n"th page [6] of the next book (n=37 to 38 when the papers are A4 sized and one-side printed).
5. The M11 stops to stop the SC entrance roller when the PS2 detects [7] the trailing edge of "n+1"th page.
6. When the PS2 detects [8] "n+2"th paper trailing edge, the M11 starts to turn at high speed [9] to convey the
"n+1"th and "n+2"th papers at a time.
7. The rest of the papers for the second book are conveyed in the same manner as for the first book, and the
papers for the subsequent books are conveyed in the same manner as for the second book.
[1] [2] [3] [4] [5] [6] [7] [8]

High
SC entrance conveyance speed
motor (M11) Medium
speed
[9]
a075t2c031ca
[1] Print start signal ON [7] Trailing edge detection of "n+1"th page of
[2] Detection of the trailing edge of paper second book
[3] Change M11 to low speed [8] Trailing edge detection of "n+2"th page of
[4] Last page of the first book second book
[5] First page of the second book [9] M11 turns at high speed
[6] "n"th page of the second book
1 30
5.3.3 SC switchback conveyance control

• The SC switchback conveyance motor (M12) drives the SC switchback roller. The SC switchback release
PB-501/502
motor (M13) drives the releasing operation of the roller.
A. SC switchback roller release mechanism

• The SC switchback release motor (M13) drives the pressure cam [3] and the switchback cam [5].
The forward rotation of the motor drives the pressure cam [3] and the reverse rotation of the motor drives
the switchback cam [5].
• The SC switchback roller [4] has 3 preset positions for releasing (kept away from the driven roller), pressing
strongly or slightly against the driven roller.
• The "pressing strongly" status of the SC switchback roller [4] is used when conveying inside paper to the
clamp section, and the roller becomes the "pressing slightly" status when conveying inside paper to the SC
section so that the SC stopper stops the papers properly.
• The SC switchback arm pressure detection sensor (PS12) [2] detects the pressure cam position, and the
SC switchback spring pressure detection sensor (PS13) [6] detects the position of the switchback cam.
The PS12 is ON when the pressure cam is at its home position, and the PS13 is OFF when the switchback
cam is at its home position.
PS12 PS13 SC switchback roller status (position)
ON OFF Release
OFF OFF Press strongly
ON ON Light pressure
OFF ON Not used (press strongly status)
31 1
[6] [1]
PB-501/502
[2]
[5]
[3]
[4]
a075t2c032ca
[1] SC switchback release motor (M13) [4] SC switchback roller

[2] SC switchback arm pressure detection sen- [5] Switchback cam
sor (PS12) [6] SC switchback spring pressure detection
[3] Press cam sensor (PS13)
32
(1) Switchback cam drive (light pressure)

• The switchback cam [1] rotates counterclockwise [5] to switch the SC switchback roller [4] position
PB-501/502
between releasing and light pressing while the pressure cam [3] is at its home position.
• While the SC switchback spring pressure detection sensor (PS13) is OFF, the SC switchback roller is in the
release position (kept away from the driven roller).
• When the PS13 is ON [2], the SC switchback roller moves to press slightly against the driven roller.
• The PS13 is kept OFF while the switchback cam is at its home position.
[1] [2]
[5]
[3]
[4]
a075t2c033ca
[1] Switchback cam (home position) [4] SC switchback roller

[2] Switchback cam (light pressure) [5] Rotating direction of the switchback cam
[3] Press cam
33
(2) Pressure cam drive (strong pressure)

• The pressure cam [2] rotates clockwise [4] to switch the SC switchback roller [5] position between releasing
PB-501/502
and strong pressing. The switch operation of the pressure cam is made while the switchback cam [1] is at
its home position.
• While the SC switchback arm pressure detection sensor (PS12) is ON, the SC switchback roller is in the
release position (kept away from the driven roller).
• When the PS12 is OFF [3], the SC switchback roller moves to press strongly against the driven roller.
[1]
[2]
[3]
[4]
[5]
a075t2c034ca
[1] Switchback cam (home position) [4] Rotation direction of the pressure cam
[2] Pressure cam (home position) [5] SC switchback roller
[3] Pressure cam (PS12 is OFF)
34
B. SC switchback roller control

• Inside papers of the first book are conveyed to the clamp section one by one without being stacked at the
PB-501/502
SC section.
• When conveying inside papers to the clamp section without stacking them in the SC section, the SC
switchback roller position is switched between releasing and strong pressing. The rotation direction of the
roller is also switched between forward and reverse.
• When conveying inside papers of the next and subsequent books, a certain number of papers (n) are first
stacked in the SC section, and the stacked inside papers are conveyed to the clamp section at a time.
"n+1"th paper and the subsequent papers are conveyed to the clamp section one by one without being
stacked at the SC section.
• When stacking papers in the SC section, the SC switchback roller position is switched between releasing
and light pressing. During the stacking, the SC switchback roller rotates in the reverse direction.
(1) First book

1. The SC switchback conveyance motor (M12) starts to turn in the reverse direction [1] when detecting that
the print start signal turns ON. The switchback roller is in its release position to make paper go to the SC
section.
2. The M12 reverses the direction of rotation (starts to turn in the forward direction) after the SC entrance sen-
sor (PS2) detects the trailing edge of paper [2]. At the same time, the SC switchback release motor (M13)
starts to rotate in the forward direction. When the SC switchback arm pressure detection sensor (PS12)
turns OFF, the M13 stops and the switchback roller is strongly pressed against the driven roller [4].
3. The inside papers are nipped between the switchback roller and the driven roller strongly [4] and conveyed
to the SC section by the forward rotation of the roller.
4. When a prescribed time has elapsed after the PS2 detects the trailing edge of the paper, the M12 reverses
the direction of rotation [5] to convey inside papers to the clamp section.
5. When a prescribed time has elapsed after the PS2 detects the trailing edge of the paper, the M13 starts to
turn in the forward direction again to move the switchback roller away from the driven roller [6], and when the
PS12 turns ON, the motor stops.
6. The above operations are repeated until the last page [7] of the first book reaches the clamp section.
[1] [2] [3] [7]
Forward
SC switchback
conveyance motor (M12) Reverse
SC switchback Forward
release motor (M13)
Reverse
SC switchback arm pressure detection sensor (PS12)
[4] [6]
[5] a075t2c035ca
[1] Print start signal ON [5] Switchback conveyance start

[2] Detection of the trailing edge of paper [6] Release
[3] M12 forward rotation and strong pressure [7] Last page of the first book
[4] Strong pressure status
35
(2) The second and subsequent books

1. The SC switchback conveyance motor (M12) continues to turn in the reverse direction after the last page [1]
PB-501/502
of the previous book is conveyed to the clamp section [2].

2. When a prescribed time has elapsed after the SC entrance sensor (PS2) detects the trailing edge of the first
page of the next book [3], the SC switchback release motor (M13) starts to rotate in the reverse direction [4].
3. When the SC switchback spring pressure detection sensor (PS13) turns ON, the M13 stops and the switch-
back roller is lightly pressed against the driven roller. The inside papers are then conveyed to the SC section
and stopped by the SC stopper.
4. After the PS2 detects the trailing edge of the paper, the M13 reverses the direction of rotation again. Then
the switchback roller is moved away from the driven roller to accept the next page.
5. The above operations are repeated until a certain number of papers (n) are stacked in the SC section. (every
book)
6. While the next 2 papers ("n+1"th page [5] and "n+2"th page [6]) are set in the bypass gate, the stacked n
papers are conveyed to the clamp section at a time.
7. When the PS2 detects the trailing edge of the "n+2"th page, the M12 starts to turn in the forward direction.
At the same time, the M13 also starts to turn in the forward direction to push strongly the switchback roller
against the driven roller. After the "n+1"th page and the "n+2"th page are conveyed to the clamp section
through the SC section at a time, the following papers are conveyed to the clamp section one by one in the
same manner as for the first book.
[1] [3] [5] [6]
SC switchback con- Forward

veyance motor (M12)
Reverse
SC switchback Forward
release motor (M13)
Reverse
SC switchback arm pressure detection sensor (PS12)
SC switchback spring pressure detection sensor (PS13)
[2] [4]
a075t2c036ca
[1] The last page of the previous book [4] Light pressing start
[2] Conveyance of the last page of the first book [5] "n+1"th page
[3] Detection of the first page of the next book [6] "n+2"th page
36
5.3.4 SC main scan alignment control

• The SC alignment motor (M15) drives the SC alignment plate/Fr and /Rr via the belt to move them by 9mm
PB-501/502
as they are oscillated. This movement aligns the edges of the papers stacked in the SC section in the main
scan direction.
• The alignment operation is carried out every time a page is stacked in the SC section when stacking a cer-
tain number of papers of the second or subsequent books.
• While inside papers are conveyed to the clamp section without being stacked in the clamp section, this
alignment operation is not performed.
(1) Control
1. Upon receiving of a print job, the SC alignment motor (M15) starts to turn in the reverse direction to shift the
SC alignment plate/Fr and /Rr to the position9mm outer the paper edges[1].
2. After the SC entrance sensor (PS2) detects the trailing edge of the first page of the second or subsequent
book, the M15 starts to turn in the reverse direction to carry out the main-scan- direction alignment with the
SC alignment plate/Fr and /Rr.
3. When a prescribed time has elapsed after the PS2 detection, the M15 starts to turn in the forward direction
to move the SC alignment plate /Fr and /Rr back to their standby positions.
4. Every time a page is stacked in the SC section, this alignment operation is performed.
Note
• The set positions of the 2 alignment plates (the distance between the 2 plates) can be adjusted in
the service mode.
[1]

Forward
SC alignment motor (M15) (open)
Reverse
(close)
SC alignment HP sensor (PS14)
a075t2c037ca
[1] Print start signal ON
37
5.3.5 Sub scan alignment control

• The FD alignment solenoid (SD11) drives the FD alignment plate [4] so that the inside papers [2] are hit
PB-501/502
against the reference plate [3] of the clamp section to be aligned in the sub scan direction.
• The SC paper detection sensor (PS16) detects the timing of the movement.
[1]
[4]
[2]
[3]
a075t2c038ca
[1] SC paper detection sensor (PS16) [3] Reference plate

[2] Paper [4] FD alignment plate
(1) Control
1. When a prescribed time has elapsed after the PS16 detects the trailing edge of the first page of the first
book [1], if the clamp alignment plate /Fr and /Rr are closed for alignment operation, the SD11 turns ON.
2. The SD11 turns OFF after a prescribed time has passed since it became ON, and waits for the next page.
3. Until the last page [2] reaches the clamp section, the sub-scan-direction alignment is performed every time a
page comes to the section.
4. After the PS16 detects trailing edge of n paper (from the first page to the "n"th page) of the second book [3],
the alignment operation is performed.
5. The alignment operation is also carried out for the 2 papers ("n+1"th and "n+2"th page) laid one on top of
another at the bypass gate.
[1] [2] [3]
SC paper detection sensor (PS16)
FD alignment solenoid (SD11)
a075t2c039ca
[1] Paper trailing edge detection by PS16 [3] Bundle of paper

[2] Last page of the first book
38
5.3.6 SC paper bundle conveyance control

• The SC bundle conveyance motor (M17) [9] drives the SC roller and the clamp entrance roller.
PB-501/502
• The SC roller release motor (M18) [5] drives the SC driven roller [7] via the cam [8] to move the roller away
from (release) or contact with (press) the opposite roller.
• The SC roller release sensor (PS17) [6] detects the press/release operation of the roller. While the roller is
pressed against the opposite roller, the PS17 is kept On.
• The clamp entrance roller release motor (M20) [1] drives the cam [3] and the clamp entrance roller [4] to
move them away from (release) or contact with (press) the opposite roller.
• The clamp entrance roller release sensor (PS19) [2] detects the press/release operation of the roller. While
the roller and the cam are in the pressed status, the PS19 is kept ON.
[7]
[8]
[9]
[6]
[5] [4] [3] [2] [1]

a075t2c040ca
[1] Clamp entrance roller release motor (M20) [6] SC roller release sensor (PS17)
[2] Clamp entrance roller release sensor (PS19) [7] SC driven roller
[3] Cam [8] Cam
[4] Clamp entrance driven roller [9] SC bundle conveyance motor (M17)
[5] SC roller release motor (M18)
39
(1) Control
1. Upon receiving of a print job, the SC bundle conveyance motor (M17) starts to rotate [1], and the inside
PB-501/502
paper are conveyed to the clamp section one by one with the SC roller and the clamp entrance roller.
2. When the SC paper detection sensor (PS16) detects the trailing edge of the last paper [2], the SC roller
release motor (M18) starts to rotate to start stacking paper in the SC section. When a prescribed time has
elapsed after the M18 starts to rotate, the M17 stops to stop conveying paper to the clamp section. The
clamp entrance roller release motor (M20) also starts to rotate to release the clamp entrance roller [3].
3. The M18 stops when the PS17 becomes OFF, and the M20 stops when the PS19 becomes OFF. The next
bundle of paper is kept stacked in the SC section until the clamp section is ready for them.
4. The M18 turns ON and starts to rotate again [5] after a specified period of time after the SC entrance sensor
(PS2) detects [4] the trailing edge of the last page of the stacked paper in the SC section.
5. When the pressing of the SC roller is finished after the PS17 turns ON, the M17 turns ON and starts to con-
vey the stacked paper.
6. When the leading edges of the paper go through the clamp entrance, the M20 starts to rotate to convey the
paper to the clamp section.
7. Then the next 2 pages set in the bypass gate are conveyed to the clamp section at a time. All the above
operations are repeated for the subsequent books.
[1] [2] [4]

SC bundle conveyance motor (M17)
SC roller release motor (M18)
SC roller release sensor (PS17)
Clamp entrance roller release motor (M20)

Clamp entrance roller release sensor (PS19)
[3] [5]
a075t2c041ca
[1] Print start signal ON [4] Trailing edge of "n"th page detection
[2] Trailing edge of the last page of each book [5] The SC roller is set in the position for paper
detection conveyance
[3] Clamp entrance roller moves away from the
paper conveyance position
40
5.3.7 Clamp entrance movement control

• The clamp entrance movement motor (M19) drives the clamp entrance assy [4] via the belt.
PB-501/502
• The clamp entrance assy consists of the clamp entrance roller [2], FD alignment plate [3], SC pressure arm
[1], and the SC paper detection sensor (PS16) [5].
• The clamp entrance assy movement moves the FD alignment plate in accordance with the paper size.
[1]
[2]
[5] [3]
[4]
a075t2c042ca
[1] SC pressure arm [4] Clamp entrance assy

[2] Clamp entrance roller [5] SC paper detection sensor (PS16)
[3] FD alignment plate
(1) Control
1. When the clamp rotation pressure sensor (PS25) turns ON [1] and the clamp section is set at the compiling
position, the clamp entrance movement motor (M19) reverses its rotation direction to lower the clamp assy.
The motor stops [2] when the clamp assy is set at the position corresponding to the paper size, and the
clamp assy becomes ready for accepting the next paper.
2. When the clamp motor (M22) initiates clamping operation [3], the M19 starts to turn in the forward direction
to lift the clamp entrance assy until the assy reaches the position out of way of the clamping operation. The
clamp entrance movement HP sensor (PS18) detects that the assy reaches the position (the sensor
becomes ON), and the M19 is stopped [5].
3. The above operations are repeated for each book.
[1] [2] [4]

Forward
Clamp entrance movement motor
(M19) Reverse
Clamp entrance movement HP sensor (PS18)
Clamp rotation pressure sensor (PS25)
Clamp motor (M22)
[3] a075t2c043ca
[1] Clamp section is set at the compiling position [3] Clamping starts
[2] Movement of clamp entrance assy in accor- [4] Clamp entrance assy home position
dance with paper size
41
5.3.8 SC stopper control

• In order to stack paper in the SC section, the SC stopper is activated by the SC stopper solenoid (SD12)
PB-501/502
and closes the paper feed path toward the clamp section.
(1) Control
1. When detecting that the print start signal turns ON [1], the SC stopper solenoid (SD12) turns ON to release
the SC stopper.
2. When the SC paper detection sensor (PS16) detects the trailing edge of the last page of each book, the
SD12 turns OFF to set the SC stopper to close the path [2].
3. When the SC roller release sensor (PS17) becomes ON and the SC roller holds down a bundle of paper, the
SD12 turns ON to move the SC stopper out of the path [3].
[1] [2] [3]
SC stopper solenoid (SD12)
SC roller release sensor (PS17)

a075t2c044ca
[1] Print start signal ON [3] Move SC stopper out of the paper path
[2] Set SC stopper to close the paper path
42
5.3.9 SC pressure arm control

• The SC pressure arm [2] presses paper [3] conveyed from the SC section to stack paper neatly in the clamp
PB-501/502
section. The SC pressure arm assists to stack paper to the clamp section.
• The SC paper detection sensor (PS16) [1] detects the timing of the movement.
[1]
[2]
[3]
a075t2c045ca
[1] SC paper detection sensor (PS16) [3] Paper

[2] SC pressure arm
(1) Control
1. When a prescribed time has elapsed after the SC paper detection sensor (PS16) detects the paper trailing
edge [1], the SC pressure arm solenoid (SD13) turns ON to make the SC pressure arm press paper [2].
2. The SD13 becomes OFF to move the SC pressure arm back to its original position [3] after a prescribed time
has passed since the PS2 detected the trailing edge of the paper.
3. The above operations are also performed when a bundle of paper [4] or 2 sheets of paper [5] are conveyed
to the clamp section.
[1] [4] [5]

SC pressure arm solenoid (SD13)
[2] [3]
a075t2c046ca
[1] Trailing edge of paper detected [4] Conveyance of a bundle of paper

[2] Pressure arm presses paper [5] Conveyance of 2 pages at a time
[3] SC pressure arm goes back to its original
position
43
6. CLAMP SECTION Theory of Operation Ver.2.0 Jul. 2009
6. CLAMP SECTION
PB-501/502
6.1 Configuration
Clamp rotation assy
Reference plate
Clamp paper sensor (PS28) Clamp alignment plate

Clamp fixing plate /Rr
Book thickness sensor

(PS29)
Clamp pressure plate
Clamp alignment plate /Fr Clamp paper LED (LED21)
a075t2c047ca
44
Theory of Operation Ver.2.0 Jul. 2009 6. CLAMP SECTION
6.2 Drive
PB-501/502
A. Clamp drive
[7] [8]
[6]
[1]
[5]
[4] [3] [2]
a075t2c048ca
[1] Clamp pressure sensor (PS23) [5] Front side

[2] Clamp pressure plate [6] Clamp motor (M22)
[3] Clamp fixing plate [7] Book thickness sensor (PS29)
[4] Pressure drive plate [8] Clamp HP sensor (PS22)
45
B. Clamp rotation drive

PB-501/502
[4] [5] [1]
[3]
[2]
a075t2c049ca
[1] Clamp rotation assy [4] Clamp rotation motor (M23)

[2] Reference plate [5] Clamp rotation pressure sensor (PS25)
[3] Clamp rotation HP sensor (PS24)
46
C. Clamp alignment drive
PB-501/502
[4] [1]
[3] [2]
a075t2c050ca
[1] Clamp alignment HP sensor (PS21) [3] Clamp alignment plate /Fr
[2] Clamp alignment plate /Rr [4] Clamp alignment motor (M21)
47
6.3 Operation
PB-501/502
6.3.1 Clamp alignment control

• In order to line up edges of paper stacked in the clamp section in the main scan direction, the clamp align-
ment motor (M21) drives the clamp alignment plate/Fr and /Rr via the belt.
• The main-scan-direction alignment operation is performed when the following paper are set in the clamp
section; all inside paper of the first book, "n" paper of the subsequent books stacked in the SC section, the
next 2 pages ("n+1"th and "n+2"th paper) of the subsequent books, and "n+3"h and the subsequent page.
(1) Control
1. Upon receiving a print job, the clamp alignment motor (M21) starts to turn in the reverse direction to shift the
clamp alignment plate/Fr and /Rr offset 9mm from the paper edges [1].
2. When a prescribed time has elapsed after the SC paper detection sensor (PS16) detects [2] the trailing edge
of the first page of the first book, the M21 starts reverse rotation again to perform the main-scan-direction
alignment [3] with the clamp alignment plate/Fr and /Rr.
3. Then, while the FD alignment solenoid (SD11) turns ON and paper edges in the sub scan direction are lined
up [4], the M21 turns in the forward direction to move the clamp alignment plate /Fr and /Rr away from the
paper [5].
4. The SD11 is kept ON until the sub-scan-direction alignment for the last page of the first book [6] is finished.
When the SD11 turns OFF and the pressure toward the papers is released, the M21 starts to turn in the
reverse direction to press the bundle of paper from its front and back sides [8].
5. When the clamp pressure sensor (PS23) turns ON and clamping the paper is finished, the M21 starts to turn
in the forward direction to release the paper [9].
6. After a prescribed time has passed since the PS16 detects the trailing edge of the "n"th paper [10] stacked
in the SC section, the alignment operations are performed.
7. The alignment operation is also carried out for the 2 papers ("n+1"th and "n+2"th page) laid one on top of
another [11] at the bypass gate.
[1] [2] [4] [6] [7] [9] [10] [11]

FD alignment solenoid (SD11)

Forward
Clamp alignment (open)
motor (M21) Reverse
(close)
Clamp alignment HP sensor (PS21)
Clamp pressure sensor (PS23)
[3][5] [8]
a075t2c051ca
[1] Movement of clamp plates in accordance with paper size [6] Last page of the first book
[2] Trailing edge of the first page [7] Alignment in sub scan direction is in progress
[3] Line up edges in main scan direction [8] Standby position movement
[4] Alignment in sub scan direction is in progress [9] A bundle of "n" paper
[5] Standby position movement [10] 2 sheets of paper
48
6.3.2 Clamp control

• The clamp fixing plate and the clamp pressure plate clamp a bundle of paper stacked in the clamp section.
PB-501/502
A. Mechanism
1. The gap between the clamp fixing plate [7] and the clamp pressure plate [1] is 45mm when the clamp HP
sensor (PS22) [6] is ON [2].
2. Before applying pressure by the clamp motor (M22), the pressure drive plate [5] is move to the left side.
3. The clamp pressure plate moves together with the pressure drive plate [5].
4. When the clamp pressure sensor (PS23) [4] becomes On after applying pressure to the papers, the clamp-
ing operation is finished [3].
[6] [7]
[1]
[2]
[5]
[3]
[4]
a075t2c052ca
[1] Clamp pressure plate [5] Pressure drive plate

[2] Home position [6] Clamp HP sensor (PS22)
[3] Finish of clamping [7] Clamp fixing plate
[4] Clamp pressure sensor (PS23)
49
B. Control
1. When alignment of the last page is finished [1] by the clamp alignment motor (M21), the clamp motor (M22)
PB-501/502
starts to turn in the reverse direction to close the clamp pressure plate.
2. Upon completion of clamping, the clamp pressure sensor (PS23) turns ON and the M22 stops [2].
3. After the spine edges of the compressed inside paper is evened up, the cover paper table up down motor /
Fr (M46) and /Rr (M47) lift the cover paper table, and the M22 starts to turn in the forward direction. Then,
the clamp pressure plate opening operation is started [3].
4. The M22 stops when the clamp HP sensor (PS22) becomes ON.
[1] [3] [4]

Forward
Clamp alignment motor (open)
(M21) Reverse
(close)
Forward
(open)
Clamp motor (M22)
Reverse
(close)
Clamp HP sensor (PS22)
Cover paper table up Forward (up)

down motors /Fr (M46)
and /Rr (M47) Reverse
(down)
[2]
a075t2c053ca
[1] Start to close of the clamp pressure plate [3] Start to open
[2] Completion of clamping [4] Returning to the home position
50
6.3.3 Clamp rotation control

• A bundle of inside papers of a book is clamped and rotated to be glued on its spine.
PB-501/502
A. Clamp assy angle change /fixing mechanism
• The drive force of the clamp rotation motor (M23) rotates the clamp rotation assy.
There are 3 preset tilt angles of the clamp rotation assy as following.
Home position : 45°
Clamped : 50°
Glue applied : 90°
51
(1) Angle change mechanism

• The tilt angle of the clamp assy is changed for clamping and gluing as following.
PB-501/502
• When the clamp rotation assy is in its home position and the clamp pressure plate [7] is also in its home
position [3], the tab [6] of the pressure plate presses [2] the release cover [4], and the pin [1] of the switch
arm [12] is inserted in the clamp angle stopper notch [11] to stop the rotation of the clamp rotation assy at
the angle for clamping.
• When the clamp rotation assy is in its home position, and the clamp pressure plate is not [5], the switch arm
drops by its own weight as the tab of the clamp pressure plate is not pressing the release cover. For this
reason, the switch arm pin is not inserted in the clamp angle stopper notch, and the clamp rotation assy
keeps rotating until the glue angle stopper notch [10] is inserted over the shaft [8] [9].
• The tilt angle of the clamp assy cannot be changed directly between the clamping angle and the gluing
angle. To change the angle, the assy first must go back to the home position to release the stoppers.
[10] [11] [12] [1]

[9]
[8]
[2]
[5] [3]
[7] [6] [4] a075t2c124ca
[1] Pin [7] Clamp pressure plate

[2] Release [8] Regulation shaft
[3] Clamp pressure plate is at its home position [9] Engaging of notch and shaft to stop at gluing angle
[4] Release bar [10] Glueing angle stopper notch
[5] Clamp pressure plate is out of its home position [11] Clamping angle stopper notch
[6] Tab of the clamp pressure plate [12] Switch arm
52
(2) Fixing of the clamp rotation assy

• While clamping or gluing is performed, the corresponding stopper locks the clamp rotation assy. Moreover,
PB-501/502
in order to reinforce the fixing state of the assy, the clamp rotation motor (M23) [5] rotates the gear [1] 10°
[2] to pull the spring [4] applying the spring force to the assy. The operations fix the clamp rotation assy
securely.
• The clamp rotation pressure sensor (PS25) detects that the prescribed pressure is applied to the clamp
rotation assy and becomes On.
[3] [4] [5]
[2]
[1]
a075t2c125ca
[1] Gear [4] Spring

[2] Gear rotates 10° to apply spring force to the assy [5] Clamp rotation motor (M23)
[3] Clamp rotation pressure sensor (PS25)
53
B. Reference plate opening/closing mechanism

(1) Opening/closing of the reference plate
PB-501/502
• The reference plate [5] opens/closes in synchronization with the rotation of the clamp rotation assy [1].
1. When the clamp rotation assy stops at the angle for glueing, the release arm [8] presses down the reference
plate mounting bracket [6], and the reference plate is separated from a bundle of inside papers. The separa-
tion of the reference plate prevents the plate from damaging the paper edges when the clamp rotation assy
is upstanding.
2. Further rotation [3] of the reference plate mounting bracket [6] makes the pin [7] go down [2], and the refer-
ence plate is released [4] from the spring [9].
3. The reference plate goes back to its home position with the reference mounting bracket [6] which pushes up the pin [7].
4. While clamping operation is in progress, the reference plate is fixed at the upper position with the spring [10].
5. When the clamp pressure plate returns to its home position, the release arm [8] is pushed up by the tab [11]
of the clamp pressure plate and moved back to its standby position.
[7] [8]
[1]
[2]
[3]
[4]
[6]
[5]
[8] [12] [11] [10] [8] [7] [9] a075t2c126ca
[1] Clamp rotation assy [7] Pin

[2] Pin of the reference plate goes down [8] Release arm
[3] Rotation of the reference plate mounting bracket [9] Spring (for release)
[4] Release of the reference plate [10] Spring (for applying pressure)
[5] Reference plate [11] Tab of the clamp pressure plate
[6] Reference plate mounting bracket [12] Pin
54
(2) Paper guard tabs mechanism for clamping

• The reference plate [6] has paper guard tabs [2] to prevent inside papers [4] from going off the reference
PB-501/502
plate while they are clamped [1].
• While the reference plate contacts with the stopper, the paper guard tabs are protruding.
• When the reference plate is opened [3], the paper guard tabs are retracted [5] so as not to damage the
paper edges.
[1]
[2]
[3]
[4]
[6] [5]
a075t2c127ca
[1] Clamped [4] Inside paper

[2] Paper guard tabs [5] Paper guard tabs retracted
[3] When the reference plate is opened [6] Reference plate
55
C. Control
1. When detecting that the print start signal turns ON [1], the clamp rotation motor (M23) starts to turn in the
PB-501/502
reverse direction.
2. The M23 stops when the clamp rotation pressure sensor (PS25) becomes On, and the clamp rotation assy
is set at the compiling position [2].
3. When clamping of the inside papers by the clamp motor (M22) is finished [3], the M23 starts to turn in the
forward direction to rotate the clamp rotation assy 15° counterclockwise.
4. The M23 stops [4] when the clamp rotation HP sensor (PS24) becomes On. The tilt angle of the gear is 15°
when the assy returns to the home position, however, the clamp rotation assy rotates 5° as the gear has
rotated 10 ° more separately for fixing the assy. As the result, the clamp rotation assy tilt angle changes from
50° for clamping to 45° (home position). At this time, since the clamp pressure plate is out of the home posi-
tion, the pin is free from the clamp angle stopper notch, which allows the clamp rotation assy to rotate to the
gluing angle.
5. After a prescribed time has elapsed, the M23 starts to turn in the reverse direction to rotate the clamp rota-
tion assy clockwise [5].
6. When the PS25 turns ON, the spring fixes the assy, and the M23 stops [6].
At this time, the gear has rotated 55°, however, in order to secure the assy, it has rotated 10 ° more than the
clamp rotation assy, the clamp rotation assy rotates
45° clockwise from its home position and becomes upright state (90°).
7. When the clamp paper sensor (PS28) detects [7] that the bundle of paper is released from the clamp, the
M23 starts to turn in the forward direction to return the clamp rotation assy to the home position.
8. The M23 stops [8] when the PS24 becomes ON, and the clamp rotation assy stops at its home position (tilt
angle of 45°). At this time, since the clamp pressure plate is in the home position, the pin is engaged with the
clamp angle stopper notch, which allows the clamp rotation assy to rotate to the clamping angle.
9. Then, the M23 starts to turn in the reverse direction [9] to move the clamp rotation assy to the clamping
position [10] and stops when the PS25 becomes On.
[1] [2] [3] [4][5] [7] [8] [9] [10]

Clamp paper sensor (PS28)
Forward
(open)
Clamp motor (M22)
Reverse
(close)
Forward
Clamp rotation motor (M23) (release)
Reverse (apply
pressure)
Clamp rotation HP sensor (PS24)
[6] a075t2c128ca
56
6.3.4 Book thickness detection control

• The book thickness sensor (PS29) detects the book thickness.
PB-501/502
• The detected thickness is used to determine the trimming amount of the cover paper.
A. Mechanism
• The clamp pressure plate [1] is moved by winding up the wire[6].
• When the wire [6] is wound up, the encoder plate [4] rotates.
• The book thickness sensor (PS29) [5] detects and counts how much the encoder scale is rotated.
• The sensor continue the counting until the clamp pressure sensor (PS23) [2] turns ON.
[5]
[4] [6]
[3]
[2] [1]
a075t2c054ca
[1] Clamp pressure plate [4] Encoder scale

[2] Clamp pressure sensor (PS23) [5] Book thickness sensor (PS29)
[3] Clamp HP sensor (PS22) [6] Wire
57
B. Control
1. When the clamp HP sensor (PS22) switches to ON from OFF, pulse count by the book thickness sensor
PB-501/502
(PS29) is started [1].

2. The pulse count is stopped [2] when the clamp pressure sensor (PS23) turns ON.
3. During the initial operation at power-ON, the no paper status data is detected and memorized as an initial
data. The book thickness is determined according to the difference.
Forward
Clamp motor (M22) (open)
Reverse
(close)
Book thickness sensor (PS29)
[1] [2]
a075t2c055ca
[1] Count start [2] Count end
58
Theory of Operation Ver.2.0 Jul. 2009 7. PELLET SUPPLY SECTION
7. PELLET SUPPLY SECTION
PB-501/502
7.1 Configuration
Stirring stick
Pellet remaining amount

Stirring comb
Front
side
Pellet count sensor (PS37)

Conveyance belt
Shutter
Pellet count
LED (LED32)
Pellet supply arm

a075t2c056ca
59
7. PELLET SUPPLY SECTION Theory of Operation Ver.2.0 Jul. 2009
7.2 Drive
PB-501/502
A. Pellet supply drive
[5] [1]
[4]
[2]
[3]
[1]
a075t2c057ca
[1] Plate cam [4] Stirring comb

[2] Pellet supply motor (M33) [5] Oscillating plate
[3] Pellet conveyance belt
60
B. Pellet supply arm drive
PB-501/502
[6]
[1]
[2]
[5]
[4]
[3]
a075t2c058ca
[1] Pellet supply arm lower limit sensor (PS39) [4] Pellet supply arm upper limit sensor (PS38)
[2] Shutter [5] Drive arm
[3] Pellet supply arm [6] Pellet supply arm motor (M34)
61
7.3 Operation
PB-501/502
7.3.1 Pellet supply operation overview

• The pellet supply arm [4] is moved above the glue tank [5] to supply pellets [1].
Then the pellets [1] are conveyed by the pellet conveyance belt [2] to drop them into the glue tank.
• The glue tank temperature sensor/Up (TH2) provided in the glue tank unit determines the timing to supply
pellets into the glue tank. As the molten glue inside the glue tank decreases, the TH2 surface not soaked in
the glue becomes wider. It finally causes the TH2 temperature lower than a prescribed level, and it is judged
that the glue is getting low and another pellets must be supplied.
• Checking the TH2 temperature is carried out in the following timing. a. When the glue tank home sensor
(PS33) turns ON after gluing operation.
• The number of pellets supplied at a time varies depending on the thickness of the book.
[1]
[2]
[3]
[4]
[5]
a075t2c059ca
[1] Pellet [4] Pellet supply arm

[2] Pellet conveyance belt [5] Glue tank
[3] Shutter
62
7.3.2 Pellet supply arm control

• The pellet supply arm motor (M34) activates the pellet supply arm. When the pellet supply arm moves
PB-501/502
above the glue tank, the shutter is opened to drop pellets in the glue tank.
• In order to prevent the arm from the evaporated glue or radiant heat rose from the glue tank, the arm is kept
at its home position except when supplying pellets. In this case, the shutter shuts down to stop the pellets
from dropping down by the vibration. They are dropped next time the pellets are supplied.
A. Control
1. When the glue tank temperature sensor /Up (TH2) detects a temperature lower than 34°, the pellet supply
arm motor (M34) starts to turn in the forward direction [1].
2. When the pellet supply arm reaches the pellet supply position (above the glue tank) and the pellet supply
arm upper limit sensor (PS38) becomes ON, the M34 stops [2].
3. When a prescribed time has elapsed after a certain number of pellets is counted by the pellet count sensor
(PS37), the M34 starts reverse rotation to move the arm back to its home position [3].
4. When the pellet supply arm reaches the home position and the pellet supply arm lower limit sensor (PS39)
becomes ON, the M34 stops.
[1] [2] [3] [4]
Glue tank temperature 132C°

sensor /Up (TH2)
Forward
Pellet supply
Reverse
Pellet supply arm upper limit sensor (PS38)
Pellet supply arm lower limit sensor (PS39)
a075t2c060ca
[1] Pellet supply arm motor (M34) forward rotation starts [3] Start to evacuate
[2] Pellet supply position stop [4] Evacuation complete
B. Stop operation during pellet supply

• When all the inside papers have stacked up, while the pellet supply arm motor (M34) is turning in the for-
ward direction, the M34 reverses the rotation direction to move the pellet supply arm back to the home
position.
63
7.3.3 Pellet supply control

PB-501/502
A. Mechanism
• The pellet supply motor (M33) drives the pellet conveyance belt, the oscillating plate, and the stirring comb.
(1) Pellet conveyance belt

• The pellets [5] are conveyed by the pellet conveyance belt moved by the motor.
• The conveyance roller [3] presses the pellet conveyance belt [4] with the spring force.
• In order to keep the belt in a constant tension while the belt is oscillating to convey pellets, the tension plate
[2] is pulled by the spring and applies tension [1] to the pellet conveyance belt.
[1]
[5]
[2]
[4]
[3]
a075t2c061ca
[1] Belt tension [4] Pellet conveyance belt

[2] Tension plate [5] Pellet
64
(2) Oscillating of the pellet conveyance belt

• The pellet supply motor (M33) rotates the plate cam [2] and the rotation force is transmitted to the oscillat-
PB-501/502
ing plate [1] via the connecting plate [3]. Then the introduction roller [5] is driven to oscillate the pellet con-
veyance belt [4] in synchronization with the belt rotation movement.
[1] [1]
[2]
[3]
[5]
[4]
a075t2c062ca
[1] Oscillating plate [4] Conveyance belt

[2] Plate cam [5] Introduce roller
[3] Connecting plate
65
(3) Stirring comb

• The pellets are stirred by the stirring comb which is shaking.
PB-501/502
• In order to shake the stirring comb [1], the pellet supply motor (M33) moves the plate cam [4] in synchroni-
zation with the pellet conveyance belt movement, and the cam moves the stirring comb mounting plate [2]
up and down via the shaking plate [3].
[1]
[2]
[3]
[4]
a075t2c063ca
[1] Stirring comb [3] Oscillating plate

[2] Mounting plate [4] Plate cam
66
B. Control
(1) Normal operation
PB-501/502
1. When the pellet supply arm moves to the pellet supply position and the pellet supply arm upper limit sensor
(PS38) becomes On, the pellet supply motor (M33) starts to rotate to start supplying pellets [1] to the glue
tank.
2. The M33 stops to stop the pellet supply operation when the pellet count sensor (PS37) counts a certain
number of pellets.
[1] [2]
Pellet supply motor (M33)
Pellet supply arm upper limit sensor (PS38)
a075t2c064ca
[1] Supplying pellets is started [2] Supplying pellets is finished
(2) When the PS37 does not count the prescribed number of pellets
• When the number of pellets counted by the pellet count sensor (PS37) do not reach the specified amount
within the specified time, the pellet supply motor (M33) stops. At the next pellet supply, the M33 rotates in
reverse direction for 3 seconds and then starts forward rotation. It prevents the pellets from getting stuck in
the conveyance belt section.
(3) Stop operation during pellet supply

• When all the inside papers have stacked up, while the pellet supply motor (M33) is turning, the M33 stops.
67
7.3.4 Pellet supply amount control

(1) Pellet passage detection
PB-501/502
• The pellet count LED (LED32) and the pellet count sensor (PS37) detect the pellets passed through the pel-
let supply path. (the sensor turns ON/OFF for every 2 or 3 pellets.)
(2) Control
• The number of pellets to be supplied is calculated as a required number of counts to be counted by the pel-
let count sensor (PS37) based on the glue consumption expected according to the book thickness
detected at the last time.
• When the calculated count is reached, pellet supply is stopped.
7.3.5 Pellet remaining amount detection control

• While the pellet supply arm is in the home position turning the pellet supply arm lower limit sensor (PS39)
ON, the detection of remaining number of pellets inside the pellet supply hopper is carried out.
• When the remaining number of pellets becomes about 300g, the pellet supply hopper is detected as
empty.
• When 1 second has elapsed after the pellet remain sensor (PS36) switches to OFF from ON, a message to
notify the empty status appears on the main body touch panel.
7.3.6 Pellet supply door opening/closing detection control

• The pellet supply door switch (MS1) [1] and the pellet supply door sensor (PS40) [2] detect the open/close
of the pellet supply door.
• When the MS1 is turned OFF, a 24VDC supplied to the pellet supply motor (M33) is shut off to stop the
motor.
• When the PS40 detects the above status, a message appears on the main body touch panel.
[1]
[2]
[3]
a075c2c130cb
[1] Pellet supply door switch (MS1) [3] Stirring stick

[2] Pellet supply door sensor (PS40)
7.3.7 Stirring stick

• The stirring stick is provided to stir the pellets manually when the pellets are stuck to the lower part of the
pellet supply hopper.
1 68
Theory of Operation Ver.2.0 Jul. 2009 8. GLUE TANK SECTION
8. GLUE TANK SECTION
PB-501/502
8.1 Configuration
Glue apply position LED Scrape plate Scrape bar

(LED31)
Glue apply position

detection sensor
(PS32)
Glue apply roller
Cover paper glue
roller
Glue tank Glue tank temperature

Glue apply roller
sensor /Up (TH2)
heater (H2)
Glue tank temperature

sensor /Md (TH3) Glue tank temperature
sensor /Lw (TH4)
Glue tank heater (H1)
Timing belt
a075t2c065ca
69
8. GLUE TANK SECTION Theory of Operation Ver.2.0 Jul. 2009
8.2 Drive
PB-501/502
A. Glue tank movement drive
[5] [6]
[1]
[2]
[4]
[3]
a075t2c066ca
[1] Front side [4] Glue tank HP sensor (PS33)

[2] Glue tank movement limit sensor (PS31) [5] Glue tank movement motor (M31)
[3] Glue tank unit [6] Timing belt
B. Glue apply roller drive
[3] [4]
[1]
[2] a075t2c067ca
[1] Front side [3] Glue apply roller

[2] Glue apply roller motor (M32) [4] Cover paper glue roller
70
C. Glue apply roller drive
PB-501/502
[8]
[6] [7]
[5] [2]
[4] [3] [1]
a075t2c068ca
[1] Arm [5] Left-side view

[2] Front side view [6] Glue apply roller
[3] Glue tank up solenoid /1 (SD31) [7] Cover paper glue roller
[4] Glue tank up solenoid /2 (SD33) [8] Glue tank
D. Cover paper glue lifting drive
[5] [6]
[4] [1]
[3] [2] a075t2c069ca
[1] Front side view [4] Left-side view

[2] Glue tank base plate [5] Glue apply roller
[3] Cover paper glue up solenoid (SD32) [6] Cover paper glue roller
71
8.3 Operation
PB-501/502
8.3.1 Glue tank unit movement control

A. Mechanism
• The glue tank unit is moved by the drive force of the glue tank movement motor (M31) transmitted via the
timing belt. The gap [5] between the glue tank HP sensor (PS33) and the center [7] of the inside papers [6]
is 322.5mm.
• The glue apply position detection sensor (PS32) [3] detects the edge of the inside papers.
[5] [6] [7] [1]
[10]
[2]
[4]
[3]
a075t2c070ca
[1] Front side [5] 322.5mm

[2] Glue tank movement limit sensor (PS31) [6] Inside paper
[3] Glue apply position detection sensor (PS32) [7] Center of the inside papers
[4] Glue tank HP sensor (PS33)
72
B. Control
1. When the upright movement of the clamp section is finished turning the clamp rotation pressure sensor
PB-501/502
(PS25) ON, the glue tank movement motor (M31) starts to turn in the forward direction at high speed to
move the glue tank frontward [1]. This operation applies glue to the spine of the inside papers.
2. When the glue tank movement limit sensor (PS31) becomes ON after a prescribed time has elapsed since
the PS25 turns ON, the M31 pauses [3].
3. Then, the M31 starts reverse rotation at low speed [4], and the glue apply position detection sensor (PS32)
starts to detect edges of the inside papers.
4. After the PS32 becomes ON upon detection of the inside papers edge, the M31 shifts to high speed [5] to
move the glue tank backward applying glue to the spine again.
5. When the glue tank HP sensor (PS33) becomes ON after a prescribed time has elapsed since the PS32
turns ON, the M31 stops [7].
[1] [2] [3] [4] [5] [6]

High speed
Forward
Glue tank Low speed
movement motor
(M31) Low speed
Reverse
High speed
Glue tank HP sensor (PS33)
Glue tank movement limit sensor (PS31)
Glue apply position detection sensor (PS32)
a075t2c071ca
[1] Clamp rotation assy is upright [4] Shifts to high speed upon the edge detection of inside papers
[2] Decelerates at the position 2mm before the limit [5] Decelerates before the home position
[3] Stops at the limit position [6] Stopped at home position
73
8.3.2 Glue apply roller control

A. Mechanism
PB-501/502
• The glue apply roller motor (M32) drives the glue apply roller and the cover paper glue roller via the gear.
• As the glue apply roller rotates, a 1.5mm-thickness layer of molten glue is formed on the roller metal surface
due to the viscosity of the glue.
B. Control
• The glue apply roller motor (M32) starts to rotate when the glue tank temperature sensor/Md (TH3) detects
a prescribed temperature *1.
• When the glue applying mode is switched to standby mode, the M32 stops.
*1 Default: 145°C (changeable in the service mode)

74
8.3.3 Glue tank lifting control

A. Mechanism
PB-501/502
• The glue apply roller is lifted to the glue apply position when the glue tank up solenoid /1 (SD31) [3] and /2
(SD33) [4] become On.
• The SD31 and SD33 activate the arm [5] to lift the roller [2], and the glue tank [1] is lifted being rotated piv-
oted to the cover paper roller shaft.
[5] [1]
[4] [3] [2] a075t2c072ca
[1] Glue tank [4] Glue tank up solenoid /2 (SD33)

[2] Roller [5] Arm
[3] Glue tank up solenoid /1 (SD31)
75
• While the glue tank up solenoid /1 (SD31), /2 (SD33) are ON, the gap between the level tangent line [5] of
the metal surface [1] of the glue apply roller and the spine surface [7] of inside papers [6] is about 1mm *1.
PB-501/502
• The glue apply thickness is changed by the thickness of paper to keep the book strength.
-1200/1200P/1051-
Regardless of the book thickness, the glue apply thickness is 0.8mm
-C6501/C6501P/C65hc-
Thickness of paper is less than 7mm: The glue apply thickness is 0.8mm
Thickness of paper is 7mm or more: The glue apply thickness is 1.2mm
• The scrape plate [2] and the scrape bar [4] scrape off excess glue from the spine of inside papers.
• While the SD31 and SD33 are ON, the scrape plate is placed 0.5mm *2 away from the metal surface of the
glue apply roller.
• While the SD31 and SD33 are ON, the scrape bar contacts with the metal surface of the glue apply roller
(0.0mm *2 gap).
*1 The mechanical adjustment "Glue apply roller gap adjustment" can adjust the glue application quantity.
*2 The mechanical adjustment "Glue tank positioning" can adjust the thickness of molten glue layer to be
formed on the roller surface.
[6] [7] [8] [1]
[2]
[5]
[4]
[3]
a075t2c073ca
[1] Metal surface of the glue apply roller [5] Level tangent line
[2] Scrape plate [6] Inside paper
[3] Front side [7] Spine surface
[4] Scrape bar [8] Layer of molten glue
1 76
B. Control
1. When a prescribed time has elapsed after the clamp section is set at its upright position [1] turning the
PB-501/502
clamp rotation pressure sensor (PS25) ON, the glue tank assy starts movement toward the front side.
While the glue tank assy is moving, the glue tank up solenoids /1 (SD31) and /2 (SD33) turn ON to lift the
glue apply roller to apply glue to the spine of inside papers [2].
2. When the glue has applied along the inside paper spine by a length of 5mm longer than the paper length
during a predetermined time period after the PS25 turns ON, the SD31 and SD33 become OFF to lower the
glue apply roller [3]. Then, the glue tank assy starts to move backward.
3. The second glue application [4] during the backward movement is activated when the SD31 and SD33 turn
ON again at the time the glue apply roller passed the inside paper edge through by 4mm, which is the timing
when a predetermined time has elapsed after the glue apply position detection sensor (PS32) detects the
inside paper edge.
4. During a predetermined time period after the PS32 turns ON, the SD31 and SD33 turn OFF [5] at the posi-
tion the glue apply roller passed trailing edge of the inside paper through by 4mm.
Note
• The sensors ON/OFF timing can be changed in the service mode.
[1] [2] [3] [4] [5]
Glue tank up solenoid /1 (SD31), /2 (D33)
Glue apply position detection sensor (PS32)
a075t2c074ca
[1] Clamp rotation assy is upright [4] Glue application during backward movement
[2] Glue application during frontward movement [5] Completion of glue application
[3] Completion of glue application
77
8.3.4 Cover paper glue control

A. Mechanism
PB-501/502
• The cover paper glue up solenoid (SD32) [5] lifts the cover paper roller side [9] of the glue tank base plate
[2].
• The glue tank up solenoid/1 (SD31) [4] and /2 (SD33) [3], which lift the glue apply roller [8] side of the glue
tank, are also attached to the glue tank base plate, and as the result, the whole glue tank assy is lifted.
[8] [9]
[1]
[2]
[3]
[4]
[5]
[6]
a075t2c075ca
[1] Glue tank [6] Fulcrum shaft

[2] Glue tank base plate [7] Left-side view
[3] Glue tank up solenoid /2 (SD33) [8] Glue apply roller
[4] Glue tank up solenoid /1 (SD31) [9] Cover paper roller
[5] Cover paper glue up solenoid (SD32)
B. Control
• The control varies according to the thickness of the book. When the thickness of the book is 6mm or less,
the cover paper glue up solenoid (SD32) turns ON and off at the same time as the glue tank up solenoid/1
(SD/31), /2 (SD/33).
However, during backward movement of the glue tank, SD32 turns OFF with a specified time delay after
the SD31 and SD33 turns OFF. It always turns OFF when the thickness of the book is 7mm or more.
78
8.3.5 Glue temperature control
PB-501/502
A. Mechanism
• The glue tank heater (H1) heats the glue tank bottom to melt the pellets.
• The glue apply roller heater (H2) heats the glue apply roller to keep the glue adhered to the roller surface at
a constant viscosity.
B. Temperature detection
The glue apply roller temperature sensor (TH1) [7] detects the temperature of the glue apply roller [8], and the
glue tank temperature sensor /Up (TH2) [6], /Md (TH3) [3], and /Lw (TH4) [2] detects the temperature of the glue
tank [5].
(1) TH1
• Detects temperature of the center portion of the glue apply roller, and the glue apply roller heater (H2) [9] is
controlled according to the detected temperature.
• The target temperature is 165°C.
(2) TH2
• This sensor is provided on the inner surface of the glue tank, at the position 29mm above the bottom of the
tank, in order to detect glue level.
• When the glue runs low, the glue surface becomes lower, and finally the TH2 comes out of the glue. It
causes a sudden drop in temperature of the TH2.The temperature drop is detected as a low glue level, and
activates the pellet supply operation.
• The target temperature is 132°C. *1
*1 Changeable in the service mode.
(3) TH3
• This sensor is also provided on the inner surface of the glue tank, at the position 15.4mm above the tank
bottom, to detect the viscosity of the molten glue. According to the detected result, rotating or not rotating
the glue apply roller is determined.
• The target temperature is 145°C. *1
*1 Changeable in the service mode.
79
(4) TH4
• The glue tank temperature sensor/Lw (TH4) is provided on the inner bottom surface of the glue tank and
PB-501/502
detects temperature of the glue tank heater (H1) [3] to control the heater.
• The target temperature is 185°C.
[5] [6] [7] [8]
[1]
[4]
[3] [2] a075t2c076ca
[1] Glue apply roller heater (H2) [5] Glue tank

[2] Glue tank temperature sensor /Lw (TH4) [6] Glue tank temperature sensor /Up (TH2)
[3] Glue tank heater (H1) [7] Glue apply roller temperature sensor (TH1)
[4] Glue tank temperature sensor /Md (TH3) [8] Glue apply roller
C. Control
(1) Glue apply roller heater (H2) control
• The H2 is turned ON/OFF according to a temperature detected by the glue apply roller temperature sensor
(TH1) in order to keep 165°C.
• When the temperature drops/rises 1°C from the target temperature, the H1 turns ON/OFF.
(2) Glue tank heater (H1) control

• The H1 is turned ON/OFF according to a temperature detected by the glue tank temperature sensor/Lw
(TH4) in order to keep 185°C.
• When the temperature drops/rises 1°C from the target temperature, the H1 turns ON/OFF.
80
Theory of Operation Ver.2.0 Jul. 2009 9. COVER PAPER SUPPLY SECTION
9. COVER PAPER SUPPLY SECTION
PB-501/502
9.1 Configuration
Cover paper empty sensor (PS71)
Cover paper tray fan /1 (M71), /2 (M72) Pick-up roller
Conveyance roller
Paper feed roller
Separation roller
Cover paper tray lift plate

a075t2c012ca
81 1
9. COVER PAPER SUPPLY SECTION Theory of Operation Ver.2.0 Jul. 2009
9.2 Drive
PB-501/502
9.2.1 Cover paper tray lift drive
[1] [2]
[7] [8] [3]

[4]
[6] [5] [4]

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[1] Cover paper tray lift wire/Fr1 and /Rr1 [5] Cover paper tray lift motor (M73)
[2] Cover paper tray lift wires /Fr2 and /Rr2 [6] One-way clutch
[3] Cover paper tray lift plate [7] Lift release coupling gear
[4] Pulley [8] Torque restriction gear (oil damper)
82
PB-501/502
[4]
[1]
[5]
[6] [7] [2]
[8]
[10] [3]
[9]
[13] [12] [11]

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[1] PB backside [8] Cover paper separation clutch (MC72)

[2] Backside of cover paper tray [9] Pick-up Roller
[3] Center of cover paper tray [10] Paper feed Roller
[4] Cover paper feed motor (M74) [11] Conveyance roller
[5] Coupling [12] Torque limiter
[6] Cover paper pick up clutch (MC71) [13] Separation roller
[7] Coupling
83
9.2.3 Pick-up drive

PB-501/502
[2]
[1]
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[1] Cover paper pick up solenoid (SD71) [2] Pick-up Roller
84
9.3 Operation
PB-501/502
9.3.1 Up/down control
A. Up operation
• The cover paper tray lift plate is lifted with the cover paper tray lift wire wound up around the pulley by the
drive force of the cover paper tray lift motor (M73) [1].
B. Down operation
• When the cover paper tray is pulled out, the release lever [5] separates the coupling gear [4] that transmits
the motor drive force from the motor shaft [2] to the pulley [3]. (the lever goes down by its own weight)
[4]
[3]
[2] [1] [5]

a075t2c016ca
[1] Cover paper tray lift motor (M73) [4] Coupling gear
[2] Motor shaft [5] Release lever
[3] Pulley
• In order to lower the plate slowly by its own weight, the torque limiting gear [1] works only when lowering
the cover paper tray lift plate.
[1]
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[1] Torque restriction gear
85
C. Operation timing
(1) When cover paper is set
PB-501/502
• When cover papers are loaded on the tray, the cover paper tray lift motor (M73) starts to rotate to lift the
cover paper lift plate.
• The M73 stops when the cover paper tray upper limit sensor (PS74) [1] turns On.
(2) While feeding cover paper
• While cover papers being fed, the PS74 turns OFF due to a decrease in stacking height of papers, and the
M73 starts to rotate again.
• The M73 keeps rotating to lift the cover paper lift plate until the PS74 turns ON again.
[1]
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[1] Cover paper tray upper limit sensor (PS74)
86

• Picking up the cover paper is activated when the cover paper pick-up solenoid (SD71) turns OFF.
PB-501/502
A. Control
1. With cover paper feed signal, cover paper feed motor (M74), cover paper pick up clutch (MC71) and cover
paper separation clutch (MC72) turn ON, and rotate the pick-up roller which is pressing down the cover
paper with its own weight, and starts the paper feeding of the cover paper [1].
2. When the cover paper conveyance sensor/1 (PS75) is turned on by the leading edge of the cover paper,
M74, MC71, MC72 are temporary turned off, and cover paper feeding is stopped [2].
3. After the specified time, M74, MC71, MC72 are turned back on, and the leading edge of the cover paper is
sent to the cover paper conveyance sensor/2 (PS76), then M74, MC71 are turned off again [3].
4. After the specified time, M74, MC71, MC72 are turned back on, and the leading edge of the cover paper is
sent to the cover paper conveyance sensor/3 (PS77), then M74, MC71, MC72 are turned off again [4].
5. After the specified time, M74, MC71, MC72 and the cover paper pick up solenoid (SD71) are turned on, the
pick up roller is put back to its original position, and the cover paper is conveyed by only the paper feed roller
and the conveyance roller [5].
6. When the leading edge of the cover paper turns ON the cover paper conveyance sensor/4 (PS78), M74,
MC71, MC72, SD71 turn OFF [6].
7. After the specified time, M74 rotates at high speed, cover paper is conveyed by only the conveyance roller
while MC72 turns ON and the next cover paper is sent to the reverse direction to be separated [7].
8. After the back edge of the cover paper has passed the PS76, MC72 and SD71 turn OFF, and the paper
feeding of the first sheet of cover paper completes [8].
[1] [2] [3] [4] [5] [6] [7] [8]

High
Cover paper feed motor speed
(M74) Low
speed
Cover paper pick up clutch (MC71)
Cover paper separation clutch (MC72)
Cover paper pick up solenoid (SD71)
Cover paper conveyance sensor /1 (PS75)
a075t2c018ca
[1] Cover paper supply signal on [5] Pick up roller goes back to its original position
[2] Conveyed to PS75 [6] Conveyed to PS78
[3] Conveyed to PS76 [7] Conveyance of conveyance roller only
[4] Conveyed to PS77 [8] Pick up paper feeding of first sheet of cover
paper complete
87

• The drive force of the cover paper feed motor (M74) is transmitted to the separation roller [4] via the torque
PB-501/502
limiter [3] when the cover paper separation clutch (MC72) [2] is ON.
• The separation roller [4] is driven in the direction opposite to the cover paper feeding direction. However, the
roller rotates in the same direction with the paper feed direction as long as 1 sheet of cover paper or no
paper is fed because the friction force between the cover paper feed roller [1] and separation roller [4], or
paper and the separation roller is larger than the torque limited by the torque limiter [3].
• When multi-feed occurs, the separation roller reverses the rotation direction to feed the lower sheet that
contacts with the roller back to the tray because the friction force drops due to the multi-feed and becomes
lower than the torque limited by the torque limiter.
[7] [1]
[6] [2]
[5]
[3]
[4]
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[1] Paper feed roller [5] Second sheet of cover paper

[2] Cover paper separation clutch (MC72) [6] First sheet of cover paper
[3] Torque limiter [7] Pick-up roller
[4] Separation roller
9.3.4 Paper feed mechanism

• The cover paper feed motor (M74) drives the conveyance roller. Cover papers fed from the feeding section
are conveyed to the conveyance section by the conveyance roller.
88
9.3.5 Air assist mechanism

• The cover paper tray is equipped with the cover paper tray fan/1 (M71) and /2 (M72), which blow air [4] to
PB-501/502
the cover papers [3] from the front and back cover paper guides.
• Using the tray fans is effective especially when feeding heavy paper or coated paper. However, in the case
of plain paper, it may not be fed smoothly.
[4]
[1]
[2]
[3] a075t2c020ca
[1] Cover paper tray fan /1 (M71) [3] Cover paper

[2] Cover paper tray fan /2 (M72) [4] Blow-out of air
A. Operation timing
• When receiving a print job, cover paper tray fan/1 (M71), /2 (M72) turn ON, and after the specified time,
cover paper feed motor (M74) turns ON.
9.3.6 Cover paper empty detection control

• The cover paper empty sensor (PS71) detects an empty status of the cover paper tray.
89
9.3.7 Paper feed assist plate

(1) Purpose
PB-501/502
The paper feed assist plate (P/N 56UA4070) can be attached to the pick-up roller to adjust the pressure to cover
paper applied from the roller. By changing the number of plates to be attached to the roller depending on the
cover paper type, paper feed accuracy can be improved.
Using the plates is effective especially when feeding coated cover paper or similar type that is likely to stick
tightly causing no-feed trouble.
The paper feed assist plate weighs about 10g and up to 4 plates can be attached to 1 pick-up roller in normal
condition. When the surface of the cover paper is powdery, up to 8 plates can be attached. Increase or
decrease the number of plates according to paper type or condition to improve cover paper feed accuracy.
(2) Configuration
The package contains the following as a set.
• [1] Paper feed assist plate : 4 sheets
• [2] Screws : 2 (M3 x 8)
Only 4 paper feed assist plates are packaged together with the main body. When required additionally, can be
purchased as service parts.
[1]
[2]
1050to2312c
90
Theory of Operation Ver.2.0 Jul. 2009 10. COVER PAPER TABLE SECTION
10. COVER PAPER TABLE SECTION
PB-501/502
10.1 Configuration
Cover paper lift plate /Lt Book exit belt /Fr

Cover paper conveyance arm /Lt
Cover paper Book exit belt /Rr
Cover paper
conveyance roller/Lt conveyance roller/Rt
Cover paper sensor /Lt (PS46) Cover paper align-
ment plate /Rr Cover paper lift
plate /Rt
Cover paper
conveyance
arm /Rt
Cover
Cover paper paper sen-
folding plate /Lt sor /Rt
(PS45)
Cover paper
folding plate /Rt
Front side
Cutter
Cover paper align- Cover paper table entrance roller
ment plate /Fr
Cover paper switchback sensor (PS44)
Cover paper table up down belt /Fr_Rr

Cover paper table up down belt /Rr_Rt
Cover paper table

Cover paper table up down belt
up down belt / /Fr_Lt
Rr_Lt Front side
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91
10. COVER PAPER TABLE SECTION Theory of Operation Ver.2.0 Jul. 2009
10.2 Drive
PB-501/502
A. Cover paper table up down/Fr and /Rr drive
[6]
[5]
[4]
[1]
[3] [2]
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[1] Cover paper table up down belt /Rr_Rt [4] Cover paper table up down belt /Fr_Lt
[2] Cover paper table up down belt /Fr_Rt [5] Cover paper table up down belt /Rr_Lt
[3] Cover paper table up down motor /Fr (M46) [6] Cover paper table up down motor /Rr (M47)
92
B. Cover paper alignment drive
PB-501/502
[3]
[4]
[2]
[1]
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[1] Cover paper alignment motor (M41) [3] Cover paper alignment plate /Rr
[2] Cover paper alignment HP sensor (PS41) [4] Cover paper alignment plate /Fr
C. Cover paper conveyance drive
[3] [4] [1]
[2] a075t2c080ca
[1] Cover paper table entrance roller [3] Cover paper conveyance roller/Lt
[2] Cover paper conveyance motor (M45) [4] Cover paper conveyance roller/Rt
93
D. Book exit drive

PB-501/502
[1]
[2] a075t2c081ca
[1] Book exit belt /Fr, /Rr [2] Book exit motor (M42)
94
E. Cover paper folding plate /Rt and /Lt drive
PB-501/502
[8]
[9]
[8]
[1]
[7]
[6]
[2]
[5]
[4] [3] a075t2c082ca
[1] Cover paper folding plate /Rt [6] Cover paper folding plate HP sensor /Lt (PS49)
[2] Cover paper folding plate HP sensor /Rt (PS48) [7] Cover paper folding plate position sensor (PS51)
[3] Cover paper folding pressure sensor (PS52) [8] Cover paper folding plate /Lt
[4] Cover paper folding motor /Rt (M48) [9] Cover paper folding motor /Lt (M49)
[5] Cover paper folding plate encoder sensor (PS50)
95
F. Cover paper conveyance arm /Rr and /Lt drive

PB-501/502
[7]
[6]
[1]
[2]
[5]
[4] [3]
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[1] Cover paper conveyance arm /Rt [5] Cover paper conveyance arm HP sensor /Lt (PS43)
[2] Cover paper conveyance arm HP sensor /Rt (PS42) [6] Cover paper conveyance arm /Lt
[3] Cover paper conveyance arm motor /Rt (M43) [7] Cover paper lift plate /Lt
[4] Cover paper conveyance arm motor /Lt (M44)
G. Cover paper lift drive
[1]
[2] a075t2c084ca
[1] Cover paper lift plate /Rt [2] Cover paper lift solenoid (SD41)
96
H. Cutter drive
PB-501/502
[2] [3]
[4]
[1]
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[1] Cutter [3] Cutter end switch (SW42)
[2] Cutter HP switch (SW41) [4] Cutter motor (M50)
97
10.3 Operation
PB-501/502
10.3.1 Cover paper table section operation overview

1. The cover paper conveyance arms /Rt [4] and /Lt [10] are activated when detecting that the print start signal
turns ON, and they are pressed against the cover paper conveyance rollers /Rt [5] and /Lt [8].
2. When a cover paper is fed [7], alignment operation is carried out by the cover paper alignment plate /Rr and
/Fr [6].
3. After the thickness of inside papers [11] is detected by clamping operation made by the clamp pressure
plate [12], the cover paper is fed backward (switchback) [2].
4. The backward feeding is made to feed the cover paper to the roller cutter assy so that the paper edge pro-
trudes away from the cover paper switchback sensor (PS44) [3] by the trimming amount.
5. The roller cutter [1] trims the cover paper edge and then the paper is conveyed to the left side again.
6. Alignment operation to attach the cover paper to the inside papers is carried out.
7. The cover paper is moved to left and right by the reverse/forward rotation of the cover paper conveyance
roller/Rt and /Lt for positioning properly with reference to the cover paper sensor/Lt (PS46) [9] as starting
point.
[11] [12]
[1]
[2]
[10]
[9]
[8] [7] [6] [5] [4] [3]
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[1] Roller cutter [7] Cover paper conveyance

[2] Switchback conveyance [8] Cover paper conveyance roller/Lt
[3] Cover paper switchback sensor (PS44) [9] Cover paper sensor /Lt (PS46)
[4] Cover paper conveyance arm /Rt [10] Cover paper conveyance arm /Lt
[5] Cover paper conveyance roller/Rt [11] Bundle of inside papers
[6] Cover paper alignment plate /Rr, /Fr [12] Clamp pressure plate
98
8. When the alignment operation of the cover paper completes and CD alignment plate returns to home posi-
tion, the cover paper folding plate /Rt [3] and /Lt [5] are opened [4].
PB-501/502
9. When the cover paper on the lifted unit attaches to the spine of inside papers [8], the book spine backing
plate [1] presses against the spine to attach the cover paper securely.
10. The cover paper folding plate /Rt and /Lt are moved inward to press [6] both edge surfaces of the spine to
create the perfect corners. During up and down operation of the cover paper table unit, the cover paper
conveyance arm /Rt [9] and /Lt [7] are moved away from the cover paper so as not to let the paper pulled by
the arms.
11. The pressures to the spine are applied for 3 seconds for the glue to harden fully.
[7] [8] [9]
[6]
[1]
[5] [4] [3] [2]
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[1] Book spine backing plate [6] Pressurize

[2] Lift of cover paper table unit [7] Cover paper conveyance arm /Lt
[3] Cover paper folding plate /Rt [8] Bundle of inside papers
[4] Opening [9] Cover paper conveyance arm /Rt
[5] Cover paper folding plate /Lt
99
12. The cover paper folding plate /Rt and /Lt are opened, and the cover paper table unit is lowered [3].
13. While the cover paper table is going down, the inside papers of the book [7] are held by the clamp pressure
PB-501/502
plate [8]. Since both sides of the cover paper [9] bow, the cover paper lift plate /Lt [5] integrated with the
cover paper conveyance arm /Lt [6] supports the left-side of the cover paper. The right-side of the paper
triggers the cover lift plate /Rt [2] and supports the cover. The cover paper conveyance arm /Rt [1] is moved
away from the cover paper lift plate /Rt.
14. The book exit belt [4] is moved to the position to receive the book.
[7] [8] [9]
[1]
[6]
[2]
[5]
[4] [3]
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[2] Cover paper lift plate /Rt [7] Book
[3] Down [8] Clamp pressure plate
[4] Book exit belt [9] Cover paper
[5] Cover paper lift plate /Lt
100
15. When the book exit belt is set at the receiving position, the cover paper table unit is lifted again.
16. When lifting the unit is started, the cover paper conveyance arm /Rt [2] and /Lt [3] are folded [1] [4] to keep
PB-501/502
them from contact with the clamp section.
[4] [1]
[3]
[2]
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[1] The arm is folded [3] Cover paper conveyance arm /Lt
[2] Cover paper conveyance arm /Rt [4] The arm is folded
101
17. When the book (inside papers) [8] is released from the clamp pressure plate [9], the cover paper table unit is
lowered.
PB-501/502
18. At the start of the unit lowering operation, the cover paper conveyance arm /Rt [2], /Lt [7], and the cover
paper folding plate /Rt [3], /Lt [4] are returned to their home positions. When the cover paper lift plate /Lt [6]
returns to its home position, it flips up the left-side of the cover paper toward the inside papers.
19. The book exit belt [5] is activated after a prescribed time has elapsed since the table unit lowering operation
is started so that the belt starts to move at the same time the book contacts with the belt and the book is
laid down on the belt.
[8] [9]
[1]
[7]
[2]
[6]
[5] [4] [3]

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[1] Releasing the book [6] Cover paper lift plate /Lt
[3] Cover paper folding plate /Rt [8] Book
[4] Cover paper folding plate /Lt [9] Clamp pressure plate
[5] Book exit belt
102
20. The cover paper table unit goes down to its home position, and then goes up until the book exit belt surface
becomes horizontal to the book conveyance belt [3] surface.
PB-501/502
21. The book exit belt [1] starts to move again to convey the book [3] on it to the book stock section.
[3]
[2]
[1]
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[1] Book exit belt [3] Book

[2] Book conveyance belt
103
10.3.2 Cover paper conveyance control

A. Mechanism
PB-501/502
• The cover paper conveyance motor (M45) drive force transmitted via the gear and the belt drives the cover
paper table entrance roller [3], the cover paper conveyance rollers /Rt [5] and /Lt [6]
• A cover paper is conveyed being nipped between the driven rollers [9] and [10] provided on the tips of the
cover paper conveyance rollers /Rt and /Lt and the cover paper conveyance arms /Rt [1] and /Lt [8].
• On the cover paper conveyance path, the cover paper sensor/Rt (PS45) [4], /Lt (PS46) [7] and the cover
paper switchback sensor (PS44) [2] are provided.
• The PS44 is used to position the cover paper for trimming.
• PS45 is the starting point of when carrying in cover paper to the up/down cover paper section. Cover paper
is carried in after specified time from when PS45 detected the leading edge of the paper, cover paper stops
and alignment operation is carried out.
• The PS46 is used to position the cover paper to be attached to the spine of inside papers.
[9]
[10]
[8]
[1]
[7] [2]
[6] [5] [4] [3]
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[1] Cover paper conveyance arm /Rt [6] Cover paper conveyance roller/Lt
[2] Cover paper switchback sensor (PS44) [7] Cover paper sensor /Lt (PS46)
[3] Cover paper table entrance roller [8] Cover paper conveyance arm /Lt
[4] Cover paper sensor/Rt (PS45) [9] Driven roller/Rt
[5] Cover paper conveyance roller/Rt [10] Driven roller/Lt
104
B. Control
(1) When conveying cover paper from the PB cover paper tray
PB-501/502
1. Upon receiving of a print job, the cover paper conveyance motor (M45) starts to turn in the forward direction
[1].
2. The M45 stops [2] when a prescribed time has elapsed after the cover paper sensor/Rt (PS45) detects the
leading edge of the cover paper.
3. When clamping the inside papers is finished, the book thickness sensor (PS29) detects the last pulse and
the book thickness information is obtained. Then the M45 starts reverse rotation [3] to convey the cover
paper toward the roller cutter assy.
4. The cover paper moves until it reaches the position to be trimmed off by the amount determined according
to the paper size setting and the book thickness information, and the M45 stops [4].
5. When the cutter end position switch (SW42) detects the finish of the cutting operation [5], the M45 starts for-
ward rotation to convey the cover paper to the left-hand for the alignment.
6. The M45 stops [6] when a prescribed time has elapsed after the PS44 detects the trailing edge of the cover
paper.
7. When the alignment operation by the cover paper alignment motor (M41) is finished [7], the cover paper is
conveyed to the right-hand by the M45 reverse rotation for the next positioning operation.
8. The M45 keeps rotating to position the cover paper properly to be attached to the inside papers until the
cover paper sensor /Lt (PS46), the reference sensor for the positioning, turns OFF [8].
9. After a prescribed time has elapsed, the M45 starts forward rotation to convey the cover paper to the left
hand [9] and stops [10] after the PS46 detects the leading edge of the cover paper.
[1] [2] [3] [4] [6] [7] [9] [10]

Cover paper alignment Forward

motor (M41)
Reverse
Forward
motor (M45) Reverse
Cover paper sensor /Rt (PS45)
Cover paper sensor /Lt (PS46)
Cover paper switchback sensor (PS44)
Cutter end switch (SW42)
[5] [8] a075t2c093ca
[1] Print start signal ON [6] Trimming is completed

[2] Cover paper conveyance to the cover paper [7] Cover paper stops for alignment
table is finished [8] Starting conveyance toward the roller cutter
[3] Cover paper alignment is finished assy
[4] Cover paper positioning reference search [9] Starting cover paper positioning
[5] Trimming is completed [10] Cover paper positioning is completed
105
10.3.3 Cover paper cutting control

A. Mechanism
PB-501/502
• The cutter motor (M50) drives the roller cutter via the pulley and the wire.
• The front side is the home position and the trimming is carried out when the cover paper is moved to the
back side from the front side.
B. Control
1. When the cover paper is conveyed to the trimming position by the cover paper conveyance motor (M45), the
motor stops [1] and the cutter motor (M50) starts forward rotation to start the trimming operation.
2. When the cutter blade cut the paper and reaches the limit position, the cutter end position switch (SW42)
turns ON and the M50 stops. At the same time, the M45 starts forward rotation to convey the cover paper.
3. When the conveyance by the M45 is finished [3], the M50 starts to rotate again to make the cutter return to
its home position.
4. When the cutter is set in its home position [4], the cutter HP switch (SW41) becomes On and the M50 stops.
[1] [3]
Cover paper conveyance Forward

motor (M45) Reverse
Forward
Cutter motor (M50)
Reverse
Cutter HP switch (SW41)
Cutter end switch (SW42)
[2] [4] a075t2c094ca
[1] Start of cutting [3] Starting HP return operation

[2] Trimming is completed [4] Cutter is set in its HP
106
10.3.4 Cover paper alignment drive

A. Mechanism
PB-501/502
• The cover paper alignment motor (M41) drives the cover paper alignment plates /Fr [2] and /Rr [5], the book
exit belts /Fr [3] and /Rr [4] for changing their positions.
• The cover paper alignment plate /Rr presses the cover paper against the cover paper alignment plate /Fr to
position the cover paper properly, and the cover paper alignment /Fr judges the alignment accuracy.
[5]
[4]
[1]
[3] [2]
a075t2c095ca
[1] Cover paper [4] Book exit belt /Rr

[2] Cover paper alignment plate /Fr [5] Cover paper alignment plate /Rr
[3] Book exit belt /Fr
107
B. Control
(1) Cover paper trimming mode
PB-501/502
1. When detecting that the print start signal turns ON [1], the cover paper alignment motor (M41) starts forward
rotation to set the alignment parts in the positions for the alignment operation, and stops [2].
2. After the conveyance arm/Rt and /Lt move away from the cover paper conveyance roller/Rt and /Lt by the
cover paper conveyance arm motor/Rt (M43) and /Lt (M44), and the arms stops, the M41 starts forward
rotation to position the cover paper to be trimmed [3].
3. When the cover paper is set at the trimming position with the cover paper alignment plate /Rr and /Fr hold-
ing down both sides of the paper, the M41 stops [4].
4. The conveyance arm/Rt and /Lt are pressed against the cover paper conveyance roller/Rt and /Lt [5] by the
M43 and M44 drive force. Then the M41 starts reverse rotation to move the cover paper alignment plate/Rr
and /Fr away from the cover paper, and stops.
5. When the cover paper trimming is finished, the cover paper alignment operation [6] to be attached to the
inside papers is performed in the same manner as for the trimming.
6. When positioning the cover paper by the cover paper conveyance motor (M45) is finished, the M41 starts
reverse rotation to perform preparation operation [7] for the next cover paper table lifting operation.
7. The M41 stops [8] when the cover paper alignment HP sensor (PS41) becomes ON.
[1] [2]
Cover paper alignment
HP sensor (PS41)
Cover paper Forward
alignment motor
(M41) Reverse
Cover paper con- Forward

veyance arm motor
/Rt (M43), /Lt (M44) Reverse
Cover paper con- Forward

veyance motor
(M45) Reverse
[5] a075t2c093ca
[1] Print start signal ON [5] Positioning (alignment) cover paper to be

[2] Setting the plates and belts ready for the conveyance attached to inside papers
[3] Positioning (alignment) for cover paper trimming [6] Starting preparation for cover table lifting operation
[4] Stops at the trimming position [7] Alignment-related parts return to its home position
[8] Returning to the home position
(2) Cover paper Not trimming mode

When the sub-scanning direction length of inside papers is over 182mm, the first positioning operation for trim-
ming is not performed. Only the positioning operation for attaching the cover to the inside papers is performed.
However, when the inside paper is smaller than B5 size, alignment is done twice. Once when cover paper is car-
ried in, and once after leading edge positioning is done.
1 108
10.3.5 Cover paper table up down control

A. Mechanism
PB-501/502
• The cover paper table up down motor /Fr (M46) drives the cover paper table up down belts /Fr_Rt [9] and /
Fr_Lt [5], and the cover paper table up down motor /Rr (M47) drives the cover paper table up down belts /
Rr_Rt [1] and /Rr_Lt [2].
• The cover paper table upper limit sensor/Fr (PS26) [3] detects that the front side of the cover paper table
that is driven by the M46 reaches the upper limit.
• The cover paper table upper limit sensor /Rr (PS27) [4] detects that the rear side of the cover paper table
that is driven by the M47 reaches the upper limit.
• The cover paper table HP sensor/Fr (PS47) [7] detects that the front side of the cover paper table is in its
home position, and the cover paper table HP sensor/Rr (PS53) [8] detects that the rear side of the cover
paper table is in the home position.
[3] [4]
[1]
[2]
[1] [9]
[5]
[6]
[2] [8] [7] a075t2c097ca
[1] Cover paper table up down belt /Rr_Rt [6] Front side
[2] Cover paper table up down belt /Rr_Lt [7] Cover paper table HP sensor /Fr (PS47)
[3] Cover paper table upper limit sensor/Fr (PS26) [8] Cover paper table HP sensor /Rr (PS53)
[4] Cover paper table upper limit sensor/Rr (PS27) [9] Cover paper table up down belt /Fr_Rt
[5] Cover paper table up down belt/Fr_Lt
109
B. Control
1. When applying glue to the spine of inside papers is finished and the glue tank HP sensor (PS33) turns ON, the
PB-501/502
cover paper table up down motor/Fr (M46) and /Rr (M47) start forward rotation to lift the cover paper table [1].
2. During a prescribed time period after the cover paper table upper limit sensor/Fr (PS26) and /Rr (PS27)
become ON, the cover paper is pressed against the spine of inside papers, and then M46 and M47 stop [2].
3. After the book spine ends are neatly folded, the cover paper folding motor/Rt (M48) moves the cover paper folding plate/
Rt away from the book and stops, and then the reverse rotation of the M46 and M47 lowers the cover paper table [3].
4. The M46 and M47 keeps rotating until the cover paper table reaches the position to receive the book, and they stop [4].
5. When the cover paper alignment motor (M41) drives the book exit belt (attached to the cover paper align-
ment plate/Fr and /Rr) to the position to receive the book, and stops, the M46 and M47 start forward rota-
tion to lift the cover paper table [5].
6. The motors stop [6] when the cover paper table reaches to the position to receive the book.
7. When the clamp HP sensor (PS22) turns ON upon completion of opening movement of the clamp pressure plate (the book
is released from the plate), the M46 and M47 starts reverse rotation to lower the cover paper table [7] to receive the book.
8. The M46 and M47 stop when the cover paper table HP sensor/Fr (PS47) and /Rr (PS53) detect that the
cover paper table reaches its home position.
9. When the book exit motor (M42) drives the book exit belt to convey the book to the predetermined position
and stops, the M46 and M47 starts forward rotation to lift the cover paper table [9].
10. In order to align the surface of the book exit belt with that of the book conveyance belt in the book stock
section, the cover table is lifted by 60mm and the M46 and M47 stop [10].
11. When the book end sensor (PS61) turns ON detecting that the book has exit to the book stock section [11], the M46 and
M47 starts reverse rotation to lower the cover paper table until the PS47 and PS53 turn ON, and then the motors stop [12].
[1] [2] [3] [5] [8] [9][10] [12]

Glue tank home sensor (PS33)

Forward
motor (M41) Reverse
Cover paper table Forward

up down motor/Fr
(M46), /Rr (M47) Reverse
Cover paper table upper limit
sensor/Fr (PS26), /Rr (PS27)
Cover paper table HP sensor/Fr
(PS47), /Rr (PS53)
Cover paper folding Forward
motor /Rt (M48)
Reverse
Book exit motor (M42)
Book end sensor (PS61)
[4] [6] [7] [11]

a075t2c098ca
[1] Completion of glue application [7] Starting book receiving operation

[2] Completion of pressing the book spine [8] Stopped at home position
[3] Starting to lower the cover paper table for [9] Starting lifting to the book exit position
preparing book receiving operation [10] Lifting by 60mm
[4] Standby for receiving book [11] Book exit is finished
[5] Book exit belt movement is finished [12] Returning to the home position
[6] Going up and stopping at the position to receive book
110
10.3.6 Cover paper folding plate control

A. Mechanism
PB-501/502
(1) OUTLINE
• In order to let the book spin ends to form perfect corners, the cover paper folding motors /Rt (M48) and /Lt
(M49) move the cover paper folding plates /Rt [1] and /Lt [3] respectively inward to press the book spine [6]
from both left and right side with the spine pressed by the book spine backing plate [2].
• The cover paper folding plate /Lt is used as the reference position [4], and the cover paper folding plate /Rt
presses the book against the plate /Lt with spring force.
• The standby position of the cover paper folding plate /Lt is 15mm [5] left from the reference position [4], and
that of the cover paper folding plate /Rt is 15mm [7] right from the right end of the book regardless of the
book thickness.
[5] [6] [7] [8]
[3] [2] [4] [1] [3] [2] [1]
a075t2c099ca
111
(2) Pressure mechanism

1. The cover paper folding motor/Rt (M48) [5] drives the cover paper folding operation via the gear.
PB-501/502
2. The cover paper folding pressure sensor (PS52) [4] detects the pressure applied to the book.
3. The cover paper folding plate encoder sensor (PS50) [6] detects how much the M48 has rotated.
[2] [3] [4]
[1]
[2]
[3]
[4]
[6]
[5]
a075t2c100ca
[1] Cover paper folding plate /Rt [4] Cover paper folding pressure sensor (PS52)
[2] Book [5] Cover paper folding motor /Rt (M48)
[3] Pressure drive plate /Rt [6] Cover paper folding plate encoder sensor
(PS50)
112
B. Control
1. When the cover paper table up down motor /Fr (M46) and /Rr (M47) start to rise to stick the cover paper to the book
PB-501/502
spine and cover paper alignment completes, when the CD alignment plate returns to home position, the cover paper
folding motor /Rt (M48) and /Lt (M49) start forward rotation to move the cover paper folding plate/Rt and /Lt outward [1].
2. The M49 stops [2] when a prescribed time has elapsed after the cover paper folding plate position sensor
(PS51) turns ON.
3. The M48 stops [3] when the cover paper folding plate encoder sensor (PS50) has count certain pulses cor-
respond to the book thickness.
4. When the M46 and M47 stop upon completion of pressing the cover paper against the spine of inside
papers, the M48 and M49 start reverse rotation to move the cover paper folding plate/Rt and /Lt inward
(toward the book) [4].
5. When the cover paper folding plate/Lt has moved to the reference position during a prescribed time period
after the cover paper folding plate HP sensor/Lt (PS49) turns ON, the M49 stops [5].
6. When the cover paper folding pressure sensor (PS52) turns ON [6], the PS50 starts to count again until the
pressure plate moves 3mm pressing the book, and then the M48 stops [7].
7. The M48 and M49 start forward rotation to release the book from the pressure [8].
8. The M49 stops [9] when the cover paper folding plate /Lt reaches its standby position after the PS51 turns ON.
9. The M48 stops [10] when the cover paper folding plate /Rt reaches its standby position after the PS50
counted certain pulses.
10. When the M46 and M47 start to rotate to lower the cover paper table, the M48 and M49 start to drive to
return the cover paper folding plates to their home positions [11].
[1] [3] [4] [7] [8] [10] [11]

Cover paper table up Forward
down motor/Fr (M46), /Rr
(M47) Reverse
Forward
Cover paper folding
motor /Rt (M48) Reverse
Cover paper folding plate
home sensor /Rt (PS48)
encoder sensor (PS50)
Cover paper folding
pressure sensor (PS52)
Forward
Cover paper folding
motor /Lt (M49) Reverse
HP sensor /Lt (PS49)
position sensor (PS51)
[2] [5] [6] [9] a075t2c101ca
[1] Overlay stopper moved to its standby position [7] Stops applying a certain pressure to the book
[2] Cover paper folding plate /Lt stops at the [8] Releasing book after pressing it for a certain
standby position time to harden the glue
[3] Cover paper folding plate /Rt stops at the [9] Cover paper folding plate /Lt stops at the
standby position standby position
[4] Starts to fold cover paper [10] Cover paper folding plate /Rt stops at the
[5] Cover paper folding plate /Lt stops at the standby position
reference position [11] Returning to the home position
[6] Start to apply pressure to the book
113
10.3.7 Cover paper conveyance arm control

A. Mechanism
PB-501/502
• The cover paper conveyance arms /Rt [5] and /Lt [9] press/separate the driven rollers [4] and [11] against/
from the cover paper conveyance rollers /Rt [7] and /Lt [8].
• The cover paper conveyance arm /Lt is equipped with the cover paper lift plate /Lt [10] which lifts the left-
side of the cover paper to prevent it from being fold while the cover paper alignment plates are moved
inward to attach the cover paper to the inside papers.
• The cover paper conveyance arm motors /Rt (M43) and /Lt (M44) drive the cover paper conveyance arms /
Rt and /Lt via the pins [2] and [14].
• While conveying a cover paper, the pins [2] and [14] come off the notches [1] and [12] of the cover paper conveyance
arms, and the cover paper conveyance rollers /Rt and /Lt are pressed against the paper with the spring force [3] and [13].
• The cover paper conveyance arm HP sensor/Rt (PS42) [6] and /Lt (PS43) [15] detect that the arms are in their
home positions. The upright positions of the paper cover conveyance arm /Lt and /Rt are their home positions.
[1]
[14]
[2]
[13]
[3]
[12]
[11]
[10]
[4]
[9]
[5]
[6]
[8]
[7]
a075t2c102ca
• The following table shows the preset angles of the cover paper conveyance arms for each operation.
Operation Cover paper conveyance arm /Lt Cover paper conveyance arm /Rt
[1] [2]
Home position [1] [2] +90° +90°
Cover paper conveyance [3] -30.4° -8°
Cover paper alignment, attachment [4] -29.4° -7°
Temporary lowering of cover paper table +25.4° +41.2°
(for book exit belt preparation) [5]
Re-lifting of cover paper table (to receive book) [6] -14.1° +15.3°
114
PB-501/502
[1] [5]
[2]
[6]
[4]
[3] a075t2c103ca
[1] Cover paper conveyance arm /Lt [5] Temporary lowering of cover paper table (for
[2] Cover paper conveyance arm /Rt book exit belt preparation)
[3] Cover paper conveyance [6] Re-lifting of cover paper table (to receive
[4] Cover paper alignment, attachment book)
115
B. Control
(1) Cover paper trimming mode
PB-501/502
1. When detecting that the print start signal turns ON [1], the cover paper conveyance arm motors /Rt (M43)
and /Lt (M44) start forward rotating to make the driven rollers provided on the tips of the arms press against
the conveyance rollers /Rt and /Lt, and the motors stop [2].
2. When the cover paper conveyance motor (M45) stops [3] after conveying the cover paper to the cover paper
table, the M43 and M44 start reverse rotation to move the driven rollers away from the paper [4].
3. When the cover paper alignment motor (M41) stops [5] after making the arms press against both edges of the cover paper for align-
ment, the M43 and M44 start forward rotation to hold down the paper with the driven rollers [6] to prevent the paper from moving.
4. When the cover paper trimming is finished, the cover paper alignment operation [7] to be attached to the
inside papers is performed in the same manner as for the trimming.
5. When a prescribed time has elapsed after the cover paper table is lifted [8] by the cover paper table up down motor/Fr
(M46) and /Rr (M47), the cover paper folding plate/Rt and /Lt start to move inward to fold the cover paper along the inside
papers, and at the same time, the M43 and M44 start reverse rotation to move the driven rollers away from the paper [9].
6. When the cover paper table starts temporary lowering to prepare for receiving the book with the M46 and M47 drive
forces, the M43 and M44 start reverse rotation [10] to support both sides of the cover paper with the cover paper lift
plate/Lt and /Rt. It prevents the cover paper alignment plate/Fr and /Rr from unexpectedly folding the cover paper.
7. When the M41 stops [11] after setting the book exit belt /Fr and /Rr at the book receiving position, the cover
paper table starts to move upward again, and at the same time, the M43 and M44 start forward rotation to
move the arms so that they do not contact with the clamp section.
8. When the cover paper table starts downward movement receiving the book, the M43 and M44 drives the
arms to return them to the home positions [13].
[1] [2] [3] [5] [7] [9] [11][12][13]
Forward
motor (M41) Reverse
Forward
arm motor /Rt (M43)
Reverse
Cover Paper conveyance
arm HP sensor /Rt (PS42)
Forward
arm motor /Lt (M44) Reverse
Cover paper conveyance arm home
sensor /Lt (PS43)
Forward
motor (M45) Reverse
Cover paper table Forward

up down motor/Fr
(M46), /Rr (M47) Reverse
[4] [6] [8] [10] a075t2c104ca
[1] Print start signal ON [8] Starting lifting the cover paper table
[2] Driven rollers are pressed against the conveyance rollers [9] Driven rollers release the paper for cover paper folding operation
[3] Cover paper conveyance is completed [10] Temporary lowering of the cover paper table
[4] Release [11] Book exit belt is set to standby
[5] Completion of positioning (alignment) cover paper for trimming [12] Moving the arms to avoid contact with clamp section
[6] Driven rollers are pressed against the paper [13] Returning to the home position
[7] Positioning (alignment) cover paper to be attached to inside papers
116
(2) Cover paper Not trimming mode

When the sub-scanning direction length of inside papers is over 182mm, the first positioning operation for trim-
PB-501/502
ming is not performed. Only the positioning operation for attaching the cover to the inside papers is performed.
However, when the inside paper is smaller than B5 size, alignment is done twice. Once when cover paper is car-
ried in, and once after leading edge positioning is done.
10.3.8 Cover paper lifting (supporting) control

A. Mechanism
• The cover paper lift solenoid (SD41) activates the cover paper lift plate /Rt.
• The cover paper lift plate /Rt supports the right-side of the cover paper to prevent it from bowing down and
being unexpectedly folded when the cover paper table is temporary lowered for setting the book exit belt at
the standby position.
B. Control
1. When the cover paper table up down motor/Fr (M46) and /Rr (M47) stop after lowering the table for setting
the book exit belt at the standby position, the cover paper lift solenoid (SD41) is activated to move the cover
paper lift plate for supporting the right side of the cover paper.
2. The SD41 turns OFF when the cover paper alignment motor (M41) stops after setting the book exit belt at
the standby position.
Forward
Cover paper alignment motor
(M41)
Reverse
Forward
Cover paper table up down motor/
Fr (M46), /Rr (M47)
Reverse
Cover paper lift solenoid (SD41)
[1] [2]
a075t2c105ca
[1] Supporting cover page with the cover lift [2] Ending supporting cover paper
plate
117
10.3.9 Book paper exit control

A. Mechanism
PB-501/502
• The book exit motor (M42) drives the book exit belt/Fr and /Rr.
B. Control
1. After the cover paper is folded along the inside papers, the cover paper table up down motor/Fr (M46) and /
Rr (M47) start reverse rotation to lower the cover paper table [1].
2. When the book spine corner touches the book exit belt surface (when a prescribed time has elapsed after
the table starts to go down), the book exit motor (M42) starts to rotate at low speed so that the book is
slowly laid down on the belt [2].
3. When a prescribed time has elapsed after starting the rotation, the M42 stops [3].
4. The M42 starts high-speed rotation to exit the book [4] toward the book stock section when the M46 and
M47 have moved the cover paper table upward by 60mm so that the book exit belt horizontally aligns with
the book conveyance belt in the book stock section.
5. The M42 stops [5] when the book end sensor (PS61) turns ON detecting that the book has conveyed to the
book stock section.
Forward
Cover paper table up
down motor/Fr (M46),
/Rr (M47) Reverse
[1] [2] [3] [4] [5]

a075t2c106ca
[1] Cover paper table goes down to convey the [3] Temporary stop of M42
book to the belt [4] Paper exit of the book
[2] Receiving the book [5] Paper exit completed
118
10.3.10 Waste paper control

• The waste box full sensor (PS80) [1] detects a full status of the waste box by receiving a light reflected off
PB-501/502
the waste paper in the box.
• The waste box set sensor (PS81) [2] is provided to detect whether the waste box is properly set or not. The
actuator of the waste box activates the sensor.
[2]
[1]
a075t2c107ca
[1] Waste box full sensor (PS80) [2] Waste box set sensor (PS81)
119
11. BOOK STOCK SECTION Theory of Operation Ver.2.0 Jul. 2009
11. BOOK STOCK SECTION

PB-501/502
11.1 Configuration
Book end sensor (PS61) Upper limit sensor (PS65)
Book upper limit

LED (LED61)
Book conveyance
arm /Rr
Book conveyance
arm /Fr
Book guide /Rr
Book guide /Fr Book conveyance belt

/Rr
Book convey-
ance belt /Fr
Book sensor /2
(PS67)
Book sensor /1 (PS66) Book stopper
Book movement belt

a075t2c108ca
120
Theory of Operation Ver.2.0 Jul. 2009 11. BOOK STOCK SECTION
11.2 Drive
PB-501/502
A. Book conveyance drive
[11]
[10] [1]
[2]
[3]
[9]
[4]
[8]
[7]
[6] [5]
a075t2c109ca
[1] Book conveyance belt movement motor (M62) [7] Book conveyance arm /Fr
[2] Book conveyance arm /Rr [8] Guide shaft /Rt
[3] Book guide /Rr [9] Guide shaft /Lt
[4] Book conveyance belt /Rr [10] Timing belt
[5] Book conveyance belt /Fr [11] Book conveyance belt movement HP sensor (PS62)
[6] Book guide /Fr
121
B. Book conveyance belt drive

PB-501/502
[3] [1]
[2]
a075t2c110ca
[1] Book conveyance belt /Rr [3] Book conveyance belt motor (M61)
[2] Book conveyance belt /Fr
122
C. Book conveyance up down drive
PB-501/502
[5]
[4]
[1]
[3]
[2]
a075t2c111ca
[1] Book conveyance belt up down motor (M63) [4] Guide shaft /Lt
[2] Guide shaft /Rt [5] Book lift wire/Rr
[3] Book lift wire /Fr
123
D. Book movement drive

PB-501/502
[2] [3] [1]

a075t2c112ca
[1] Book movement motor (M64) [2] Book movement belt
E. Book stopper drive
[1]
[4]
[3] [2]
a075t2c113ca
[1] Book stopper [3] Front side

[2] Book stopper HP sensor (PS68) [4] Book stopper motor (M65)
124
11.3 Operation
PB-501/502
11.3.1 Book stock section operation overview
1. When detecting that the print start signal turns ON, the book conveyance arms /Fr and /Rr [3] and the book
stopper [1] are moved to the positions correspond to the selected paper size.
2. The book conveyance belt [5] is driven in synchronization with the drive of the book exit belt [6] in the cover
paper table section, and the conveyance belt receives the book from the exit belt.
3. The book guide /Fr and /Rr [4] are moved to the positions where they contact with the book side edges to
align the book.
4. The book is conveyed downward until it reaches to the position to be stacked.
5. The book conveyance arm /Fr and /Rr are opened to drop the book onto the book movement belt [3].
[4] [5]
[6]
[3] [2] [1]
a075t2c114ca
[1] Book stopper [4] Book guide /Fr, /Rr

[2] Book conveyance arm /Fr, /Rr [5] Book conveyance belt
[3] Book movement belt [6] Book exit belt
125
6. When books have been stacked to the upper limit, the stack of books [1] is moved to the second row [3] by
the book movement belt [2], and then it keeps stacking the subsequent books in the first row.
PB-501/502
[4]
[3]
[2] [1]
a075t2c115ca
[1] Stack of books at the first row [3] Second row

[2] Book movement belt
126
11.3.2 Book conveyance and movement control

A. Mechanism
PB-501/502
• The book conveyance belt movement motor (M62) [1] drives the book movement arms /Fr [8] and /Rr [2] via
the timing belt.
• The book movement arm /Fr and /Rr move in the main scan direction along the guide shaft /Rt [5] and /Lt
[9].
• The book conveyance belt movement HP sensor (PS62) is provided to detect whether the arms in their
home position or not.
• The guide shaft/Fr and /Rr are moved up or down by the book conveyance belt up down motor (M63).
• The book movement arm /Fr and /Rr include the book conveyance belt /Fr [6], /Rr [3], and the book guide /
Fr [7], /Rr [4].
• Registration regulating plate /Fr [7], /Rr [4] slides along the guide shaft /Rt [5], /Lt [9].
[9] [10] [11] [1]
[2]
[3]
[8] [7] [6] [5] [4]

a075t2c116ca
[1] Book conveyance belt movement motor (M62) [7] Book guide /Fr
[2] Book movement arm /Rr [8] Book movement arm /Fr
[3] Book conveyance belt /Rr [9] Guide shaft /Lt
[4] Book guide /Rr [10] Timing belt
[5] Guide shaft /Rt [11] Book conveyance belt movement HP sensor (PS62)
127
(1) Operation
1. When receiving a book from the cover paper table section [1], the book movement arm /Fr [6] and /Rr [11]
PB-501/502
are moved to the positions correspond to the book size, and the book guide /Fr [7] and /Rr [10] are set at
the positions 17mm outer the book edges [9].
2. Then the book guides are moved inward to the positions 2mm away from the book edges to align the book
to be stacked.
3. When the book is conveyed downward to the position to be stacked, the book movement arm /Fr [6] and /
Rr [10] are moved outward to drop the book [3].
[10] [9] [8] [7]

[6]
[11]
[1]
[5]
[2]
[3]
[4] a075t2c118ca
[1] Standby/receiving book [7] Book guide /Fr

[2] Aligning the book and moving down [8] Gap between the book edge and the guide
[3] Releasing the book is 17mm in the standby status
[4] Book drops [9] Book
[5] Gap between the book edge and the guide [10] Book guide /Rr
is 2mm during alignment [11] Book movement arm /Rr
[6] Book movement arm /Fr
128
B. Control
1. When detecting that the print start signal turns ON [1], the book conveyance belt movement motor (M62)
PB-501/502
starts forward rotation to move the book movement arms /Fr and /Rr to the positions correspond to the
book size [2].
2. When the book end sensor (PS61) turns ON [3], the M62 starts forward rotation again to move the regulation
plates /Fr and /Rr inward until the gap between the regulation plates and book edges become 2mm to per-
form alignment [4].
3. When the book conveyance belt lower limit sensor (PS64) turns ON [5], the M62 starts reverse rotation to
move the arms to home position and stops [6]. However, when there are subsequent books, book convey-
ance assy moves the book movement arms to standby position after returning to the upper limit home posi-
tion.
4. After releasing the book, the M62 reverse rotation is continued until the arms stop at their home positions [7]
turning ON the book conveyance belt movement HP sensor (PS62).
[1] [2] [3] [6]
Forward
Book conveyance belt
movement motor (M62) Reverse
Book conveyance belt movement HP sensor (PS62)
Book conveyance belt lower limit sensor (PS64)
[4] [5] [7]

a075t2c119ca
[1] Print start signal ON [5] Start to move the arms to their standby position
[2] Stop the arms at the positions correspond to the book size [6] Stopping at the standby position
[3] Receiving the book is completed [7] Returning to the home position
[4] Guides stop at the positions for alignment
129
11.3.3 Book conveyance belt control

A. Mechanism
PB-501/502
• The book conveyance belt motor (M61) drives the book conveyance belt.
• The book conveyance belt /Fr [2] and /Rr [1] receive the book conveyed from the cover paper table section.
• The book presses the book end sensor (PS61) [3] and turns it ON. It detects the completion of the receiving
operation.
[3]
[2]
[1]
a075t2c120ca
[1] Book conveyance belt /Rr [3] Book end sensor (PS61)
B. Control
1. The book conveyance belt motor (M61) starts to drive upon starting of the book exit motor (M42) to receive
the book [1] conveyed from the cover paper table section.
2. The M61 stops [2] when the book end sensor (PS61) turns ON.
Book conveyance belt motor (M61)
[1] [2]
a075t2c121ca
[1] Book conveyance belt drive [2] Receiving the book is completed
130
11.3.4 Book conveyance up down control

A. Mechanism
PB-501/502
• The book conveyance assy [5] is moved up and down with the book lift wires /Fr [4] and /Rr [3] driven by
the book conveyance belt up down motor (M63) [1].
• The book conveyance belt HP sensor (PS63) [6] detects whether the book conveyance assy is at its upper
limit home position or not. The book conveyance belt lower limit sensor (PS64) [2] provided at the bottom of
the book movement arm/Rr detects whether the book conveyance assy is at its lower limit position (top
surface of the stacked books or the movement belt position).
[1]
[6]
[5]
[2]
[3]
[4]
a075t2c122ca
[1] Book conveyance belt up down motor [4] Book lift wire/Fr
(M63)
[2] Book conveyance belt lower limit sensor [5] Book conveyance assy
(PS64)
[3] Book lift wire/Rr [6] Book conveyance belt HP sensor (PS63)
131
B. Control
1. When the book alignment driven by the book conveyance belt movement motor (M62) is finished, the book
PB-501/502
conveyance belt up down motor (M63) starts forward rotation to lower the book conveyance assy [1].
2. M63 stops when the book conveyance belt lower limit sensor (PS64) turns ON [2].
3. When the M62 stops [3], the M63 starts reverse rotation to lift the book conveyance assy.
4. The M63 stops [4] when the book conveyance belt HP sensor (PS63) detects that the assy reaches its
upper home position.
[1] [3]
Book conveyance belt move- Forward

ment motor (M62)
Reverse
Book conveyance belt up down Forward

motor (M63)
Reverse
Book conveyance belt HP sensor (PS63)
Book conveyance belt lower limit sensor (PS64)

[2] [4]
a075t2c123ca
[1] Book conveyance assy starts to go down [3] Releasing book is completed
[2] Stopping at the book release position [4] Returning to the home position
132
11.3.5 Book movement control

A. Mechanism
PB-501/502
• The book movement motor (M64) drives the book movement belt.
• The belt moves the first row of books to the second row.
B. Control
(1) While in the print
• The book movement motor (M64) is allowed to drive only when the book sensor/2 (PS67) is OFF (no stack
of books exist at the second row).
• When the book load limit sensor (PS65) detects that book has been stacked up to the limit at the first row,
the M64 starts to drive the belt and stops when the PS67 turns ON.
(2) Book manual movement

• The book sensor/1 (PS66) is ON. The book movement motor (M64) is allowed to drive only when the book
sensor/2 (PS67) is OFF.
• When the book movement button is turned ON, the book movement motor (M64) starts to drive the belt,
and stops when the PS67 turns ON.
133
11.3.6 Book stopper control

A. Mechanism
PB-501/502
• The book stopper supports the stacked books to prevent them from falling down.
• The book stopper motor (M65) drives the book stopper.
• The book stopper HP sensor (PS68) detects whether the book stopper is at is home position or not.
B. Control
• Upon receiving of a print job, the book stopper motor (M65) starts forward rotation to move the stopper to
the position correspond to the book size.
• When the job is finished, the M65 starts reverse rotation to return the stopper to its home position, and the
motor stops when the book stopper HP sensor (PS68) turns ON.
11.3.7 Book full status detection control

• When books have been stacked up to the limit at the first row, the full-status is detected by the book load
limit sensor (PS65) and notified by the book upper limit LED (LED61).
• Since any light to the PS65 is blocked while the book conveyance assy is moving up or down, the PS65
status is checked only while the book conveyance belt HP sensor (PS63) is ON.
• Even when the PS65 is not detecting the full-status, continuing stacking books cannot be made under the
following conditions.
(1) When the stacked book size is the same
Book thickness is classified into 3 levels; a, b, and c, and allowable number of books to be stacked is
determined according to the combination of a, b, and c as shown in the following table.
Book a: 10 to 30 sheets
Book b: 31 to 150 sheets
Book c: 151 to 300 sheets
Mixing more than 2 among a, b, and c-level books in 1 stack is not allowed.
Books already stacked Books to be stacked over
Book a Book b Book c
Book a 50 copies in total (30 - a) copies (20 - a) copies
Book b (35 - b) copies 35 copies in total (20 - b) copies
Book c 30 copies 30 copies Until detected by
PS65
*Stacking more books is stopped when the result of the calculations shown in the table become negative
value.
*Stacking more books is stopped when the PS65 detects full status even when the result of the calculations
is positive.
(2) When the stacked book size is different from each other
It stacks only 1 copy on the stacked books on the first row, moves to the second row, and then stacks the
rest of the copies on the first row.
134
12. OTHERS
PB-501/502
12.1 Fan control
1. Configuration
[1]
[3]
[2]
a075t2c129ca
[1] Exhaust fan /1 (M80) [3] Pellet supply cooling fan motor (M4)
[2] Exhaust fan /2 (M81)
A. Pellet supply cooling fan motor (M4)

(1) Purpose
• The fan cools the air above the molten glue surface in the glue tank for the maintenance of a temperature
differential to molten glue. This allows the glue tank temperature sensor/Up (TH2) to detect a drop in tem-
perature precisely when it comes out of the molten glue that is getting low for the notification that pellets
need to be supplied.
(2) ON timing
• The M4 turns ON upon completion of warm-up of the glue tank.
• The M4 turns ON when the temperature sensor/Md (TH3) detects the temperature around the middle in the
glue tank is higher than the preset temperature.
(3) OFF timing

• The M4 turns OFF when the temperature sensor/Md (TH3) detects the temperature around the middle in
the glue tank is lower than the preset temperature.
135
B. Exhaust fan/1 (M80), /2 (M81)

(1) Purpose
PB-501/502
• The fans are provided to prevent an excessive increase in temperature inside the PB-501/502 exhausting
air and deodorize.
(2) ON timing
• The M80 and M81 turn ON upon completion of warm-up of the glue tank.
• The M80 and M81 turn ON when the temperature sensor/Md (TH3) detects the temperature around the
middle in the glue tank is higher than the preset temperature.
(3) OFF timing

• The M80 and M81 turn OFF when the temperature sensor/Md (TH3) detects the temperature around the
middle in the glue tank is lower than the preset temperature.
12.2 Door opening/closing control

• When the front door, upper door, and stacker door are opened with the front door switch (MS2), upper door
switch (MS3), and stacker door switch (MS4) [3] turned OFF, a 24VDC/2 (DCPU/2) supply is shut down to
stop all operations instantly.

• When the pellet supply door is opened with the pellet supply door switch (MS1) turned OFF, the pellet sup-
ply motor (M33) is stopped instantly.
• During initialization and printing operations, the front door lock solenoid (SD80), book door solenoid (SD61)
turn ON, and disables the stacker door to open/close. During idling, jam occurrence or in service mode,
SD80 and SD61 turn OFF and open/close of the front door is enabled.
• A message is displayed in the touch panel when the stacker door sensor (PS57) switches from on to off.
[1]
[2]
[3]
a075t2c131ca
[1] Book door solenoid (SD61) [3] Stacker door switch (MS4)
[2] Stacker door sensor (PS57)
136
MAINTENANCE
PB-501/502
13.1 Sub compile (SC) section
CAUTION:
• Make sure to unplug the power code of the main body from the power outlet when it is connected
to the main body.
13.1.1 Replacing the switchback roller

• Switchback roller : Every 600,000 prints *1
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Procedure
1. Open the upper door [1] to open the SC door [2].
[6] [7] [5] [4] [5]
Then close the upper door [1].
Note
• To keep the SC door open, insert a screw-
driver into the hole [3]. Be sure to remove the
screwdriver when closing the sub clamp door,
or the cover gets damaged.
[3] [8] [2] [1] 2. Remove the 2 C-clips [4], and slide the 2 bearings
[5] into the inside.
Note
• Before removing the C-clips, be sure to
spread a sheet of paper and so on under the
switchback roller assy to prevent the C-clips
from dropping into inside of the machine.
3. Release the pulley [7] from the belt [6] gently, and
remove the switchback roller assy [8].
a075f2c001ca
137 1
Note
[2] [1]
• After reinstalling the switchback roller assy,
PB-501/502
use a mirror to check that the belt [1] is prop-

erly looped over the pulley [2] without any
slackness. If the belt has comes off the pulley,
remove the SC cover /Up to correct that.
(Refer to P.169)
a075f2c002ca
4. Remove the E-ring [1], and remove the roller [2]

[9] [4] [3]
and the pin [3].
[8]
Note
[6] • Be sure to install the bearing [4] so that its
collar faces toward the switchback roller.
[5] 6. Remove the E-ring [5], slide the switchback roller

[8] in the direction of the arrow [6] (toward the pul-
ley) and remove the pin [7]. Then remove the
switchback roller [8] in the direction of the arrow
[9].
steps in reverse.
[7] [2] [1]

a075f2c003ca
1 138
13.1.2 Lubrication to the sub scan alignment plate shaft

PB-501/502
• Sub scan alignment plate shaft : Every 600,000 prints * 1
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Procedure
1. Remove the upper cover /Lt. (Refer to P.165)

2. Remove the left cover. (Refer to P.166)
3. Apply the plas guard No.2 to the 4 positions [1]
the sub scan alignment plate shafts.
[1]
a0v9t3c001ca
139 1
13.2 Cover paper table section

PB-501/502
CAUTION:
to the main body.
• The glue tank unit is extremely hot immediately after turning off the main power switch (SW1) or
the power switch (SW2) of the main body. To prevent burn injuries, leave the unit until it cools
enough before performing the maintenance work.
Note
• Before performing the maintenance work, be sure to carry out the initial operation so that each
part/unit is at the home position.
13.2.1 Cleaning the cover paper folding plate and the book spine backing plate
• Cover paper folding plate and the book spine backing plate : Every 600,000 prints*1
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Simplified cleaning procedure

1. Carry out the I/O check in service mode in the
[1]
order of following output check code, and turn off
the power switch (SW) and the main power switch
(SW) with the cover paper folding plate opened.
"77-55", "77-45", "77-58", "77-61"
[2] 2. Clean the cover paper folding plate [1] and the
book spine backing plate [2].
a075f2c004cb
1 140
13.2.2 Lubrication to the cover paper alignment plate shaft

PB-501/502
• Cover paper alignment plate shaft : Every 600,000 prints * 1
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Procedure
1. Turn the knob [1] to move the cover paper align-
ment plate inward.
2. Apply plas guard No.2 to the 4 cover paper align-
ment plate shafts [2].
Note
• Apply plas guard No.2 to the outside of the
cover paper alignment plate bearing on both
sides.
[3] [2]
[2] [1]
[3]
a075f2c094ca
141 1
13.3 Cover paper supply section

PB-501/502
13.3.1 Removing/reinstalling the pick-up roller assy and the separation roller assy
A. Procedure
2. Unlock the cover paper tray [3] by slightly pushing
[2] up the cover paper tray lock lever [2] with a
screwdriver or a similar tool, and pull out the cover
paper tray [3].
[1]
[3]
a075f2c008ca
[2] [3]
3. Turn the pick-up roller [1] in the direction of the
arrow (counterclockwise as seen from the front
side) to make the coupling [2] upright.
Note
• Be sure not to rotate the pick-up roller [1]
against the direction of the arrow (clockwise)
forcibly, as the roller is not designed to rotate
in that direction.
[1]
a075f2c009ca
142
5. Remove the bearing /Fr [1].

[2] [1]
6. Move the bearing /Rr [2] to the rear side.
PB-501/502
Note
• When reinstalling them, insert the bearing /Rr
[2] into the notch [5] on the metal frame while
keeping on the level the flat face [4] of the
bearing, and slightly pressing down the metal
frame [3] of the pick-up roller assy. Then insert
the bearing /Fr [1] in the same manner.
[2] [4]
[5] [3]
a075f2c010ca
143
[1] [5] [4] 7. Hold the pick-up roller assy [1] by hand and lift
and tilt the paper feed roller [3] so that it rotates on
PB-501/502
the shaft [2] of the pick-up roller to remove it from

the notch of the bearing [4] and the coupling [5].
Note
• When removing the pick-up roller assy [1], be
careful not to damage the sensor [7] with the
metal frame [6].
[3] [2] [6]
[7]
a075f2c011ca
144
8. Remove the pick-up roller shaft [2] from the arm

[3]
[1] of the paper feed guide plate and then remove
PB-501/502
the pick-up roller assembly [3].
steps in reverse.
Note
• After installing the pick-up roller assy, rotate
the pick-up roller counterclockwise as seen
from the front side.
• Make sure the paper feed roller and the belt
rotate smoothly.
[1] • The pick-up roller rotates in counterclockwise
direction only. Be sure not to rotate it in the
opposite direction.
[2]
[3]
a075f2c081ca
145
[1]
entrance guide plate [2].
PB-501/502
[2] a075f2c012ca
[1]
a075f2c013ca
146
12. Open the frame [1] of the separation roller assy in

[2]
the direction of the arrow, and remove the cou-
PB-501/502
pling pin [2] from the joint [3]. Then remove the
separation roller assy [4].
Note
[3] • When reinstalling, make sure to engage the
coupling pin [2] with the joint [3].
• When reinstalling the separation roller assy
[4], fasten it with the screws while pressing it
down.
[1]

steps in reverse.
[4]
a075f2c014ca
147
13.3.2 Replacing the pick-up roller and the paper feed roller
PB-501/502

• Pick-up roller : Spot replacement (Actual replacement cycle: Every 500,000 feeds)
• Paper feed roller : Spot replacement (Actual replacement cycle: Every 500,000 feeds)
B. Procedure
Note
• The outward appearance of the collar is identical for the paper feed roller and the separation roller.
However, the collar of the paper feed roller has a one-way mechanism on the inside while the col-
lar of the separation roller does not. Be careful not to confuse one with the other.
1. Remove the pick-up roller assy. (Refer to P.142)

[4] [2] [1] 2. Remove the C-clip [1] of the pick-up roller assy.
3. Slide 2 bearings [2] and remove the pick-up roller
[3] together with the shaft [4].
[3]
a075f2c015ca
4. Remove the bearing [1] and pull out the pick-up

[2] [1] roller [2] from the shaft [3].
5. Remove the pick-up roller [2] from the collar [4].
6. Replace the pick-up roller.
[4] [3]
a075f2c082ca
148
7. Remove the C-clip [1] and pull out the bearing /Fr
[1]
[2] from the shaft [3].
PB-501/502
8. Move the bearing /Rr [4] and remove the paper
feed roller [5] together with the shaft [3].
[4] [5] [2] [3] a075f2c086ca

[2] [1] 10. Pull out the paper feed roller [3] from the collar [2].
11. Replace the pick-up roller [3].
[3]
a075f2c087ca
Note
[2] [1]
• There is no big difference in appearance
between the 2 collars (one for the paper feed
roller, and the other one is for the separation
roller). However, they are different in the
inside. The collar [1] for the paper feed roller
has a one-way mechanism in it, and the other
one [2] does not. Make sure to attach them
correctly.

a075f2c016ca steps in reverse.
counter reset of parts counters No.229 and No.
230.
149 1
13.3.3 Replacing the separation roller

PB-501/502

• Separation roller : Spot replacement (Actual replacement cycle: Every 500,000 feeds)
B. Procedure
1. Remove the separation roller assy. (Refer to P.142)
[3] [2]
2. Remove the C-clip [1] and remove the separation
roller [3] together with the shaft [2].
[1] a075f2c017ca
3. Pull out the gear [2], the collar [3] and the separa-
[2] [3] [4] [1]
tion roller [4] from the shaft [1] in the direction of
the arrow.
4. Replace the separation roller [4].
steps in reverse.
Note
• There is no big difference in appearance
between the 2 collars (one for the paper feed
roller, and the other one is for the separation
[6] [5] roller). However, they are different in the
inside. The collar [5] for the paper feed roller
has a one-way mechanism in it, and the other
one [6] does not. Make sure to attach them
correctly.

a075f2c018ca
1 150
13.3.4 Replacing the paper feed clutch (MC71) and the cover paper separation clutch (MC72)
PB-501/502
• Cover paper pick up clutch (MC71) : Spot replacement (Actual replacement cycle: Every 300,000 feeds)
• Cover paper separation clutch (MC72) : Spot replacement (Actual replacement cycle: Every 300,000 feeds)
B. Procedure
1. Remove the stopper screws, 1 each, attached on
the right and left rails of the cover paper tray and
pull out the tray. (Refer to P.203)
2. Remove the 5 screws [1] and remove the clutch
cover [2].
[1] [2]
a075f2c019ca

[4] [2] [3] [5] [6]
4. Remove the C-clips [2], 1 each, and remove the
cover paper feed clutch (MC71) [3] and the cover
paper separation clutch (MC72) [4].
Note
• When reinstalling, be sure to insert the stop-
per [5] of the clutch over the tab [6] of the
metal frame.

steps in reverse.
[5] [6] [1] 6. After replacing the parts, be sure to conduct the
a075f2c020ca counter reset of parts counters No.231 and No.
232.
151 1
13.4 Framework section

PB-501/502
CAUTION:
to the main body.
13.4.1 Replacing filter

• Filter : Every 600,000 prints*1
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Procedure
[2] [1] 1. Remove 2 screws [1] and remove the filter cover
[2].
a075f2c021ca
2. Remove the 4 magnets [1] and remove the filter

[2].
steps in reverse.
[2] [1] a075f2c022ca
1 152
13.5 Glue tank section
PB-501/502
13.5.1 Replacing the cover paper glue roller drive gear bearing
• Cover paper glue roller drive gear bearing : Actual replacement cycle: Every 6,000 hours *1
: Every 30,000,000 prints
(Actual replacement cycle: Every 6,000 hours) *2
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Procedure
1. Remove the glue tank unit. (Refer to P.173)
[1]
2. Remove 6 screws[1] and remove the gear cover /
Lt [2].
[2] [1] a075f2c124ca
153 1
3. Remove the screw [1] and remove the gear cover

[2] [1]
/Rt[2].
PB-501/502
a075f2c125ca
4. Remove the E-rings [1] and [2] of the cover paper

[2] [1]
glue roller drive gears /1 and /2.
a075f2c126ca
5. Remove the bearing [1] of the cover paper glue

[3] [4] [5] roller drive gear /1 [2] to move the gear.
6. Remove the bearing [3] of the cover paper glue
roller drive gear /2, the cover paper glue roller
drive gear /2 [4] and the bearing [5] of the cover
paper glue roller drive gear /2.
[1] [2]
a075f2c127ca
154

[1]
PB-501/502
Note
• When reinstalling the slope, be sure to align 4
positioning projections [2].
[2]
a075f2c128ca
8. While lifting up the glue tank [1], remove the cover

[2] [3] [1] paper glue roller drive gear /1 [2] and the bearing
[3] of it.
steps in reverse.
a075f2c129ca
155
13.5.2 Lubrication to the glue apply roller motor drive connecting gear
• Glue apply roller motor drive connecting gear : Every 600,000 prints *1
PB-501/502
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Procedure
[1]
a075f2c091ca
1 156
3. Open the front door, move the glue tank unit [1] to
[4] [3]
the front side, and then remove 2 screws [2].
PB-501/502
Note
• When moving the glue tank unit, be sure to
hold it by the metal frame [3] on the right side
of the unit.
4. Remove the gear cover [4].
[2] [1]
a075f2c092ca
157
5. Apply the multemp FF-RM to the glue apply roller

motor drive connecting gear [1].
PB-501/502

steps in reverse.
[1]
a075f2c093ca
158
13.5.3 Replacing the pellet supply cooling fan (M4)

PB-501/502
• Pellet supply cooling fan motor (M4):Every 600,000 prints *1
:Every 750,000 prints *2
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Procedure
[1] [3]
3. Remove 2 screws [2] and remove the pellet sup-
ply cooling fan (M4) [3].
steps in reverse.
Note
• When reinstalling the pellet supply cooling fan
(M4) [3], be sure to reinstall it to the same
direction as shown in the picture.
• Be sure not to nip the wiring harness.
[2] 8050ma3141
159 1
13.6 Clamp section

PB-501/502
13.6.1 Lubrication to the clamp pressing board shaft

Clamp pressure plate shaft : Every 600,000 prints*1
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Procedure
1. Pull out the clamp unit.
2. Apply the plas guard No.2 to 2 positions on the
clamp pressing board shaft [2].
[2]
[1]
[2]
a075f2c122ca
1 160
13.7 Book stock section
PB-501/502
13.7.1 Lubrication to the guide shafts /Rt and /Lt
Guide shafts /Rt and /Lt : Every 600,000 prints*1
*1 C6501/C6501P/C65hc
*2 1200/1200P/1051
B. Procedure
1. Apply the plas guard No.2 to 4 positions on 4
positions [1] on the guide shaft /Rt, /Lt.
[1]
a075f2c123ca
161 1

PB-501/502

1 Cover Front door P.163
3 Upper cover /Rr P.164
4 Upper cover / Lt P.165
5 Rear cover P.165
6 Left cover P.166
7 Pellet supply cover P.167
8 SC cover /Fr P.168
9 SC cover /Lt P.168
10 SC cover /Up P.169
11 Book stock cover /Up P.169
12 Book stock cover /Fr P.170
13 Book stock cover /Rr P.171
14 Pellet supply section Pellet supply unit P.172
15 Glue tank section Glue tank unit P.173
16 SC section SC unit P.177
17 SC switchback release motor (M13) and the one-way P.180
clutches /A and /B
18 SC pressure arm solenoid (SD13) P.185
19 FD alignment solenoid (SD11) P.187
20 Clamp section Clamp unit P.189
21 Book stock section Book stock unit P.191
22 Book lift wire P.194
23 Conveyance section Conveyance unit /Lw P.198
24 Paper exit section Sub tray exit solenoid (SD4) P.199
25 Cover paper supply Cover paper tray P.203
26 section Cover paper lift wire P.206
27 Cover paper table Roller cutter blade assy P.212
section
1 162
14.2 Removing procedure for disassembly/reassembly parts
PB-501/502
CAUTION:
to the main body.
14.2.1 Front door

A. Procedure
[4]
[6] [5] [3] [2]
2. Remove the screw [2] and remove the wire [3].
3. Remove the 2 screws [4] and slide the mounting
bracket [5] into the direction of the arrow and
remove the pin [6]. Then release the front door [1]
from the pin [7].
steps in reverse.
Note
• When installing the wire [3], be sure to twist it
1 turn in counter clockwise before securing
with a screw to prevent the wire from con-
tacting with the tab.
[1]
[7]
a075f2c023ca
163
14.2.2 Upper cover /Fr

A. Procedure
PB-501/502
1. Open the front door [1] and the upper door [2].
[1] [5] [3] [2]
3. Pull the left part of the upper cover /Fr [4] in the
arrow-marked direction [5]. Then release the
cover from the projection [6] and disconnect it
from the connector [7].
Note
• When reinstalling it, be sure to put the con-
nector [7] under the upper cover /Fr [4] prop-
erly so as not to let the cables get caught
between the cover and the frame.
[4]
steps in reverse.
[7] [6] a075f2c024ca
14.2.3 Upper cover /Rr

A. Procedure
[3] [1]
2. Remove 4 screws [2] and then remove the upper
cover /Rr [3].
steps in reverse.
[2] a075f2c025ca
164
14.2.4 Upper cover / Lt

A. Procedure
PB-501/502
1. Remove the 2 screws [1] and remove the upper
[1] [2]
cover /Lt [2].
steps in reverse.
a075f2c026ca
14.2.5 Rear cover

A. Procedure
[1] [2]
rear cover [2].
Note
• When installing the rear cover, make sure to
attach the metal plates [3] to the bottom of
the rear cover.

steps in reverse.
[3] a075f2c027ca
165
14.2.6 Left cover

A. Procedure
PB-501/502

[2] [1]
cover [2].
steps in reverse.
a075f2c028ca
166
14.2.7 Pellet supply cover

A. Procedure
PB-501/502
1. Remove the upper cover /Rr. (Refer to P.164)
[3]
4. Open the pellet supply door [2]. Remove the pellet
supply cover [4] to the arrowed direction [5] care-
fully so as not to damage the wire binding [3].
Note
• When removing/installing the glue supply
cover, be careful not to cut or damage the
wire binding [3].

[1]
[2]
a075f2c029ca
167
14.2.8 SC cover /Fr

A. Procedure
PB-501/502
1. Remove the screw [1] and remove the SC cover /

[1] [2]
Fr [2].
steps in reverse.
a075f2c030ca
14.2.9 SC cover /Lt

A. Procedure
[1] [2]
1. Remove the 2 screws [1] and remove the SC
cover /Lt [2].
steps in reverse.
a075f2c031ca
168
14.2.10 SC cover /Up

A. Procedure
PB-501/502
[4]
3. Remove the SC cover /Lt.
(Refer to P.168)
4. Remove the pellet supply cover. (Refer to P.167)
5. Remove the SC cover /Fr. (Refer to P.168)
6. Remove 4 screws [1] and remove the SC cover /
Up [3] in the direction of the arrow [4] while slightly
lifting up the circled part [2].
[3] [1] [1]
steps in reverse.
[2] a075f2c032ca
14.2.11 Book stock cover /Up

A. Procedure
[2]
2. Slightly move the book stock cover /Up [2] to the
left and lift it a little. Then disconnect the connec-
tor [3] to remove the cover.
steps in reverse.
[1] [3]
a075f2c033ca
169
14.2.12 Book stock cover /Fr

A. Procedure
PB-501/502

2. Remove the book stock cover /Up.
(Refer to P.169)
[8]
3. Move the lever [1] up and pull out the cover paper
tray [2].
[1]
4. Open the stacker door [5].
[9] 6. Tilt the upper part of the book stock cover /Fr [6]
to the left [7], and remove the built-in from the
[5] [3] [7] [6] [4] [10]
screws [4] avoiding the screw [8] and the arm [9].
Then pull the right edge in the direction of the
arrow [10] and remove the book stock cover /Fr
[6].
[2]
[12] [11]
a075f2c034ca
170
14.2.13 Book stock cover /Rr

A. Procedure
PB-501/502
[3] [1] [2]
2. Open the stacker door [2] and remove the book
stock cover /Rr [3].
steps in reverse.
[1] a075f2c035ca
171
14.2.14 Pellet supply unit

A. Procedure
PB-501/502

[4] [2]
6. Loosen the screw [2].
7. Remove 3 screws [3] and remove the pellet sup-
ply unit [4] upward while releasing it from the
screw [2].
Note
• When removing the unit, be careful not to spill
the pellet.

steps in reverse.
[3]
[1] a075f2c036ca
172
14.2.15 Glue tank unit
PB-501/502
CAUTION:
the power switch (SW2) of the main body. To prevent burn injuries, leave the unit until it cools
enough before performing the maintenance work.
A. Procedure
[2] 2. Remove the upper cover /Rr. (Refer to P.164)
3. Remove the screw [1] and disconnect 2 connec-
tors [2], and then remove the suction unit [3].
5. Remove the C-clip [5] and pull out the pin [6]
straight up to release the coupling arm [7].
[1]
[3]
[4] [5] [6] [7]

a075f2c118ca
173
6. Remove 2 screws [1] and then uncouple the belt

[2] [1]
coupling bracket [2].
PB-501/502
a075f2c119ca
174
7. Pull out the glue tank unit [1] and remove 4

[2] [2] screws [2].
PB-501/502
Note
• When moving the glue tank unit, be sure to
hold it by the metal frame [3] on the right side
of the unit.
• When removing the screw [2], be careful to
avoid injury from sharp metal edges around
the screw.
8. Further pull out the glue tank unit [1].

9. Remove the glue tank unit from the rail [4].
[4] [5] [1]
steps in reverse.
Note
• After installing the glue tank unit, make a test
print and binding to check that no glue is
squeezed out of the top and bottom edges of
the created book and no pages come off the
cover when opening the book.
[3]
a075f2c038ca
175
Note
[1]
• Never loosen or tighten the 2 screws because
PB-501/502
they are keeping the levelness and vertical

position of the glue tank unit.
a075f2c084ca
176
14.2.16 SC unit
A. Procedure
PB-501/502
[3] [2] 1. Remove the upper cover /Fr. (Refer to P.164)
5. Remove the left cover. (Refer to P.166)
7. Remove the SC cover /Fr.
(Refer to P.168)
8. Remove the SC cover /Lt.
(Refer to P.168)
9. Remove the SC cover /Up.
(Refer to P.169)
(Refer to P.169)
[1]
a075f2c040ca
11. Remove the pellet supply unit. (Refer to P.172)
12. Disconnect 5 relay connectors [1].
13. Remove the wire binding [3] from the SC unit [2]
by releasing the wire binding from the saddles.
177

15. Remove 2 screws [2] and remove the wire [3] and
PB-501/502
[1]
the knob [4]. Then remove the belt [5].
Note
• After installing the belt [5], check that the lug
belt is properly engaging with the pulleys with
no slack and turns smoothly when the knob is
turned.
16. Hold the metal frames [6] on the rear and front
side of the unit, and remove the SC unit [7] to the
[6] [7] [6]
arrowed direction.
[1]
[4]
[5] [3] [2]

a075f2c041ca
178
Note
• When the SC unit [1] is removed, the lock arm
PB-501/502
[2] is released from the stopper [3]. Therefore,
when installing the SC unit, be sure to put the
lock arm [2] under the stopper [3] while lifting
and tilting the unit in the direction of the
arrow [4].

steps in reverse.
[2] [4] [3]
[1]
a075f2c042ca
179
14.2.17 SC switchback release motor (M13) and the one-way clutches /A and /B
A. Procedure
PB-501/502
1. Remove the SC cover /Up. (Refer to P.169)

[2] [3] [1]
2. Open the upper door [1] to open the SC door [2]
and set the paper [3].
3. Close the SC door [2].
Note
• Before removing the C-clips, be sure to
spread a sheet of paper under the switchback
roller assy to prevent the C-clips from drop-
ping into the machine inside.
a0v9t3c020ca
4. Remove the screw [1] and remove the switchback

cam [2].
Note
[2] • The switchback cam [2] is tensioned by the
spring [4] via the switchback arm [3]. When
[3]
removing the screw [1], the switchback arm
[3] is pulled by the spring [4] and the switch-
[4] back cam [2] moves. At this time, be careful
[1] not to drop the screw [1].
a0v9t3c021ca
1 180
Note
• When reinstalling the switchback cam [2], be
[2] [1]
PB-501/502
sure to install it following the positional rela-
tion with the actuator [2] as shown in the pic-
ture.
a0v9t3c022ca
5. Remove 2 E-rings [1] and remove 2 bearings [2].

[1] [3]
[2] a0v9t3c023ca
7. Disconnect 3 connectors [1] and remove the wir-

[1]
ing harness from 2 wiring harness clamps [2].
[2] a0v9t3c024ca
181 1
[1] 8. Remove 2 screws [1] and remove the SC switch-

back release motor assy [2].
PB-501/502
[2] a0v9t3c025ca
9. Remove 2 screws [1] and remove the SC switch-

[1]
back release motor [2].
[2] a0v9t3c026ca
10. Remove the E-ring [1] and remove the one-way

[2]
clutch /B [2].
[1] a0v9t3c027ca
1 182
Note
[1]
• When reinstalling the one-way clutch /B [1],
PB-501/502
be sure to install it in the direction shown in
the picture.
a0v9t3c028ca
11. Remove the screw [1] and remove the pressure

[4] [3] [1] [2]
cam [2].
12. Remove the E-ring [3] and remove the one-way
clutch /A [4].
steps in reverse.
a0v9t3c029ca
Note
[2] [1]
• When reinstalling the pressure cam [1], be
sure to install it following the positional rela-
tion with the actuator [2] as shown in the pic-
ture.
a0v9t3c030ca
183 1
Note
[1]
• When reinstalling the one-way clutch /A [1],
PB-501/502
be sure to install it in the direction shown in

the picture.
a0v9t3c033ca
Note
• When reinstalling the SC switchback release
motor assy, be sure to set so that the dis-
tances "a" and "b" become same value.
a b
Standard value: The difference of distances
"a" and "b" = 0.2mm or less
a0v9t3c004ca
1 184
14.2.18 SC pressure arm solenoid (SD13)

A. Procedure
PB-501/502
1. Remove the SC unit. (Refer to P.177)
[1]
Note
• When putting down the SC unit, be sure not to
pin the wiring harness under it.
• Put the SC unit on a table so that the bottom
surface of the sub scan alignment unit [1]
does not contact the floor.
2. Pull out the sub scan alignment unit [1] in the

arrow-marked direction.
a0v9t3c005ca

[1] 4. Remove 2 screws [2] and remove the SC pressure
arm solenoid (SD13) [3].
steps in reverse.
[2] a0v9t3c006ca
185 1
Note
[1]
• When reinstalling the SC pressure arm sole-
PB-501/502
noid, adjust the position so that the distance

"a" obtains a standard value with the plunger
[1] pulled, and then fix with the screw [2].
Standard value: a = 16.4 ± 1mm
[2]
a a0v9t3c007ca
1 186
14.2.19 FD alignment solenoid (SD11)

A. Procedure
PB-501/502
1. Remove the SC unit. (Refer to P.177)
[1]
Note
• When putting down the SC unit, be sure not to
pin the wiring harness under it.
• Put the SC unit on a table so that the bottom
surface of the sub scan alignment unit [1]
does not contact the floor.
2. Remove 4 screws [1] and remove the SC door [2].
[3] [2]
a0v9t3c008ca
3. Put the SC unit with the FD alignment solenoid

[2] [3] [4]
assy [4] faced up.
Note
• Put the SC unit on a table so that the SC
switchback release motor assy [3] does not
contact the floor.

5. Remove 2 screws [3] and pull out 2 shafts, and
then remove the sub scan alignment plate [2].
[1] a0v9t3c009ca
6. Remove the E-ring [1] and remove the sub scan

[1]
alignment arm [2].
[5] 7. Disconnect the connector [3] and remove the
screw [4], and then remove the FD alignment
solenoid assy [5].
Note
• FD alignment solenoid When removing the
assy, be careful not to drop the pin.
[4] [3] [2]

a0v9t3c010ca
187 1
[1] [2] 8. Remove 2 screws [1] to remove the mounting

plate [2], and then remove the FD alignment sole-
PB-501/502
noid (SD11) [3].
Note
• When reinstalling the FD alignment solenoid,
adjust the position so that the distance "a"
obtains a standard value with the plunger [4]
pulled.
Standard value: a = 17.5 ± 0.5mm
[4] [3] a0v9t3c011ca

a
steps in reverse.
a0v9t3c012ca
1 188
14.2.20 Clamp unit

A. Procedure
PB-501/502
[2]
(Refer to P.169)
6. Remove the pellet supply unit. (Refer to P.172)
7. Disconnect the connector (CN32) [1] and 2 con-
nectors (CN73, and CN82) [2].
9. Remove the E-ring [5] and pull out the pin [6]
downward to release the coupling arm [7].
10. Disengage the saddles to release the wire binding
[8] that is heading toward the circuit board.
[1]
[5] [6]
[7] [8] [4] [3]

a075f2c043ca
189
11. Pull out the clamp unit [1] carefully watching the
[2] [3]
wire binding and the coupling arm on the rear of
PB-501/502
the unit.
lock bracket [3].
13. While lifting the clamp unit [1] by holding its left
and right metal frames [4], release the 4 cutouts
[5] from the hooks [6] and remove the clamp unit.
Note
• When reinstalling the clamp unit, make sure
that the 4 hooks [6] are properly fitted in the
cutouts [5] of the unit.
[4]

steps in reverse.
Note
• After installing the clamp unit, make a test
print and binding to check that the cover and
inside papers are neatly aligned without
skewing.
[1]
[5] [6]
a075f2c044ca
190
14.2.21 Book stock unit

A. Procedure
PB-501/502
[5] 2. Remove the rear cover. (Refer to P.165)
[6] 3. Remove the book stock cover /Up.
(Refer to P.169)
4. Remove the book stock cover /Fr. (Refer to P.170)
5. Remove the book stock cover /Rr. (Refer to P.171)
6. Disconnect the connectors (illustrated as white
[2] boxes) on the PB control board (PBCD) [1] and
the PB drive board (PBDB) [2].
Note
• Do not disconnect the connectors that illus-
trated as the dark gray boxes on the PBCB [1]
and the PBDB [2]. The connectors illustrated
as the light gray boxes are reserved.
• Disconnect the connector [4] from the con-
[1] nector (CN29) [3] when connecting the FD.
When the FD is not connected, the short plug
is connected to the connector (CN29).
[3] [2] • Note that both connectors, CN73 (white wire
binding) [5] and CN68 (yellow wire binding) [6]
have 6 pins.

8. Release the wire binding from the saddles.
Note
• When reinstalling, be sure to secure the wire
properly binding with saddles, Especially
those routed over the coupling section [8] of
[8] [4] [7] the unit so as not to damage the wires with
metal frames such as the cover.
[9]
[10]
a075f2c056ca
191

[1]
PB-501/502
[1]
a075f2c057ca
192
11. Slightly open the front side of the book stock unit
[3] [2] [1]
[3] to the left side [1] to release the unit from the 2
PB-501/502
pins [2] on the far side, and then separate the unit
from the main body.
Note
• The casters of the book stock unit [3] are
installed at only 2 positions on the left-side of
the unit. The main body side of the unit is sup-
ported by the 2 metal plates [4] protruded
from lower left of the main body. Because of
this, be sure to support the unit by hand while
separating the unit to avoid the right bottom
[5] of the unit falling down. When you release
your hand from the unit, be sure to put some
support under the right bottom of the unit.
• "When installing the book stock unit, put the
right bottom of unit [5] on the metal plates [4]
before engaging the 2 pins [2]."
[2] [5] [4] a075f2c058ca

steps in reverse.
193
14.2.22 Book lift wire

A. Procedure
PB-501/502
1. Carry out the I/O check in service mode in the fol-

[3] [2] [3]
lowing order of output check code, and turn off
the power switch (SW) and the main power switch
(SW) after moving the carriage section to its low-
[1] [1] est position.
"77-55", "77-45", "77-58", "77-61"
(Refer to P.169)
4. Remove the book stock cover /Fr. (Refer to P.170)
[5] [6] 5. Remove the book stock cover /Rr. (Refer to P.171)
6. Remove 3 screws [1] and remove the 4 mounting
brackets [2] on the front and rear of the book
stock unit.
Note
• When reinstalling, route the book lift wires /Fr
[3] and /Rr [4] between 2 screws and 1 screw
[1], and secure them with the mounting
brackets [2].
7. Loosen the 2 screws [6] of the tension bracket /Fr

[4]
[5].
Note
• When installing the tension bracket /Fr [5], be
sure to tighten the screws [6] while pulling the
[1]
[1] bracket downward by the specified tension.
Standard value: 5kgf
8. Loosen the 2 screws [8] of the tension bracket /Rr

[7].
[8] [7] [2]
a075f2c059ca
Note
• When installing the tension bracket /Rr [7], be
sure to tighten the screws [8] while pulling the
bracket downward by the specified tension.
Standard value: 5kgf
194
9. Remove the E-ring [1], pulley [2], pin [3], and the
[11]
wire end [4]. Then remove the book lift wire/Fr [5].
PB-501/502
[4]
[2] Note
• Install the book lift wire/Fr [5] as following.
Route the wire so that it comes out of the
[1]
[5] lower right [6] of the pulley [2]. Loop the wire
over the pulley [7], then loop it over the [8],
[9], [10] pulleys in that order. Then wind the
[3] wire 6 times counterclockwise [11] over the
pulley [2], and put the wire end [4] into the
pulley.
[7]
[2]
[6]
[5]
[9]
[2]
[8]
[10]
a075f2c060ca
195
10. Remove the E-ring [1], then remove the washers

[5]
[2] and [3], spring [4], and gear [5].
PB-501/502
[3] 11. Remove the coupling [6] and the pin [7].
[2]
[4]
[1]
[6]
[7]
a075f2c061ca
196
12. Remove the E-ring [1], pulley [2], pin [3], and the
[4] [2] [1] [3] wire end [4]. Then remove the book lift wire/Rr [5].
PB-501/502
Note
• Install the book lift wire/Rr [5] as following.
[5] Route the wire so that it comes out of the
lower left [6] of the pulley [2]. Loop the wire
over the pulley [7], then loop it over the [8],
[11] [9], [10] pulleys in that order. Then wind the
[7] wire 6 times counterclockwise [11] over the
pulley [2], and put the wire end [4] into the
pulley.
[5]

steps in reverse.
[6]
[9]
[8]
[10]
a075f2c062ca
197
14.2.23 Conveyance unit /Lw

A. Procedure
PB-501/502
1. Disconnect the 3 connectors [1] and release the

[7] [5] [7]
wire binding from the 6 saddles.
2. Remove the screw [2] and slide the coupling [3]
into the arrow-marked direction.
[4] [4] 4. Release the conveyance unit /Lw [6] from the
hooks [5] and remove the unit.
Note
• When installing the conveyance unit /Lw,
insert the hooks [5] into the holes [7] of the
[6] [1] unit.

steps in reverse.
[2]
[3]
a075f2c063ca
198
14.2.24 Sub tray exit solenoid (SD4)

A. Procedure
PB-501/502
1. Remove the upper cover /Fr. (Refer to P.164)
[7] 2. Remove the upper cover /Rr. (Refer to P.164)
[4]
4. Remove 2 screws [1] and remove the metal frame
[2].
5. Remove 6 screws [3] and disconnect the connec-
tors [4] and [5].
[6] [10] [11] 7. Remove the screws of 3 knobs [7] and remove
the knobs.
[9]
[10].
9. Remove 6 screws [8] and remove the conveyance
unit [11].
[8] Note
• Put the conveyance unit on a table so that the
paper entrance guide does not contact the
floor.
[3]
[1]
[2]
[5] [3] a0v9t3c013ca
199 1
10. Loosen the screws [1], 2 each, on the upper cover

[1] [2]
/Rt, and remove the upper cover /Rt.
PB-501/502
a0v9t3c014ca

[3]
12. Remove 3 screws [2] and remove the sub tray exit
solenoid assy [3].
[2]
[1] a0v9t3c015ca
1 200
13. Remove 2 screws [1] and remove the sub tray exit
[1] [2] solenoid assy (SD4) [2].
PB-501/502
steps in reverse.
a0v9t3c016ca
Note
[1]
• When reinstalling the sub tray exit solenoid,
adjust the position so that the distance "a"
[2] obtains a standard value with the plunger [2]
pulled.
Standard value: a = 3.7 ± 0.5mm
a a0v9t3c017ca
• While pulling the plunger of the sub tray exit

solenoid, adjust the position so that the dis-
tance "a" (the distance between the paper
exit roller and the paper exit driven roller)
obtains a standard value.
Standard value: a = 0 ± 1.5mm
a a0v9t3c018ca
201 1
• After reinstalling the conveyance unit, check

a the points "a" shown in the picture, to see
PB-501/502
that the conveyance unit does not contact the

upper door. When they are in contact, loosen
4 fixing screws on the upper cover /Rt and
adjust the position so that the upper door and
the upper cover /Rt does not come in contact.
a0v9t3c019ca
1 202
14.2.25 Cover paper tray
PB-501/502
CAUTION:
• As the cover paper tray is heavy, be sure to perform the following work with 2 people.
Note
• When lifting the cover paper tray, be sure to hold it by the specified positions. Holding it at posi-
tions other than those positions specified damage the tray, thus resulting in a paper feed jam.
A. Procedure
2. Unlock the cover paper tray [3] by slightly pushing
up the cover paper tray lock lever [2] with a
screwdriver or a similar tool, and pull out the cover
paper tray [3].
[2]
[1]
[3]
a075f2c064ca
203
3. Remove the 2 stopper screws [2], 1 for each right

and left rail [1] and further pull out the cover paper
PB-501/502
tray.
[2] [1]
a075f2c065ca
204
4. Remove 4 screws [1], 2 for each left and right rail,

hold the cover paper tray [2] by the specified posi-
PB-501/502
tions [5], and remove it straight up.
Note
• When installing the cover paper tray, make
sure that the 4 knobs [3] on the rails are prop-
erly fitted in the cutouts [4] of the cover paper
tray.
• When lifting the cover paper tray, be sure to
hold the specified positions [5] by 2 people.
[5] [1] [6] [2] Do not hold the part indicated with [6] as the
part can easily become deformed, which
adversely affects paper feed resulting in a
paper jam.

steps in reverse.
[2] [1] [5]

[3] [4]
a075f2c066ca
205
14.2.26 Cover paper lift wire

A. Procedure
PB-501/502
1. Remove the cover paper tray. (Refer to P.203)

[2] 2. Remove 6 screws[1].
cover paper tray front cover [3].
[1] [1] [3]
a075f2c067ca
206
4. Remove the E-ring [1], and remove the knob [2]

[5] [3] [2] [1]
and the belt [3].
PB-501/502
5. Remove 6 screws[4] and remove the gear cover
[5].
[4]
a075f2c068ca

[1]
a075f2c069ca
7. Slide the pulley [1], and pull out the wire ends of
[3] [2]
the lift wire/Fr1 [2] and /Fr2 [3] from each hole of
the shaft [4].
Note
• The wire end of the shorter wire, lift wire/Fr2
[1]
[3], must be inserted into the shaft hole near
the frame of the cover paper tray. The wire
end of the shorter wire, lift wire/Fr2 [3], must
be inserted into the shaft hole near the frame
of the cover paper tray.
• When installing the pulley, lift the cover paper
[4] lift plate slightly to give slack to the wires and
a075f2c070ca
insert the wire ends one by one into the shaft
holes. Then secure them with the pulley [1].
207
8. Remove the E-rings [1], 1 each, and then remove

[2] the wire cover [2].
PB-501/502
9. Remove the cover paper lift wires/Fr1 [4] and /Fr2

[5] from each pulley [3].
[4]
Note
[1]
• When installing the wires, make sure that the
[5]
[3] wires are properly routed inside the wire cov-
ers [2] and are not crossed each other.
[4] [5]
a075f2c071ca
10. Pull out each wire end [2] through each hole of the
cover paper lift plate arm [1].
Note
• When pulling out the wire, pull it out carefully
so as not to damage it with sharp metal
edges.
[2]
[1]
a075f2c072ca
208
11. Remove 6 screws[1] and remove the gear cover

[2].
PB-501/502
[1]
[1] [2]
[1]
[2]
a075f2c073ca

[3] [2]
Note
drop and lose the bearing [3].
[1] a075f2c074ca
209
13. Remove the bearing [1] and the E-ring [2], and
[3] [4]
then remove the gear [3].
PB-501/502
Note
drop the pin[4].
[1] [2] a075f2c075ca

[1]
Note
drop the bearing [3].
[3] [2] a075f2c076ca

[1] [3]
Note
drop and lose the pin [3].
[2] a075f2c077ca
210

[1] [2] [3]
17. Pull out the cover paper lift wire/Rr1 [2] and /Rr2
PB-501/502
[3] from the shaft holes in the same manner as
step7.
a075f2c078ca
18. Remove the cover paper lift wire/Rr1 [1] and /Rr2
[2] [1]
[2] in the same manner as step8 to step10.
steps in reverse.
Note
• When pulling out the wire end [3] of the cover
paper lift wire/Rr2 [2], lift the cover paper lift
plate until the cover paper lift plate arm [4]
appears.
• The wire /Fr is gray in color and the wire /Rr is
black.
• When the installation is completed, make
[3] [4]
sure that the lift plate is horizontal.
a075f2c079ca
211
14.2.27 Roller cutter blade assy

A. Procedure
PB-501/502
1. Remove the PB from the main body.

2. Remove the conveyance unit /Lw. (Refer to P.198)
3. Remove 2 screws [1] and the roller cutter blade
assy [2]. Then disconnect the connector [3].
[1]
Note
• Pull out the cover paper waste box before
removing the roller cutter assy.
• When reinstalling the roller cutter assy, be
sure to route the wire binding [4] under the
cutter motor (M50) [5].
[2]
• Push the roller cutter blade assy [2] against
the metal plate [6] to reinstall the assy.

steps in reverse.
[6]
[1]
[4] [5] [3] a075f2c007ca
1 212
14.2.28 Binding mode procedure with manual operating function
PB-501/502
• When a problem occurs at the clamp section or the cover paper table section, the binding can be checked
with the manual operation.
Note
• Disconnect the connector (CN5) on the PB control board (PBCB) after the check. (Manual opera-
tion forbidden state)
A. Procedure
[1]
(Refer to P.169)
2. Connect the connector (CN5) on the PB control
board (PBCB).
3. Install the book stock cover /Up.
a075f2c120ca
4. Press the button /1 [1].

5. Open the front door and pull out the clamp unit.
[1] [2] [3]
6. Set the inside paper to the clamp unit.
7. Adjust the clamp alignment plates /Fr and /Rr to
the inside paper edge on the shorter side by
hand.
9. Set the clamp unit.
Note
• Set the clamp unit gently. Setting it roundly
causes the misalignment of inside papers
widening the clamp alignment plate.
10. Close the front door.

a075f2c121ca
Note
• Disconnect the connector (CN5) on the PB
control board (PBCB) after the check.
213
14.2.29 Multi feed detection boards /1 (MFDTB71) and /2 (MFDTB72)

PB-501/502
Note
• When replacing the multi feed detection board /1 (MFDTB71), be sure to replace the multi feed
detection board /2 (MFDTB72) at the same time.
• When the multi feed detection board is replaced, be sure to conduct the adjustment in replacing
multi feed detection board. (Refer to Field Service P.324)
A. Procedure
1. Remove the conveyance unit /Lw [1].
[1]
(Refer to P.198)
2. Remove 2 screws [2] and then remove the cover
paper multi feed detection board /1 (MFDTB71)
cover [3].
[2]
[3] a075f2c095ca

[1] [2] 4. Remove 2 screws [2] and then remove the cover
[3].
[3]
a075f2c096ca
214
5. Remove 2 screws [1] and then remove the cover

PB-501/502
cover [2].
[1]
[2] a075f2c097ca

[1] [2] 7. Remove 2 screws [2] and then remove the cover
[3].
steps in reverse.
[3]
a075f2c098ca
215
B. Notes to keep in mind when installing the multi feed detection boards /1 (MFDTB71) and /2
(MFDTB72)
PB-501/502
• The multi feed detection boards /1 (MFDTB71)

[2] and /2 (MFDTB72) are installed on the same
type board. Be careful not to confuse one
with the other when installing them.
• Be sure to confirm the marking on the board
when installing it.
• Multi feed detection board /1 (MFDTB71) [1]:
56UA
• Multi feed detection board /2 (MFDTB72) [2]:
15AG
• The connector shape is different for the multi
feed detection boards /1 (MFDTB71) and /2
(MFDTB72). So, even if it is installed incor-
[1] a075f2c099ca rectly, the connector cannot be connected.
216
GP-501
2009.07
Ver. 1.0
Revision history
Revision mark:
corresponding page.
NOTE

CONTENTS
GP-501
GP-501
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1
DESCRIPTION ITEMS FOR SAFTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1
PRODUCT POSITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2
LONG EDGE FEED (LEF) ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2
OUTLINE
3. PAPER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CONFIGURATION / OPERATION
4. CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5. PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.1 Punch conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2 Punch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.3 Chip tray control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.4 Bypass conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
MAINTENANCE
6. DIE SET SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1 Die Set Life Expectancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2 Die Set Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2.1 Serviceable Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2.2 Felt Pad Retaining Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2.3 Reassembling the Felt Pad Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.2.4 Floating Pressure Bar Spring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.3 Checking and Replacing the Die Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.4 Checking and lubricating the Die Set pins and Die Set shoulder bolts . . . . . . . . . . . . . . . . . . . . . . . . 25
6.5 Hole Alignment inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7. CHECK, CLEANING, AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.1 External Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.2 Internal Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.3 Operational Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.4 Internal Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.5 Cleaning the base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.5.1 Chip Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.6 Cleaning the Die guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.7 Checking the Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.8 Cleaning and Checking the aligner paper path and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.8.1 Cleaning and Checking the Aligner Idler Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.8.2 Cleaning the Aligner (Green) Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.9 Cleaning and Checking the Back Gauge Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.10 Cleaning and Checking the Idler Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.10.1 Cleaning and Checking the Bypass Idler Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
i
7.10.2 Cleaning and Checking the punch idler rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

7.11 Cleaning and Checking the Drive Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.12 Checking the Aligner Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
GP-501
7.13 Cleaning the Optical Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

7.14 Cleaning and Checking the Bypass Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.15 Cleaning and Checking the Punch Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.16 Cleaning and Checking the Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.17 Bypass panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.17.1 Bypass Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.18 Aligner panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.18.1 Aligner Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.18.2 Aligner Idler Roller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.18.3 Aligner Drive Belt Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.19 Cleaning and checking the energy drive roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.20 Replacing the back gauge mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.20.1 Back Gauge Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.20.2 Solenoid Spring Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.20.3 Back Gauge Paddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.20.4 Back Gauge Assembly Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

7.21 Punch module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.21.1 Punch Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.21.2 Lubricating to the Punch Drive Cams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7.21.3 Punch Clutch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7.21.4 Punch Module Brake Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.21.5 Punch Module Brake Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.21.6 Punch Module Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.21.7 Punch Module Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7.21.8 Punch Module Motor Drive Belt Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
7.21.9 Punch Module Drive Roller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7.22 Belt replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
7.23 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
8.1 Centering punched holes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
8.2 Door latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
8.2.1 Door Latch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
8.2.2 Door Latch and Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
8.3 Preparing the GP-501 punch for service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
8.3.1 Separating the Punch From the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
8.3.2 Removing the Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
8.4 Leveling and aligning to the printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
ii
PREFACE
PREFACE
DESCRIPTION ITEMS FOR SAFTY
These symbols are used in this documentation alert you to danger or important information.
WARNING: Indicates a potentially hazardous situation which, if not avoided, could result
in death or serious Injury.
WARNING: Risk of electrical shock. This warning statement indicates situations where
there is a risk of death by electric shock.
CAUTION: This notice indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. It may also be used to alert against
unsafe practices.
Certain components in this product are susceptible to damage from electro-
static discharge. Observe all ESD procedures to avoid component damage.
INTRODUCTION
This service manual is provided for use by an authorized service technician for the repair and maintenance of the
GP-501 Punch.
The GP-501 Punch is an innovative, labor saving solution for punching paper in-line and includes the following
design features:
• Maximum productivity saver with punching in-line at the speed of the printer! Does not slow up or stop the
print system.
• Quick-change die sets that are self-latching without tools or levers.
• GP-501 Punch die sets are available in all of the most common hole patterns and include an Identifying Label
providing user with the hole pattern and name.
• Convenient storage area for three extra Die Sets located above the sheet bypass.
• Accurate hole punching with consistent alignment.
With each GP-501 Punch, the customer receives a user manual. They are encouraged to keep this manual for
future reference. The information contained in the user manual is also helpful to the service technician. Please
refer to it for detailed information regarding dies sets, operation or specifications.
1. Setting the Right Expectations

The following excerpts are copied from sales and marketing literature. This customer expectation information is
helpful for the service technician.
S-1
PREFACE
PRODUCT POSITIONING
The GP-501 Punch provides a flexible, cost effective punching solution for light to medium level production ori-
ented customers.
• Designed for customers that have the need to punch their documents at a maximum of 60-70% of their over-
all workflow.
• Recommended punching limit to 200K sheets per month. (600k sheets in bypass mode)
• Die Sets will decrease in performance over time based on the types of stocks and weights that are being
punched.
• The expected life of a dieset is 500K punches. However, if paper stock punched is typically 20 lb. bond, then
up to 2 million punches can be achieved.
• Should be regarded as a long-term supply item.
LONG EDGE FEED (LEF) ONLY

The GP-501 Punch is designed to punch LEF only. No exceptions. Attempting to punch a sheet size other than
LEF will cause a misfeed.
• Use a colored sheet insert (instead of the tab) in the job workflow for easier tab insertion after the job has
been run.
S-2
OUTLINE
GP-501
The GP-501 In-Line punch system is compatible with copiers and finishing devices and is used for punching a
variety of die set patterns.There are two base units configured to punch Letter (81/2 x 11) and A4 (210mm x
297mm) document sizes, both configurations are similar but different to accommodate power & edge registra-
tion.
A. Type
Type Multi-hole punch unit for ring binding
B. Modes of Operation
Bypass mode The paper moves straight from the printer to the finisher without passing
through the punch module. In this mode the paper in not punched.
Punch mode with Punch The paper moves from printer to the punch module where it gets punched and
then is routed to the finisher.
C. Machine Data
Punch unit size 12” (305mm) W x 40” (1016mm) H x 30.5” (775mm) D

Weight 170 lbs (80kg) unpackaged,
270 lbs (123kg) packaged (Pallet, Carton, PKG Inserts)
Color Top Cover – Orca Black, Lower covers – Cuttle Gray
AC Power Supply to GP- External power cord according to market destination.
501
DC 5V Supply to GP-501 Supplied by system to PCB contained within GP-501
System Power Supply GP-501 Internal Lead-Through
Lines • On upstream side: Wiring with connectors through cover-recess.
• On downstream side: Lock-style connector panel on left side cover.
D. Software
Communication method i) Start-stop synchronization style, full duplex.

ii) 1 Start Bit, 8bit Data length, 1 Parity Bit, 1 Stop bit. Max Frame Length: 128
byte
iii) Hard flow control (CTS/RTS).
iv) Baud rate:
[Standard] 19200 bps
[ISW=Log file Transmissions] 78000 bps
Communication Content According Interface Specification (See also Appendix B)
1
E. Electronic
Required signals to UP & RXD, RTS, CTS, TXD

GP-501
Downstream connected units
F. Inputs
(1) Media Input from Printer
Alignment/ skew variance Center justified ± 4mm

at pick up
Line speed 290 to 1250 mm/s (Fixed speeds within this range)
Speed variance at pick up ± 2%
Sheet frequency 120 ppm maximum
1) For Punching
Paper weight 20lb bond – 80lb cover

Plain Paper: 75gsm – 216gsm
Other Paper: 120gsm-216gsm
Exception ProClick: LTR & A4 Limited to 200gsm
Paper type See appendix D
Maximum Sheet size Letter configuration 279 x 216mm
A4 configuration 297 x 210mm
2) For Bypass

64gsm – 350gsm
Paper type Coated, Pre-printed, High Quality, Plain, Book, Color, Rough, Post Card, Label,
OHP, Index
Transparency weight 5 -10 mil (0.127mm to 0.254mm)
Maximum bypass sheet 13” x 24.8” (330 x 630mm)
size
Minimum bypass sheet size 3.74” x 5.47” (95 x 139mm)
(2) Power
Supply GP-501 individual power supply and power cord required.

Configurations by market See table below
Machine Market Voltage (V) Current (A) Frequency (Hz) Paper size
1 US, Canada 115 +10/-15 % 3 60 81/2 x 11
2 Europe, Australia 220-240 +10/-15 % 1.8 50 A4
2
G. Outputs
Alignment/ skew at delivery ± 2mm or less for the pick up position
GP-501
Speed variance at delivery ± 1% compared to speed variance at pick up
Chip tray capacity 2500 cycles (based on punched sheet count)
H. Performance
Punch accuracy Hole size ± 2%

Alignment ±0.5mm
Back gauge depth ±0.3mm
(1) Reliability
MCBJ: Punch 1 in 15,000 (20lb bond)

MCBJ: Bypass 1 in 65,000 (20lb bond)
I. Operation Environment, Storage, Transport
Normal Operation Temper- 10degC – 30 deg C

ature
Normal Operation Humidity 10% - 80%
Storage Temperature -10degC – 40 deg C
Storage Humidity 10% - 80%
J. Safety /Regulatory
Noise emissions (measured Punch Maximum of 78dBA (punching 216gsm cover)

to ISO7779) Bypass Maximum of 70dBA
(1) Safety Compliance
UL & CSA standards CAN/USA-C22.2 No. 60950-01

UL60950-1 First Edition
TUV standards IEC 60950-1:2001
EN60950-1:2001
(2) Electromagnetic Compliance
EMC standards EN55024:1998 Amendments A1:2001 & A2:2003

EN61000-3-2:2000
EN61000-3-3:1995 Amendment A1:2001
EN55022:1998 Amendments A1:2000 & A2:2003
EN61000-4-2, EN61000-4-4, EN61000-4-5, EN61000-4-6, EN61000-4-11
FCC standards Class B
Part 15, Subpart B, Section A 15.107A &15.109a
3
K. Appendix A
GP-501
Figure 1.1 Front
4
GP-501
Figure 1.2 Entrance
5
L. Appendix B
GP-501
No. Model Die set type # Pins Pin Hole size Paper size Label artwork
shape (WxH or D)
1 DS-501 Ring Binder 3 3 Round 8mm 81/2 x 11
Hole (0.316")
2 DS-502 Plastic Bind 19 Rect. 8mm x 2.9mm 81/2 x 11

Cerlox (0.313" x 0.116")
3 DS-503 WireBind –3:1 32 Square 4mm x 4mm 81/2 x 11

Square (0.156" x 0.156")
4 DS-504 WireBind –2:1 21 Rect. 6.4mm x 5.4mm 81/2 x 11

Rectangular (0.250" x 0.214")
5 DS-505 Color Coil 44 Round 4.4mm 81/2 x 11

(0.174")
6 DS-506 VeloBind 11 Round 3.2mm 81/2 x 11

(0.125")
7 DS-507 To be determined
8 DS-508 Ring Binder 4 4 Round 8mm A4
Hole (0.316")
9 DS-509 Plastic Bind 21 Rect. 8mm x 2.9mm A4

Cerlox (0.313" x 0.116")
10 DS-510 WireBind –3:1 34 Round 4mm A4

Round (0.158")
11 DS-511 WireBind –2:1 23 Round 6.38mm A4

Round (0.251")
12 DS-512 Color Coil 47 Round 4.4mm A4

(0.174")
13 DS-513 VeloBind 12 Round 3.2mm A4

(0.125")
Hole (0.316")

Cerlox (0.313" x 0.116")
17 DS-517 WireBind –2:1 23 Rect. 6.4mm x 5.4mm A4

(Australia)
6
shape (WxH or D)
18 DS-518 WireBind –3:1 34 Square 4mm x 4mm A4
GP-501
Square (0.156" x 0.156")
(Australia)
M. Appendix C
Paper Type for Punching

Destination Paper Name Weight (g/m2) Punch *2
(1) US Hammermill Color Copy Paper - 120 Q-Zone
Photo White
Hammermill Tidal MP 75 All
Hammermill Fore MP 75 All
Color Copy (Mondi) *1 120 Q-Zone
Wausau Exact Gloss Coated 215 Q-Zone
(C1S) *1
Hammermill Color Copy Cover *1 163 Q-Zone
216 Q-Zone
(2) EU Konica Minolta Original 80 All
Konica Minolta Profi 80 All
Mondi BIO TOP 3 extra 80 All
Mondi Color Copy 200 Q-Zone
*1 For only C6501/C6501P/C65hc

*2 Q-Zone: Guaranteed only in Q-zone
All: Guaranteed in all environments
*Refer to the below graph
80
70
A
Humidity (%RH)
60
B Q
40
30
20 C
10
10 18 20 23 30
Temperature (°C)
a03ut1c004ca
7
N. Glossary of Terms
These terms are common to the punch and bindery industry.

GP-501
Cerlox The trade name GBC uses for its Plastic Binding
Color coil A plastic coil that looks like a spring which is threaded through round
holes punched in the document then the ends are cut off and
crimped. The holes are either 4:1 or 5:1 (4 holes per inch or 5 holes
per inch). This type of bind lays flat and even folds around for easy
handling of the document.
Flush-cut covers Covers stock that is the same size as the paper contents and has
round corners.
Plastic binding The name used to describe GBC's most common binding method.
The 19 and 21 rectangular hole, Plastic Comb type.
ProClick A plastic element that snaps together. This style requires holes that
appear to be the same as Twin Loop but are actually slightly larger.
The larger holes enable correct operation of the ProClick Pronto fin-
ishing devise.
Tabbing Tabbing or hanging chad is when a hole is not punched cleanly
(hanging chad) through the material leaving a piece of paper hanging from the edge.
This condition occurs when a die set is worn and will usually result in
miss-feeds.
Twin loop Looped wire element that is feed into square or round holes in the
document in a similar fashion to Plastic Binding. The holes are either
2:1 or 3:1 (2 holes per inch or 3 holes per inch). It is then squeezed
together or crimped to create an attractive bind that lays flat.
Velobind A heat seal plastic bind that is best known for it's security and it's
attractive look. The one draw-back for VeloBind is that it is not a lay-
flat bind style. It is most often used in the Legal market for it's security
feature.
8
GP-501
BYPASS
CONVEYANCE
SECTION
PUNCH
CONVEYANCE
SECTION
PUNCH
SECTION
Figure 1.3 Unit Configuration Diagram
9
3. PAPER PATH
GP-501
Bypass Mode
Punch Mode
Figure 1.4 Paper Path
10
Theory of Operation Ver.1.0 Jul. 2009 4. CONFIGURATION
CONFIGURATION / OPERATION
GP-501
4. CONFIGURATION
[5]
[1]
[2]
[2]
[3]
[4]
Figure 2.1 Configuration
[1] Diverter [4] Back Gauge Mechanism

[2] Aligner Panel [5] Bypass Assembly
[3] Punch Module
11
5. PRINCIPLE OF OPERATION Theory of Operation Ver.1.0 Jul. 2009
5. PRINCIPLE OF OPERATION
The GP-501 Punch is a machine that punches various die set hole patterns into single sheets of paper. The
GP-501
machine is placed between a printer and a finisher. The punch has two paper paths.
• The punch mode

• The bypass mode
The bypass moves the paper from the printer to the finisher without punching holes. The punch path routes the
paper from the printer through the punch to be punched and then routes the paper to the finisher.
5.1 Punch conveyance control

(1) Communication system alerts the punch machine of the paper entry from the up-stream device.
On receiving the 40 command, AC motors and stepper motor turns on. Diverter gate moves to up
position.
(2) The paper enters the punch machine through entrance feed section
(3) Enter sensor (S1) detects paper and acknowledges transfer of sheet from up-stream device
(4) Paper passes through entry guide. Stepper 1 speed sensor (S2) is provided to detect paper jam.
Entrance stepper motor RPM increases to accelerate sheet to aligner path. After trailing edge of
sheet leaves S2, entrance stepper motor slows down in preparation for next sheet.
(5) Paper enters aligner panel. Entrance stepper motor accelerates to match sheet speed with
aligner speed. Paper is edge aligned in preparation for punch.
(6) Back gauge solenoid is energized and back gauge pedal blocks the paper path. Sheet arrives at
Punch module sensor (S3). Punch module brake disengages and Punch clutch engages. After
Punch clutch is engaged punch shaft begin to rotate. Paper punching is done. Leading edge of
flag leaves Punch flag sensor (S9). Then Punch module brake engages and back gauge gate
comes down. Trailing edge of sheet unblocks S3 and back gauge pedal comes up.
(7) Paper passes through U-channel. U-channel sensor (S4) and Back gauge sensor (S5) are pro-
vided to detect any paper jam
(8) Stepper 2 speed sensor (S6) detects paper and triggers exit stepper motor for speed which
decelerates sheet
(9) Exit sensor (S7) detects paper and determines the paper has passed through completely for
other operation or for stacking purpose
12
Theory of Operation Ver.1.0 Jul. 2009 5. PRINCIPLE OF OPERATION
[9]
ENTRANCE
GP-501
EXIT
[1]
[4]
[8]
[2]
[2]
[10]
[10]
[5]
[7]
[6]
[3]
[1] Diverter [6] U-Channel Sensor (S4)

[2] Aligner Panels [7] Back Gauge Sensor (S5)
[3] U-Channel [8] Stepper 2 Speed Sensor(S6)
[4] Stepper 1 Speed Sensor (S2) [9] Exit Sensor (S7)
[5] Punch Module Sensor (S3) [10] Aligner Drive Belt
13
GP-501
[1]
[2]
[3]
[5]
[4]
[1] Entrance Stepper Motor [4] Transport Motor

[2] Exit Stepper Motor [5] Back Gauge Solenoid
[3] Punch Motor
14
5.2 Punch operation

[1] Punch motor (AC motor) rotates continually after receiving start commend from printer.
[2] Belt turns continually when motor is powered.
GP-501
[3] Punch clutch (Electromagnetic 24V DC clutch) when energized connects Punch motor to the punch mechanism
which transmits power.
[4] Belt only turns when Punch clutch is energized.
[5] Punch module brake is a 24V DC electromagnetic type and is energized when the Punch clutch is not powered.
Punching Operation - Back gauge solenoid is energized and back gauge pedal blocks the paper path. Sheet
arrives at Punch module sensor (S3). Punch module brake disengages and Punch clutch engages. After clutch
is engaged punch shaft begin to rotate. Paper punching is done through cam mechanism which pushes the
pins forward. Leading edge of flag leaves flag sensor. Punch module brake engages and back gauge gate
comes down. Trailing edge of sheet unblocks S3 and back gauge pedal comes up.
[1]
[3]
[2]
[4]
[5]
15
5.3 Chip tray control

Chip tray switch determines when chip tray is present and informs GP-501 processor that chip tray is present. A
signal voltage is communicated to Punch Controller PCB. If the chip tray is pulled out GP-501 processor notifies
GP-501
printer that chip tray is out. Printer will show the error message on the screen.
Chip tray full occurs after 2500 punches. Clear occurs when chip tray is removed to empty the bin and GP-501
is powered on.
16
5.4 Bypass conveyance control

(1) Communication system alerts the punch machineof the paper entry from the up-stream device.
GP-501
Motor starts on receiving 40 commend from printer, Diverter solenoid goes ’ON’ on receiving 15
command from printer.
(2) Diverter gate remains in closed position
(3) Enter sensor (S1) detects paper and acknowledges transfer of sheet from up-stream device
(4) Bypass sensor (S8) is provided in bypass panel to detect jam
(5) Exit sensor (S7) detects paper and determines the paper has passed through completely for
other operation or for stacking purpose
[3] [4] [2] [1]
[7] [6] [5] [8]
[1] Enter Sensor (S1) [5] Entrance Roller

[2] Bypass Sensor (S8) [6] Intermediate Roller
[3] Exit Sensor (S7) [7] Exit Roller
[4] Bypass Panel [8] Diverter
17
[1] [2] [3] [4]

GP-501
[5]
[6]
[1] Divert Solenoid [4] Exit Roller

[2] Entrance Roller [5] Entrance Stepper Motor
[3] Intermediate Roller [6] Exit Stepper Motor
18
Theory of Operation Ver.1.0 Jul. 2009 6. DIE SET SERVICE
MAINTENANCE
This section contains cleaning and maintenance procedures.
GP-501
CAUTION:
• GP-501 uses screws of inch standard. Therefore, do not mix them with other products (metric
standard screws). Otherwise, the screw hole is damaged.
to the main body.
6. DIE SET SERVICE

The Die Set assembly is not serviceable other than inspection and periodic lubrication. The one exception is the
felt pad on the Twin Loop Die Set can be replaced.
If a Die Set is at its end of life, it will tend to cause mis-feeds due to hanging chips. This is a result of die plate
wear, and not pin wear, which cannot be corrected. When this occurs, the Die Set should be replaced with a
new one.
6.1 Die Set Life Expectancy

The GP-501 Punch Die Sets have a minimum life expectancy of 500K cycles (sheets of paper punched). With
periodic lubrication and optimum paper types, life can exceed this number. Variables that affect life expectancy:
• Failure to follow the lubrication schedule or using the incorrect lubricant
• Variety and types of paper being punched
• Cover stocks being punched
• Length of the average job
• Other environmental conditions
6.2 Die Set Components

The GP-501 Punch uses two types of Die Sets.
Table 3.1 Die Set Types
Type Description Bindery Style

Felt Pad Retainer Assembly Felt oiler pad on one side (with DS-501, 503, 504, 506, 508,
magnet and retaining plate) 510, 511, 513, 515, 517, 518
Encircled Felt Oiler Pad Felt oiler pad surrounds the DS-502, 505, 507, 509, 512,
punch pins 514, 516
19
6. DIE SET SERVICE Theory of Operation Ver.1.0 Jul. 2009
6.2.1 Serviceable Components

• Shoulder bolt and spring [1]
• Punch pins [2]
GP-501
• Felt pad [3]

• Floating pressure bar spring (not shown). (Refer to P.23)
[3] [2] [1]

[1]
Figure 3.1 Die Set Serviceable Components.
20
6.2.2 Felt Pad Retaining Assembly

The twin loop Die Set has a removable felt pad assembly. The felt pad [1] provides lubrication to the punch pins
under normal usage and helps keep them clean. The magnet [2] and retainer [3] keeps the felt pad in place dur-
GP-501
ing normal handling and operation.
[1]
[2]
[3]
Figure 3.2 Felt Pad Assembly.
Note
• The felt pad assembly on the Twin Loop Die Set is the only assembly that can be replaced.
21
6.2.3 Reassembling the Felt Pad Assembly

The felt pad assembly consists of the felt pad [1], magnet [2], and retainer [3].
GP-501
A. To assemble the felt pad retaining assembly:
1. Lay the die assembly on a table so that the open side of the top bar is facing up.
2. Lay the felt pad [1] along the punch pins so that it spans all pins.
3. If the pad needs oil, apply it along the full length of the pad.
4. Insert the magnet [2] into the retainer [3].
[1]
Figure 3.3 Placing Felt Oil Pad on Die Set.
[1]
[2]
[3]
Figure 3.4 Die Set Felt Pad Assembly Order.
22
5. Place the magnet and retainer [1] over the pad [2] and lightly press them against the pad and the Die Set
base. Make sure the assembly is sitting on the base [3] and that the felt pad is against the punch pins [4].
[4]
GP-501
[1]
[2]
[3]
Figure 3.5 Die Set Felt Pad Assembly.
6.2.4 Floating Pressure Bar Spring Replacement
Some Die Sets use springs to hold the top plate above the pressure bar [1]. Detentes in the top plate hold the
springs in place [2]. Ensure all springs are in place.
[2]
[1]
Figure 3.6 Die Set Floating Pressure Bar Springs.
A. To replace pressure bar springs:
1. Compress the spring and insert between the top bar and pressure bar.
2. Use a flat screwdriver to position the spring so that the detent holds it in place.
3. Compress the top bar to ensure it moves freely and that it returns.
23
6.3 Checking and Replacing the Die Set

A. Periodically Checked and replaced parts/cycle
GP-501
• Dieset: Every 2,000,000 prints *1(Actual replacement cycle: Every 500,000 punches)
*1 Replace as needed. Replacement is recommended if hanging chips are usually generated.
B. Procedure
Set the Die Set on a table and press the top plate straight down at both ends [1] at the same time and look for a
smooth operation. The top plate and pins should retract fully when you release.
[1]
Figure 3.7 Check For Free Movement.
Reinstall the Die Set into the punch and run several sheets of the customer’s paper through the punch. Inspect
the holes.
• Holes should be clean and even with no tearing or frayed edges.
• Holes should be punched completely, leaving no chip attached.
• Holes should be straight (no skew) and evenly spaced from the edge of the paper and aligned. (Refer to
P.39)
24
6.4 Checking and lubricating the Die Set pins and Die Set shoulder
bolts
GP-501
A. Periodically Checked and lubricated parts/cycle
• Die Set pins: Every 200,000 prints (Actual lubrication cycle: Every 50,000 punches)
• Die Set Shoulded bolts: Every 800,000 prints (Actual lubrication cycle: Every 200,000 Punches)
B. Procedure
Inspect the punch pins for signs of wear or mis-alignment. Periodic lubrication extends the life of the Die Sets.
The customer or operator can perform this maintenance between technician inspections.
Figure 3.8 Inspect Punch Pins.
25
C. To lubricate Die Set pins:

• Lubricate with 3-IN-ONE oil (high quality machine oil).
• Apply oil lightly along the length of the pad [1], but do not over saturate.
GP-501
• Do not use spray lubricants because they tend to dry up quickly and leave a sticky residue.
For the felt pad retaining assembly instructions, refer to P.21.
D. To lubricate shoulder bolts:

• Lubricate the shoulder bolts and springs [2] using a brush to apply Magnalube-G Teflon Grease.
• Make sure the grease coats the bolts.
[1]
[2]
Figure 3.9 Die Set Lubrication Points.
26
6.5 Hole Alignment inspection

Inspect the hole alignment on the customer’s punched paper. Fold the punched sheet of paper in half [1] and the
GP-501
punched holes should be aligned evenly along the edge and centered between the ends [2]. If the punched
holes are not aligned, then the Die Set cradle must be adjusted. For adjustment procedures. (Refer to P.113)
[2]
[1]
Figure 3.10 Hole Alignment on Finished Sheet.
27
7. CHECK, CLEANING, AND LUBRICATION Theory of Operation Ver.1.0 Jul. 2009
7. CHECK, CLEANING, AND LUBRICATION

If operating properly, the GP-501 will punch the same types of copy paper and cover materials handled by the
GP-501
copier and run at the same speed. Hole quality will vary between different grades of paper.
The following maintenance should be performed according to the schedule.
Table 3.2 Maintenance Schedule
Description Qty. Part Number Period Check Clean Lubricate Replace Materials, Tools See..
Used
Aligner belt 12,000K X a soft cloth P.37
(green belt) prints and alcohol
Aligner idler 12,000K X a soft cloth P.39
roller assem- prints and alcohol
bly
Aligner idler 3,000K X X a soft cloth P.35
rollers prints and alcohol
Aligner latch- 3,000K X - P.45
ing mecha- prints
nisms
Back gauge 3,000K X X Blower brush/ P.38
solenoid prints vacuum
cleaner
Back gauge 1 A0N9PP59## 4,000K X - P.77
mechanism punches
Base 3,000K X Vacuum P.31
prints cleaner
Die guide 3,000K X Vacuum P.32
prints cleaner
Die set 500K Y - P.24
punches
Punch die 50K X Oil 3-IN-ONE P.25
(pins) punches (WD-40 Com-
pany)
Die set 200K X Grease Magnalube-G P.25
shoulder punches Teflon Grease
bolts
Door clos- 3,000K X - P.33
ing latch prints
Drive rollers 3,000K X X a soft cloth P.44
prints and alcohol
Idler rollers 3,000K X X a soft cloth P.39
prints and alcohol
Optical sen- 3,000K X Blower brush P.46
sors prints
Paper path, 3,000K X X a soft cloth P.34
Aligner Pan- prints and alcohol
els
28
Theory of Operation Ver.1.0 Jul. 2009 7. CHECK, CLEANING, AND LUBRICATION
Table 3.2 Maintenance Schedule
Description Qty. Part Number Period Check Clean Lubricate Replace Materials, Tools See..
Used
GP-501
bypass prints and alcohol
punch prints and alcohol
Punch drive 3,000K Grease Magnalube-G P.95
cams punches Teflon Grease
Roller energy 3,000K X X a soft cloth P.76
drive prints and alcohol
Timing belts 3,000K X X a soft cloth P.50
prints and alcohol
29
7.1 External Cleaning

The cover may be cleaned with a soft cloth moistened with mild detergent and warm water.
GP-501
Do not use chemical cleaners or solvents as these may have a harmful effect. Use detergent sparingly to avoid
contact with electrical components.
WARNING:
• Make sure you disconnect the GP-501 Punch from its power source before cleaning. Failure to
observe this warning could result in death or serious Injury.
7.2 Internal Cleaning

Occasionally remove the covers and remove paper dust and chips. Paper dust can accumulate throughout the
punch including around the motors and other electrical components. Use a vacuum cleaner if possible. A small
paintbrush can also be used but extreme care should be used around electrical components.
Non-electrical components may be cleaned with alcohol, an approved cleaner, or a soft cloth moistened with
mild detergent and warm water. Rollers can be cleaned with alcohol.
WARNING:
• Make sure you disconnect the GP-501 Punch from its power source before cleaning. Failure to
observe this warning could result in death or serious Injury.
7.3 Operational Inspection

Make sure the punch operates smoothly and produces the desired holes in the customer’s paper.
7.4 Internal Inspection

Whenever the cover has been removed for corrective maintenance, visually inspect for defects and problems
such as damaged components, loose screws or nuts, abraded wire insulation, loose terminals, etc. Correct any
problems before returning the machine to service.
30
7.5 Cleaning the base

GP-501
• Base: Every 3,000,000 prints
B. Procedure
Chips and paper dust falls to the bottom of the punch. Clean with a vacuum cleaner each time the machine is
serviced. The customer can also do this between the technician’s visits.
7.5.1 Chip Bin

Remove the Chip bin tray and empty. Vacuum out paper chips and dust from the Chip bin [1], especially at the
back around the chip tray switch.
[1]
31
7.6 Cleaning the Die guide

GP-501
• Die guide: Every 3,000,000 prints
B. Procedure
Remove the Die Set and clean the guide [1] with a vacuum cleaner.
[1]
Figure 3.11 Die Guide.
32
7.7 Checking the Door Latch

The door latch must hold the door closed and ensure that the switch activation tab is depressing the door
GP-501
switch [1]. The switch tab [2] should press the switch button just so that it is close to bottoming.
A. Periodically checked parts/cycle

• Door latch: Every 3,000,000 prints.
B. Procedure
• Ensure latch holds door closed.
• Ensure switch is activated when the door is closed.
• To adjust the door latch. (Refer to P.119)
[2]
[1]
Figure 3.12 Door Switch Tab and Switch.
33
7.8 Cleaning and Checking the aligner paper path and panels
A. Periodically cleaned and checked parts/cycle
GP-501
• Aligner paper path and panels: Every 3,000,000 prints.
B. Procedure
Inspect for worn or damaged parts. Clean with alcohol, an approved cleaner, or a soft cloth moistened with mild
detergent and warm water as needed.
C. To clean the Aligner Panels:

1. Lift the Aligner latches to open panels.
2. Clean surfaces [1].
3. Clean paper alignment channels [2].
[1]
[2]
Figure 3.13 Aligner Panel Components.
34
7.8.1 Cleaning and Checking the Aligner Idler Roller

Aligner idler rollers press the paper against the green drive belts and align the paper for punching and exiting. To
replace the idler rollers. (Refer to P.59)
GP-501
• Aligner Idler Roller: Every 3,000,000 prints.
B. Procedure
• Make sure the aligner rollers are clean.
• Ensure that the idler rollers maintain pressure against the green drive belt.
• Inspect for bent or damaged parts.
WARNING:
• Disconnect the GP-501 Punch from power and retain the power cord in your possession for your
safety. Failure to observe this warning could result in death or serious Injury.
C. To inspect the aligner idler rollers:

1. Press the top of each roller’s bracket [1]. The roller should move away from the green belt drive and then
when released, they spring back into place.
[1]
Figure 3.14 Alignment Roller Inspection.
35
2. Ensure the torsion springs [1] are hooked over the bracket [2].
GP-501
[1]
[2]
Figure 3.15 Aligner Roller Torsion Spring Hooked on Bracket.
D. To clean idler rollers:

1. Clean the idler rollers with a soft cloth and alcohol.
2. Inspect the idler rollers for wear patterns or groves. Surface should be evenly textured and clean.
36
7.8.2 Cleaning the Aligner (Green) Drive Belt

• Aligner (Green) Drive Belt: Every 12,000,000 prints. *1
GP-501
*1 1200/1200P/1051
B. Procedure
• Ensure the Aligner Drive Belts are clean.
• Inspect for frayed edges and wear.
C. To clean the Aligner Drive Belts:

1. Clean Green Drive Belt [1] with a plastic scouring pad.
2. Use the drive knob [2] to turn the belt.
[1]
[2]
[2]
Figure 3.16 Cleaning Green Drive Belt.
To adjust or replace the Aligner Drive Belt. (Refer to P.59)
37
7.9 Cleaning and Checking the Back Gauge Solenoid

GP-501
• Back Gauge Solenoid: Every 3,000,000 prints.
B. Procedure
1. Inspect and ensure the Back Gauge solenoid linkage moves freely. Press linkage down and release [1]. Link-
age should return.
2. Clean out the solenoid and surrounding area with a vacuum cleaner and canned air [2]. Make sure the sole-
noid is clean and dry.
Note
• Do not apply lubricants to the solenoid or linkage.
To remove and repair the back gauge. (Refer to P.77, P.78)
[1]
[2]
Figure 3.17 Inspect and Clean Back Gauge Solenoid.
38
7.10 Cleaning and Checking the Idler Roller

GP-501
• Idler rollers: Every 3,000,000 prints.
B. Procedure
Idler rollers press against the drive rollers and move the paper through the bypass [1] or the punch [2].
Inspect rollers for wear patterns or groves. The roller surface should be even and have a textured surface. Where
practical, remove the roller assembly to clean [3].
Please see the referance page about the maintainence procedure of each roller.
Bypass Idler roller [3]. (Refer to P.40)
Punch Idler roller [4]. (Refer to P.41)
[3]
[1]
[2]
[4]
[4]
[4]
39
7.10.1 Cleaning and Checking the Bypass Idler Rollers
Idler rollers press against the drive rollers and move the paper through the bypass. Rollers can usually be ser-
GP-501
viced without removing the bypass panel.

1. Separate the punch from the printer.
2. Disconnect the power.
3. Lift the retaining spring over the end of the idler roller shaft. The illustration shows moving the spring [1] on
the bypass plate, which has been removed from the machine for clarity.
4. Pull the released shaft end out of the bushing fork [2], releasing the opposite end of the shaft from the other
retaining spring.
5. Clean the idler rollers with a soft cloth and alcohol.
6. Ensure the rollers turn freely on the shaft.
7. To install idler roller assemblies reverse the steps.
[1]
[2]
Installation Note:
• Make sure the flat surface of the bushing aligns in the fork.
• Rollers are non-directional so it does not matter which end goes in each fork.
• After the assembly is in place, gently pull the assembly outward and release to ensure it moves freely in the
fork.
40
7.10.2 Cleaning and Checking the punch idler rollers
Idler rollers press against the drive rollers and move the paper through the GP-501 Punch. Most can be serviced
GP-501
without disassembling punch components. Unplug unit and separate from the printer. (Refer to P.123).
Also remove two side panels as described in P.51 and P.57.
A. Procedure
Inspect rollers for wear patterns or groves [1],[2]. The roller surface should be even and have a textured surface.
Replace per the maintenance schedule.
Note
• Pull out the chip bin to access the idler roller [2]
[1]
[1]
[2]
Figure 3.18 Punch Idler Roller Locations.
41
• Use the drive knob [1] to turn the rollers to continue inspection and cleaning.
GP-501
[1]
42
To remove the Punch Idler rollers:

1. Lift the retaining spring [1] over the end of the idler roller shaft.
2. Pull the released shaft end out of the bushing fork [2], releasing the opposite end of the shaft from the other
GP-501
retaining spring.
3. To install idler roller assemblies reverse the steps.
[1]
[2]
Figure 3.19 Releasing Idler Roller Retaining Spring.
Installation Note:
• Make sure the flat surface of the bushing aligns in the fork.
• Rollers are non-directional so it does not matter which end goes in each fork.
• After the assembly is in place, gently pull the assembly outward and release to ensure it moves freely in the
fork.
43
7.11 Cleaning and Checking the Drive Rollers

Drive rollers are located opposite the idler rollers.
GP-501

• Drive rollers: Every 3,000,000 prints
B. Procedure
Inspect for wear patterns or groves. The roller surface should be even and not glazed.
Some drive rollers are not easily accessible. Those that are [1], should be inspected and cleaned when the idler
rollers are removed. Where practical, make sure the rollers are clean. Clean with a soft cloth and alcohol. Refer
to also P.39.
[1] [1] [1]
[1]
[1]
[1]
44
7.12 Checking the Aligner Latch

Latches [1] on both sides of the punch hold the Aligner Panels in place, which in turn keeps even pressure on
the idler rollers.
GP-501
• Aligner Latch: Every 3,000,000 prints
B. Procedure
• Inspect the latches for worn or damaged parts.
• Open and close the latches and ensure they lock into place when closed.
• Ensure the nylon wheel [2] turns freely on its bearing and that it aligns with its locking
[2]
[1]
45
7.13 Cleaning the Optical Sensors

• Optical Sensors: Every 3,000,000 prints
GP-501
B. Procedure
Inspect and clean Optical Sensors [1] per the maintenance schedule or as needed.
C. Supplies Needed
Canned air or vacuum cleaner
[1]
[1]
[1]
[1]
[1]
[1] [1]
46
Use canned air to blow the debris off each sensor. The illustration shows examples of three sensors [1].
GP-501
[1]
[1]
[1]
47
7.14 Cleaning and Checking the Bypass Paper Path

GP-501
• Bypass paper path: Every 3,000,000 prints
B. Procedure
• Inspect the Bypass panel [1], rollers [2], and entrance guide [3] for wear, damage, and obstructions.
• Inspect the rollers for wear patterns or groves. The surface should be rough and even. Make sure the rollers
are clean. Clean rollers with a soft cloth and alcohol. (Refer to P.39, P.44)
• Raise the panel and ensure the magnet holds it in open [4]. Inspect the path for obstructions. Clean as
needed.
• Close the panel and check that it is flat and that paper will pass under it.
• Ensure the bypass diverter moves freely and returns to the bypass position.
[4]
[3]
[1]
[2]
[5]
Figure 3.20 Bypass Path Inspection. Shown With Bypass Panel Raised.
48
7.15 Cleaning and Checking the Punch Paper Path

GP-501
• Punch Paper path: Every 3,000,000 prints
B. Procedure
• Inspect the entire paper path through the punch. Look for wear, damage, and obstructions.
• Inspect the rollers for wear patterns or groves.
• Open the Aligner Panels [1] and U-channel [2] and make sure there are no obstructions.
• Confirm that the latch [3] holds the U-channel tightly in place. Re-shape it if necessary.
• Clean as needed.
[1]
[1]
[2]
[3]
49
7.16 Cleaning and Checking the Timing Belt

• Timing Belt: Every 3,000,000 prints
GP-501
B. Procedure
Inspect all timing belts [1], [2] for wear, missing teeth, frayed edges, and cracks. For replacement, refer to P.110.
[1]
[1]
[2]
[1]
[2]
[2]
[2]
[2]
Check for proper deflection of belts. The belts should be slightly loose with approximately 1/4” (6.35mm) deflec-
tion [1]. Belts that are too loose will not drive properly and belts that are too tight can wear out prematurely or
damage their driven components. Five belts [2] have tensioners, it is these five belts that should be checked.
[1]
Figure 3.21 Typical Belt Deflection
50
7.17 Bypass panel

A. Tools Needed
GP-501
• Phillips screwdriver or 1/4" nut driver
• Flat bladed screwdriver
• Needle nose pliers
B. Procedure
Separate the punch from the printer and remove the rear cover. (Refer to P.123, P.124)
7.17.1 Bypass Panel Removal
A. To remove the Bypass panel:

1. If removing the Bypass panel, remove the side panel cover by removing the 4 screws [1].
[1]
[1]
Figure 3.22 Removing Side Panel
51
2. Disconnect the grounding strap by removing the screw [1] on the exit side of the bypass.
3. Unplug the exit side connector [2] at the rear frame.
GP-501
[2]
[1]
Figure 3.23 Disconnect the Grounding Strap and Unplug the Sensor.
4. Disconnect the connectors [1] of Enter sensor (S1) and Bypass sensor (S8).
[1]
Figure 3.24 Sensor Connectors
52
5. From the rear of the punch, remove one of the E-rings [1] from the Bypass shaft.
GP-501
[1]
[1]
Figure 3.25 Remove E-Ring.
53
6. From the side of the punch, slide the shaft towards the end of the shaft [1] without the E-Ring [2] until the
other end of the shaft clears the nylon bushing and bracket.
7. Lift the opposite end of the shaft [3] and slide it out of the Bypass panel in the opposite direction of the
GP-501
removed E-Ring [4].
Installation Note: Make sure the nylon bushing is installed so that it protrudes through the mounting
bracket of the rear frame into the Bypass panel [5].
[5]
[3]
[4]
[2]
[1]
[5]
Figure 3.26 Bypass Panel, Shaft, and Rear Frame.
54
8. Rotate the rear of Bypass panel [1] so that it extends past the entrance side of the punch [2].
GP-501
[1]
[2]
Figure 3.27 Rotate the Bypass Panel Out the Entrance Side of the Punch.
55
Installation Note: Position the Bypass panel so that it is outside the shaft mounting brackets. The nylon
bushings go through the mounting brackets [1], into the Bypass panel [2].
GP-501
[1]
[2]
Figure 3.28 Exploded View of Bypass Panel and Mounting Brackets On the Rear Frame.
9. Remove the Bypass panel.

10. To install the Bypass panel, reverse the steps.
56
7.18 Aligner panels

The entrance side Aligner panel positions the paper in the Back Gauge for punching. The exit side Aligner panel
positions the paper for the finisher. Prior to servicing the Aligner Panels, separate the GP-501 Punch from the
GP-501
printer. (Refer to P.123).
7.18.1 Aligner Panel Removal

Removing the Aligner panels provides access to the paper path and the Aligner Green Drive Belt. The procedure
is the same for the entrance and exit Aligner panels except that the exit side has a docking plate which must be
removed first.
A. To remove the Aligner panel:

1. If removing the exit side Aligner panel, remove the side panel cover by removing the 6 screws [1].
[1] [1]
Figure 3.29 Exit Side Panel Cover.
Note
• The rest of the steps are the same for both Aligner panels.
57
2. Release the Aligner latch [1].

3. Remove the E-clips from both ends of the Aligner shaft [2].
4. Remove the shaft nylon bushings [3]
GP-501
[3]
[3]
[2]
[2]
[1]
Figure 3.30 Entrance Side Aligner Panel.

5. Slide the shaft out the front of the punch.
6. Remove aligner latch stop by removing screws [1]
[1]
7. Unhook the tension spring from the panel [1].

8. Remove the Aligner panel [2] out the front of the punch.
9. Reverse the steps to install the Aligner panel.
[1]
[2]
58
7.18.2 Aligner Idler Roller Replacement

A. Tools Required
• Flat head screw driver
GP-501
• Needle nose plyers
B. Procedure
1. Pull off E-Clips [1]
2. Remove the pins [2]. During removal of pins hold on to spring with fingers
3. Completely remove the springs [3] and then slide roller assembly [4] down and then out.
Note
• Aligner rollers must be moved downwards. Hence all the rollers need to be removed.
[2]
[3]
[1]
[4]
Figure 3.31 Idler Roller Replacement
59
7.18.3 Aligner Drive Belt Replacement

A. Procedure
Before replacing the green drive belts, remove the Aligner panels. (Refer to P.57) Then follow the procedures
GP-501
below for the entrance side (Refer to P.61) or exit side green drive belt service (Refer to P.68).
B. Tools Required
• Phillips screw driver
• Nut drivers, 1/4 and 5/16"
• Hex wrenches, 5/64 and 9/64"
• Snap ring pliers
• E-Ring tool
• Twelve inch metal ruler or similar straight edge
CAUTION:
• Disconnect the GP-501 Punch from power and retain the power cord in your possession for your
safety. Failure to observe this caution can result in injury.
Note
• Empty the paper chip bin and replace it. This makes it easier to find small parts that you may drop
into the bin.
60
C. Paper Entrance Side Green Drive Belt Replacement
1. Disconnect the enter sensor (S1) wire from the side frame [1].
GP-501
EXIT SIDE
[1]
ENTRANCE SIDE
Figure 3.32 Opening Door and Removing Chip Tray.
2. Remove the 4 screws that secure the front paper chute [1] to remove the entrance guide [2].
[1] [1]
[2]
Figure 3.33 Remove 4 Paper Chute Screws.
61
3. To remove the GP2 aligner latch [1], do the following:

a. Unhook the spring of the GP2 aligner latch on the right end.
b. Remove only one (the one closest to the frame) of the E-rings of the GP2 aligner latch on the left end
GP-501
(front Door side).

c. Push the GP2 aligner latch in toward the front door until it clears the rear frame.
d. Pull the entire GP2 aligner latch, door latch out and set it aside.
4. To remove Entrance Idler Aligner panel [2] assembly. (Refer to P.57)

5. Remove the fan [7] that prevents access to the flexible cable. To remove it simply pull it off the shaft.
6. Remove the flexible cable using a hex wrench.
FRONT DOOR SIDE
[7]
[2]
[7]
[8]
[1]
Figure 3.34 Remove Idler Paper Guide Assembly.
7. Remove the 2 screws [3]

8. Loosen screw from the solenoid link.
9. Remove the solenoid assembly [5] and link from the Diverter Shaft[6], leave it hanging.
[3]
[5]
[6]
62
10. Remove the 2 E-Rings of the Entrance Diverter assembly, slide the Diverter out and set it aside.
11. To remove the Entrance Drive Aligner assembly [7], which is the large sheet metal assembly that actually
contains the green drive belt and Aligner.
GP-501
a. Remove the 6 Screws that secure the face of this assembly.
b. Remove the 2 screws that secure this assembly from the side frame.
c. Disconnect the sensor connector [8]
d. Pull and walk the entire sheet metal assembly of the Paper Guide Aligner assembly up and outward.
You can grab the assembly at the roller cut out with your fingers.
CAUTION:
• As you pull the assembly out, disconnect the sensor harness behind the assembly as soon as you
are able to reach it. Failure to observe this notice may damage the wiring.
63
12. Remove the green drive belt Aligner Roller assembly by removing the 4 screws [1].
GP-501
CAUTION:
• Leave the Flex Shaft [2] attached.
[1]
[3]
STRETCH
[2]
Figure 3.35 Removing the green drive belt.
D. Green Drive Belt Assembly

1. Stretch the new Belt [3] onto the Aligner Roller assembly, green side out. Rotate the Flex Shaft [2] to confirm
that the belt tracks properly.
2. Slide the Aligner into place, loosely attach the 4 Pan Head Screws with the 4 Lock Washers.
a. Check that the metal surface of the Aligner Roller assembly is flush with the Sheet Metal surface of the
Paper Guide. A 12" metal ruler works well to check this adjustment. Slip the ruler under the green drive
belt and press it flat against the two surfaces.
b. Adjust the Aligner and snug the screws when perfectly flush.
Note
• The green drive belt should look like the drawing shown in Figure 3.35.
c. As a double check, hold the entire Paper Guide assembly up so that you can visually inspect the align-
ment between the sheet metal surface and the metal surface of the Aligner. The green drive belt should
appear to be even or parallel, and just floating above the surface of the sheet metal.
64
3. To install the Paper Guide assembly into the GP-501 Punch:

a. As you slide the Paper Guide assembly into place,
- Hook up the Sensor Harness to the Sensor on the back.
GP-501
- Lift it up slightly to clear the lower Transition Paper Guide.
- Be sure to clear the Sensor Bracket at the top left.
- Be sure that the Flex Coupling Shaft is sticking out of the rear of the GP-501 Punch properly.
b. Visually check all around the mounting area of the Paper Guide assembly and that the Sensor Harness
is properly connected.
c. Loosely secure it in place with 3 screws on the left and 3 on the right.
d. Loosely install the 2 top screws.
e. Once all 8 mounting screws have been properly started you have good alignment. You may now go
back and tighten the screws until they are snug.
ALIGN
& FIX SCREWS
Figure 3.36 Aligning and Tightening Paper Guide Assembly Into the Machine.
65
4. Install the Flexible Shaft.

5. Install the curved sheet metal Exit Paper Guide (item 7) with Idler Roller 4 Screws.
Start all 4 screws, (2 on front and 2 on back) then tighten.
GP-501
6. Connect the Sensor Wire Harness at the top rear of the Exit Paper Guide.
7. Install the GP2 Shaft back into place by inserting it first into the front, then the back.
INSTALL GP2 SHAFT
Figure 3.37 Installing GP2 Shaft.
8. Close the GP2 Flipper Latch.

Repeat the test of rotating the pulleys to ensure smooth rotation of the Idler Rollers.
9. Attach the GP2 Shaft Spring.
10. Install the front E-Ring to secure GP2.
66
E. Entrance Aligner Panel Installation

To install the Idler Aligner panel, refer to P.57. Then insert the punch into the printer and finisher and connect the
power cord.
GP-501
(1) Test the GP-501 Punch by doing the following:
1. Run10 copies in bypass mode.

2. Run 1 sheet in punch mode.
3. Run 10 sheets in punch mode.
67
F. Paper Entrance and Exit Side Green Drive Belt Replacement

1. To remove the GP6 Flipper (C), Door Latch:
a. Remove only one (the one closest to the frame) of the E-Rings of the GP6 Flipper on the right end (front
GP-501
door side).
b. Push the GP6 Flipper in toward the front door until it clears the rear frame.
c. Pull the entire GP6 Flipper, door latch out and set it aside.
PAPER ENTRANCE
FRONT DOOR SIDE
PAPER EXIT SIDE
Figure 3.38 Removing Rear Aligner.
68
2. To remove the Rear Aligner, Idler Paper Guide assembly:

a. Remove 2 E-Rings from the Pivot Shaft.
b. Slide the Shaft all the way out through the front of the GP-501 Punch.
GP-501
c. Remove the 2 nylon bearings.
d. Remove and set aside the Rear Aligner, Idler Paper Guide assembly.
3. To remove the curved sheet metal Exit Paper Guide assembly:

a. Remove the 4 screws (2 rear and 2 front) of the curved sheet metal Exit Paper Guide assembly.
b. Unplug the sensor.
c. Pull the entire sheet metal Exit Paper Guide assembly out, set aside.
4. To remove the Rear, Drive Side, and Paper Guide Aligner assembly. This is the large sheet metal assembly
within the GP-501 Punch that contains the green drive belt Aligner.
PAPER ENTRANCE FRONT DOOR SIDE

SIDE
PAPER EXIT SIDE
ASSEMBLE BACK
Figure 3.39 Removing the Aligner assembly.
CAUTION:
• Walk the Belt off of the Aligner Pulley at the rear.
69
a. Remove the 2 screws that hold the block to the frame. The Coupler is loose and the rear panel will come out.
b. Remove the 6 screws that secure the face of this assembly.
c. Remove the 2 screws that secure this assembly from the top.
GP-501
d. Pull and walk the entire sheet metal assembly of the Paper Guide Aligner up and outward. You can grab
the assembly at the roller cut out with your fingers.
CAUTION:
• Handle the helical coupling carefully. It is very delicate.
Note
• In order to access these screws, you must first remove the Die Set storage shelf and the cable
shield attached to the Die storage shelf at the paper entrance side. Moving the Die Storage shelf
aside will enable better access to the 2 screws with a short Phillips screw driver.
ALIGNER DRIVE
BELT ASSY
Figure 3.40 Removing the Aligner Drive Belt.
CAUTION:
• As you do this, disconnect the sensor harness behind the assembly as soon as you are able to
reach it. Failure to do this can damage the unit.
5. Remove the green drive belt Aligner Roller assembly by removing the 4 screws (S).
CAUTION:
• Leave the Flex Shaft (FS) attached.
70
6. Remove the green drive belt Aligner Roller assembly by removing the 4 screws.
CAUTION:
GP-501
• Leave the Coupler attached.
71
G. Green Drive Belt Assembly

1. Stretch the new green drive belt onto the Aligner Roller assembly, green side out.
• Take care when handling the Aligner Roller assembly so as not to damage the Flex Coupling.
GP-501
• Rotate the shaft to confirm that the belt tracks properly.

2. Slide the Aligner into place, loosely attach the 4 pan head screws with the 4 lock washers.
ROTATE
STRETCH
BELT
Figure 3.41 Installing Green Drive Belt.
Check that the metal surface of the Aligner Roller assembly is flush with the sheet metal surface of the Paper
Guide. A 12" metal ruler works well to check this adjustment. Slip the ruler under the green drive belt and press
it flat against the two surfaces. Adjust the Aligner and snug the screws when perfectly flush.
72
GP-501
ALIGN
& FIX SCREWS
Figure 3.42 Final Assembly of the Green Drive Belt.
The green drive belt should look like the drawing shown in Figure 3.41.
To ensure proper assembly, hold the entire Paper Guide assembly up so that you can visually inspect the align-
ment between the sheet metal surface and the metal surface of the Aligner. The green drive belt should appear
to be even and just floating above the surface of the sheet metal.
73
3. To install the Paper Guide assembly into the GP-501 Punch:
FRONT DOOR SIDE

GP-501
PAPER ENTRANCE SIDE
ASSEMBLE BACK
PAPER EXIT SIDE
Figure 3.43 Installing the Paper Guide Assembly.
a. As you slide the Paper Guide assembly into place:

- Hook up the Sensor Harness to the Sensor on the back.
- Lift it up slightly to clear the lower Transition Paper Guide.
- Be sure to clear the sensor bracket at the top left.
- Be sure that the Flex Coupling shaft is sticking out of the rear of the GP-501 Punch properly.
b. Visually check all around the mounting area of the Paper Guide assembly and that the sensor
harness is properly connected.
c. Loosely secure it in place with 3 screws on the left and 3 on the right.
d. Loosely install the 2 top screws.
e. Once all 8 mounting screws have been properly started go back and tighten the screws until they
are snug.
CAUTION:
• Do not over tighten the 2 screws on top.
74
4. Install the 2 screws to secure the bearing block for the pulley arrangement at the rear of the GP-501 Punch.
Press the block to the top of the punch before tightening
5. Install the pulley and belt onto the pulley block. Once properly aligned, check belt and pulley movement.
GP-501
Tighten the set screw.
6. Install the Die Set storage rack with 3 screws front and 3 screws back. Remember to attach the ground
strap at the middle screw on the rear (belt side). Start each screw to achieve proper alignment, then go back
over each screw and tighten it.
7. Install the Cable Guard on top of the Die Set storage rack (2 Screws).
8. Install the curved sheet metal Exit Paper Guide with Idler Roller 4 screws.
9. Start all 4 screws, (2 on front and 2 on back) then tighten.
10. Connect the sensor wire harness at the top rear of the Exit Paper Guide.
11. To install the Idler Aligner Paper Guide:
a. Hold it loosely in place.
b. Press the nylon flange bearings into place, through both pieces of sheet metal, with the flange to the
inside
c. Slide the shaft through the front of the machine, while holding the nylon flange bearing in place.
d. Secure with 2 E-rings on the inside of the bearing.
e. Inspect by pressing in on the bottom area of the sheet metal for:
- A slight deflection of each Idler Roller as you press.
- As you press, you can turn the pulleys at the rear of the GP-501 Punch and see the Idler Rollers rotate
smoothly.
12. Bend the small metal tab back into place.
13. Install the GP6 shaft back into place by inserting it first into the front, then the back.
14. Close the GP6 Flipper Latch.
Repeat the test of rotating the pulleys to ensure smooth rotation of the Idler Rollers.
15. Attach the GP6 shaft spring.
16. Install the front E-Ring to secure GP6.
H. Aligner Panel Installation

To install the Idler Aligner panel, refer to P.57. Then insert the punch into the main body and finisher and connect
the power cord.
(1) Test the GP-501 Punch by doing the following:

1. Run10 copies in bypass mode.
2. Run 1 sheet in punch mode.
75
7.19 Cleaning and checking the energy drive roller

A. Periodically cleaned and checked parts/ cycle
GP-501
• Energy drive rollers 3,000,000 prints
B. Procedure
Reference Figure 3.44 Energy Roller as you perform this procedure.
1. Without disconnecting either retaining spring [1], roll one of them gently to one side to release the Energy
Drive Roller shaft from its mounting bracket.
2. Lift the shaft [2] from the mounting bracket.
3. Using a clean cloth and alcohol, clean the surfaces of the rollers [3] to remove any paper dust or toner that
may have accumulated over time.
4. Reverse steps 2 & 1 above to replace the shaft into the holder.
5. Ensure the flats of the bearings are seated properly in the mounting brackets.
6. Ensure the springs are straight on the bearing to apply sufficient force for the rollers to turn when you rotate
the knob at the front of the machine.
[1]
[3]
[2]
Figure 3.44 Energy Roller
76
7.20 Replacing the back gauge mechanism

The Back Gauge assembly pauses the paper just as the edge has entered the die set. Working properly, the
GP-501
sheet will pause only long enough for the holes to be punched correctly. The Back Gauge assembly also con-
trols the paper chad falling into the chad bin, significantly reducing the amount of chad that could flow through
the paper path. Some chad falls outside the chad bin and should be cleaned up with a vacuum cleaner during
each servicing.
WARNING:
• Disconnect the GP-501 Punch from its power source before removing the Back Gauge assembly.
Failure to observe this warning can result in severe injury or death and damage the punch.

• Back gauge mechanism: Every 16,000,000 prints (Actual replacement cycle: Every 4,000,000 punches) *1
*1 1200/1200P/1051
B. Procedure
Remove Back Gauge assembly to clean and service the solenoid or to replace the Back Gauge. Also allows the
removal of the Punch Module.
To repair or replace the Back Gauge, separate the GP-501 Punch from the printer and finisher and then remove
the rear cover. (Refer to P.123)
C. Tools Required
• Phillips screw driver or 1/4" nut driver
Note
into the bin.
77
7.20.1 Back Gauge Removal

A. To remove the Back Gauge assembly:
1. Turn the Punch Cycle knob [1] so that the punch drive indicator [2] lines up the position indicator [3].
GP-501
[1]
[2]
[3]
Figure 3.45 Punch Cycle Knob and Drive Indicator.
2. Remove the Die Set and Chip Bin.
78
3. Remove the two Die Set Chip Brush bracket screws [1].
GP-501
[1]
Figure 3.46 Die Set Chip Brush Bracket.
4. On the rear of the punch, unplug the drive punch flag sensor connector [1].
5. Remove the 2 Die Set Adjustment Bracket screws [2] and pull the bracket aside [3].
[1]
[2]
[3]
Figure 3.47 Die Set Adjustment Bracket and Drive Punch Flag Sensor Connection.
79
6. Remove the 2 Back Gauge rear mounting screws [1].

GP-501
[1]
Figure 3.48 Rear Back Gauge Mounting Screws.
7. Disconnect the Back Gauge connector from the Punch Controller PCB [1].
[1]
Figure 3.49 Back Gauge Solenoid Connector on the PCB.
8. Cut wire harness ties as needed to free the solenoid wires.
80
9. Cut the 2 harness ties on the entrance side of the punch.
GP-501
[1]
Figure 3.50 Wire Harness Ties on Entrance Side.
10. Remove the grommet from the frame [1].
Note
• If you are not replacing the Back Gauge or are removing it for access to the Punch Module, it is not
necessary to pull the wire through the hole in the frame. The Back Gauge can be set aside.
11. Feed the connector through the hole in the frame and the grommet separately [2].
[1]
[2]
Figure 3.51 Hole Through Frame and Grommet.
81
12. Remove one top screw [1] of chip tray full sensor bracket [2] and pivot the bracket down.
GP-501
[1]
[2]
13. Gently slide the Back Gauge assembly to the rear of the punch [1] so that it extends through the slot [2] and
clears the wiring harness [3].
[1]
[2] [3]
Figure 3.52 Sliding Back Gauge Toward Rear of Punch.
CAUTION:
• Do not damage the wires in the wiring harness. Failure to observe this precaution may damage the
wiring.
82
14. Make sure the left end of the Back Gauge clears the opening on the front of the punch [1] and pull it out [2]
while sliding it to towards the front.
GP-501
[1]
[2]
Figure 3.53 Pulling Back Gauge Out Toward Entrance Side of the Punch.
15. Remove the Back Gauge and rail as an assembly.
BACK GAUGE ASSY
Figure 3.54 Removing Back Gauge.
16. To install the Back Gauge, reverse these steps.
83
B. Testing
(1) To test the Back Gauge:
1. Install a Die Set.
GP-501
2. Rotate the punch drive knob to ensure the drive and cams turn easily.
3. Test for proper hole alignment to the paper edge by doing the following.
a. Run 1 page at a time.
b. Run 2 pages at a time.
c. Run 5 pages at a time.
d. Run 10 pages at a time.
e. Run 50 pages at a time.
7.20.2 Solenoid Spring Replacement

A. Procedure
Removal of spring [1] and [2] -
Grasp the loop of the spring with needle nose plyers and then pull them off the shaft.
Removal of spring [3] -
Grasp the loop of the spring with needle nose plyers and then pull them off the sheet metal part.
[3]
[1]
[2]
Figure 3.55 Back Gauge Solenoid Springs.
84
7.20.3 Back Gauge Paddle

A. Procedure
First remove Back gauge assembly as described in P.78.
GP-501
Deep or angled deep punches may be caused by a broken weld on the Paddle shaft [1]. Inspect the Paddle and
press down on it while holding the linkage to keep the linkage from moving. If the paddle [2] moves, replace the
Back Gauge assembly.
[1]
[2]
Figure 3.56 Testing for Broken Paddle Weld.
85
7.20.4 Back Gauge Assembly Adjustment

The Back Gauge can be adjusted up and down for optimum operation for specific Die Sets.
The Back Gauge should be at its highest position for VeloBind or PB Die Sets. If it is not, the Back Gauge Pad-
GP-501
dle may not completely close the paper path gap. This can result in paper (especially with excessive curl) slip-
ping through the gap created by the Paddle and the top plate of the Die Set. This causes a deep punch.
Initially, move the assembly to its highest position and then adjust accordingly after testing each Die Set.
Ensure it is easy to insert and remove three hole Die Sets. If the Die Set is too tight, evenly lower the Back Gauge
slightly to achieve the tightness required, while still retaining the PB and VeloBind functionality mentioned above.
A. To adjust the Back Gauge:

1. Loosen the 3 phillips head screws [1].
2. Move the entire assembly [2] upward or downward as needed while keeping it even.
3. While holding the assembly up, tighten the 3 screws.
[1] [2]
[1] [1]
Figure 3.57 Adjusting the Back Gauge Assembly.
86
B. Testing
(1) To test the Back Gauge adjustment:
1. Run a few sheets of paper and check for skew with each Die Set.
GP-501
Refer to Figure 3.58.
2. Adjust the Back Gauge as needed and re-test.
3. Run 200 to 500 sheets of paper and check for mis-feeding, deep punching, and skew.
Correct Alignment
Skew
Figure 3.58 Examples of Normal and Abnormal Hole Registrations.
87
7.21 Punch module

A. Tools Required
GP-501

• Hex wrench, 5/64"
Note
into the bin.
B. Procedure
Remove the module to lubricate the cams, or to service or replace the following components.
• Punch motor
• Drive motor belt
• Punch module brake
• Cams
• Flexible drive coupling
• Punch Module drive rollers
The clutch can be replaced without removing the module. (Refer to P.96).
WARNING:
• Disconnect the GP-501 Punch from its power source before removing the Back Gauge assembly.
Failure to observe this warning can result in severe injury or death and damage the punch.
88
7.21.1 Punch Module Removal

The Back Gauge assembly must be removed before removing the Punch Module. (Refer to P.77).
GP-501
A. To remove the Punch Module:
1. Remove the Back Gauge assembly.
2. Use a 5/64” hex wrench to remove the Punch Cycle knob [1].
[1]
Figure 3.59 Removing the Punch Cycle Knob on the Front Panel.
3. Remove the 4 Punch Module retaining screws [1] from the front panel.
[1]
[1]
Figure 3.60 Punch Module Front Retaining Screws.
89
4. Release the cable ties on the left wiring harness [1] to free the Punch Module wiring. Remove the connector
from flag sensor [2]. Remove harness from brake and clutch as per image below
GP-501
[2]
[1]
Figure 3.61 Wiring Harness at Rear of Punch.
90
5. Remove the belts in the following order.

a. Remove the bottom left and right vertical belts [1] by walking the belts over the pulleys.
b. Remove the 4 power supply screws [5].
GP-501
[5]
[5]
Figure 3.62 Power Supply.
91
c. Loosen the belt idler rollers [2] and remove the upper vertical belt [3].
d. Remove the bottom triangular belt [4] after loosening the respective tensioner.
GP-501
Tensioner Free to
Rotate
Loosen
Screw
[2]
[3]
[1]
[1]
[4]
Figure 3.63 Order of Belt Removal.
92
6. Remove the two rear Punch Module screws [1].
GP-501
[1]
[1]
Figure 3.64 Punch Module Retaining Screws on Rear of Punch.
7. Cut wire harness ties as needed to release the punch wiring.

8. Unplug the punch connector [1] from the control board.
[1]
Figure 3.65 Punch Connector on Control Board.
93
9. Carefully slide the Punch Module out the back of the punch.
Ensure that the wiring harness does not get caught or prevent removal of the module.
GP-501
Figure 3.66 Removing the Punch Drive Module.
94
7.21.2 Lubricating to the Punch Drive Cams

A. Periodically lubricated parts/cycle
• Punch drive cams: Every 12,000,000 prints (Actual lubrication cycle: Every 3,000,000 punches) *1
GP-501
*1 1200/1200P/1051
B. Procedure
Back gauge and rail needs to be removed for accessing punch module cams. Refer to P.78 for removing back
gauge. Use brush for reach to cams for further cleaning operation.
Grease cams
(Magnalube-G Teflon Grease)
Figure 3.67
Installation Note: Make sure the wires on the rear of the punch are not obstructing the Die Set or Chip Bin.
95
7.21.3 Punch Clutch Replacement

A. Procedure
Replace if Punch clutch is malfunctioning.
GP-501
Note
• The Punch clutch can be removed without removing the Punch Module.
B. Tools Required
• Phillips screwdriver or 1/4" nut driver
• Hex wrench, 5/64"
C. To remove the clutch:

1. Unplug the punch flag sensor (S9) connector [1].
[1]
Figure 3.68 Punch Flag Sensor Connector on Rear of the Punch.
96
2. Slide the fan [1] off the shaft.
GP-501
[1]
Figure 3.69 Punch Fan
3. Remove the lower drive belt [1].
[1]
Figure 3.70 Punch Drive Belt.
97
4. Loosen the 2 pulley socket head set screws [1].

5. Remove the pulley and its shaft key [2].
GP-501
[1]
[2]
Figure 3.71 Drive Upper Pulley.
6. Remove the 2 clutch bracket screws [1].
[2]
[1]
[1]
Figure 3.72 Clutch Bracket.
Installation Note: When installing the clutch bracket, ensure that the fork of the clutch engages the tab on
the bracket [2].
98
7. Loosen the 2 clutch socket head set screws [1], slide the Punch clutch [2] off the shaft, and remove the shaft
key [3].
GP-501
[2]
[1]
[3]
Figure 3.73 Punch Clutch.
Installation Note: When installing the Punch clutch, be sure to install the shaft key. Press the Punch clutch
against the drive gear plate. While pressing the clutch against the plate, tighten the 2 set screws. The
assembly does not require a gap between the Punch clutch and clutch plate.
8. Cut wire ties as needed and unplug the clutch connector [1] from the Punch Controller PCB.
[1]
Figure 3.74 Punch Clutch Connector on the PCB.
99
9. Slide the back portion of the clutch [1] off the shaft.
The motor drive belt [2] can be removed at the same time.
GP-501
[2]
[1]
Figure 3.75 Drive Belt and Back Portion of Clutch.
10. To install the clutch, reverse these steps.
100
7.21.4 Punch Module Brake Replacement and Adjustment

A. Procedure
To replace the Punch module brake, first remove the clutch and related drives. (Refer to P.96). The Punch mod-
GP-501
ule brake must be adjusted while on drive shaft. To adjust the Punch module brake. (Refer to P.103)
B. Tools Needed
• Feeler gauge, 0.0001" (0.00254 mm)
• Hex wrenches, 0.05" and 3/32"
• Flat blade screwdriver
• Pliers
7.21.5 Punch Module Brake Replacement
A. To replace the Punch module brake

1. Remove the 4 socket head set screws [1].
2. Loosen the 2 set screws [2] until the brake pad [3] slides freely on the shaft.
[3]
[1]
[2]
Figure 3.76 Punch module brake Assembly and Drive Shaft.
Installation Note: When installing the Punch module brake, ensure that the 2 set screws engage the flats
on the shaft. To adjust the Punch module brake. (Refer to P.103)
101
3. Remove the E-Ring at the opposite end of the shaft [1].

4. Slide the shaft [2] out of the bearing bracket, away from the clutch end.
5. Slide the Punch module brake assembly off the shaft.
GP-501
[1]
[2]
Figure 3.77 Shaft E-Ring.
6. To install the Punch module brake assembly, reverse these steps.
102
7.21.6 Punch Module Brake Adjustment

A. Procedure
The Punch module brake can be adjusted without removing the Punch module brake from the shaft. The gap
GP-501
between the brake and the pad is 0.0001" (0.00254 mm) .
B. To adjust the Punch module brake

1. Loosen the 2 set screws [2] until the brake pad slides freely on the shaft.
0.0001" (0.00254 mm)
[1]
Figure 3.78 Punch module brake Assembly Gap Adjustment.
2. Use a 0.0001" (0.00254 mm) feeler gauge to set the gap between the brake and the brake pad.
3. Tighten the 2 set screws and check the gap.
103
7.21.7 Punch Module Motor Replacement

A. Procedure
Replace motor when it malfunctions.
GP-501
B. To replace the Punch Module motor:

1. Cut any wire ties as necessary to release the motor wires.
2. Unplug motor wire connections from the capacitor [1].
[1]
Figure 3.79 Punch Capacitor.
3. Remove the metal spring clip [1] from the fan and slide the fan [2] off the shaft.
[1]
[2]
Figure 3.80 Punch Fan and Spring Clip.
Installation Note: When installing the fan, be sure to align the flat of the fan hub with the flat on the shaft.
Also, make sure the hub and spring clip are facing away from the motor.
104
4. Loosen the 2 socket head set screws[1] on the pulley and slide the pulley and belt off the shaft.
5. Remove the motor mounting 4 nuts [2].
GP-501
[2] [2]
[1]
Figure 3.81 Motor Pulley and Mounting Nuts.
6. To install the motor, reverse these steps.
105
7.21.8 Punch Module Motor Drive Belt Replacement

A. Procedure
Replace the belt when it is frayed, missing teeth, or worn out.
GP-501
B. To replace the Punch Module drive belts:

1. With the fan removed from the shaft, work the belt [1] off the clutch gear [2].
[1]
[2]
Figure 3.82 Motor Pulley and Belt.
2. Install a new belt by looping it over the motor pulley and then work it onto the clutch gear.
The belt requires no adjustment. It should have slight deflection when pressed.
106
7.21.9 Punch Module Drive Roller Replacement

A. Procedure
Inspect for wear patterns or groves. The roller surface should be even and not glazed.Clean with a soft cloth and
GP-501
alcohol.
B. Tools Required
• Flat bladed screwdriver
With the Punch Module out of the machine, the punch entrance side [1] and exit [2] drive rollers can be cleaned
or replaced.
[1]
[2]
Figure 3.83
C. To clean the punch entrance drive rollers:

1. Remove the idler roller assembly [1].
2. Rotate and clean the drive rollers [2].
[1] [2]
Figure 3.84 Punch Entrance Rollers.
107
D. To replace the punch entrance drive rollers:

1. Unplug the sensor [1].
2. Remove the 2 screws at the ends of the idler roller assembly [2].
GP-501
3. Remove the 2 screws at the ends of the drive roller assembly [3].
[3] [3]
[2]
[2]
[1]
Figure 3.85 Punch Entrance Drive Roller Assemblies.
4. Remove the E-Ring at the end of the drive roller shaft [1].
5. Slide the drive roller shaft and bracket towards the opposite end of the Punch Module so that the end of the
shaft clears the bearing at the end where you removed the E- Ring [1].
6. Lift the drive roller and bracket out of the Punch Module.
[1]
Figure 3.86 Drive Roller Shaft and E-Ring.
108
E. To clean the punch exit drive rollers:

1. Move one retaining spring [1] to the side and then remove the idler roller assembly [2].
2. Rotate and clean the drive rollers [2].
GP-501
[1] [2]
F. To replace the punch exit drive rollers:

1. Move one retaining spring [1] to the side and then remove the idler roller assembly [2].
2. Remove the 2 screws at each end of the idler roller assembly [3].
3. Remove the E-Ring [4] at the end of the drive roller shaft.
4. Slide the drive roller shaft and bracket towards the opposite end of the Punch Module so that the end of the
shaft clears the bearing at the end where you removed the E-Ring [4].
5. Lift the drive roller and bracket out of the Punch Module [5].
6. Remove the sensor [6].
7. To install the drive roller, reverse these steps.
[5] [2] [1]

[6]
[4]
[3]
109
7.22 Belt replacement

A. To replace belts:
GP-501
1. Loosen the screws of the 3 belt idlers [1].

Installation Note: When setting the belt tension, adjust the belt idlers so that the belt has approximately 1/4"
(6.35mm) of deflection.
[1]
[1]
[1]
Figure 3.87 Belt Idler Locations.
110
2. Remove the belts in order as follows

[1]=>[2]=>[3]=>[4]=>[5]
GP-501
[4]
[3] [2]
[5]
[1]
Figure 3.88 Order of Belt Removal.
3. To install and adjust the tension of the belts, reverse these steps.
111
7.23 Tools
Tools (needs to be reviewed by Engineering for current design accuracy)
GP-501
Tools recommended for service of the GP-501 Punch:
A. Standard Measure Tools (English as opposed to metric)

• Open end ignition wrench - 1/4" (required only for chad kit installation)
• Phillips screwdriver or 1/4” and 5/16" nut drivers
• Hex wrenches, 3/32", 5/64", and 9/64"
B. Other Recommended Tools and Supplies

• Wire cutters
• Screw driver, flat head, small
Supply of wire tie wraps
112
8. OTHER PROCEDURES
This section contains information related to the quality of the output such as hole quality or alignment.
GP-501
8.1 Centering punched holes
Die Set Position Cradle Adjustment, The die set position cradle is set in the factory; however, because of the
punched-hole spacing on the PB die sets, there is a minimal amount of paper on each edge of the punched
paper. The die set position cradle may have to be fine adjusted to center the punched-hole pattern in the paper.
Listed below are the step-by-step instructions to adjust the die set to the proper position.
1. The punched-hole alignment must be checked on a piece of punched paper. Fold the punched sheet of
paper in half [1] and the punched-holes should be aligned evenly along the edge and centered between the
ends [2]. If the punched-holes are not aligned, then the die set cradle must be adjusted to align the punched
holes.
Note
• The paper path is always constant, if the holes are not centered, you must adjust the die set cra-
dle.
[1]
[2]
Figure 3.89 Folding Punched Paper to Check Alignment.
113
2. The two back covers on the GP-501 Punch must be removed to access the die set position cradle [1]. Refer
to P.124 for information on removing rear cover.
GP-501
[1]
Figure 3.90 Removing Back Cover to Access the Die Set Position Cradle.
114
3. Before adjusting the die set position cradle, you must first note what direction the die set cradle [1] must
move.
GP-501
[1]
Figure 3.91 Die Set Position Cradle Adjustment.
115
4. Loosen the lock-down screw [1].

5. Using a flat-blade screwdriver, turn the adjustment screw [2] clockwise or counter-clockwise to move the die
set position cradle.
GP-501
[1]
[2]
Figure 3.92 Adjusting Die Set Position.
116
6. Observe the punched paper. If the punched-holes are too close to the rear of the machine, then you must
turn the adjustment screw counter-clockwise [1].
GP-501
[1]
Figure 3.93 Adjustment if Holes Are Too Close to the Rear.
7. If the punched-holes are too close to the front of the machine, then you must turn the adjustment screw
clockwise [1].
[1]
Figure 3.94 Adjustment if Holes Are Too Close to the Front.
Note
• Seven full turns of the adjustment screw result in a 1/4" (6.35 mm) change in the punched hole
position.
117
8. Before tightening the lock-down screw [1], tilt or bias the assembly towards the bottom of the machine [2]
and tighten the lock-down screw. This will ensure positive engagement between the locking lever and the
die set.
GP-501
[2]
[1]
Figure 3.95 Tightening the Lock-Down Screw.
9. Run a test sample of punched paper and recheck paper alignment. Re-adjust if necessary.
118
8.2 Door latch

A. Procedure
GP-501
Ensure the door latch holds the door closed and that the activating bracket tab [1] depresses the door switch
[2]. The tab should press the switch button just so that it is close to bottoming out.
[1] [2]
Figure 3.96 Door Latch and Switch.
119
8.2.1 Door Latch Adjustment

A. To adjust the door latch:
GP-501
2. Loosen the two adjustment screws [1] on the door latch.
[1]
Figure 3.97 Door Latch Adjustment Screws.
3. Do one of the following.

• To move the door in, move the latch towards the front of the door.
• To move the door out, move the latch away from the front of the door.
4. Tighten the 2 screws [1] and close the door.
5. Test its operation.
120
8.2.2 Door Latch and Switch Replacement

A. To replace the door latch:
GP-501
[1]
Figure 3.98 Door Latch and Screws.
121
B. To replace the door switch:

GP-501
3. Unplug connectors from switch [2].
[2]
[1]
Figure 3.99 Door Switch.
122
8.3 Preparing the GP-501 punch for service

Most service requires that the GP-501 Punch be separated from the printer and finisher and the rear cover be
GP-501
removed.
WARNING:
• Disconnect the unit from power and maintain the cord in your possession. Failure to observe this
warning can result in injury or electrical shock.
A. Procedure
• Unplug the unit from power.
• Disconnect the communication cable
• Empty Chip Bin
8.3.1 Separating the Punch From the Printer

Follow the instructions as described in Installation Manual.
123
8.3.2 Removing the Rear Cover

Separate the punch from the printer and finisher first. (Refer to P.123).
GP-501
Note
• It is not necessary nor recommended that you remove the top cover.
A. Procedure
B. Tool Required
• Phillips screwdriver or 1/4" hex head nut driver
C. To remove the rear cover:

1. Remove the 5 screws on the entrance side [1] and remove the 6 rear cover screws [2].
2. Slide the cover out from under the top cover. Do not remove the top cover.
[1]
[2]
Figure 3.100 Removing Rear Cover.
124
8.4 Leveling and aligning to the printer

The punch must be level and in line with the printer and finisher. If the printer and GP-501 Punch are moved or
GP-501
relocated, the system must be re-leveled.
Note
• It is important that the punch is not twisted or skewed. It must be level front to back and side to
side.
A. Procedure
Raise or lower the GP-501 Punch’s castors to level it.
B. Tool Required
• 2 3/8" open ended wrenches
• Level
C. To level the punch:

1. Remove the rear cover and put the punch back in line with the printer and finisher.
2. Place the level on a flat surface of the top [1] and determine which castor needs adjustment.
[1]
Figure 3.101 Leveling the Punch to the Printer and Finisher.
125
3. Loosen the locking nut [1] of the castor.

4. From below the frame and at the top of the castor [2], adjust the height of the castor as needed.
5. Check the level and adjust as necessary.
GP-501
6. Tighten the locking nut [1].

7. Ensure punch is level and in line with main body and finisher.
8. Install rear cover.
[1]
[1]
[2]
Figure 3.102 Castors Locking Nuts.
126
Ⅰ 調整
Ⅱ サービスツール
Ⅲ サービス
Ⅳ ジャムコード
Ⅴ 異常コード
© 2008 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.

Printed in Japan
Use of this manual should be strictly supervised to avoid
CCA0U0-M-TE3
disclosure of confidential information.
SERVICE MANUAL Field Service
C6501/C6501P/
C65hc/C5501
2009.07
Ver. 3.0
Revision history
Revision mark:
corresponding page.
NOTE
Revision in relation to launching of GP-501 and RU-506.

2009/07 3.0 2 Revision due to the commonization of the options of
bizhub PRO 1200/1200P/1051.
Revision in relation to launching of bizhub PRO C65hc.
2009/03 2.0 1 Addition of relay connector layout.
Field Service Ver.3.0 Jul. 2009 CONTENTS
CONTENTS
/C6501P/C65hc/C5501
bizhub PRO C6501
SAFETY AND IMPORTANT WARNING ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1
IMPORTANT NOTICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1
DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1
SAFETY WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-13
IMPORTANT NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-13
INDICATION OF WARNING ON THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-14
MEASURES TO TAKE IN CASE OF AN ACCIDENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-19
Legal restrictions on copying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Composition of the service manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Notation of the service manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
OUTLINE
1. SYSTEM CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 Main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 DF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 PF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3.1 PF-602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3.2 HT-504 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 LU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.4.1 LU-202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.4.2 HT-503 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.5 RU-504 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.6 RU-506 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.7 FD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.8 LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.9 FS-521 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.10 FS-520/607 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.11 PI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.12 PK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.13 SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.14 PB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.15 GP-501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
MAINTENANCE
3. PERIODIC CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.1 Maintenance item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.1.1 Main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.1.2 DF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.1.3 PF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.1.4 LU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.1.5 RU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.1.6 FD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.1.7 FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
i
CONTENTS Field Service Ver.3.0 Jul. 2009
3.1.8 PI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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3.1.9 SD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
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3.1.10 PB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.1.11 GP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.2 Replacement parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.2.1 Periodically replacement parts list (PRO C6501/C6501P/C65hc) . . . . . . . . . . . . . . . . . . . . . . 81
3.2.2 Spot replacement parts list (PRO C6501/C6501P/C65hc) . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.2.3 Periodically replacement parts list (PRO C5501) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.2.4 Spot replacement parts list (PRO C5501) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.3 Concept of parts life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.3.1 Life value of consumables and parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.3.2 Conditions for life specifications values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4. SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.1 Service material list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.2 Jig list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.3 Mail remote notification system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.3.1 Outline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.3.2 Operating environments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.3.3 Major functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.3.4 Initial setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.3.5 Usage of the mail remote notification system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.3.6 Mail sending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.4 Job history list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.4.1 OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.4.2 Major functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.4.3 Setting method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5. FIRMWARE VERSION UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.1 ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.1.1 Types of ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.1.2 Firmware data flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.1.3 Settings on the main body side while in ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.2 ISWTrns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.2.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.2.2 Installation of the ISWTrns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.2.3 Usage of the ISWTrns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.2.4 Error list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
5.3 USB memory ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.3.1 Usage of the USB memory ISW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.3.2 Main body error list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
5.4 Internet ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.4.1 OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.4.2 Operating environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.4.3 Initial settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.4.4 Internet ISW using the Web Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.4.5 Internet ISW using the mail remote notification system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.4.6 Notes for use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5.4.7 Internet ISW using the operation panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.4.8 Authentication of the proxy server in the Internet ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.5 Counter list obtaining with USB memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.5.1 Outline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
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5.5.2 List that can be obtained. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
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5.5.3 Obtaining method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
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ADJUSTMENT/SETTING
6. HOW TO USE THE ADJUSTMENT/SETTING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
6.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7. UTILITY MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.1 List of utility mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.1.1 Density Unevenness Adj.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
8. ADJUSTMENT LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
9. SERVICE MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
9.1 List of service mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
9.2 Setting method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
9.2.1 Start and exit service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
9.3 Machine adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
9.3.1 Restart Timing Adjustment (Printer Adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
9.3.2 Centering Adjustment (Printer Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
9.3.3 FD-Mag. Adjustment (Printer Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
9.3.4 CD-Mag. Adjustment (Printer Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
9.3.5 Lead Edge Erase Adjustmet (Printer Adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
9.3.6 Registration Loop Adj. (Printer Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
9.3.7 Pre-registration Adj. (Printer Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
9.3.8 Belt Line Speed Adj. (Printer Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
9.3.9 Writing Init. Pos. Memory (Printer Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
9.3.10 Color Registration Adj. (Printer Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
9.3.11 Color Registration/Manual (Printer Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
9.3.12 Adjustment when replacing multi feed detection board (PF). . . . . . . . . . . . . . . . . . . . . . . . . 172
9.3.13 CD Skew Adj. (Printer Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
9.3.14 Recall Standard Data (Printer Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
9.3.15 Restart Timing Adjustment (Scanner Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
9.3.16 Centering Adjustment (Scanner Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
9.3.17 FD-Mag. Adjustment (Scanner Adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
9.3.18 Recall Standard Data (Scanner Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
9.3.19 Scanner smooth tone/color (Quality Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
9.3.20 Printer gamma adjustment (Quality Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
9.3.21 Sharpness adjustment (Quality Adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
9.3.22 Contrast adjustment (Quality Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
9.3.23 Image Distinction Level (Quality Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
9.3.24 ACS adjustment (Quality Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
9.3.25 Density adjustment (Quality Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
9.3.26 Tone adjustment (Quality Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
9.3.27 Recall standard data (Quality Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
9.3.28 Non-Image Area Erase Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
9.4 Process Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
9.4.1 1st transfer manual adj. (High Voltage Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
9.4.2 2nd transfer manual adj. (High Voltage Adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
9.4.3 HV adj. (separation AC) (High Voltage Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
9.4.4 HV adj. (sepration DC) (High Voltage Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
9.4.5 Pre-transfer Guide HV check (High Voltage Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
9.4.6 Blade setting mode (Drum Peculiarity Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
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9.4.7 Automatic drum potential (Drum Peculiarity Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

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9.4.8 Auto gamma adjustment (Drum Peculiarity Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

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9.4.9 LD bias adjustment (Drum Peculiarity Adj.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

9.4.10 Automatic Developer Charge (Drum Peculiarity Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
9.4.11 Toner density sensor Init. (Drum Peculiarity Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
9.4.12 Initial drum rotation (Drum Peculiarity Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
9.4.13 Surface potential sensor (Sensor output check) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
9.4.14 Maximum density sensor (Sensor output check) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
9.4.15 Gamma sensor output (Sensor output check) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
9.4.16 Toner Density Sensor (Sensor output check) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
9.4.17 Drum Surfase potential (Sensor output check) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
9.4.18 Humidity/Temperature (Sensor output check) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
9.4.19 Toner Density Return Mode (Sensor output check) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
9.4.20 Covered Margin Fine Adj. (Process Fine Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
9.4.21 Develop AC Bias Fine Adj. (Process Fine Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
9.4.22 Develop AC Frequency (Process Fine Adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
9.4.23 Toner Density Fine Adj. (Process Fine Adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
9.4.24 Drum Tiny Rotation Interval (Interval/Quantity Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
9.4.25 Auto. Refresh Interval (Interval/Quantity Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
9.4.26 Toner Dens. Sensor Interval (Interval/Quantity Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
9.4.27 Recall standard data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
9.5 System Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
9.5.1 Software SW Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
9.5.2 Telephone Number Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
9.5.3 M/C Serial Number Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
9.5.4 Setup Date Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
9.6 Counter/data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
9.6.1 Maintenance Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
9.6.2 Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
9.6.3 Count of special parts (Parts Counter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
9.6.4 Count of each parts (Parts Counter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
9.7 State Confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
9.7.1 I/O Check Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
9.7.2 Input check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
9.7.3 Output check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
9.7.4 Adjustment when replacing multi feed detection board (PI) . . . . . . . . . . . . . . . . . . . . . . . . . 322
9.7.5 Adjustment when replacing multi feed detection board (PB). . . . . . . . . . . . . . . . . . . . . . . . . 324
9.7.6 Storing FD, SD, FS, PB adjustment data into EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
9.7.7 Storing main body adjustment data into NVRAM board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
9.7.8 Line memory check on image processing board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
9.7.9 Hard disk check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
9.7.10 Replacement of the hard disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
9.8 ADF adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
9.8.1 ADF Original Size Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
9.8.2 ADF Orig. Stop Position Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
9.8.3 ADF Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
9.8.4 ADF Registration Loop Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
9.9 Finisher Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
9.9.1 Staple Center Position (Stapler Position Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
9.9.2 Paper Width (staple) (Stapler Position Adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
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9.9.3 Paper Width (straight) (Stapler Position Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
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9.9.4 Exit Guide Center Adj. (Stapler Position Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
bizhub PRO C6501

9.9.5 Exit Guide Paper Width (Stapler Position Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
9.9.6 Paper Width Adjustment (Multi Folder (Punch) Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
9.9.7 Hole-Punch Vertical Pos. (Multi Folder (Punch) Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
9.9.8 Half Fold Position Adj. (Multi Folder (Fold) Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
9.9.9 Tri-Fold-in Pos. Adj. (Multi Folder (Fold) Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
9.9.10 Tri-Fold-out Pos. adj. (Multi Folder (Fold) Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
9.9.11 Double Parallel Folds Pos. Adj. (Multi Folder (Fold) Adj.). . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
9.9.12 Z-Fold Position Adj. (Multi Folder (Fold) Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
9.9.13 Gate Fold Position Adj. (Multi Folder (Fold) Adj.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
9.9.14 Fold Regist Loop Adj. (Multi Folder (Fold) Adj.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
9.9.15 Multi Folder (PI) Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
9.9.16 Stacker Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
9.9.17 Staple Center Adj. (Saddle Stitcher Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
9.9.18 Staple Paper Width Adj. (Saddle Stitcher Adj.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
9.9.19 Staple Pitch Adjustment (Saddle Stitcher Adj.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
9.9.20 Half Fold Position Adj. (Saddle Stitcher Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
9.9.21 Tri-Fold Position Adj. (Saddle Stitcher Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
9.9.22 Fold Paper Width Adj. (Saddle Stitcher Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
9.9.23 Trimming Adjustment (Saddle Stitcher Adj.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
9.9.24 Trimmer Receiver Adj. (Saddle Stitcher Adj.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
9.9.25 Curl Reform Direction (RU Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
9.9.26 Cover Trimming Adjustment (Perfect Binder Adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . 360
9.9.27 Cover Lead Edge Adj. (Perfect Binder Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
9.9.28 Spine Corner forming Pos. (Perfect Binder Adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
9.9.29 Pasting Start Postion (Perfect Binder Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
9.9.30 Pasting Finish Position (Perfect Binder Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
9.9.31 Paste Formation Finish Pos. (Perfect Binder Adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . 365
9.9.32 Temperature Adjustment (Perfect Binder Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
9.9.33 Sub Compile CD Width Adj. (Perfect Binder Adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . 367
9.9.34 Clamp CD Width Adjustment (Perfect Binder Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . 368
9.9.35 Cover Up/Down CD Width Adj. (Perfect Binder Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . 369
9.9.36 Clamp FD Position Adj. (Perfect Binder Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
9.9.37 Paper Width Adjustment (Relay Stacker Adjustment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
9.9.38 Paper Length Adjustment (Relay Stacker Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
9.9.39 Recall Standard Data (Finisher Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
9.9.40 Saddle Stitcher Stopper Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
9.9.41 Half Fold Stopper Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
9.9.42 Vertical Position Adj. (Punch Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
9.9.43 Horizontal Position Adj. (Punch Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
9.9.44 Registration Adjustment (Punch Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
9.9.45 Paper Edge Detect Sensor Adj. (Punch Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
9.9.46 Tri-Fold Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
9.9.47 2 Pos. Staple Pitch Adj.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
9.9.48 Paper Inserter Tray Size Adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
9.9.49 Output quantity limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
9.9.50 Curl adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
9.10 Firmware version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
9.11 CS Remote Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
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9.11.1 Outline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384

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9.11.2 Setup procedure of the CS Remote Care (When using the E-mail). . . . . . . . . . . . . . . . . . . . 384
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9.11.3 Setup procedure of the CS Remote Care (When using the phone line modem) . . . . . . . . . . 388
9.11.4 Setup procedure of the CS Remote Care (When using the WebDAV server) . . . . . . . . . . . . 390
9.11.5 List of combinations of E-Mail CS Remote Care and Mail remote notification system. . . . . . 393
9.11.6 E-Mail Initial Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
9.11.7 http communication Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
9.11.8 Software SW setting for CS Remote Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
9.11.9 Setup confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
9.11.10 Maintenance call . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
9.11.11 Center call from manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
9.11.12 Confirm communication log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
9.11.13 Initialization of RAM for CS Remote Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
9.11.14 Error code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
9.11.15 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
9.12 List output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
9.12.1 List Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
9.13 Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
9.13.1 Running Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
9.13.2 Test Pattern Output Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
9.14 ISW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
9.15 CE/Administrator Security Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
9.15.1 List of CE/Administrator Security Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
9.15.2 Start and exit CE/Administrator Security Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
9.15.3 CE Authentication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
9.15.4 CE Auth. Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
9.15.5 Admin. Authentication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
9.15.6 Administrator Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
9.16 Fee Collection Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
9.16.1 List of Fee Collection Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
9.16.2 Start and exit Fee Collection Setting Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
9.16.3 Coin Vendor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
9.16.4 Management Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
10. MECHANICAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
10.1 Main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
10.1.1 Adjusting the paper feed roller/BP pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
10.1.2 (Maximum) paper feed (bypass) height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
10.1.3 Pick-up movement amount adjustment (bypass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
10.1.4 Mis-centering adjustment of the paper feed tray /1, /2 and /3 . . . . . . . . . . . . . . . . . . . . . . . 428
10.1.5 Separation pressure adjustment of the paper feed tray/1, /2 and /3 . . . . . . . . . . . . . . . . . . 429
10.2 DF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
10.2.1 Adjustment of the hinge opening/closing angle (70 degrees and 40 degrees) . . . . . . . . . . . 430
10.2.2 Adjustment of the hinge opening/closing angle (90 degrees) . . . . . . . . . . . . . . . . . . . . . . . . 430
10.3 PF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
10.3.1 Paper feed pick-up amount adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
10.3.2 Pick-up roller height adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
10.3.3 Separation pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
10.3.4 Lift plate horizontal adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
10.3.5 Horizontal adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
10.4 LU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
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10.4.1 Separation pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
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10.4.2 Paper lift plate horizontal adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
bizhub PRO C6501

10.4.3 Paper centering adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
10.4.4 Paper skew adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
10.4.5 (Maximum) Paper feed height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
10.4.6 Pick-up roller separation adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
10.5 RU-506 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
10.5.1 Straight gate solenoid (SD1) position adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
10.5.2 Position adjustment of the stacker exit shutter solenoid (SD2) . . . . . . . . . . . . . . . . . . . . . . . 449
10.5.3 Position adjustment of the stack switching solenoid (SD3). . . . . . . . . . . . . . . . . . . . . . . . . . 451
10.5.4 Position adjustment of the stacker entrance guide plate solenoid (SD4). . . . . . . . . . . . . . . . 453
10.6 FD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
10.6.1 Roller solenoids /1 (SD5), /2 (SD6), /3 (SD7), /4 (SD8) position adjustment . . . . . . . . . . . . . 455
10.6.2 2nd folding roller solenoid (SD18) position adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
10.6.3 Punch centering adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
10.6.5 Paper feed control gear position adjustment (PI tray) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
10.6.6 Paper feed pick-up volume adjustment (PI tray). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
10.7 LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
10.7.1 Paper press solenoid /1 (SD6) adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
10.7.2 Adjusting the paper press solenoid /2 (SD7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
10.7.3 Adjusting the paper press solenoid /3 (SD8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
10.7.4 Adjusting the job partition solenoid (SD2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
10.7.6 Grip conveyance home sensor adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
10.8 FS-521 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
10.8.1 Adjusting the flat-stapling stopper position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
10.8.2 Adjusting the alignment plate position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
10.9 FS-520/607 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
10.9.1 Adjusting the bypass gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
10.9.2 Shift position adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
10.9.3 Adjusting the paper exit solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
10.9.4 Adjusting the mounting position of the paper exit arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
10.9.5 Adjusting the mounting position of the alignment plate /Up (FS-520) . . . . . . . . . . . . . . . . . . 483
10.9.6 Adjusting the mounting position of the alignment plate /Up (FS-607) . . . . . . . . . . . . . . . . . . 484
10.9.7 Adjusting the mounting position of the alignment plate /Lw (FS-607) . . . . . . . . . . . . . . . . . . 486
10.9.8 Adjusting the flat-stapling staple position (FS-520). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488
10.9.9 Adjusting the flat-stapling staple position (FS-607). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
10.9.10 Staple position adjustment (flat-stapling) (FS-607) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
10.9.11 Stapler vertical position adjustment (FS-607) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
10.9.12 Folding stopper tilt adjustment (FS-607) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
10.9.13 Adjusting the folding pressure (FS-607) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
10.9.14 Adjusting the tri-folding position (FS-607) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
10.10 PI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
10.10.1 PI tilt adjustment (with PK installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
10.11 PK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
10.11.1 Punch hole position tilt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
10.12 SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
vii
10.12.2 Folding skew adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504

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10.12.3 Second folding position stabilization adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505

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10.12.4 Staple position adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506

10.12.5 Stapler position adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
10.12.6 Tilt/gap adjustment of the clincher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
10.12.7 Trimming skew adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
10.12.8 Trimming adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
10.12.9 Note to keep in mind when replacing the board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
10.13 PB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
10.13.1 Clamp sub scan direction alignment adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
10.13.2 Clamp main scan direction alignment adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
10.13.3 Pellet supply arm angle adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
10.13.4 Glue apply roller gap adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
10.13.5 Cover paper glue roller gap adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
10.13.6 Glue tank movement rail tilt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524
10.13.7 Cover paper folding plate nipping adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
10.13.8 Cover paper folding plate parallel adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
10.13.9 Cover paper table up down belt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
10.13.10 Cover paper alignment plate adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
10.13.11 Cover paper cutting skew adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
10.13.12 Cover paper table positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
10.13.13 Cover paper tray pick-up adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
10.13.14 Cover paper tray pick-up roller height adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535
10.13.15 Cover paper tray separation pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
10.13.16 Cover paper tray centering adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
10.13.17 Cover paper tray lift plate horizontal adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540
TROUBLESHOOTING
11. JAM CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
11.1 Jam code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
12. MALFUNCTION CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
12.1 Malfunction code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
13. TROUBLESHOOTING (GP-501). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
13.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
13.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
13.1.2 Back Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644
13.1.3 Die Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645
13.2 Initial Service Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646
13.3 Mis-Feed Service Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 647
13.4 Final Service Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650
APPENDIX
14. PARTS LAYOUT DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651
14.1 Main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651
14.1.1 Switch/sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651
14.1.2 Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663
14.1.3 Boards and others. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 672
14.2 DF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677
14.3 PF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 678
14.4 LU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 684
viii
14.5 RU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 687
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14.5.1 RU-504 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 687
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14.5.2 RU-506 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 689
14.6 FD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 692
14.7 LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700
14.8 FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704
14.8.1 FS-521 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704
14.8.2 FS-520/607 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710
14.9 PI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714
14.10 PK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715
14.10.1 PK-512 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715
14.10.2 PK-513 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716
14.11 SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 717
14.12 PB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 731
14.13 GP-501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746
15. CONNECTOR LAYOUT DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 754
15.1 Main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 754
15.1.1 Connector in the board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 754
15.1.2 Relay connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764
15.2 DF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 777
15.3 PF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 778
15.4 LU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 779
15.5 RU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 780
15.6 FD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 782
15.7 LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 786
15.8 FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 788
15.9 PI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 792
15.10 PK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 793
15.11 SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 794
15.11.2 Relay connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 798
15.12 PB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
15.12.2 Relay connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
15.13 GP-501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 815
16. TIMING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 816
16.1 Main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 816
16.2 DF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 818
16.3 PF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 820
16.4 LU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 821
ix
16.5 RU-506 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 823

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16.6 FD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 824
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16.7 LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 832
16.8 FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 836
16.8.1 FS-521 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 836
16.8.2 FS-520/607. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 839
16.9 PI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 843
16.10 PK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 844
16.10.1 PK-512 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 844
16.10.2 PK-513 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 845
16.11 SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 846
16.12 PB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 852
17. OVERALL WIRING DIAGRAM
17.1 Main body 1/3
17.2 Main body 2/3
17.3 Main body 3/3
17.4 Main body 1/12
17.5 Main body 2/12
17.6 Main body 3/12
17.7 Main body 4/12
17.8 Main body 5/12
17.9 Main body 6/12
17.10 Main body 7/12
17.13 Main body 10/12
17.14 Main body 11/12
17.15 Main body 12/12
17.16 DF
17.17 PF
17.18 PF 1/4
17.19 PF 2/4
17.20 PF 3/4
17.21 PF 4/4
17.22 LU
17.23 RU
17.23.1 RU-504
17.23.2 RU-506
17.24 FD
17.25 LS
17.26 FS
17.26.1 FS-521
17.26.2 FS-520/607
17.27 PI
17.28 PK
17.29 SD
17.30 SD 1/4
17.31 SD 2/4
17.32 SD 3/4
17.33 SD 4/4
x
17.34 PB
/C6501P/C65hc/C5501
17.35 PB 1/4
bizhub PRO C6501

17.36 PB 2/4
17.37 PB 3/4
17.38 PB 4/4
17.39 GP-501
xi
/C6501P/C65hc/C5501 CONTENTS Field Service Ver.3.0 Jul. 2009
bizhub PRO C6501
Blank page
xii

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

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

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

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

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

copier. General Unplug Ground/Earth
instruction
S-1
SAFETY WARNINGS
[1] MODIFICATIONS NOT AUTHORIZED BY KONICA MINOLTA
BUSINESS TECHNOLOGIES, INC.
Konica Minolta brand products are renowned for their high reliability. This reliability is
achieved through high-quality design and a solid service network.
Product design is a highly complicated and delicate process where numerous mechanical,
physical, and electrical aspects have to be taken into consideration, with the aim of arriving
at proper tolerances and safety factors. For this reason, unauthorized modifications involve
a high risk of degradation in performance and safety. Such modifications are therefore
strictly prohibited. The points listed below are not exhaustive, but they illustrate the reason-
ing behind this policy.
Prohibited Actions
DANGER
• Using any cables or power cord not specified by KMBT.
• Using any fuse or thermostat not specified by KMBT.

injury.
• Disabling fuse functions or bridging fuse terminals with

wire, metal clips, solder or similar object.
• Disabling relay functions (such as wedging paper between

relay contacts)
• Disabling safety functions (interlocks, safety circuits, etc.)

injury.
• Making any modification to the product unless instructed

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

In some countries or areas, the power plug provided with the product may not fit wall outlet
used in the area. In that case, it is obligation of customer engineer (hereafter called the CE)
to attach appropriate power plug or power cord set in order to connect the product to the
supply.
Power Cord Set or Power Plug
WARNING
• Use power supply cord set which meets the following
criteria:
AC230V
- provided with a plug having configuration intended for
the connection to wall outlet appropriate for the prod-
uct's rated voltage and current, and
- provided with three-conductor cable having enough cur-
rent capacity, and
AC208V 240V
- the cord set meets regulatory requirements for the area.
Use of inadequate cord set leads to fire or electric shock.
• Attach power plug which meets the following criteria:
- having configuration intended for the connection to wall
outlet appropriate for the product's rated voltage and
current, and
- meets regulatory requirements for the area.
Use of inadequate cord set leads to the product connect-
ing to inadequate power supply (voltage, current capac-
ity, grounding), and may result in fire or electric shock.
• Conductors in the power cable must be connected to ter-

minals of the plug according to the following order:
•Black or Brown:L (line)
•White or Light Blue:N (neutral)
•Green/Yellow:PE (earth)
Wrong connection may cancel safeguards within the
product, and results in fire or electric shock.
S-3
[3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE

Konica Minolta brand products are extensively tested before shipping, to ensure that all
applicable safety standards are met, in order to protect the customer and CE from the risk
of injury. However, in daily use, any electrical equipment may be subject to parts wear and
eventual failure. In order to maintain safety and reliability, the CE must perform regular
safety checks.
1. Power Supply
WARNING
• Check that mains voltage is as specified.
Connection to wrong voltage supply may result in fire or
electric shock. ?V
• Connect power plug directly into wall outlet having same

configuration as the plug.
Use of an adapter leads to the product connecting to kw
inadequate power supply (voltage, current capacity,
grounding), and may result in fire or electric shock.
If proper wall outlet is not available, advice the customer
to contact qualified electrician for the installation.
• Plug the power cord into the dedicated wall outlet with a
capacity greater than the maximum power consumption.
result.
• If two or more power cords can be plugged into the wall

outlet, the total load must not exceed the rating of the wall
outlet.
result.
• Make sure the power cord is plugged in the wall outlet

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

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

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

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

Current that can flow in the extension cord is limited, so
using a too long extension cord may result in fire.
Do not use an extension cable reel with the cable taken
up. Fire may result.
S-6
2. Installation Requirements
Prohibited Installation Places
WARNING
• Do not place the product near flammable materials or vol-
atile 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 case of an earthquake and so on, the product may
slide, leading to a injury.
S-7
3. Servicing
Inspection before Servicing
CAUTION
• Before conducting an inspection, read all relevant docu-
mentation (service manual, technical notices, etc.) and
proceed with the inspection following the prescribed pro-
cedure in safety clothes, using only the prescribed tools.
Do not make any adjustment not described in the docu-
mentation.
If the prescribed procedure or tool is not used, the prod-
uct may break and a risk of injury or fire exists.
• Before conducting an inspection, be sure to disconnect

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

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

detached.
High-voltage exists around the drum unit. A risk of elec-
tric shock exists.
S-8
Safety Checkpoints
WARNING
• When taking a report of problems from a user, check each
part and repair properly.
A risk of product trouble, injury, and fire exists.
• Check the exterior and frame for edges, burrs, and other
damages.
The user or CE may be injured.
• Do not allow any metal parts such as clips, staples, and
screws to fall into the product.
They can short internal circuits and cause electric shock
or fire.
• Check wiring for squeezing and any other damage.

fire.
• Carefully remove all toner remnants and dust from electri-

cal parts and electrode units such as a charging corona
unit.
Current can leak, leading to a risk of product trouble or
fire.
• Check high-voltage cables and sheaths for any damage.

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

deterioration and sign of leakage.
Current can leak, leading to a risk of trouble or fire.
• Before disassembling or adjusting the write unit (P/H unit)

incorporating a laser, make sure that the power cord has
been disconnected.
loss of eyesight.
S-9
Safety Checkpoints
WARNING
• Do not remove the cover of the write unit. Do not supply
power with the write unit shifted from the specified mount-
ing position.
loss of eyesight.
• When replacing a lithium battery, replace it with a new lith-

ium battery specified in the Parts Guide Manual. Dispose
of the used lithium battery using the method specified by
local authority.
Improper replacement can cause explosion.
• After replacing a part to which AC voltage is applied (e.g.,
optical lamp and fixing lamp), be sure to check the instal-
lation state.
• Check the interlock switch and actuator for loosening and

check whether the interlock functions properly.
If the interlock does not function, you may receive an
electric shock or be injured when you insert your hand in
the product (e.g., for clearing paper jam).
• Make sure the wiring cannot come into contact with sharp
edges, burrs, or other pointed parts.
fire.
• Make sure that all screws, components, wiring, connec-

tors, etc. that were removed for safety check and mainte-
nance have been reinstalled in the original location. (Pay
special attention to forgotten connectors, pinched cables,
forgotten screws, etc.)
A risk of product trouble, electric shock, and fire exists.
S-10
Handling of Consumables
WARNING
• Toner and developer are not harmful substances, but care
must be taken not to breathe excessive amounts or let the
substances come into contact with eyes, etc. It may be
stimulative.
If the substances get in the eye, rinse with plenty of water
immediately. When symptoms are noticeable, consult a
physician.
• Never throw the used cartridge and toner into fire.

You may be burned due to dust explosion.
Handling of Service Materials
CAUTION
• Unplug the power cord from the wall outlet.
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
4. Fuse
Fuse
CAUTION
• CAUTION
Double pole / neutral fusing
• ATTENTION
Double pôle / Fusible sur le neutre
5. Used Batteries Precautions

Handling of batteries
CAUTION
• ALL Areas
CAUTION
Danger of explosion if battery is incorrectly replaced.
Replace only with the same or equivalent type recommended by the manufacturer.
Dispose of used batteries according to the manufacturer’s instructions.
• Germany
VORSICHT!
Explosionsgefahr bei unsachgemäßem Austausch der Batterie.
Ersatz nur durch denselben oder einen vom Hersteller empfohlenen gleichwertigen Typ.
Entsorgung gebrauchter Batterien nach Angaben des Herstellers.
• France
ATTENTION
Il y a danger d’explosion s’il y a remplacement incorrect de la batterie.
Remplacer uniquement avec une batterie du même type ou d’un type équivalent recom-
mandé par le constructeur.
Mettre au rebut les batteries usagées conformément aux instructions du fabricant.
• Denmark
ADVARSEL!
Lithiumbatteri - Eksplosionsfare ved fejlagtig håndtering.
Udskiftning må kun ske med batteri af samme fabrikat og type.
Levér det brugte batteri tilbage til leverandøren.
• Finland, Sweden
VAROlTUS
Paristo voi räjähtää, jos se on virheellisesti asennettu.
Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin.
Hävitä käytetty paristo valmistajan ohjeiden mukaisesti.
VARNING
Explosionsfara vid felaktigt batteribyte.
Använd samma batterityp eller en ekvivalent typ som rekommenderas av apparat-
tillverkaren.
Kassera använt batteri enligt fabrikantens instruktion.
• Norway
ADVARSEL
Eksplosjonsfare ved feilaktig skifte av batteri.
Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten.
Brukte batterier kasseres i henhold til fabrikantens instruksjoner.
S-12
SAFETY INFORMATION
SAFETY INFORMATION
IMPORTANT NOTICE
The Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Admin-
istration implemented regulations for laser products manufactured since August 1, 1976.
Compliance is mandatory for products marketed in the United States.
This copier is certified as a "Class 1" laser product under the U.S.
Department of Health and Human Services (DHHS) Radiation Performance Standard
according to the Radiation Control for Health and Safety Act of 1968. Since radiation emit-
ted inside this copier is completely confined within protective housings and external covers,
the laser beam cannot escape during any phase of normal user operation.
S-13
SAFETY INFORMATION
INDICATION OF WARNING ON THE MACHINE

Caution labels shown below are attached in some areas on/in the machine.
When accessing these areas for maintenance, repair, or adjustment, special care should
be taken to avoid burns and electric shock.
a03up0e001ca
S-14
SAFETY INFORMATION
a03up0e002ca
S-15
SAFETY INFORMATION
CAUTION
The paste tank
unit is very hot.
To avoid getting
burned DO NOT
TOUCH.
a03up0e003ca
S-16
SAFETY INFORMATION
(Large Capacity Unit LU-202)
CAUTION
To avoid any unexpected
injury, DO NOT put your hand
into the holes (3 places) on
the bottom plate of the LU.
(Finisher FS-520/FS-607)
CAUTION
To avoid injury, DO NOT
put your hand on top of
the printed sheets.
Be sure to hold both
sides of the printed
sheets when removing
them, and DO NOT leave
your hand on the printed
sheets while the primary
(main) tray goes up.
a03up0e004ca
S-17
SAFETY INFORMATION
WARNING
This safety message you could
get an electrical shock because
disconnecting power from this
section does not cut off power
from adjacent sections of the
machine.
WARNING
This safety message means
that you might get seriously
hurt or killed if you open the
product and expose yourself to
hazardous voltage. NEVER
remove the screwed on covers.
ALWAYS refer service
requirements to qualified
service personnel.
a0g6m0e004ca
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-18
MEASURES TO TAKE IN CASE OF

AN ACCIDENT
1. If an accident has occurred, the distributor who has been notified first must immediately
take emergency measures to provide relief to affected persons and to prevent further
damage.
2. If a report of a serious accident has been received from a customer, an on-site evalua-
tion must be carried out quickly and KMBT must be notified.
3. To determine the cause of the accident, conditions and materials must be recorded
through direct on-site checks, in accordance with instructions issued by KMBT.
4. For reports and measures concerning serious accidents, follow the regulations speci-
fied by every distributor.
S-19
Blank page
S-20
Legal restrictions on copying
Certain types of originals must never be copied with the purpose or intent to pass copies of
such originals off as the originals.
The following is not a complete list, but is meant to be used as a guide to responsible copy-
ing.
<Financial Instruments>
• Personal checks
• Traveler’s checks
• Money orders
• Certificates of deposit
• Bonds or other certificates of indebtedness
• Stock certificates
<Legal Originals>
• Food stamps
• Postage stamps (canceled or uncanceled)
• Checks or drafts drawn by government agencies
• Internal revenue stamps (canceled or uncanceled)
• Passports
• Immigration papers
• Motor vehicle licenses and titles
• House and property titles and deeds
<General>
• Identification cards, badges, or insignias
• Copyrighted works without permission of the copyright owner
In addition, it is prohibited under any circumstances to copy domestic or foreign currencies,

or works of art without permission of the copyright owner.
When in doubt about the nature of an original, consult with legal counsel.
Detail
In order to prohibit the illegal reproduction of certain originals, such as paper currency, this
machine is equipped with a counterfeit prevention feature.
Due to the counterfeit prevention feature that this machine is equipped with, images may
be distorted.
C-1
Composition of the service manual
This service manual consists of the following sections and chapters:
<Theory of Operation section>
OUTLINE: System configuration, product specifications,

unit configuration, and paper path
COMPOSITION/OPERATION: Configuration of each unit, explanation of the operating
system and explanation of the control system
MAINTENANCE: Maintenance steps,
removal/reinstallation methods of major parts
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. This section
also explains the procedure of maintenance.
<Field service section>
OUTLINE: System configuration, and product specifications

MAINTENANCE: Service schedule,
list of service tools and directions for use,
and firmware version up method
ADJUSTMENT/SETTING: Utility menu mode, Service mode, security and mechanical
adjustment
TROUBLESHOOTING: List of jam codes, their causes, operation when a jam
occurs and its release method, and list of error codes,
their causes, operation when a warning is issued and esti-
mated abnormal parts.
APPENDIX: Parts layout drawings, connector layout drawings, timing
chart, overall layout drawing
This section gives, as information required by the CE at the site (or at the customer's
premise), a rough outline of the service schedule and its details, the object and role of each
adjustment, error codes and supplementary information.
C-2
Notation of the service manual
A. Product name
In this manual, each of the products is described as follows:
(1) bizhub PRO C6501/C6501P/C65hc/C5501: Main body

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

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

IN
PS
Sensor PS Door PS1 Sensor detection signal
SIG
102 PS
24V Power to drive the solenoid
Solenoid SD DRV
Drive signal
SOL
24V Power to drive the clutch
Clutch CL DRV
Drive signal
SOL
C-3
24V Power to drive the motor
CONT Drive signal
DRV1
Motor M
DRV2
Drive signals of two kinds
D1
D2
_U
_V
_W
Drive signals (control signals) of three kinds
DRV1
DRV2
DRV3
D1
D2
D3
D4
DRV A
DRV A
DRV B Drive signals (control signals) of four kinds
DRV B Motor, phases A and B control signals
A
Motor M /A
B
/B
AB
BB
CLK, PLL PLL control signal
LCK, Lock, LD PLL lock signal
FR Forward/reverse rotation signal
EM, Lock, LCK, LD Motor lock abnormality
BLK Drive brake signal
P/S Power/stop
S/S
Operating load start/stop signal
SS
CW/CCW, F/R Rotational direction switching signal
ENB Effective signal
TEMP_ER Motor temperature abnormality detection signal
24V Power to drive the fan motor
CONT, DRIVE Drive signal
Fan FM
HL Speed control signal (2 speeds)
EM, Lock, LCK, FEM Detection signal
Others TH1.S, ANG Analog signal
C-4
SG, S.GND, S_GND Signal ground
Ground
PG, P.GND Power ground
DCD Data carrier detection
SIN Serial input
SOUT Serial output
DTR Data terminal operation available
GND Signal ground (earth)
Serial com-
DSR, DSET Data set ready
munication
RTS Transmission request signal
CTS Consent transmission signal
RI Ring indicator
TXD Serial transmission data
RXD Serial reception data
D. Paper feed direction

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

Transverse feed A4
A4
Longitudinal feed A4S
A3 Longitudinal feed A3
C-5
Blank Page
C-6
Field Service Ver.3.0 Jul. 2009 1. SYSTEM CONFIGURATION
OUTLINE
/C6501P/C65hc/C5501
bizhub PRO C6501
1. SYSTEM CONFIGURATION
A. System configuration (PRO C6501/C6501P/C65hc)
[24]
[23]
[2]
[19] [9]
[3]
[20] [21] [10]
[25] [4]
[18] [1]
[5]
[22]
[8]
[13]
[6]
[17] [7]
[12]
[11]
[16] [13]
[15]
[12]
[14]
a0u0t1e001ca
1 2
/C6501P/C65hc/C5501 1. SYSTEM CONFIGURATION Field Service Ver.3.0 Jul. 2009
[1] Main body [14] Flat stitching staple finisher (FS-520)

bizhub PRO C6501
[2] Dehumidifier fan heater (HT-503) [15] Simplified perfect binding machine (PB-501/502)
[3] Large capacity paper feed tray (LU-202) [16] Saddle stitching unit (SD-506)
[4] Large capacity paper feed tray (PF-602) [17] Large capacity stacker (LS-505)
[5] Dehumidifier fan heater (HT-504) [18] Punch and folding unit (FD-503)
[6] Built-in type image controller (IC-408) *1 [19] Staple finisher (FS-521)
[7] Server type image controller (IC-304/305) [20] Relay unit RU-506
[8] Hard disk (HD-506) *1 [21] Multi punch unit GP-501
[9] Output tray (OT-502) [22] Die set (DS-5##) *3
[10] Conveyance cooling unit (RU-504) [23] Original cover (OC-506) *1
[11] Saddle stitching staple finisher (FS-607) [24] Auto double sided original feeder (DF-609) *2
[12] Punch kit (PK-512/513) [25] Key counter
[13] Post inserter (PI-502)
*1 PRO C6501 only.

*2 In the case of PRO C6501P/C65hc, no scanner/DF function is provided.
*3 Selectable arbitrarily in accordance with the number and shape of pins.
Model Paper size The number Shape of pin Model Paper size The number Shape of pin
of pins of pins
DS-503 81/2 x 11 32 Square DS-512 A4 47 Round
DS-505 81/2 x 11 44 Round DS-514 To be determined
DS-507 To be determined DS-516 A4 20 Rectangle
DS-508 A4 4 Round DS-517 A4 23 Square
DS-509 A4 21 Rectangle DS-518 A4 34 Square
2 2
B. Configuration for optional device connection (PRO C6501/C6501P/C65hc)
/C6501P/C65hc/C5501
bizhub PRO C6501
Note
• IC-304/305 is available with all combinations.
• IC-408 is available with combination No.3, 9, 10 or 19.
• IC-408 is for C6501 only.
No. Paper feed option Combinations for finishing AC power to be connected

1 RU-504 FS-521 External (RU-504)
2 RU-504 FD-503 External (RU-504/FD-503)
3 RU-504 SD-506 External (RU-504)
4 RU-504 LS-505 External (RU-504/LS-505)
5 RU-504 FD-503 FS-521 External (RU-504/FD-503)
6 RU-504 LS-505 FS-521 External (RU-504/LS-505)
7 RU-504 LS-505 SD-506 External (RU-504/LS-505)
8 RU-504 FD-503 LS-505 External (RU-504/FD-503)
9 FS-607*3 —
10 OT-502 —
11 RU-504 PB-501/502 External (RU-504/PB-501/502)
12 RU-504 FD-503 PB-501/502 External (RU-504/FD-503/PB-501/
502)
13 PF-602*1/ RU-504 SD-506 PB-501/502 External (RU-504/PB-501/502)
14 LU-202*2 RU-504 FD-503 SD-506 PB-501/ External (RU-504/FD-503/PB-501/
502 502)
15 RU-504 LS-505 PB-501/502 External (RU-504/LS-505/PB-501/
502)
16 RU-504 FD-503 SD-506 External (RU-504/FD-503)
17 RU-504 SD-506 FS-521 External (RU-504)
18 RU-504 FD-503 SD-506 FS-521 External (RU-504/FD-503)
19 FS-520*3 —
20 RU-504 GP-501 RU-506 FS-521 External (RU-504/GP-501)
21 RU-504 GP-501 RU-506 FD-503 FS-521 External (RU-504/GP-501/FD-503)
22 RU-504 GP-501 RU-506 SD-506 FS-521 External (RU-504/GP-501)
23 RU-504 GP-501 RU-506 LS-505 FS-521 External (RU-504/GP-501/LS-505)
24 RU-504 GP-501 RU-506 LS-505 PB-501/ External (RU-504/GP-501/LS-505/
502 PB-501/502)
*1 HT-504 can be connected to PF-602 arbitrarily.

*3 PK-512, PK-513 or PI-502 can be connected to FS-520/607 arbitrarily.
*4 Metric destination : External (RU-504/FD-503)
Inch destination : External (RU-504)
3 2
1. SYSTEM CONFIGURATION Field Service Ver.3.0 Jul. 2009
C. System configuration (PRO C5501)

/C6501P/C65hc/C5501
bizhub PRO C6501
[10]
[13]
[12]
[9] [2]
[7]
[3]
[11]
[14]
[1]
[10]
[9]
[6]
[4]
[8] [5]
a03ut1c005cc
[1] Main body [8] Saddle stitching staple finisher (FS-607)

[2] Dehumidifier fan heater (HT-503) [9] Punch kit (PK-512/513)
[3] Large capacity paper feed tray (LU-202) [10] Post inserter (PI-502)
[4] Built-in type image controller (IC-408) [11] Staple finisher (FS-520)
[5] Server type image controller (IC-304/305) [12] Original cover (OC-506)
[6] Hard disk (HD-506) [13] Auto double sided original feeder (DF-609)
[7] Output tray (OT-502) [14] Key counter
4
D. Configuration for optional device connection (PRO C5501)
/C6501P/C65hc/C5501
bizhub PRO C6501
Note
No. Paper feeding option Combinations for finishing AC power to be connected to
1 LU-202 *1 FS-607 *2 —
2 LU-202 *1 FS-520 *2 —
3 LU-202 *1 OT-502 —

*2 PK-512/513 or PI-502 can be connected to FS-520/607 arbitrarily.
5
2. PRODUCT SPECIFICATIONS Field Service Ver.3.0 Jul. 2009
/C6501P/C65hc/C5501
bizhub PRO C6501
2.1 Main body

A. Type
Type Console type (floor-mounted type)

Copying method Four-drum tandem laser electrostatic method
Original stand Fixed
Original alignment Left rear standard
Photo conductor OPC
Writing method Two-beam laser scanning method
Paper capacity Three trays (500 sheets x 3, 80g/m2)
Multi bypass (250 sheets, 80g/m2)
PF-602 (3000 sheets x 2, 80g/m2)*1 *2
LU-202 (2500 sheets, 80g/m2)*1
*1 PF-602 and LU-202 are optional.

*2 PRO C6501/C6501P/C65hc only.
B. Functions
Original Sheet, book, solid object

Max. original size A3, or 11 x 17 (Custom paper is Max.303 x 438mm)
Copy size Tray1, 2, 3 SRA3, A3, B4, SRA4, A4, SRA4S, A4, A4S, B5, B5S, A5S
13 x 19, 12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S,
51/2 x 81/2S
81/2 x 13, 81/4 x 13, 8 1/8 x 131/4, 8 x 13
8K, 16K, 16KS
Bypass feed SRA3, A3, B4, SRA4, SRA4S, A4, A4S, B5, B5S, A5, A5S,
B6S, A6S,
13 x 19, 12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11,
81/2 x 11S, 51/2 x 81/2S
81/2 x 13, 81/2 x 13, 81/8 x 131/4, 8 x 13
8K, 16K, 16KS
ADU SRA3, A3, B4, SRA4, SRA4S, A4, A4S, B5, B5S, A5, A5S
13 x 19, 12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11,
81/2 x 11S, 51/2 x 81/2S
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
8K, 16K, 16KS
1 6
Field Service Ver.3.0 Jul. 2009 2. PRODUCT SPECIFICATIONS
/C6501P/C65hc/C5501
Magnification Fixed magnifi- Inch: x 1.000, x 2.000, x 1.545, x 1.294, x 1.214,
cation x 0.785, x 0.772, x 0.647, x 0.500
bizhub PRO C6501

Metric: x 1.000, x 2.000, x 1.414, x 1.224, x 1.154,
x 0.866, x 0.816, x 0.707, x 0.500
Zoom magnifi- x 0.25 to x 4.00 (at the step of 0.001 step)
cation
Warm-up time Inch: 390 seconds or less
Metric: 420 seconds or less
First copy out time Full color 6.5 seconds or less (A4 / 81/2 x 11)
Monochrome 6.5 seconds or less (A4 / 81/2 x 11)
Black-and-white 5.0 seconds or less (A4 / 81/2 x 11)
Continuous copy speed Full color 65 copies /min. (A4 / 81/2 x 11)*3
55 copies /min. (A4 / 81/2 x 11)*4
Monochrome 65 copies /min. (A4 / 81/2 x 11)*3
55 copies /min. (A4 / 81/2 x 11)*4
Black-and-white 65 copies /min. (A4 / 81/2 x 11)*3
55 copies /min. (A4 / 81/2 x 11)*4
Continuous copy count Up to 9,999 sheets
Resolution Scan Main scanning : 600 dpi Sub-scanning : 600 dpi
Write Main scanning : 600 dpi Sub-scanning : 600 dpi (1800 dpi *1)
Standard memory 256 MB for each color (Y, M, C, K)
Expansion memory 30 GB for each color (Y, M, C, K)
(HD-506)*5
No. of originals in memory Full color Line1/Line2/Dot1/Dot2: 23 sheets [5461 sheets*2]
(Reference value)*5 Priority in high compression: 110 sheets [16384 sheets *2]
Conditions Original: KM #101/A3 (color)
Density: Standard
Black-and- Line1/Line2/Dot1/Dot2: 126 sheets or more [16384 sheets *2]
white/mono- Priority in high compression: 271 sheets or more [16384
chrome sheets *2]
Conditions Original: FAX test chart #4 /A4
Density: Standard
Interface section RJ45 Ethernet, Serial port (RS232-C), Service port, Serial port (USB
TypeB),Connector for printer controller
*1 When "smoothing" is selected at the printer driver.

*2 When HD-506 is installed.
*3 PRO C6501/C6501P/C65hc
*4 PRO C5501
*5 C6501/C5501 only.
7 1
C. Available types of paper and ranges of paper weight

/C6501P/C65hc/C5501
bizhub PRO C6501
Type of paper Tray1, 2, 3 Bypass feed

Plain paper
High Quality paper
2
A4 or smaller than 8 /2 x 11 : 64 to 209 g/m
1
Color Specific paper

Coated_GL, ML, GO , MO U U
paper A4 or 81/2 x 11 or larger : 81 to 256 g/m2 64 to 300g/m2
Label paper*1 —
OHP film*1 *2
Index paper*1 *3
:Available U: Available only one sheet at a time —: Not available
*1 Paper type of the label paper can be Plain, High Quality, Color Specific, or Coated_GL, ML, GO, MO
paper. Available ranges of paper weight (thickness) of the label paper are the same with those of the corre-
sponding paper type.
*2 Print quality not guaranteed.
*3 Paper loading direction predetermined, single-sided printing only.
8
D. Materials
/C6501P/C65hc/C5501
bizhub PRO C6501
Parts name Useful life Type name
26,000 prints*1 TN612Y*5
Toner bottle /Y
25,000 prints*3 TN614Y*6
26,000 prints*1 TN612M*5
Toner bottle /M
25,000 prints*3 TN614M*6
26,000 prints*1 TN612C*5
Toner bottle /C
25,000 prints*3 TN614C*6
38,500 prints*1 TN612K*5
Toner bottle /K
37,400 prints*3 TN614K*6
200,000 prints *2
Drum cartridge DU-102C
150,000 prints *4
200,000 prints *2
Developer /Y DV610Y
150,000 prints *4
200,000 prints *2 DV610M*5
Developer /M
150,000 prints *4 DV611M*5
200,000 prints *2 DV610C*5
Developer /C
150,000 prints *4 DV611C*5
200,000 prints *2
Developer /K DV610K
150,000 prints *4
*1 PRO C6501/C6501P/C65hc (A4 original at 5% coverage for each color.)

*2 PRO C6501/C6501P/C65hc (The end of actual useful life is reached when the number of sheets is
printed, or when the total drive distance reaches a certain level, whichever comes first.)
*3 PRO C5501 (A4 original at 5% coverage for each color.)
*4 PRO C5501 (The end of actual useful life is reached when the number of sheets is printed, or when the
total drive distance reaches a certain level, whichever comes first.)
*5 PRO 6501/C6501P/C5501
*6 PRO 65hc
9 2
E. Maintenance
/C6501P/C65hc/C5501
bizhub PRO C6501

Maintenance cycle
Ave. number of prints*1 35,000 to 75,000 per month
Max. number of prints*1 Q zone*2 : 300,000 per month*3, 250,000 per month*4, 10,000 per day
B,C zone*2 : 150,000 per month, 8,500 per day
A zone*2 : 100,000 per month, 5,000 per day*3, 4,200 per day*4
*1 The number of prints include all monochrome, solid color, and full color printings.
*2 The zone mean a temp&humidity range indicated in the graph below.
*3 PRO C6501/C6501P/C65hc
*4 PRO C5501
80
70
A
Humidity (%RH)
60
B Q
40
30
20 C
10
10 18 20 23 30
Temperature (°C)
a03ut1c004ca
1 10
F. Machine data
/C6501P/C65hc/C5501
bizhub PRO C6501
Power source Inch: AC208 to 240V 16A, 60Hz
Metric: AC230V 15A, 50Hz
Maximum power consump- Inch: 5,100W or less : PRO C6501 (B. When the type of the optional unit
tion connection configuration (P3) is No. 14)
Metric: 4,800W or less : PRO C6501 (B. When the type of the optional unit
connection configuration (P3) is No. 14)
Dimensions Main body + OC-506 786 (W) x 992 (D) x 1,056 (H)*1 mm
+ DF-609 + RU-504 + LS-505
+ SD-506
+ DF-609 + LU-202 + FS-607
Weight Approx. 360kg(PRO C6501/C5501)
Approx. 323kg (PRO C6501P/C65hc)
*1 Exclude the operation panel.

*2 Include the operation panel.
G. Operating environment
Note
11 1
2.2 DF
/C6501P/C65hc/C5501
bizhub PRO C6501
A. Type
Type Belt conveyance type original auto feeder
B. Functions
Original size A3, B4, A4, A4S, B5, B5S, A5, A5S, B6S
11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2, 51/2 x 81/2S
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
8K, 16K, 16KS
Max. original size 297 x 431.8mm
Min. original size 128 x 139.7mm
• Various sizes of paper can be accommodated
C. Original type
Paper type Plain paper High quality paper of 35 to 210 g/m2 (single side)
High quality paper of 50 to 210 g/m2 (double side)
Paper of less than 49g/m2: conveyed in thin paper mode
Paper of more than 129g/m2: conveyed in thick paper
mode
Special paper Same as plain paper. However, paper feed and convey-
ance performance are not guaranteed.
• Recycled paper, coarse paper, thermal paper, binding-
holed paper, user-defined paper, paper with smooth
surface, paper with rough surface, and paper with folds
Following types of special paper cannot be used.
• OHP film, blueprint master paper, label paper, off-set
master, bonded original, high quality paper (paper
weight: Less than 34g/m2 or more than 211g/m2)
Paper curl amount Up to 10 mm with 5 originals overlapped one another
[1]
a
15sat1c001na
a Curing: 10 mm or less
[1] Original
Max. tray capacity 100 sheets (80g/m2 paper)
Scan speed Single-sided mode (including thin-paper mode): 39 sheets/min.
(81/2 x 11) Double-sided mode (including thin-paper mode): 26 sheets/min.
Single-sided mode (thick-paper mode): 28 sheets/min.
Double-sided mode (thick-paper mode): 14 sheets/min.
Scanning system After the original that is conveyed on the belt stops, the scanner moves and
scans the original.
12
/C6501P/C65hc/C5501
D. Machine data
bizhub PRO C6501

Power consumption Max. 60W or less
Weight Approx. 14.5kg
Dimensions 588 (W) x 519 (D) x 135 (H) mm (Excluding paper feed tray)
E. Maintenance
Note
13
2.3 PF
/C6501P/C65hc/C5501
bizhub PRO C6501
2.3.1 PF-602
A. Type
Type Front loading type two-tray paper feeder
B. Functions
Number of trays Two trays (All trays universal)

Tray capacity 6,000 sheets (80 g/m2 standard paper) = 3,000 sheets x 2 trays
C. Paper type
Paper size SRA3, A3, B4, SRA4, SRA4S, A4, A4S, B5, B5S, A5*1, A5S, B6S, A6S*1
13 x 19, 12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
8K, 16K, 16KS
Tray/4: Custom paper (Max. 330 x 487mm, Min. 100 x 182 mm)
Tray/5: Custom paper (Max. 330 x 487mm, Min. 100 x 148 mm)
Paper weight Tray/4 64 to 256g/m2
Tray/5 64 to 300g/m2
*1 A5 and A6S are fed only from the tray/5.
D. Maintenance
E. Machine data
tion
14
2.3.2 HT-504
/C6501P/C65hc/C5501
bizhub PRO C6501
A. Type
Type Fan heater type dehumidifier heater
B. Machine data
Power source 24/5VDC (supplied from the main body), 200 to 240VAC*1
tion
Power supply unit: 121 (W) x 80 (D) x 160 (H) mm
Weight Dehumidifier fan heater unit: Approx. 1.5kg/1 unit
Power supply unit: Approx. 0.9kg
*1 North America model: Supplied from the main body.

Europe model: Supplied from external.
15
2.4 LU
/C6501P/C65hc/C5501
bizhub PRO C6501
2.4.1 LU-202
A. Type
Type Side mount type large volume paper feed tray
B. Functions
Max. tray capacity 2500 sheets (80 g/m 2)*1
*1 Stacked height 275 mm
C. Paper type
Paper size SRA3, A3, B4, SRA4, SRA4S, A4, A4S, B5

13 x 19, 12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S
8K, 16K
Custom paper (Max. 330 x 487mm, Min. 210 x 182 mm)*1
64 to 300 g/m2 *1
*1 Available types of paper weighing 300 g/m2 are limited to specific types.
D. Maintenance
E. Machine data
Maximum power consump- DC: 70W or less, AC: 50W or less (not including HT-503)
tion
Weight Approx. 42kg
16
2.4.2 HT-503
/C6501P/C65hc/C5501
bizhub PRO C6501
A. Type
Type Fan heater type dehumidifier device
B. Machine data
Power source 24/5VDC, 200 to 240VAC (supplied both from the main body)
tion
Power unit: 121 (W) x 80 (D) x 160 (H) mm
Weight Dehumidifier fan heater unit: Approx. 1.5 kg
Power supply unit: Approx. 0.9 kg
Note
17
2.5 RU-504
/C6501P/C65hc/C5501
bizhub PRO C6501
A. Type
Type Conveyance unit with paper cooling and decurler functions
B. Functions
(1) Functions
Accelerated conveyance To accelerate for the finisher standard line speed.

mode
Decurler conveyance mode Reduces paper curl and conveys at an accelerating rate with posttreatment lin-
ear velocity.
(2) Operation capacity

65PPM (A4, B5, 81/2 x 11, 16K)
C. Paper type
Paper size SRA3, A3, B4, SRA4, SRA4S, A4, A4S, B5, B5S, A5, A5S, B6S, A6S
13 x 19, 12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 8 1/2S
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
8K, 16K, 16KS
Custom paper (Max. 330 x 487mm, Min. 100 x 148 mm)
Paper type Plain paper, high quality paper, color paper, coated paper, tab paper (five-tab
type): same as the main body.
Paper weight Accelerated con- 64 to 300g/m2
veyance mode
Decurler convey- 64 to 209g/m2
ance mode
D. Maintenance
E. Machine data
Power source RU-504 AC100 to 240V/5V DC*1

Maximum power consump- 90VA or less
tion
Dimensions Including main body: 175 (W) x 723 (D) x 1 (H) mm
Weight RU-504 Approx. 35 kg
*1 5VDC is supplied from the main body.
2 18
/C6501P/C65hc/C5501
bizhub PRO C6501
Note
19
2.6 RU-506
/C6501P/C65hc/C5501
bizhub PRO C6501
A. Type
Type Paper conveyance unit with paper overlap and reverse functions
B. Functions
Double sheets reverse/exit Reverses 2 sheets of paper exited from the main body, PI-PFU or GP-501 and
conveyance mode*1 conveys to finishing unit.
Single sheet reverse/exit Reverses a single sheet of paper exited from the main body, PI-PFU or GP-501
conveyance mode and conveys to finishing unit.
Straight conveyance mode Conveys papers exited from the main body, PI-PFU or GP-501 to finishing unit
without any process.
*1 1200/1200P only
C. Paper type
Paper size SRA3, A3, JISB4*1, ISOB4*2*3, SRA4S, A4, A4S, JISB5*1, ISOB5*2*3, JISB5S*1,
ISOB5S*2*3, A5, 13 x 19*4, 12 x 18, 11 x 17, 9 x 11*3, 81/2 x 14, 81/2 x 11,
81/2 x 11S, 51/2 x 81/2, 81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13, 8K*5, 16K*5, 16KS*5
Wide paper (A3W, B4W, A4W, A4SW, B5W, B5SW, A5W, 12 x 18W, 11 x 17W,
81/2 x 11W, 81/2 x 11SW, 51/2 x 81/2W, Max. 324mm x 463mm*3, Max. 324mm x 487mm*4)
Custom size paper (Max. 324mm x 463mm*3, Max. 324mm x 487mm*4, Min. 95mm x 133mm)
Tab paper (A3, B4, A4, A4S, B5, B5S, 11 x 17, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2,
Max. 324mm x 463mm*3, Max. 324mm x 487mm*4)
Paper type Plain, Fine, Coat, recycled paper: same as the main body.
Paper weight 40g/m2 to 350g/m2 *3,64g/m2 to 300g/m2 *4
2 pages reverse/exit 40g/m2 to 216g/m2 *6
conveyance mode

*3 1200/1200P/1051 only
*4 C6501/C6501P/C65hc only
*6 1200/1200P only
D. Maintenance
E. Machine data
Weight Approx. 45 kg
2 20
/C6501P/C65hc/C5501
bizhub PRO C6501
Note
21 2
2.7 FD
/C6501P/C65hc/C5501
bizhub PRO C6501
A. Type
Type Multi folding device with punch and PI functions
B. Functions
(1) Functions
Normal paper exit function Transfer paper exited from the main body is exited into the main tray/sub tray.
Punching function Transfer paper that is exited by the main body or fed to the PI is punched for
each sheet of paper and exited into the main tray/sub tray.
Folding functions Transfer paper that is exited from the main body or fed to the PI is handled for
folding (either one of the following: Z-Fold, Letter fold-out, Letter fold-in, Double
parallel fold, Gate fold, and folding) for each sheet of paper, and exited into the
sub tray/main tray (The Z-Fold exit to the main tray while in the FS connection is
limited only to B4, A3, 81/2 x 14, 11 x 17, 12 x 18 and 8K.)
PI insertion function PI tray paper is inserted in the transfer paper exited from the main body.
Manual mode PI tray paper is punched, folded and stapled, and then exited into the sub tray/
main tray. (The stapling function is available only when the other option (with
staple function) is connected to the downstream of the FD.)
22
/C6501P/C65hc/C5501
bizhub PRO C6501
Main tray 2,500 sheets : A4, A4S, JISB5*3, ISOB5*1*4, B5S, B5
2 2 *1
(Weighing 40g/m - 350g/m , 9 x 11*1, 81/2 x 11, 81/2 x 11S, 16K*2*5, 16KS*2*5
64g/m2 - 300g/m2 *2) 1,500 sheets : SRA3, A3, JISB4*3, ISOB4*1*4, SRA4, SRA4S
13 x 19*2, 12 x 18, 11 x 17, 81/2 x 14, 81/2 x 13, 81/4 x 13,
81/8 x 131/4, 8 x 13, 8K*2*5
500 sheets : A5, A5S*2, B6S*2, 51/2 x 81/2*1, 51/2 x 81/2S*2
Tab paper*6 (A3, B4, A4, A4S, B5, B5S, 11 x 17, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2,
Max. 324mm x 463mm)
11 x 17W, 81/2 x 11W, 81/2 x 11SW, 51/2 x 81/2W, Max. 324 x 463 mm)
Sub tray Folding type : Letter fold-in, Letter fold-out, Double parallel fold, Gate fold
(with folding tray) Paper size : A3, B4, SRA4S, A4S, 12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11S
8K*2*5
Custom size paper (Max. 305mm x 458mm,
Min. 210mm x 279mm)
Paper weight : Letter fold-in, Letter fold-out 50g/m2 - 130g/m2 *1,
64g/m2 - 130g/m2 *2
Double parallel fold, Gate fold 50g/m2 - 91g/m2 *1,
64g/m2 - 91g/m2 *2
Tray capacity of folding paper : 30 copies or more (less than 80g/m2, all of folding type)*6
Sub tray Maximum tray capacity : 200 Sheets
(without folding tray) SRA3, A3, JISB4*3, ISOB4*1*4, SRA4S, A4, A4S, JISB5*3, ISOB5*1*4, B5S, A5,
(Weighing 40g/m2 - 350g/m2 *1 *8, A5S*2, B6S*2, A6S*2
64g/m2 - 300g/m2 *2) 13 x 19*2, 12 x 18, 11 x 17, 9 x 11*1, 81/2 x 14, 81/2 x 11, 81/2 x 11S,
51/2 x 81/2*1, 51/2 x 81/2S*2, 81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
Tab paper*6 (A3, B4, A4, A4S, B5, B5S, 11 x 17, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2)
*1 1200/1200P/1051 only
*2 C6501/C6501P/C65hc only
*7 Paper is stacked in the exiting sequence.
23 2
C. Type of paper
/C6501P/C65hc/C5501
(1) Punching function

bizhub PRO C6501
Paper size 2 holes : SRA3, A3, JISB4*1, ISOB4*2*3, SRA4S, A4, A4S, JISB5*1,
ISOB5*2*3, B5S, A5, A5S*4
12 x 18 , 11 x 17, 9 x 11*3, 81/2 x 14, 81/2 x 11, 81/2 x 11S,
51/2 x 81/2*3, 81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13, 8K*4*5,
16K*4*5, 16KS*4*5
Tab paper (A3, B4, A4, A4S, B5, B5S, 11 x 17, 81/2 x 11,
81/2 x 11S, 51/2 x 81/2, Max. 324mm x 463 mm)
3 holes/4 holes : SRA3, A3, JISB4*1, ISOB4*2*3*6, A4, JISB5*1, ISOB5*2*3*6
12 x 18 , 11 x 17, 9 x 11*3, 81/2 x 11, 8K*4*5, 16K*4*5
Tab paper (A3, A4, B4, B5, 11 x 17,
Max. 324mm x 463 mm)
Applicable paper Plain paper, tab paper
Paper weight 50g/m2 - 216g/m2 (Conveyance of 2 pages at a time : 50g/m2 - 91g/m2 )*3,
64g/m2 - 216g/m2 *4
(2) Folding functions

Paper size A3, JISB4*1, ISOB4*2*3, SRA4S, A4S
12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11S, 8K*4*5
Custom size paper : Max. 305mm x 458mm, Min. 210mm x 279mm
Applicable paper Plain paper
Paper weight Folding, Letter 50g/m2 - 130g/m2 *3,
fold-in, Letter 64g/m2 - 130g/m2 *4
fold-out, Z-Fold
Double parallel 50g/m2 - 91g/m2 *3,
fold, Gate fold 64g/m2 - 91g/m2 *4
(3) PI functions
B5S, A5
13 x 19*4, 12 x 18, 11 x 17, 9 x 11*3, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2,
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13, 8K*4*5, 16K*4*5, 16KS*4*5
Custom size paper*7: Max. 331mm x 483mm, Min. 182mm x 279mm
Applicable paper Plain, recycled paper, Fine, special paper
Paper weight 50g/m2 - 300g/m2
Maximum tray capacity 500 sheets (80g/m2) x 2 trays

*3 1200/1200P/1051 only
*4 C6501/C6501P/C65hc only
*6 ISOB4 and ISOB5 can not use 4 holes punch
*7 When use custom size paper as a cover in the perfect binding mode: up to 307 mm x 483 mm
2 24
D. Maintenance
/C6501P/C65hc/C5501
bizhub PRO C6501
MAINTENANCE Same as the main body.
E. Machine data
(The main tray is not included in the width)

Note
25 2
2.8 LS
/C6501P/C65hc/C5501
bizhub PRO C6501
A. Type
Type Grip conveyance type horizontal stacker

Conveyance method Entrance Roller conveyance method
conveyance
Stacker tray Grip conveyance method
conveyance
Sub tray Roller conveyance method
conveyance
Coupling Roller conveyance
conveyance
Alignment method Movable alignment lever (stacker tray only)
Method of stacking Horizontal Mixing of original sizes not allowed (stacker tray only)
stacking
Shifting method Conveyance Shift amount: 20mm (stacker tray only) *1
direction shift
B. Functions
(1) Functions
Stacker tray non-sort mode Exited into the stacker tray with no processing made.
Sub tray mode Exited into the sub tray with no processing made.
Stacker tray sort mode Exited into the stacker tray after being shifted (20mm).*1
Coupling mode Exited into the post-processing unit with no processing made.
Maximum tray capacity Stacker tray • 5,000 sheets

(weighing 80g/m2 ) SRA3, A3, JISB4*1, ISOB4*2*3, SRA4, SRA4S, A4, A4S,
13 x 19, 12 x 18, 11 x 17, 9 x 11*3, 81/2 x 14, 81/2 x 11,
81/2 x 11S, 81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13, 8k*4*5, 16K*4*5
• 3,000 sheets
Coat (Sub-scan direction is 380mm or longer)
• 2,000 sheets
JISB5*1, ISOB5*2*3, A5
Sub tray Straight exit :200 sheets
Z-Folding paper :20 sheets
Center folding paper :40 sheets

*3 1200/1200P/1051 only
*4 C6501/C6501P/C65hc only
2 26
C. Type of paper
/C6501P/C65hc/C5501
Paper size Stacker tray SRA3, A3, JISB4*1, ISOB4*2*3, SRA4S, A4, A4S, JISB5*1,
bizhub PRO C6501

ISOB5*2*3, B5S, A5
13 x 19*4, 12 x 18, 11 x 17, 9 x 11, 81/2 x 14, 81/2 x 11,
81/2 x 11S, 81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13, 8K*5, 16K*5
12 x 18W, 11 x 17W, 81/2 x 11W, 81/2 x 11SW, 51/2 x 81/2W,
Max. 324mm x 463mm)
Max. 330mm x 483mm*4, Min. 210mm x 148mm)
81/2 x 11S, Max. 324mm x 463mm)
Sub tray SRA3, A3, JISB4*1, ISOB4*2*3, SRA4S, A4, A4S, JISB5*1,
ISOB5*2*3, B5S, A5, A5S*4, B6S*4, A6S*4
13 x 19*4, 12 x 18, 11 x 17, 9 x 11, 81/2 x 14, 81/2 x 11, 81/2 x 11S,
51/2 x 81/2*3, 51/2 x 81/2S*4, 81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13,
8K*4*5, 16K*4*5, 16KS*4*5
12 x 18W, 11 x 17W, 81/2 x 11W, 81/2 x 11SW, 51/2 x 81/2W,
Max. 324mm x 463mm)
Max. 330mm x 487mm*4, Min. 95mm x 133mm*3,
Min. 100mm x 148mm*4)
81/2 x 11S, 51/2 x 81/2, Max. 324mm x 463mm)
*3 *4
Paper weight Stacker tray 50g/m2 - 244g/m2 , 64g/m2 - 256g/m2
*8 *4
Sub tray 40g/m2 - 350g/m2 , 64g/m2 - 300g/m2

*3 1200/1200P/1051 only
*4 C6501/C6501P/C65hc only
*6 1 to 15 tab (4 tab and 10 tab are unavailable.) The use of the shift is unavailable with tab paper.
D. Maintenance
E. Machine data
Power source AC100 - 240V, DC5V (DC5V is supplied from the main body)*1
Maximum power consumption 143W or less
Dimensions 785 (W) x 723 (D) x 1,020 (H) mm
Humidity 10 - 80%RH
Note
27 2
2.9 FS-521
/C6501P/C65hc/C5501
bizhub PRO C6501
A. Type
Type Staple-cut type multi staple device
B. Functions
(1) Functions
Straight mode Exited into the main tray with no processing made.
Shift mode Exited into the main tray after being shifted.
Sub tray mode Exits paper to the subtray without any process.
Staple mode Exited into the main tray after being flat-stapled.
Subset staple mode Bundles of flat-stapled sheets of paper and single sheets of paper being exited
at random into the main tray.
(2) Number of staple sheets

The maximum number of staple sheets is decided according to either conditions which is met first, the combina-
tion condition of the paper type/the paper lengtht/the number of sheets for every range of paper weight, or the
combination condition of the booklet length/the booklet thickness.
• Combination condition of the paper weight/the paper type/the paper length and the number of sheets for
every range of paper weight
Paper weight Number of staple sheets

(g/m2) Paper not coated Coat/color paper
Less than 400mm 400mm or more Less than 400mm 400mm or more
50 to 71 100 50 35 35
72 to 81 100 50 35 35
82 to 91 100 50 35 35
92 to 130 50 50 30 30
131 to 161 40 40 25 25
162 to 216 25 25 20 20
217 to 244 25 25 15 15
• Combination condition of the booklet length/the booklet thickness
Length (mm) Booklet thickness (mm)

219 or less 23 or less
220 or more 20 or less
(3) Staple position
Staple position 1 staple at the rear (45°), 1 staple at the front, and 2 staples at the center
2 28
(4) Maximum tray capacity of the Main tray
/C6501P/C65hc/C5501
Straight/Shift mode Large-size : A3, JISB4*3, ISOB4*1*4, 12 x 18, 11 x 17, 81/2 x 14, SRA3,
bizhub PRO C6501

(Weight:40g/m2 - 350g/m2 SRA4 , SRA4S , 13 x 19*2 *5, 81/2 x 13, 81/4 x 13, 81/8 x 131/4,
*1
, 64g/m2 - 300g/m2 *2) 8 x 13, 8K*6
Wide paper*1 (Max. 324mm x 463mm)
Small-size : A4, A4S, JISB5*3, ISOB5*1*4, B5S, 9 x 11*1, 81/2 x 11, 81/2 x 11S,
16K*6, 16KS*6
Minimum-size : A5, A5S*2, 51/2 x 81/2S*2 *5
Others : Tab paper*7 (A3, B4, A4, A4S, B5, B5S, 11 x 17,
81/2 x 11, 81/2 x 11S, 51/2 x 81/2, Max. 324mm x 463mm),
Custom size paper (Max. 324mm x 463mm, Min. 148mm x 139mm*1,
Min. 148mm x 148mm*2, Max. 331mm x 483mm*2 *5,
Min. 128mm x 139mm*5)
Weight (g/m2) Tray capacity (sheets)
Large-size Small-size Minimum-size
40 to 71 500 750 100
72 to 81 1500 3000 (1500)*8 750
82 to 91 1000 2000 (1500)*8 500
92 to 130 750 1500 400
131 to 161 350
162 to 216 500 1000 250
217 to 300 375 750 200
301 to 350 250 500 100
Staple mode Staple sheet Number of sets
(Weight:50g/m2 - 244g/m2 2 to 9 150 (paper length 182mm to 364mm) 75 (other than paper
*1
, 64g/m2 - 244g/m2 *2) length 182mm to 364mm)
10 to 20 50
21 to 30 30
31 to 40 25
41 to 50 20
51 to 60 15
61 to 100 10
*1 1200/1200P/1051 only
*2 C6501/C6501P/C65hc only
*5 Straight mode only
*8 ( ) while in shifting
29 2
(5) Maximum tray capacity of the Sub tray

/C6501P/C65hc/C5501
Maximum tray capacity 200 sheets (20 sheets for Z-Folding/40 sheets for center folding)
bizhub PRO C6501
(Paper weight40g/m2 to 350g/m2

*1 *3, 64g/m2 to 300g/m2 *2)
SRA3, A3, JISB4*4, ISOB4*1*5, SRA4, SRA4S, A4, A4S, JISB5*4, ISOB5*1*5, B5S, A5, A5S*2, B6S*2, A6S*2,
13 x 19*2, 12 x 18, 11 x 17, 9 x 11*1, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2*1, 51/2 x 81/2S*2, 81/2 x 13, 81/4 x 13,
81/8 x 131/4, 8 x 13, 8K*6, 16K*6, 16KS*6
Wide Paper*1 :A3W, B4W, A4W, A4SW, B5W, B5SW, A5W, 12 x 18W, 11 x 17W, 81/2 x 11W,
81/2 x 11SW, 51/2 x 81/2W, Max. 324mm x 463mm
Tab paper*7 :A3, B4, A4, A4S, B5, B5S, 11 x 17, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2,
Max. 324mm x 463mm
Custom size paper:Max. 324mm x 463mm*1,Max. 331mm x 483mm*2 ,Min. 95mm x 139mm*1,Min. 100mm x
148mm*2
*1 1200/1200P/1051 only
*2 C6501/C6501P/C65hc only
*3 Loading paper weight 49g/m2 or less is not warranty
*8 95mm x 133mm when post pocessing with FS only.
C. Type of paper
(1) Staple
Paper size SRA3, A3, JISB4*1, ISOB4*2*3, SRA4, SRA4S, A4, A4S, JISB5*1, ISOB5*2*3, A5
12 x 18, 11 x 17, 9 x 11, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2*3,
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13, 8K*4, 16K*4
Wide paper*3 :A3W, B4W, A4W, A4SW, B5W, B5SW, A5W,
12 x 18W, 11 x 17W, 81/2 x 11W, 81/2 x 11SW, 51/2 x 81/2W,
Max. 324mm x 463mm
Tab paper*5 :A3, B4, A4, A4S, B5, B5S, 11 x 17,
81/2 x 11, 81/2 x 11S, 51/2 x 81/2,
Max. 324mm x 463mm
Custom size paper :Max. 324mm x 463mm, Min. 203mm x 139mm
Applicable paper Same as the main body.
Paper weight Main tray 50g/m2 - 244g/m2 *3, 64g/m2 - 244g/m2 *6

*3 1200/1200P/1051 only
*6 C6501/C6501P/C65hc only
D. Maintenance
2 30
E. Machine data
/C6501P/C65hc/C5501
bizhub PRO C6501
Maximum power consumption 110VA
Dimensions When the main tray is pulled out: 915 (W) x 723 (D) x 1020 (H) mm
When the main tray is set in: 798 (W) x 723 (D) x 1020 (H) mm
When the main tray is removed: 544 (W) x 723 (D) x 1020 (H) mm
Weight Approx. 80kg
Note
• The information herein may be subject - change for improvement without notice.
31
2.10 FS-520/607
/C6501P/C65hc/C5501
bizhub PRO C6501
A. Type
Type Stapling device (FS-520)

Multi folding multi stapling device (FS-607)
B. Functions
(1) Functions
Non-sort mode Exited to the main tray with no processing made.

Sort/group mode Exited to the main tray after being shifted for every copy.
Sub tray mode Exited to the sub tray with no processing made.
Stapling mode Exited to the main tray after being stapled.
Saddle stitching mode Exited to the booklet tray with the paper folded into two after being stitched and
folded at the center of the paper (FS-607 only).
Folding mode Exited to the booklet tray with the paper folded into two at its center (FS-607
only).
Tri-folding mode Exited to the booklet tray after being overlapped up to 3 sheets and being tri-
folded (FS-607 only).
32
(2) Stapling
/C6501P/C65hc/C5501
bizhub PRO C6501
Max. flat-stapling FS-520 50 sheets of 64 to 80 g/m2 (plain paper, high-quality paper, color paper)
capacity 40 sheets of 81 to 105 g/m2 (plain paper), 30 sheets (high-quality paper,
color paper), 25 sheets (coated paper)
(color paper), 20 sheets (coated paper)
(color paper)
staple position At coner Parallel or skew depending on
the paper size
At 2 places Symmetry at the center with
162 mm pitches
FS-607 50 sheets of 64 to 80 g/m2 (plain paper, high-quality paper), 30 sheets
(color paper)
(color paper, coated paper)
staple position Front parallel / back 45° 1 position diagonally, 2 posi-
tions at the center
Max. saddle stitching FS-607 20 sheets of 64 to 80 g/m2
capacity 16 sheets of 81 to 105 g/m2
staple position variable (128 to 168mm)
(3) Folding (FS-607)
Max.Folding 3 sheets of 64 to 105 g/m2 paper

Max.Tri-folding 3 sheets of 64 to 80 g/m2 paper
1 sheet of 81 to 105 g/m2 paper
33
(4) Max. paper capacity

/C6501P/C65hc/C5501
bizhub PRO C6501
Main tray FS-520 Non-sort 3000 sheets: A4, A4S, B5, B5S
(Weighing 80g/ mode, sort/ 81/2 x 11, 81/2 x 11S
m2) group mode 16K, 16KS
1500 sheets: SRA3*1, A3, B4, SRA4*1, SRA4S
12 x 18, 11 x 17, 81/2 x 14,
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
8K
500 sheets: A5, A5S *1, B6S *1
51/2 x 81/2S *1
*3
Tab paper : A4, 81/2 x 11
scan direction is
150 to 417 mm
FS-607 Non-sort 2500 sheets: A4, A4S, B5, B5S
mode, sort/ 81/2 x 11, 81/2 x 11S
group mode 16K, 16KS
1500 sheets: SRA3*1,A3, B4, SRA4*1, SRA4S,
12 x 18, 11 x 17, 81/2 x 14,
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
8K
500 sheets: A5, A5S *1, B6S *1
51/2 x 81/2S *1
Tab paper*3 : A4, 81/2 x 11
scan direction is
418mm or longer
34
/C6501P/C65hc/C5501
Booklet tray Saddle stitch- Size in the sub scan direction is 299 mm or longer : 15 cop-
(Weighing 80g/m2) ing mode ies in 5 sheets of saddle stitching
bizhub PRO C6501

(FS-607 only) other than the above : 20 copies in 5 sheets of saddle stitching
Folding mode Size in the sub scan direction is 299 mm or longer : 25 cop-
ies in 3 sheets of folding
other than the above : 33 copies in 3 sheets of folding
Tri-folding 50 copies in 1 sheet of folding
mode
Sub tray 100 sheets : SRA3, A3, B4, SRA4, SRA4S, A4, A4S, B5, B5S, A5, A5S, B6S,
(Weighing 80g/ A6S
m2) 13 x 19, 12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
8K, 16K, 16KS
Tab paper*3 : A4, 81/2 x 11
Custom paper : Max. 330 x 487mm, Min. 100 x 148 mm
*1 Non-sort mode only

*2 Non-sort mode is 128 x 148 mm
C. Type of paper
(1) Stapling mode
Paper size A3, B4, SRA4S, A4, A4S, B5, B5S, A5

12 x 18*1, 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
8K, 16K, 16KS
Tab paper*2 (A4, 81/2 x 11)
Applicable paper Plain paper, high-quality paper, color paper, coated paper (same as the main
body)
Paper weight 60 to 209 g/m2 (FS-520)
64 to 105 g/m2 (FS-607)
*1 FS-607 only
(2) Saddle stitching mode (FS-607)

12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11S
8K
35
(3) Folding mode (FS-607)

/C6501P/C65hc/C5501
bizhub PRO C6501

12 x 18, 11 x 17, 81/2 x14, 81/2 x11S,
8K
(4) Tri-folding mode (FS-607)
Paper size A4S

81/2 x11S
D. Maintenance
E. Machine data
Power source 24/5VDC (supplied from the main body)

tion
Dimensions When the main tray is pulled out: 790.5 (W) x 656 (D) x 990 (H) mm
When the main tray is set in: 674.5 (W) x 656 (D) x 990 (H) mm
Weight Approx. 60 kg (FS-520)
Approx. 65 kg (FS-607)
Note
2 36
2.11 PI
/C6501P/C65hc/C5501
bizhub PRO C6501
A. Type
Type Torque limiter separation type seat feeding device
B. Functions
Auto sheet feeding (online Feeds the sheet to FS automatically under the instruction from the main body.
operation)
Manual sheet feeding Feeds the sheet to FS under the instruction from the operation panel of PI.
(offline operation) You can select the following 5 post processing modes:
• 1 staple/back mode
• 2 staples (flat-stapling) mode
• Punch mode (when PK-512/513 is installed on FS)
• Saddle stitching mode
• Tri-folding mode
Note
• The tray /Lw only supports the manual sheet feeding.
C. Type of paper
Paper size Tray /Up A4, A4S, B5, B5S, A5

81/2 x 11, 81/2 x 11S, 51/2 x 81/2
16K, 16KS
Tray /Lw A3, B4, SRA4S, A4, A4S, B5, B5S, A5
12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
8K, 16K, 16KS
Paper type Plain paper, recycle paper, color paper, special paper, coated paper, high-quality paper
Capacity Tray /Up, /Lw 200 sheets (80 g/m2) or 30 mm or less in height
Paper curling
[1]
a
15jft1c001na
a Curling: 10 mm or less
[1] 5 papers
37
D. Maintenance
/C6501P/C65hc/C5501
bizhub PRO C6501
E. Machine data

tion
Weight Approx. 10.5 kg
Note
38
2.12 PK
/C6501P/C65hc/C5501
bizhub PRO C6501
A. Type
Type FS-integrated type punching operation device
B. Functions
Punching method Stops and punches every paper

No. of holes PK-512: 2 holes/3 holes (inch) or 2 holes/4 holes (metric)
PK-513: 4 holes
Hole diameter φ 6.5 mm (2 holes/4 holes), φ 8.0 mm (3 holes)
Hole pitch PK-512: 80 mm (2 holes/4 holes), 108 mm (3 holes)
PK-513: 21, 70, 21 mm
Supported mode Punch mode, straight mode
Applicable post processing Sort, group, staple
mode
C. Type of paper
Paper size PK-512 (2 holes): A3, B4, SRA4S, A4, A4S, B5, B5S, A5, A5S
11 x 17, 81/2 x 14, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2S
81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
8K, 16K, 16KS
PK-512 (3 holes/4 holes): A3, B4, A4, B5
11 x 17, 81/2 x 11
8K, 16K
PK-513: A3, B4, A4, B5
Applicable paper Plain paper, high quality paper, color paper, coated paper (same as the main
body)
Punch prohibited paper Label paper, tab paper, transparency film, 2nd base paper, holed paper, and the
other paper that may interfere with the operation of the punch unit or the punch
blade.
Paper curling
a [1]
15knt1c001na
a Curling (10 mm or less)

[1] 5 sheets of paper
39
D. Maintenance
/C6501P/C65hc/C5501
bizhub PRO C6501
E. Machine data
Power source 24/5V DC (supply from the main body)

Maximum power 40 W or less
consumption
Weight Approx. 3 kg
NOTE
40
2.13 SD
/C6501P/C65hc/C5501
bizhub PRO C6501
A. Type
Type Saddle stitching unit with fore-edge trimming and multi-folding function
B. Functions
(1) Functions
Subtray paper exit mode Exit paper to the subtray without any process.
Coupling paper exit mode Convey paper to the succeeding device without any process.
Saddle stitching mode Exit paper to the bundle exit tray after the center folding/saddle stitching operation.
Saddle stitching trimming Exit paper to the bundle exit tray after the center folding/saddle stitching/trim-
mode ming operation.
Multi center folding mode Exit paper to the bundle exit tray after the center folding on 1 or more sheets of paper.
Multi center folding trim- Exit paper to the bundle exit tray after the center folding and the trimming oper-
ming mode ation on 1 or more sheets of paper.
Overlap tri-folding mode Exit paper to the tri-folding tray after the letter folding operation on 1 or more
sheets of paper.
Sub tray 200 sheets

(Weighing 80g/m2) Z-Folding 20 sheets
Center folding 40 sheets
Bundle exit tray Center stitching/ Stitching sheets Set
trimming mode 2 - 10 50 or more
11 - 20 30 or more
21 - 40 20 or more
41 - 50 15 or more
Multi center fold- 30 sets
ing mode
Tri-folding paper exit tray Overlap tri-folding 20 sets
mode
41
C. Paper
/C6501P/C65hc/C5501
bizhub PRO C6501
(1) Straight/subtray mode
B5S, A5, A5S*4, B6S*4, A6S*4
13 x 19*4, 12 x 18, 11 x 17, 9 x 11, 81/2 x 14, 81/2 x 11, 81/2 x 11S,
51/2 x 81/2*3, 51/2 x 81/2S*4, 81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13, 8K*4*5, 16K*4*5,
16KS*4*5
Custom size paper (Max. 324mm x 463mm, Min. 95 x 139mm*3,
Min. 100mm x 148mm*4)
11 x 17, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2, Max. 324mm x 463mm)
Weight 40g/m2 - 350g/m2 *3 *7, 64g/m2 - 300g/m2 *4

*3 1200/1200P/1051 only
*4 C6501/C6501P/C65hc only
2 42
/C6501P/C65hc/C5501
bizhub PRO C6501
12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11S, 81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13,
8K*4*5, 16KS*4*5
Weight 50g/m2 - 244g/m2 *3 , 64g/m2 - 244g/m2 *5
Maximum saddle stitching Plain, Coat Weight Sheet
sheets Plain Coat*5
50g/m2 - 81g/m2 50*6 30*6
82g/m2 - 91g/m2 30*6 15*6
92g/m2 - 130g/m2 20*6 10*6
131g/m2 - 161g/m2 15*6 5*6
162g/m2 - 209g/m2 10 -
210g/m2 - 244g/m2 5 -
Fine Paper brand 55kg (64g/m2) 70kg (81.4g/m2)
Kinmari 50 sheets 50 sheets
High quality
Kanabishi
OK prince -
new NPi 50 sheets 30 sheets
POD prince high
quality
shiraoi

*3 1200/1200P/1051 only
*5 C6501/C6501P/C65hc only
*6 1 sheet can be switched to a thick paper (200g/m2)
Staple position Can be automatically changed (90mm - 165mm) in accordance with paper size.
[1]
[2]
15ant1c006na

43 2
/C6501P/C65hc/C5501 2. PRODUCT SPECIFICATIONS Field Service Ver.3.0 Jul. 2009
Folding height
bizhub PRO C6501
[1]
15ant1c011na
Stitching [1] Folding height

sheets A3 B4 A4S B5S
12 x 18 81/2 x 14 81/2 x 11S (260mm or
11 x 17 (301mm to (261mm to less)
(401mm or 400mm) 300mm)
more)
2-5 35mm or less 40mm or less 45mm or less Not defined
6 - 15 45mm or less 50mm or less Not defined
(The above information is applied when paper weight is 64g/m2 and no thick
cover is not used.)
(3) Trimming mode

12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11S, 81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13,
8K*4*5, 16KS*4*5
Max. 324mm x 463mm)
Weight 50g/m2 - 244g/m2 *3 , 64g/m2 - 244g/m2 *5
Maximum trimming sheets 50 sheets (80g/m2) or 49 sheets (80g/m2) + 1 sheet (200g/m2)
(The above is the number of the printed paper before folding. The number of
fore-edge (after folding) is double.)

*3 1200/1200P/1051 only
*5 C6501/C6501P/C65hc only
2 44
/C6501P/C65hc/C5501
bizhub PRO C6501
12 x 18, 11 x 17, 81/2 x 14, 81/2 x 11S, 81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13,
8K*4*5, 16KS*4*5
Max. 324mm x 463mm)
Weight 50g/m2 - 244g/m2 *3 , 64g/m2 - 244g/m2 *5
Maximum overlap folding Weight Sheet
sheets 50g/m2 - 81g/m2 5 sheets
131g/m2 - 244g/m2 2 sheets
Folding precision (for 1
sheet)
[1]
15ant1c009na
[1] = [Paper size] /2 ± 1.5mm
[1] 15ant1c008na
[1] = 1.5mm or less

*3 1200/1200P/1051 only
*5 C6501/C6501P/C65hc only
45 2
(5) Overlap tri-folding mode

/C6501P/C65hc/C5501
bizhub PRO C6501
Paper size A4S, 8 1/2 x 11S

Weight 50g/m2 - 91g/m2 *1, 64g/m2 - 91g/m2 *2
Weight Sheet
Maximum overlap folding 50g/m2 - 81g/m2 5 sheets
sheets
Folding precision (for 1 sheet) Paper size [1] [2] [3]
A4S 97.5 ± 4mm 102.0 ± 4mm 1.5mm or less
81/2 x 11S 91.6 ± 4mm 96.1 ± 4mm
[3]
[3]
[1]
[2]
15ant1c010na
*1 1200/1200P/1051 only
*2 C6501/C6501P/C65hc only
D. Maintenance
E. Machine data
Maximum power consumption 270W
Dimension When the bundle exit tray is stored: 1,170 (W) x 775 (D) x 1,020 (H) mm
When the bundle exit tray is pulled out: 1,170 (W) x 1,441 (D) x 1,020 (H) mm

Note
2 46
2.14 PB
/C6501P/C65hc/C5501
bizhub PRO C6501
A. Type
Type Simplified perfect binding machine (Consoled hot-melt type)
B. Functions
(1) Functions
Perfect binding mode Automatically binds and stocks in a book stock section.
Subtray mode Exits paper to the subtray without any process.
(2) Binding sheets
Binding sheets Min. thickness 10 sheets

Max. thickness Plain paper :300 sheets or 30mm
Fine, color paper, Coat: 150 sheets or 15mm
Binding sheets with Z-Fold Single-sided print
sheets*1
sheets sheets
1 sheet 200 sheets 201 sheets
Double-sided -

print
sheets sheets
1 sheet 200 sheets 201sheets
Simplex/duplex When 1 or more unfold sheets is single-sided, the specifi-

mixed print cation is the same as the simplex print.
(printer function) When the z-folded sheet is single-sided, the specification is
the same as the duplex print.
*1 The limit of the total number of sheets can be released by switching DIPSW37-2 from 0 (default) to 1.

Book stock section Max. 11 books *2 x 2 rows *3 (book thickness: 30mm)
10 to 30 sheets 10 to 30 sheets book: 50 books
book
31 to 150 sheets 35 books or until the upper limit is detected.
book
151 to 300 Until the upper limit is detected
sheets book
PB cover paper tray*3 1000 sheets (82g/m2)
500 sheets (161g/m2)
Sub tray 200 sheets (80g/m2)
*1 The available number of books may decrease due to curls of papers.
47 2
*2 When books have been stacked up to the limit at the first row, the first stack is automatically moved to the
/C6501P/C65hc/C5501
second row, and piling books at the first row continues.

bizhub PRO C6501
*3 Cover paper supply is selectable from PB cover paper tray, main body tray, PI or PI-PFU (1200/1200P/
1051only).
(4) Others
Warm-up time Approx. 20 minutes
Cover trimming Selectable from Trim/Not trim.
C. Type of paper
(1) Paper size
Perfect binding mode Inside paper : A4, B5, ISOB5*1, A5, A5S*2, 81/2 x 11, 51/2 x 81/2*1, 51/2 x 81/2S*2, 16K*3
Custom size paper (Max. 307 (W) x 221 (L) mm)
Only for Z-Fold: 11 x 17, A3, B4, ISOB4*1, A4S, 81/2 x 11S, 8K*3
Cover paper : Max. 307 (W) x 472 (L) mm Vertical (main scan direction)
Same as the inside paper size.
Horizontal (sub scan direction) Wide size L
L = book size in the sub scan direction x 2 + book thickness +
3mm (for trimming)
Sub tray mode SRA3, A3, JISB4*4, ISOB4*1*5, SRA4, SRA4S, A4, A4S, JISB5*4, ISOB5*1*5,
B5S, A5, A5S*2, B6S*2
13 x 19, 12 x 18, 11 x 17, 9 x 11, 81/2 x 14, 81/2 x 11, 81/2 x11S, 8 1/4 x 13,
81/8 x 131/4, 8 x 13, 71/4 x 101/2, 51/2 x 81/2*1, 51/2 x 81/2 S*2, 81/2 x 13, 81/4 x 13, 81/8 x 131/4, 8 x 13
Wide paper*1 (A3W, B4W, A4W, A4SW, B5W, B5SW, A5W, 12 x 18W,
11 x 17W, 81/2 x 11W, 81/2 x 11SW, 51/2 x 81/2W, Max. 324mm x 463m)
Custom size paper (Max. 324 x 463mm, Min. 100 x 139mm)
11 x 17, 81/2 x 11, 81/2 x 11S, 51/2 x 81/2, Max. 324mm x 463m)
(2) Paper weight
Perfect binding mode Inside paper : 64g/m2 - 91g/m2 *1, 64g/m2 -105g/m2 *2
Cover paper : 82g/m2 - 161g/m2 *1, 82g/m2 -161g/m2 *2
Sub tray mode 50g/m2 - 300g/m2 *1, 64g/m2 - 300g/m2 *2
*1 1200/1200P/1051 only
*2 C6501/C6501P/C65hc only
D. Maintenance
2 48
E. Machine data
/C6501P/C65hc/C5501
bizhub PRO C6501
Power source Common to AC100V 50/60Hz
DC5V (supplied from the main body)
Power consumption 1000W or less
Dimensions 1,303 (W) x 1,223 (H) x 775 (D) mm
Binding section 740 (W) x 1,223 (H) x 775 (D) mm
Book stock section : 563 (W) x 740 (H) x 685 (D) mm

Note
49 2
2.15 GP-501
/C6501P/C65hc/C5501
bizhub PRO C6501
A. Type
Type Multi-hole punch unit for ring binding
B. Modes of Operation
Bypass mode The paper moves straight from the printer to the finisher without passing
through the punch module. In this mode the paper in not punched.
Punch mode with Punch The paper moves from printer to the punch module where it gets punched and
then is routed to the finisher.
C. Machine Data
Punch unit size 12” (305mm) W x 40” (1016mm) H x 30.5” (775mm) D

Weight 170 lbs (80kg) unpackaged,
270 lbs (123kg) packaged (Pallet, Carton, PKG Inserts)
Color Top Cover – Orca Black, Lower covers – Cuttle Gray
AC Power Supply to GP- External power cord according to market destination.
501
DC 5V Supply to GP-501 Supplied by system to PCB contained within GP-501
System Power Supply GP-501 Internal Lead-Through
Lines • On upstream side: Wiring with connectors through cover-recess.
• On downstream side: Lock-style connector panel on left side cover.
D. Software
Communication method i) Start-stop synchronization style, full duplex.

ii) 1 Start Bit, 8bit Data length, 1 Parity Bit, 1 Stop bit. Max Frame Length: 128
byte
iii) Hard flow control (CTS/RTS).
iv) Baud rate:
[Standard] 19200 bps
[ISW=Log file Transmissions] 78000 bps
Communication Content According Interface Specification (See also Appendix B)
E. Electronic
Required signals to UP & RXD, RTS, CTS, TXD

Downstream connected units
2 50
F. Inputs
/C6501P/C65hc/C5501
bizhub PRO C6501
(1) Media Input from Printer
Alignment/ skew variance Center justified ± 4mm

at pick up
Line speed 290 to 1250 mm/s (Fixed speeds within this range)
Speed variance at pick up ± 2%
Sheet frequency 120 ppm maximum
1) For Punching

Plain Paper: 75gsm – 216gsm
Other Paper: 120gsm-216gsm
Exception ProClick: LTR & A4 Limited to 200gsm
Paper type See appendix D
Maximum Sheet size Letter configuration 279 x 216mm
A4 configuration 297 x 210mm
2) For Bypass

64gsm – 350gsm
Paper type Coated, Pre-printed, High Quality, Plain, Book, Color, Rough, Post Card, Label,
OHP, Index
Transparency weight 5 -10 mil (0.127mm to 0.254mm)
Maximum bypass sheet 13” x 24.8” (330 x 630mm)
size
Minimum bypass sheet size 3.74” x 5.47” (95 x 139mm)
(2) Power
Supply GP-501 individual power supply and power cord required.

Configurations by market See table below
Machine Market Voltage (V) Current (A) Frequency (Hz) Paper size
1 US, Canada 115 +10/-15 % 3 60 81/2 x 11
2 Europe, Australia 220-240 +10/-15 % 1.8 50 A4
G. Outputs
Alignment/ skew at delivery ± 2mm or less for the pick up position

Speed variance at delivery ± 1% compared to speed variance at pick up
Chip tray capacity 2500 cycles (based on punched sheet count)
51 2
H. Performance
/C6501P/C65hc/C5501
bizhub PRO C6501
Punch accuracy Hole size ± 2%

Alignment ±0.5mm
Back gauge depth ±0.3mm
(1) Reliability
MCBJ: Punch 1 in 15,000 (20lb bond)

MCBJ: Bypass 1 in 65,000 (20lb bond)
I. Operation Environment, Storage, Transport
Normal Operation Temper- 10degC – 30 deg C

ature
Normal Operation Humidity 10% - 80%
Storage Temperature -10degC – 40 deg C
Storage Humidity 10% - 80%
J. Safety /Regulatory
Noise emissions (measured Punch Maximum of 78dBA (punching 216gsm cover)

to ISO7779) Bypass Maximum of 70dBA
(1) Safety Compliance
UL & CSA standards CAN/USA-C22.2 No. 60950-01

UL60950-1 First Edition
TUV standards IEC 60950-1:2001
EN60950-1:2001
(2) Electromagnetic Compliance
EMC standards EN55024:1998 Amendments A1:2001 & A2:2003

EN61000-3-2:2000
EN61000-3-3:1995 Amendment A1:2001
EN55022:1998 Amendments A1:2000 & A2:2003
EN61000-4-2, EN61000-4-4, EN61000-4-5, EN61000-4-6, EN61000-4-11
FCC standards Class B
Part 15, Subpart B, Section A 15.107A &15.109a
2 52
K. Appendix A
/C6501P/C65hc/C5501
bizhub PRO C6501
Figure 1.1 Front
53 2
bizhub PRO C6501
Figure 1.2 Entrance
2 54
L. Appendix B
/C6501P/C65hc/C5501
bizhub PRO C6501
shape (WxH or D)
1 DS-501 Ring Binder 3 3 Round 8mm 81/2 x 11
Hole (0.316")
2 DS-502 Plastic Bind 19 Rect. 8mm x 2.9mm 81/2 x 11

Cerlox (0.313" x 0.116")
3 DS-503 WireBind –3:1 32 Square 4mm x 4mm 81/2 x 11

Square (0.156" x 0.156")
4 DS-504 WireBind –2:1 21 Rect. 6.4mm x 5.4mm 81/2 x 11

5 DS-505 Color Coil 44 Round 4.4mm 81/2 x 11

(0.174")
6 DS-506 VeloBind 11 Round 3.2mm 81/2 x 11

(0.125")
Hole (0.316")

Cerlox (0.313" x 0.116")
10 DS-510 WireBind –3:1 34 Round 4mm A4

Round (0.158")
11 DS-511 WireBind –2:1 23 Round 6.38mm A4

Round (0.251")
12 DS-512 Color Coil 47 Round 4.4mm A4

(0.174")
13 DS-513 VeloBind 12 Round 3.2mm A4

(0.125")
Hole (0.316")

Cerlox (0.313" x 0.116")
17 DS-517 WireBind –2:1 23 Rect. 6.4mm x 5.4mm A4

(Australia)
55 2
shape (WxH or D)
bizhub PRO C6501
18 DS-518 WireBind –3:1 34 Square 4mm x 4mm A4

Square (0.156" x 0.156")
(Australia)
M. Appendix C
Paper Type for Punching

Destination Paper Name Weight (g/m2) Punch *2
(1) US Hammermill Color Copy Paper - 120 Q-Zone
Photo White
Hammermill Tidal MP 75 All
Hammermill Fore MP 75 All
Wausau Exact Gloss Coated 215 Q-Zone
(C1S) *1
Hammermill Color Copy Cover *1 163 Q-Zone
216 Q-Zone
(2) EU Konica Minolta Original 80 All
Konica Minolta Profi 80 All
Mondi BIO TOP 3 extra 80 All
Mondi Color Copy 200 Q-Zone
*1 For only C6501/C6501P/C65hc

*2 Q-Zone: Guaranteed only in Q-zone
All: Guaranteed in all environments
*Refer to the below graph
80
70
A
Humidity (%RH)
60
B Q
40
30
20 C
10
10 18 20 23 30
Temperature (°C)
a03ut1c004ca
2 56
N. Glossary of Terms
/C6501P/C65hc/C5501
bizhub PRO C6501
These terms are common to the punch and bindery industry.
Cerlox The trade name GBC uses for its Plastic Binding
Color coil A plastic coil that looks like a spring which is threaded through round
holes punched in the document then the ends are cut off and
crimped. The holes are either 4:1 or 5:1 (4 holes per inch or 5 holes
per inch). This type of bind lays flat and even folds around for easy
handling of the document.
Flush-cut covers Covers stock that is the same size as the paper contents and has
round corners.
Plastic binding The name used to describe GBC's most common binding method.
The 19 and 21 rectangular hole, Plastic Comb type.
ProClick A plastic element that snaps together. This style requires holes that
appear to be the same as Twin Loop but are actually slightly larger.
The larger holes enable correct operation of the ProClick Pronto fin-
ishing devise.
Tabbing Tabbing or hanging chad is when a hole is not punched cleanly
(hanging chad) through the material leaving a piece of paper hanging from the edge.
This condition occurs when a die set is worn and will usually result in
miss-feeds.
Twin loop Looped wire element that is feed into square or round holes in the
document in a similar fashion to Plastic Binding. The holes are either
2:1 or 3:1 (2 holes per inch or 3 holes per inch). It is then squeezed
together or crimped to create an attractive bind that lays flat.
Velobind A heat seal plastic bind that is best known for it's security and it's
attractive look. The one draw-back for VeloBind is that it is not a lay-
flat bind style. It is most often used in the Legal market for it's security
feature.
57 2
bizhub PRO C6501
Blank page
58
Field Service Ver.3.0 Jul. 2009 3. PERIODIC CHECK
MAINTENANCE
/C6501P/C65hc/C5501
bizhub PRO C6501
3. PERIODIC CHECK
3.1 Maintenance item
Note
• For the replacement procedure of periodically replaced parts, refer to Theory of Operation of the
main body "26.1 Housing section" to "26.13 Fusing section"
• The alcohol described in this section represents the isopropyl alcohol.
3.1.1 Main body

A. Maintenance 1 (Every 200,000 copies/prints (PRO C6501/C6501P/C65hc)/Every 150,000 copies/
prints (PRO C5501))
No. Unit Description Quantity Implementation classification Materials

classification Cleaning Check Lubrication Replacement Tools used
1 Preparation Image check
2 External Dust-proof filter /1 assy 1 Actual replacement
section A03UR701 cycle: Varies depend-
• Parts counter reset ing on the coverage,
developing roller
(service mode)
drive distance and
temp/humidity.
Dust-proof filter /2 assy 1 Must be replaced
65AAR718 when replacing the
dust-proof filter /1
assy.
dust-proof glass /Y, / Cleaning pad
M, /C, /K
3 Scanner Scaner unit (glass, Mir- ( ) Blower brush/
section ror) alcohol/cleaning pad
(C6501/C5501 only)
4 Photo con- Charging dust-proof fil-
ductor sec- ter
tion
Drum cartridge 4 Actual replacement
• Parts counter reset cycle: 106 km of
(service mode) drum drive distance,
or 130 km of lubri-
cant applying roller
drive distance,
whichever comes
first.
5 Developing Developer /Y 1 Actual replacement
section • Parts counter reset cycle: 130km of the
(service mode) developing roller
drive distance
59 2
/C6501P/C65hc/C5501 3. PERIODIC CHECK Field Service Ver.3.0 Jul. 2009

classification Tools used
bizhub PRO C6501
Cleaning Check Lubrication Replacement

5 Developing Developer /M 1 Actual replacement
section • Parts counter reset cycle: 130km of the
(service mode) developing roller
Developer /C 1 drive distance
• Parts counter reset
(service mode)
Developer /K 1
(service mode)
Developing unit /Y Alcohol/Hydro wipe
Developing unit /M
Developing unit /C
Developing unit /K
6 Intermediate Transfer belt unit 1
transfer sec- A03U5042
tion Toner collection sheet /1 1
65AAR756
Belt Cleaning blade 1 Actual replacement
A03U5530 cycle: 130km of belt
• Parts counter reset cleaning blade drive
(service mode) distance
1st transfer roller /Y 1
A03U5012
(service mode)
1st transfer roller /M 1
A03U5012
(service mode)
1st transfer roller /C 1
A03U5012
(service mode)
1st transfer roller /K 1
A03U5004
(service mode)
2nd transfer roller /Up 1
65AA2611
Belt drive roller Alcohol/Hydro wipe
2nd transfer roller /Lw 1
65AA4501
Separation discharg- 1
ing assy
A03UR704
1 60
/C6501P/C65hc/C5501
bizhub PRO C6501

7 Registration Cleaning stay Assy Alcohol/cleaning pad
section
8 Paper feed Paper feed roller rub-
section ber
Separation roller rub-
ber
Pick-up roller
9 Bypass tray Paper feed roller rub-
section ber
Separation roller rub-
ber
Pick-up roller
10 Vertical con- Intermediate convey-
veyance sec- ance Roller /1
tion
11 ADU ADU conveyance roll-
ers
12 Fusing Fusing roller /Lw 1 Multemp FF-RM
section A03U7203
Fusing paper exit roller 2
/Up
A03U7225
Fusing paper exit roller Alcohol/cleaning pad
/Lw
13 OT-502 Paper retainer roller 2
65AA4849
Paper exit roller 1
A0438907
Paper exit driven roller 4
/2
65AA4818
14 Final check Check of the image
and the paper through
(with various types of
adjustments included)
Maintenance counter
reset (service mode)
61
3. PERIODIC CHECK Field Service Ver.3.0 Jul. 2009
B. Maintenance 2 (Every 400,000 copies/prints (PRO C6501/C6501P/C65hc)/Every 300,000 copies/

/C6501P/C65hc/C5501
prints (PRO C5501))

bizhub PRO C6501

1 Paper feed paper feed roller rub- 3 Actual replacement
section ber count: 125,000 feed
25SA4096
Separation roller rub- 3
ber
25SA4096
2 reverse/ Reverse decurler roller 1
paper exit A03U8605
section Reverse gate Alcohol/cleaning pad
3 Fusing Fusing roller /2 1 Multemp FF-RM
section A03U7202
Fusing belt 1
A03U7205
Belt regulation sleeve 2
A03U7250
Insulating sleeve /Up 2 Multemp FF-RM
A03U7295
Fusing bearing /Lw 2
Fusing roller /1 1
A03U7201
Fusing bearing /Up 2
A03U8078
Fusing drive gear /O 1
A03U8095
Fusing bearing 2
56UA7507
Fusing drive gear /B 1
A03U8082
C. Maintenance 3 (Every 450,000 copies/prints (PRO C5501))

1 Photo con- Charging dust-proof fil- 1
ductor sec- ter
tion 65AAR767
2 Fusing sec- Fusing bearing /Lw 2
tion 26NA5371
Insulating sleeve /Lw 2 Multemp FF-RM
A03U7227
1 62
D. Maintenance 3 (Every 600,000 copies/prints (PRO C6501/C6501P/C65hc)
/C6501P/C65hc/C5501
bizhub PRO C6501
1 Photocon- Charging dust-proof fil- 1
ductor sec- ter
tion 65AAR767
2 Developing Developing unit /Y 1
section A03UR706
Developing unit /M 1
A03UR706
Developing unit /C 1
A03UR706
Developing unit /K 1
A03UR707
3 Intermediate Belt cleaner unit 1
transfer sec- A03UR748
tion • Parts counter reset
(service mode)
Separation claw Assy 3
65AAR753
4 Registration Cleaning stay Assy 1
section 65AAR780
5 Fusing Fusing limiter 1
section 65AA5365
Fusing bearing /Lw 2
26NA5371
Insulating sleeve /Lw 2 Multemp FF-RM
A03U7227
Fusing regulation gear 1
/A
65AA7747
Fusing duct /2 Assy 1
A03UR753
63 1
E. Maintenance 4 (Every 600,000 copies/prints (PRO C5501))

/C6501P/C65hc/C5501
bizhub PRO C6501

1 Developing Developing unit /Y 1
section A03UR706
Developing unit /M 1
A03UR706
Developing unit /C 1
A03UR706
Developing unit /K 1
A03UR707
2 Intermediate Belt cleaner unit 1
transfer sec- A03UR748
tion • Parts counter reset
(service mode)
Separation claw Assy 3
65AAR753
3 Registration Cleaning stay Assy 1
section 65AAR780
4 Fusing Fusing limiter 1
section 65AA5365
Fusing regulation gear /A 1 Multemp FF-RM
65AA7747
Fusing duct /2 Assy 1
A03UR753
F. Maintenance 4 (Every 1,000,000 copies/prints (PRO C6501/C6501P/C65hc))

Maintenance 5 (Every 900,000 copies/prints (PRO C5501))

1 Intermediate 2nd transfer earth plate 1
transfer sec- assy
tion 65AAR778
2 Reverse/ Paper exit decurler 1
paper exit roller
section A03U8926
Guide plate /Up Alcohol/cleaning pad
3 Fusing Fusing drive gear /M 1 Multemp FF-RM
section A03U8093
1 64
G. Maintenance 5 (Every 1,400,000 copies/prints (PRO C6501/C6501P/C65hc))
/C6501P/C65hc/C5501
Maintenance 6 (Every 1,350,000 copies/prints (PRO C5501))
bizhub PRO C6501

1 Intermediate Belt separation claw 1
transfer sec- solenoid
tion 26NA8251
2 Bypass feed Paper feed roller rub- 2 Actual replacement
tray section ber count: 125,000 feed
25SA4096
3 Registration Registration roller assy 1
section 65LAR707
H. Maintenance 6 (Every 2,000,000 copies/prints (PRO C6501/C6501P/C65hc))


1 Vertical con- Intermediate convey- 1
veyance sec- ance clutch /1
tion 56AA8201
2 ADU Intermediate convey- 1
ance clutch /2
56AA8201
Intermediate convey- 1
ance clutch /3
56AA8201
I. Maintenance 7 (Every 2,400,000 copies/prints (PRO C6501/C6501P/C65hc))


1 Paper feed Pick-up roller 3 Actual replacement
section 56AAR721 count: 800,000 feed
2 Fusing Fusing lamp /Up 1
section A03UM31F (Europe)
A03UM31E (U.S.A)
Fusing heater lamp /4 1
A03UM32F (Europe)
A03UM32E (U.S.A)
Sensor mounting plate 1
A assy
A03UR734
Sensor mounting plate 1
B assy
A03UR735
65 1
J. Maintenance 8 (Every 3,000,000 copies/prints (PRO C6501/C6501P/C65hc))

/C6501P/C65hc/C5501

bizhub PRO C6501

1 Intermediate Transfer roller bearing 8
transfer section 65AA2638
K. Maintenance 9 (Every 4,000,000 copies/prints (PRO C6501/C6501P/C65hc))


1 Paper feed Paper feed clutch /1 1 Actual replacement
section 56AA8201 count: 2,000,000
Paper feed clutch /2 1 feed
56AA8201
Paper feed clutch /3 1
56AA8201
Pre-registration clutch /1 1
56AA8201
56AA8201
56AA8201
2 Bypass feed Pick-up roller 1 Actual replacement
tray section 65AAR789 count: 800,000 feed
Paper feed clutch /BP 1 Actual replacement
56AA8201 count: 2,000,000
feed
L. Spotted replacement parts (PRO C6501/C6501P/C65hc/C5501)

1 ADU ADU conveyance 1 Actual replacement
clutch /1 count: 3,600,000
A03UM201 prints
2 ADU conveyance 1
clutch /2
A03UM201
3 ADU conveyance 1
clutch /3
A03UM201
4 ADU pre-registration 1
clutch
A03UM201
1 66
3.1.2 DF
/C6501P/C65hc/C5501
A. Maintenance 1 (Every 1,800,000 copies/prints (PRO C6501/C5501))
bizhub PRO C6501

section 13YH4064 count: 625,000 feed
Paper feed roller 1
13YH4039
Separation roller 1
20AJ4015
3.1.3 PF
A. Maintenance 1 (Every 200,000 copies/prints (PRO C6501/C6501P/C65hc))

1 Paper feed Pick-up rubber Alcohol/cleaning pad
section Paper feed roller
Separation roller
PF separation gear ( ) Alcohol/cleaning
section pad/multemp FF-RM
2 Conveyance Vertical conveyance Alcohol/cleaning pad
section roller /1
Horizontal convey-
ance roller /1
B. Maintenance 2 (Every 600,000 copies/prints (PRO C6501/C6501P/C65hc))

1 Paper feed Pick-up rubber 2 Actual replacement
section A03X5652 count: 300,000 feed
Paper feed roller 2
A03X5653
Separation roller 2
A03X5654
67 1
C. Maintenance 3 (Every 2,400,000 copies/prints (PRO C6501/C6501P/C65hc))

/C6501P/C65hc/C5501
bizhub PRO C6501

1 Paper feed Paper feed clutch 2 Actual replacement
Separation clutch 2 feed
56AA8201
2 Conveyance Vertical conveyance 1
section clutch /1
56AA8201
Vertical conveyance 1
clutch /2
56AA8201
Vertical conveyance 1
clutch /3
56AA8201
Horizontal convey- 1
ance clutch /1
56AA8201
Horizontal convey- 1
ance clutch /2
56AA8201
Pre-registration clutch 1
56AA8201
3.1.4 LU
A. Maintenance 1 (Every 200,000 prints (PRO C6501/C6501P/C65hc)/Every 150,000 prints (PRO
C5501))

1 Paper feed Pick-up roller Alcohol/cleaning pad
Separation roller
Pre-registration roller
Paper dust
removing brush
LU separation gear ( ) Alcohol/cleaning
section pad/multemp FF-RM
1 68
B. Maintenance 2 (Every 600,000 copies/prints (PRO C6501/C6501P/C65hc/C5501))
/C6501P/C65hc/C5501
bizhub PRO C6501

section A03X5652 count: 300,000 feed
Paper feed roller 1
A03X5653
Separation roller 1
A03X5654
C. Maintenance 3 (Every 2,400,000 copies/prints (PRO C6501/C6501P/C65hc/C5501))

1 Paper feed Paper feed clutch 1 Actual replacement
Pre-registration clutch 1 feed
56AA8201
3.1.5 RU
A. RU-504
(1) Maintenance 1 (Every 200,000 copies/prints (PRO C6501/C6501P/C65hc))
1 Conveyance Entrance roller /2 Alcohol/cleaning pad
section Entrance roller /1
Conveyance roller
B. RU-506
(1) Spotted replacement part (PRO C6501/C6501P/C65hc)
classification Cleaning Check Lubrication Replace Tools used
1 Convey- Straight gate solenoid (SD1) 1 Actual replacement
ance section A0GER709## count: 5,000,000
Straight gate spring 1 operations
15AG4587##
2 Stacker sec- Stacker exit shutter 1
tion solenoid (SD2)
A0GER700##
Stack switching sole- 1
noid (SD3)
A0GER701##
Stacker entrance guide 1
A0GER702##
69 2
3.1.6 FD
/C6501P/C65hc/C5501
A. Maintenance 1 (Every 1,400,000 prints (PRO C6501/C6501P/C65hc))

bizhub PRO C6501

1 Punch sec- Punch shaft and punch Alcohol/cleaning pad
tion support board
Punch drive section Molykote EM-30L
B. Maintenance 2 (Every 2,200,000 prints (PRO C6501/C6501P/C65hc))

1 PI section Separation rubber 2 Actual replacement
13QNR704 count: 100,000 feed
Paper feed rubber 2
50BAR702
Cleaning of each sensor Blower brush
2 Tray up/ Cleaning of each sensor
down section
3 Punch sec- Cleaning of each sensor
tion
4 Conveyance Cleaning of each sensor
section
C. Maintenance 3 (Every 5,200,000 prints (PRO C6501/C6501P/C65hc))

1 PI section Pick-up rubber 6 Actual replacement
50BAR701 count: 200,000 feed
2 Tray up/ Tray up down motor 1 Actual replacement
down section 129U-108# count: 5,000,000
feed
2 70
3.1.7 FS
/C6501P/C65hc/C5501
A. FS-521
bizhub PRO C6501

(1) Maintenance 1 (Every 600,000 prints (PRO C6501/C6501P/C65hc))

1 Main tray Paper exit roller /A 8
section 122H4825
Cleaning of each sensor Blower brush
2 Stacker Cleaning of each sensor Blower brush
section
3 Conveyance Cleaning of the paper Vacuum cleaner /
section dust removing brush Blower brush
(2) Maintenance 2 (Every 3,000,000 prints (PRO C6501/C6501P/C65hc))

1 Conveyance Slip roller pressure 2 Molykote EM-30L
section release cam
2 Stacker Warm gear and cam 1 Molykote EM-30L
section
(3) Maintenance 3 (Every 5,200,000 prints (PRO C6501/C6501P/C65hc))

1 Stacker Intermediate roller 1
section release solenoid
15AAR718
2 Main tray Paper exit opening 1
section solenoid
A0GYB904
(4) Spotted replacement parts (PRO C6501/C6501P/C65hc))

1 Stapler Stapler unit /Fr 1 Actual replacement
section A0GYA735 count: 500,000 sta-
Stapler unit /Rr 1 ples
A0GYA736
71 2
B. FS-520
/C6501P/C65hc/C5501
(1) Maintenance 1 (Every 200,000 copies/prints (PRO C6501/C6501P/C65hc)/Every 150,000 copies/

bizhub PRO C6501
prints (PRO C5501))

1 Conveyance Shift roller motor
section
Paper exit opening
motor
Bypass gate solenoid
Paper exit roller /A 6
(sponge roller)
122H4825
Paper exit roller /B 4
(sponge roller)
A04D8904
ance roller
(sponge roller)
13QE4531
2 Stacker Paper assist roller
section (sponge roller)

prints (PRO C5501))

1 Stacker Paper assist roller 1
20AK4210
Cleaning plate Assy 1
A07RA741
(3) Spotted replacement parts (PRO C6501/C6501P/C65hc/C5501)

1 Stapler sec- Stapler unit /Fr 1 Actual replacement
tion A07RA735 count: 500,000 sta-
A07RA736
1 72
C. FS-607
/C6501P/C65hc/C5501
(1) Maintenance 1 (Every 200,000 copies/prints (PRO C6501/C6501P/C65hc)/Every 150,000copies/
bizhub PRO C6501

prints (PRO C5501))

1 Conveyance Shift roller motor
section
Paper exit opening
motor
Bypass gate solenoid
Paper exit roller /A 6
(sponge roller)
122H4825
Paper exit roller /B 4
(sponge roller)
A04D8904
ance roller
(sponge roller)
13QE4531
2 Stacker Paper assist roller
3 Folding Folding knife motor
section Tri-folding gate
solenoid

prints (PRO C5501))

1 Stacker sec- Paper assist roller 1
tion (sponge roller)
20AK4210
(3) Maintenance 3 (Every 1,000,000 copies/prints (PRO C6501/C6501P/C65hc)/Every 900,000 copies/

prints (PRO C5501))

1 Stapler sec- Stapler unit /Fr 1 Actual replacement
tion 15JM-501 count: 200,000 sta-
15JM-501
73 1
3.1.8 PI
/C6501P/C65hc/C5501
A. Maintenance 1 (Every 200,000 prints (PRO C6501/C6501P/C65hc)/Every 150,000 prints (PRO

bizhub PRO C6501
C5501))

1 Paper feed Pick-up roller Alcohol/cleaning pad
Separation roller
B. Maintenance 2 (Every 600,000 prints (PRO C6501/C6501P/C65hc/C5501))

1 Paper feed Paper feed roller 2 Actual replacement
section 13QN-446 count: 100,000 feed
Separation roller 2
13QN-443
C. Maintenance 3 (Every 1,000,000 prints (PRO C6501/C6501P/C65hc)/Every 900,000 prints (PRO

C5501))

section 50BA-574 count: 200,000 feed
D. Maintenance 4 (Every 3,000,000 prints (PRO C6501/C6501P/C65hc/C5501))

1 Paper feed Torque limiter 2 Actual replacement
section 13QN4073 count: 600,000 feed
E. Spotted replacement parts (PRO C6501/C6501P/C65hc/C5501)

1 Paper feed Papaer feed clutch /Up 1 Actual replacement
section 13QN8201 count: 1,000,000
Papaer feed clutch /Lw 1 feed
13QN8201
1 74
3.1.9 SD
/C6501P/C65hc/C5501
A. Maintenance 1 (Every 600,000 prints (PRO C6501/C6501P/C65hc))
bizhub PRO C6501

1 Right angle Cleaning of each sensor
conveyance
section
2 Folding Cleaning of each sensor
section
3 Saddle Cleaning of each sensor
stitching sec-
tion
4 Bundle pro- Cleaning of each sensor
cessing sec-
tion
5 Trimmer sec- Cleaning of each sensor
tion Trimmer board assem- 1 Actual replacement
bly count: 18,900 cuts
15AN5282
• Counter reset
(I/O check mode)
B. Maintenance 2 (Every 1,400,000 prints (PRO C6501/C6501P/C65hc))

1 Trimmer sec- Trimmer blade assem- 1 Actual replacement
tion bly count: 37,500 cuts
15AN-570
C. Maintenance 3 (Every 4,000,000 prints (PRO C6501/C6501P/C65hc))

1 Trimmer sec- Slide block /Rt Actual lubricated
2 tion Slide block /Lt cycle: every 100,000
3 Trimmer blade drive cuts or 0.5 year
screw /Up (whichever comes
first.)
4 Trimmer blade drive
Molykote EM-30L
screw /Lw
5 Trimmer stopper /Rt
6 Trimmer stopper /Lt
75 1
D. Spotted replacement parts (PRO C6501/C6501P/C65hc)

/C6501P/C65hc/C5501
bizhub PRO C6501

1 Saddle Stapler assembly 2 Actual replacement
stitching sec- 15AN-550 count: 1,000,000
tion staples
2 Trimmer sec- Trimmer unit 1 Actual replacement
tion 15AN5092 count: 200,000 cuts
3 Bundle pro- Bundle press stage 1 Actual replacement
cessing sec- gear count:500,000 sets
tion 15AN7719 (Bundle exit tray)
E. Spotted lubrication (PRO C6501/C6501P/C65hc)

1 Trimmer Trimmer board gear Actual lubricated
2 section Trimmer blade gear /Up cycle: every
3 Trimmer blade gear /Lw 200,000 cuts or
1 year
4 Press drive screw /Rt
(whichever comes
5 Press drive screw /Lt
first.)
6 Trimmer press plate Molykote EM-30L
guide rail /Rt
7 Trimmer press plate
guide rail /Lt
1 76
3.1.10 PB
/C6501P/C65hc/C5501
A. Maintenance 1 (Every 600,000 prints (PRO C6501/C6501P/C65hc))
bizhub PRO C6501

1 Conveyance Entrance sensor Blower brush
section
2 SC entrance sensor
3 Sub tray conveyance Drum cleaner/
roller cleaning pad
4 Intermediate convey-
ance roller
5 Entrance conveyance
roller
6 Cover paper convey-
ance roller
7 Clamp section Reference plate
8 Clamp pressure plate *4 Plas guard No.2
shafts
9 Glue tank Glue tank *2 Tweezers, industrial
section wiper, multemp FF-RM
10 Filter 1
A0753724#
*1
11 Cover paper Cover paper folding Tweezers, industrial wiper
section plate
*1
12 Book spine backing
plate
13 Book exit belt /Rr Drum cleaner/
cleaning pad
14 Book exit belt /Fr
15 Cover paper
conveyance roller /Rt
16 Cover paper
conveyance roller /Lt
17 Cover paper table
entrance roller
18 Paper dust removing Blower brush
brush
*3
19 Cover paper alignment Plas guard No.2
plate shafts
20 Glue supply Pellet hopper Blower brush
21 Book stock Book load limit sensor
section
22 Book upper limit LED
23 Book sensor/1 and /2
*5
24 Guide shaft/Rt and /Lt Plas guard No.2
25 Book conveyance belt /Rr Drum cleaner/
cleaning pad
26 Book conveyance belt /Fr
27 Book movement belt
77 1

bizhub PRO C6501

28 Cover paper Paper dust removing brush Blower brush
29 tray section Paper dust removing roller
30 Conveyance roller Drum cleaner/
cleaning pad
31 SC section Switchback roller 1
13GQ4519#
32 Sub scan alignment Plas guard No.2
plate shaft
33 Switchback assist roller /Rr Drum cleaner/
cleaning pad
34 Switchback assist roller /Fr
35 Fan unit Pellet supply cooling fan
section motor (M4)
27LA8051#
*1 Cleaning of the cover paper folding plate and the book spine backing plate is an abbreviated cleaning.
Remove adhered glue as necessary.
*2 Lubricate the glue apply roller motor drive connecting gear.
*3 Lubricate the cover paper alignment plate shafts.
*4 Lubricate the clamp pressure plate shafts.
*5 Lubricate the guide shaft/Rt and /Lt.
B. Spotted replacement parts (Every 500,000 cycle (PRO C6501/C6501P/C65hc))

1 Cover paper Pick-up roller 1
tray section 55VAR750
Paper feed roller 1
55VAR749
Separation roller 1
55VAR749
C. Spotted replacement parts (Every 3,000,000 cycle (PRO C6501/C6501P/C65hc))

1 Cover paper Cover paper pick up 1
tray section clutch
56AA8201#
2 Cover paper separation 1
clutch
56AA8201#
D. Spotted replacement parts (Every 6,000 hours (C6501/C6501P/C65hc))

1 Glue tank Cover paper glue roller 4
section drive gear bearing
A0753799#
2 78
3.1.11 GP
/C6501P/C65hc/C5501
A. Maintenance1 (Every 200,000 copies/prints (PRO C6501/C6501P/C65hc))
bizhub PRO C6501

No. Unit classifica- Description Quantity Implementation classification Materials
tion Cleaning Check Lubrication Replace Tools used
1 Punch sec- Die Set Pins 3-IN-ONE (WD-40
tion Company)
Actual lubrication
count: 50,000 punches
This maintenance to
be done by user.
B. Maintenance2 (Every 800,000 copies/prints (PRO C6501/C6501P/C65hc))

1 Punch sec- Die Set Shoulder Bolts Magnalube-G Teflon
tion Grease
Actual lubrication count:
200,000 punches
This maintenance to be
done by user.
C. Maintenance3 (Every 2,000,000 copies/prints (PRO C6501/C6501P/C65hc))

1 Punch sec- Die Set 1 Actual replacement
tion count: 500,000 punches
Replacement is rec-
ommended if hanging
chips are usually gen-
erated.
79 2
D. Maintenance 4 (Every 3,000,000 copies/prints (PRO C6501/C6501P/C65hc))

/C6501P/C65hc/C5501
bizhub PRO C6501

1 Bypass con- Paper Path, Bypass Alcohol
veyance
section
2 Punch con- Latching Mechanisms
veyance aligner
3 section Paper Path, Aligner Alcohol
panels
4 Aligner Idler Rollers
5 Roller energy drive
6 Bypass/ Optical Sensors Blower brush
7 Punch con- Timing Belts Alcohol
8 veyance Idler Rollers
section
9 Drive Rollers
10 Punch sec- Back Gauge solenoid Blower brush/
tion vacuum cleaner
11 Die Guide Vacuum cleaner
12 Paper Path, Punch Alcohol
13 External Base Vacuum cleaner
14 section Door Closing Latch
2 80
3.2 Replacement parts list
/C6501P/C65hc/C5501
bizhub PRO C6501
3.2.1 Periodically replacement parts list (PRO C6501/C6501P/C65hc)
Note
main body "26.1 Housing section" to "26.13 Fusing section".
• The parts count No. given in the table below represents the number of "Count of special parts" in
the Service mode.
A. Main body
No. Classification Part name Part number Qt. Actual replace- Parts count
ment cycle No.
1 External sec- Dust-proof filter /1 assy A03UR701 1 Refer to P.90 2
2 tion Dust-proof filter /2 assy 65AAR718 1 Must be 3
replaced
Note when replac-
• In this filter an ozone filter is ing the dust-
included. proof filter /1
assy.
4 Photocon- Drum cartridge DU-102C 1 Refer to P.90 14, 16, 18,
ductor section 20
5 Charging corona A0U0R712 4 Refer to P.90 6, 8, 10, 12
• Parts counter reset (Service
mode)
6 Charging dust-proof filter 65AAR767 1 600,000 5
7 Intermediate Belt Cleaning blade A03U5530 1 Refer to P.90 37
8 transfer sec- 1st transfer roller /Y A03U5012 1 200,000 39
9 tion 1st transfer roller /M A03U5012 1 200,000 40
10 1st transfer roller /C A03U5012 1 200,000 41
11 1st transfer roller /K A03U5004 1 200,000 42
12 Transfer belt A03U5042 1 200,000 34
13 2nd transfer roller /Up 65AA2611 1 200,000 43
14 Separation claw assy 65AAR753 3 600,000 44
15 Belt cleaner unit A03UR748 1 600,000 35
16 Toner collection Sheet /1 65AAR756 1 200,000 36
17 2nd transfer roller /Lw 65AA4501 1 200,000 48
18 2nd transfer earth plate assy 65AAR778 1 1,000,000 50
19 Belt separation claw solenoid 26NA8251 1 1,400,000 47
20 Separation discharging assy A03UR704 1 200,000 49
21 Transfer roller bearing 65AA2638 8 3,000,000 45
22 Developing Developer /Y DV610Y 1 Refer to P.90 22
section
81 2
ment cycle No.
bizhub PRO C6501
23 Developing Developer /M DV610M 1 Refer to P.90 24

section (C6501/
6501P)
DV611M
(C65hc)
24 Developer /C DV610C 1 Refer to P.90 26
(C6501/
6501P)
DV611C
(C65hc)
25 Developer /K DV610K 1 Refer to P.90 28
26 Developing Developing unit /Y A03UR706 1 600,000 30
27 section Developing unit /M 1 600,000 31
28 Developing unit /C A03UR706 1 600,000 32
29 Developing unit /K A03UR707 1 600,000 33
30 Toner collec- Toner collection box A03UR702 1 Refer to P.90 1
tion box
31 Paper feed Pick-up roller 56AAR721 3 800,000 78, 79, 80
32 section Paper feed roller rubber 25SA4096 3 125,000 74, 75, 76
33 Separation roller rubber 25SA4096 3 125,000 74, 75, 76
34 Paper feed clutch /1 56AA8201 1 2,000,000 82
37 Pre-registration clutch /1 56AA8201 1 2,000,000 86
40 Bypass feed Pick-up roller 65AAR789 1 800,000 81
41 tray section Paper feed roller rubber 25SA4096 1 125,000 77
42 Separation roller rubber 25SA4096 1 125,000 77
43 Paper feed clutch /BP 56AA8201 1 2,000,000 85
44 Vertical con- Intermediate conveyance clutch /1 56AA8201 1 2,000,000 89
veyance sec-
tion
45 Registration Cleaning stay assy 65AAR780 1 600,000 92
46 section Registration roller assy 65LAR707 1 1,400,000 93
47 ADU section Intermediate conveyance clutch /2 56AA8201 1 2,000,000 90
48 Intermediate conveyance clutch /3 56AA8201 1 2,000,000 91
49 Reverse/ Reverse decurler roller A03U8605 1 400,000 94
50 paper exit paper exit decurler roller A03U8926 1 1,000,000 95
section
51 Fusing sec- Fusing drive gear /B A03U8082 1 400,000 61
52 tion Fusing duct 2 assy A03UR753 1 600,000 65
53 Fusing drive gear /M A03U8093 1 1,000,000 67
1 82
/C6501P/C65hc/C5501
ment cycle No.
bizhub PRO C6501

54 Fusing sec- Fusing lamp /Up A03UM31F 1 2,400,000 68
tion A03UM31E
55 Fusing roller /2 A03U7202 1 400,000 51
56 Fusing bearing 56UA7507 2 400,000 66
57 Fusing drive gear /O A03U8095 1 400,000 63
58 Fusing belt A03U7205 1 400,000 53
59 Fusing roller /1 A03U7201 1 400,000 60
60 Insulating sleeve /Up A03U7295 2 400,000 57
61 Fusing bearing /Up A03U8078 2 400,000 62
62 Belt regulation sleeve A03U7250 2 400,000 54
63 Fusing heater lamp /4 A03UM32F 1 2,400,000 69
A03UM32E
64 Fusing roller /Lw A03U7203 1 200,000 52
65 Fusing bearing /Lw 26NA5371 2 600,000 58
66 Insulating sleeve /Lw A03U7227 2 600,000 59
67 Sensor mounting plate A assy A03UR734 1 2,400,000 71
68 Sensor mounting plate B assy A03UR735 1 2,400,000 70
69 Fusing paper exit roller /Up A03U7225 2 200,000 55
70 Fusing regulation gear /A 65AA7747 1 600,000 64
71 Fusing limiter 65AA5365 1 600,000 56
72 OT-502 Paper retainer roller 65AA4849 2 200,000 113
73 Paper exit roller A0438907 1 200,000 111
74 Paper exit driven roller /2 65AA4818 4 200,000 112
B. Option
ment cycle No.
1 DF Pick-up roller 13YH4064 2 625,000 217
2 Paper feed roller 13YH4039 1 625,000 218
3 Separation roller 20AJ4015 1 625,000 219
4 PF Pick-up rubber 55VA4111 2 300,000 126, 130
5 Paper feed roller 55VA-483 2 300,000 127, 131
6 Separation roller 55VA-483 2 300,000 127, 131
9 Separation clutch /1 56AA8201 1 2,000,000 129
10 Separation clutch /2 56AA8201 1 2,000,000 133
11 Vertical conveyance clutch /1 56AA8201 1 2,000,000 134
14 Horizontal conveyance clutch /1 56AA8201 1 2,000,000 137
83
ment cycle No.
bizhub PRO C6501
15 PF Horizontal conveyance clutch /2 56AA8201 1 2,000,000 138

16 Pre-registration clutch 56AA8201 1 2,000,000 139
17 LU Pick-up roller A03X5652 1 300,000 118
18 Paper feed roller A03X5653 1 300,000 119
19 Separation roller A03X5654 1 300,000 119
20 Paper feed clutch 56AA8201 1 2,000,000 120
22 FD Separation rubber 13QNR704 2 100,000 153, 156
23 Paper feed rubber 50BAR702 2 100,000 154, 157
24 Pick-up rubber 50BAR701 6 200,000 152, 155
25 Tray up down motor 129U-108 1 5,000,000 161
26 FS-521 Intermediate roller release sole- 15AAR718 1 5,200,000 —
noid
Paper exit opening solenoid assy A0GYB904 1 5,200,000 —
27 Paper exit roller /A (sponge roller) 122H4825 8 600,000 147
28 FS-520 Paper exit roller /A (sponge roller) 122H4825 6 200,000 196
29 Paper exit roller /B (sponge roller) A04D8904 4 200,000 197
30 Intermediate conveyance roller 13QE4531 4 200,000 198
(sponge roller)
31 Paper assist roller (sponge roller) 20AK4210 1 400,000 209
32 Cleaning plate Assy A07RA741 1 400,000 215
(sponge roller)
37 Stapler unit /Fr 15JM-501 1 200,000 189
38 Stapler unit /Rr 15JM-501 1 200,000 190
39 PI Paper feed roller 13QN-446 2 100,000 201, 206
40 Separation roller 13QN-443 2 100,000 202, 207
41 Pick-up roller 50BA-574 2 200,000 200, 205
42 Torque limiter 13QN4073 2 600,000 203, 208
43 SD Trimmer board assembly 15AN5282 1 18,900 179
44 Trimmer blade assembly 15AN-570 1 37,500 178
45 PB Switchback roller 13GQ4519# 1 600,000 228
46 Filter A0753724# 1 600,000 234, 235
47 Pellet supply cooling fan motor (M4) 27LA8051# 1 600,000
48 GP Die Set DS-5## 500,000
2 84
3.2.2 Spot replacement parts list (PRO C6501/C6501P/C65hc)
/C6501P/C65hc/C5501
The parts shown below are not periodically replaced parts. However, be sure to replace them when they get to
bizhub PRO C6501

the actual count value.
A. Main body
ment cycle No.
1 ADU section ADU conveyance clutch /1 A03UM201 1 3,600,000 96
2 ADU conveyance clutch /2 A03UM201 1 3,600,000 97
4 ADU pre-registration clutch A03UM201 1 3,600,000 99
B. Option
ment cycle No.
1 RU-506 Straight gate solenoid (SD1) A0GER709## 1 5,000,000
2 Stacker exit shutter solenoid (SD2) A0GER700## 1 5,000,000
3 Stack switching solenoid (SD3) A0GER701## 1 5,000,000
4 Stacker entrance guide A0GER702## 1 5,000,000
5 Straight gate spring 15AG4587## 1 5,000,000
6 FS-521 Stapler unit /Fr A0GYA735 1 500,000 144
7 Stapler unit /Rr A0GYA736 1 500,000 145
8 FS-520 Stapler unit /Fr A07RA735 1 500,000 210
9 Stapler unit /Rr A07RA736 1 500,000 211
10 PI Paper feed clutch /UP 13QN8201 1 1,000,000 199
11 Paper feed clutch /Lw 13QN8201 1 1,000,000 204
12 SD Stapler assembly 15AN-550 2 1,000,000 176, 177
13 Trimmer unit 15AN5092 1 200,000 180
14 Bundle press stage gear 15AN7719 1 500,000 184
15 PB Pick-up roller 55VAR750 1 500,000 229
16 Paper feed roller 55VAR749 1 500,000 230
17 Separation roller 55VAR749 1 500,000 230
18 Cover paper pick up clutch 56AA8201# 1 3,000,000 231
19 Cover paper separation clutch 56AA8201# 1 3,000,000 232
20 Cover paper glue roller drive gear A0753799# 4 6,000 hours 237
bearing
85 2
3.2.3 Periodically replacement parts list (PRO C5501)

/C6501P/C65hc/C5501
bizhub PRO C6501
Note
main body "26.1 Housing section" to "26.13 Fusing section".
• The parts count No. given in the table below represents the number of "Count of special parts" in
the Service mode.
A. Main body
ment cycle No.
1 External sec- Dust-proof filter /1 assy A03UR701 1 Refer to P.90 2
2 tion Dust-proof filter /2 assy 65AAR718 1 Must be 3
replaced
Note when
• In this filter an ozone filter is replacing
included. the dust-
proof filter /1
assy.
4 Photo con- Drum cartridge DU-102C 4 Refer to P.90 14, 16, 18,
ductor section 20
5 Charging corona A0U0R712 4 Refer to P.90 6,8,10,12
• Parts counter reset (Service
mode)
6 Charging dust-proof filter 65AAR767 1 450,000 5
7 Intermediate Belt Cleaning blade A03U5530 1 Refer to P.90 37
8 transfer sec- 1st transfer roller /Y A03U5012 1 150,000 39
tion
9 1st transfer roller /M A03U5012 1 150,000 40
10 1st transfer roller /C A03U5012 1 150,000 41
11 1st transfer roller /K A03U5004 1 150,000 42
12 Transfer belt A03U5042 1 150,000 34
13 2nd transfer roller /Up 65AA2611 1 150,000 43
14 Separation claw assy 65AAR753 3 600,000 44
15 Belt cleaner unit A03UR748 1 600,000 35
16 Toner collection Sheet /1 65AAR756 1 150,000 36
17 2nd transfer roller /Lw 65AA4501 1 150,000 48
18 2nd transfer earth plate assy 65AAR778 1 900,000 50
19 Belt separation claw solenoid 26NA8251 1 1,350,000 47
20 Separation discharging assy A03UR704 1 150,000 49
21 Transfer roller bearing 65AA2638 8 3,000,000 45
22 Developing Developer /Y DV610Y 1 Refer to P.90 22
23 section Developer /M DV610M 1 Refer to P.90 24
24 Developer /C DV610C 1 Refer to P.90 26
25 Developer /K DV610K 1 Refer to P.90 28
2 86
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ment cycle No.
bizhub PRO C6501

26 Developing Developing unit /Y A03UR706 1 600,000 30
27 section Developing unit /M 1 600,000 31
28 Developing unit /C 1 600,000 32
29 Developing unit /K A03UR707 1 600,000 33
30 Toner collec- Toner collection box A03UR702 1 Refer to P.90 1
tion box
31 Paper feed Pick-up roller 56AAR721 3 800,000 78,79,80
32 section Paper feed roller rubber 25SA4096 3 125,000 74,75,76
33 Separation roller rubber 25SA4096 3 125,000 74,75,76
40 Bypass feed Pick-up roller 65AAR789 1 800,000 81
41 tray section Paper feed roller rubber 25SA4096 1 125,000 77
42 Separation roller rubber 25SA4096 1 125,000 77
43 Paper feed clutch /BP 56AA8201 1 2,000,000 85
44 Vertical con- Intermediate conveyance clutch /1 56AA8201 1 1,950,000 89
veyance
section
45 Registration Cleaning stay assy 65AAR780 1 600,000 92
46 section Registration roller assy 65LAR707 1 1,350,000 93
47 ADU section Intermediate conveyance clutch /2 56AA8201 1 1,950,000 90
48 Intermediate conveyance clutch /3 56AA8201 1 1,950,000 91
49 Reverse/ Reverse decurler roller A03U8605 1 300,000 94
50 paper exit paper exit decurler roller A03U8926 1 900,000 95
section
51 Fusing sec- Fusing drive gear /B A03U8082 1 300,000 61
52 tion Fusing duct 2 assy A03UR753 1 600,000 65
53 Fusing drive gear /M A03U8093 1 900,000 67
54 Fusing lamp /Up A03UM31F 1 2,400,000 68
A03UM31E
55 Fusing roller /2 A03U7202 1 300,000 51
56 Fusing bearing 56UA7507 2 300,000 66
57 Fusing drive gear /O A03U8095 1 300,000 63
58 Fusing belt A03U7205 1 300,000 53
59 Fusing roller /1 A03U7201 1 300,000 60
60 Insulating sleeve /Up A03U7295 2 300,000 57
61 Fusing bearing /Up A03U8078 2 300,000 62
62 Belt regulation sleeve A03U7250 2 300,000 54
87
ment cycle No.
bizhub PRO C6501
63 Fusing sec- Fusing heater lamp /4 A03UM32F 1 2,400,000 69

tion A03UM32E
64 Fusing roller /Lw A03U7203 1 150,000 52
65 Fusing bearing /Lw 26NA5371 2 450,000 58
66 Insulating sleeve /Lw A03U7227 2 450,000 59
67 Fusing sec- Sensor mounting plate A assy A03UR734 1 2,400,000 71
68 tion Sensor mounting plate B assy A03UR735 1 2,400,000 70
69 Fusing paper exit roller /Up A03U7225 2 150,000 55
70 Fusing regulation gear /A 65AA7747 1 600,000 64
71 Fusing limiter 65AA5365 1 600,000 56
72 OT-502 Paper retainer roller 65AA4849 2 150,000 113
73 Paper exit roller A0438907 1 150,000 111
74 Paper exit driven roller /2 65AA4818 4 150,000 112
B. Option
ment cycle No.
1 DF Pick-up roller 13YH4064 2 625,000 217
2 Paper feed roller 13YH4039 1 625,000 218
3 Separation roller 20AJ4015 1 625,000 219
4 LU Pick-up roller A03X5652 1 300,000 118
5 Paper feed roller A03X5653 1 300,000 119
6 Separation roller A03X5654 1 300,000 119
7 Paper feed clutch 56AA8201 1 2,000,000 120
(spongeroller)
13 Cleaning plate Assy A07RA741 1 300,000 215
(sponge roller)
18 Stapler unit /Fr 15JM-501 1 200,000 189
19 Stapler unit /Rr 15JM-501 1 200,000 190
20 PI Paper feed roller 13QN-446 2 100,000 201,206
21 Separation roller 13QN-443 2 100,000 202,207
22 Pick-up roller 50BA-574 2 200,000 200,205
23 Torque limiter 13QN4073 2 600,000 203,208
88
3.2.4 Spot replacement parts list (PRO C5501)
/C6501P/C65hc/C5501
The parts shown below are not periodically replaced parts. However, be sure to replace them when they get to
bizhub PRO C6501

the actual count value.
A. Main body
ment cycle No.
1 ADU section ADU conveyance clutch /1 A03UM201 1 3,600,000 96
4 ADU pre-registration clutch A03UM201 1 3,600,000 99
B. Option
ment cycle No.
1 FS-520 Stapler unit /Fr A07RA735 1 500,000 210
2 Stapler unit /Rr A07RA736 1 500,000 211
3 PI Paper feed clutch /Up 13QN8201 1 1,000,000 199
4 Paper feed clutch /Lw 13QN8201 1 1,000,000 204
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3.3 Concept of parts life

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bizhub PRO C6501
3.3.1 Life value of consumables and parts
Parts name Replacement cycle Actual Life/Verification method

Drum cartridge Every 200,000 prints or When 106 km of drum drive distance, or
equivalent (PRO C6501/ 130 km of lubricant applying roller drive
C6501P/C65hc) distance is reached, whichever comes
Every 150,000 prints or first.
equivalent (PRO C5501) On the user screen, the life counter shows
the remaining life with percentage (100%
is the end of life).
Developer Every 200,000 prints or 130km of developing roller drive distance.
equivalent (PRO C6501/ On the user screen, the life counter shows
C6501P/C65hc) the remaining life with percentage (100%
Every 150,000 prints or is the end of life).
equivalent (PRO C5501)
Toner collection box Assy Every 50,000 prints or When the waste toner full sensor (PS51)
equivalent detects the waste toner full status.
Charging coronas Every 100,000 prints or Charging time of the charging coronas is
equivalent (PRO C6501/ 70 hours .
C6501P/C65hc) On the user screen, the life counter shows
Every 75,000 prints or the remaining life with percentage (100%
equivalent (PRO C5501) is the end of life).
Dust-proof filter /1 assy Every 200,000 prints or Varies depending on coverage, developing
equivalent (PRO C6501/ roller drive distance, and temp./humidity.
Belt cleaner blade Every 200,000 prints or 130km of the belt cleaner blade drive dis-
equivalent (PRO C6501/ tance.
3.3.2 Conditions for life specifications values

The replacement cycles (number of prints) are values calculated based on the actual life of parts when printing is
made under the conditions listed in the table below. Since the idle running time (when not creating an image) of
each part can vary widely depending on the print mode, the actual life cycle may become different between the
parts whose replacement cycle (number of sheets) are the same.
Item Descriptions
Printing method Full color 6 copies intermittently
Paper size A4
Coverage 5% coverage for each color
Environmental temp/humidity Q zone
1 90
Field Service Ver.3.0 Jul. 2009 4. SERVICE TOOLS
4. SERVICE TOOLS
/C6501P/C65hc/C5501
bizhub PRO C6501
4.1 Service material list
Name Shape Parts No. Remark
Setting powder 000V-19-0 25g
Cleaning pad 000V-18-1 10pcs/1pack
Hydro wipe 65AA-9920 10pcs/1pack
Multemp grease 00GR00260 25g

FF-RM
Plas guard No.2 00GR00020 25g
MOLYKOTE EM-30L 00GR00220 25g
Magnalube-G Teflon A0N9PP67## 0.75 oz

Grease
91 2
4. SERVICE TOOLS Field Service Ver.3.0 Jul. 2009
4.2 Jig list

/C6501P/C65hc/C5501
bizhub PRO C6501
Name Shape Quantity Parts No. Remark

Thermostat jig /UF 1 A03UPJG2##
Thermostat jig /L 1 A03UPJG3##
Thermostat jig /UC 1 A03UPJG1##
Mirror positioning jig 2 7050K0020
Door switch jig 1 00M6-2-00
Color chart 1 9J06PJP1##

(A3 size)
Color chart 1 9J06PJP2##

(11 x 17 size)
Test chart 1 4040PJP1## Black-and-white

(A3 size)
Test chart 1 4040PJP2## Black-and-white

(11 x 17 size)
Adjustment chart 1 120A9711# For DF
Paper for fusing 1 65AA-991# For Multi-feed detec-

speed adjustment tion adjustment
(16 sheet/A3 size)
Drum cover 4 00VC-2-00
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/C6501P/C65hc/C5501
Name Shape Quantity Parts No. Remark
bizhub PRO C6501

Blower brush 1 00VD-1000
Tester 1 00VE-1005
Stapler positioning 1 13QEJG010 For FS-607

jig
93
4.3 Mail remote notification system

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bizhub PRO C6501
4.3.1 Outline
"Mail remote notification system" is a system that allows you to obtain a list print which can be output by the
main body using the Internet mail (E-mail).
Using this system dispenses not only with printing the list on paper but also visiting the users.
Sending a mail filled-in with a simple keyword to the main body allows you to receive by mail all sorts of list print
information of the main body.
4.3.2 Operating environments

In order to use the functions of "Mail remote notification system", the following conditions must be met. The
operation of the functions is available while in jams, malfunction and a low power mode. A mail sent to the main
body that is not operating does not get lost, but it is handled when the main body is activated again.
(1) The main body has a server that can receive a mail using POP3 or IMAP protocol.
(2) The main body has a mail server that can send a mail using SMTP protocol.
(3) In the following 4 cases, "Mail remote notification system" does not operate in the main body.
• When the main power switch (SW1) is turned off.
• When the power switch (SW2) is turned off.
• While the main body is in auto shut-off.
• When the "Enhance Security Mode" is set to ON (the use of the main body NIC is not allowed.)
4.3.3 Major functions

Sending a mail with a simple keyword allows you to use the following functions.
(1) The list print information of the main body you want to obtain can be received by mail.
List prints that can be obtained are the following 11 lists.
• Mode memory list
• User setting list
• Font pattern list
• Management list
• Adjustment list
• Use management list
• Counter list
• Coverage Data list
• Parameter List
• Communication log list
• Audit log report
(2) The counter list can be checked by cellular phone.
(3) A password used for certification of a mail can be changed.
(4) Directions for use of "Mail remote notification system" can be received by mail.
To make use of the above functions, it is necessary to send a mail to the main body with a simple
keyword (command).
For particulars of the command, Refer to "4.3.5 Usage of the mail remote notification system".
1 94
4.3.4 Initial setting
/C6501P/C65hc/C5501
To make use of "Mail remote notification system", it is necessary to register the network parameter on the main
bizhub PRO C6501

body and the account on the mail server.
A. Setting from the operation panel

Set the IP address of the main body from the operation panel to connect the main body to the network. When
already set, proceed to "B. Setting from the Web Utilities".
(1) Procedure
Step Operation
1 Select [Utility/Counter] on the operation panel.
2 Press the [03 Machine Admin. Setting].
3 Press the [05 Network Setting].
4 Press the [01 Machine NIC Setting].
5 Enter "IP Address," "Subnet Mask," and "Gateway Address."
6 Restart the main body.
Note
• The IP address of the main body is normally assigned by the system administrator. For particulars,
contact the system administrator.
B. Setting from the Web Utilities

Enter the setting of the mail server from the Web Utilities. To use the Web Utilities, make preparations of a PC
that can be connected to the network.
Note
• No space is available in all items to be set. The following characters cannot be used for setting an
E-mail address.
()<>;:“[]
When an improper entry or setting is made on the Web browser, be sure to make corrections fol-
lowing the error massage. When no correction is made, a down load error of the program may
result.
(1) Procedure
Step Operation
1 Start the Web browser.
When a proxy is set on the Web browser, the main body Web may not be accessible. For particulars,
contact the network administrator. For Web browser, Internet Explorer 6.02, Netscape Navigator 7.1
or Firefox 1.0 is recommended. However, no setting should be made from 2 or more browsers simul-
taneously.
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/C6501P/C65hc/C5501 4. SERVICE TOOLS Field Service Ver.3.0 Jul. 2009
Step Operation
bizhub PRO C6501
2 Specify the IP address of the main body that is entered from "A. Setting from the operating panel."
"Main page" is displayed when an access is made to the Web Utilities of the main body.
Copyright © 2000 GoAhead Software, Inc. All Rights Reserved.

3 "Main page screen"
Click [Extension for maintenance].
4 Enter the user name and the password in the window and click "OK."
User name: ce (small letter, cannot be changed)
Password: Enter the CE password. (Default: "92729272")
5 "Extension for maintenance screen"

Click "E-Mail Initial Setting."
96
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Step Operation
bizhub PRO C6501

6 "E-Mail Initial Setting screen"
Set item Details

Enable E-mail noti- When using the mail remote notification system, select "Use." Default is "Not
fication use."
Time difference The time at which a mail was send out is calculated based on this value. For
time difference setting, enter the difference from the standard time UTC in
the range from -1200 (- 12 hour 00 minute) to +1200 (-12 hour 00 minute).
When no value is entered, +0000 (UTC) is set. (Ex.: In the case of Japan,
enter + 900.)
Sending mail Set the Host Name or IP address of the SMTP server.
(SMTP) server
SMTP port number Set the port No. of the SMTP server. For default, 25 is set.
Sending mail Set the time-out of the SMTP connection. For default, 5 minutes is set.
(SMTP) server time
out
Interval between The main body check the receiving mail server to see if a mail is newly
fetching mails received. (An interval can be specified in the range from 1 minute to 60 min-
utes.) Taking into consideration the load on the network, this is usually set at
the interval of 10 minutes.
Receiving mail Set the Host Name or IP address of the incoming mail server.
server
Kind of mail spool Select either of POP3 and IMAP. For default, [POP3] is selected.
POP3 (IMAP) Port Select "Use the default value" when using 110 for POP3, and 143 for IMAP.
number When using other than the default, select "Custom" and enter a port number
to be used.
User name on the Enter an account name assigned to the main body by the receiving mail
server server.
Password Enter a password to the account name above.
E-mail address of Enter the mail address of the main body its own. This is normally "mail
this copy machine account name@receiving mail server name."
Nickname Enter a nickname that is added to the title (subject) of a mail sent from the
main body. No entry cause no problem.
97
Step Operation
bizhub PRO C6501
6
Set item Details
CE password Enter a password that is added to the title (subject) of a mail sent to the main
body. The main body uses this password for security check.
Also Notice to the • no: Default
administrator • only illegal mail: When a mail received by the main body does not match
with the password above, or when the mail size is in excess of a fixed
size (10k bytes), transfer the mail.
• all mails: Transfer all mails that use "Mail remote notification system."
Administrator When "only illegal mail" or "all mails" is selected, enter an E-mail address for
E-mail address transfer.
Announce delay A selection is made if the difference (time required) between the time when a
time in reply mail mail was sent to the main body and the time when the main body handled
the mail is indicated in the mail. For default, "No" is selected.
Enable POP (IMAP) After authentication is made by the receiving mail server, a selection is made
before SMTP to decide whether to send the mail or not. For default, "Yes" is selected.
7 After completion of entry, click the [Apply].

8 Conduct the mail sending/receiving test.
• Click "Sending and Receiving test" and a sending test and a receiving test are conducted collec-
tively to check to see if a test mail sent is correctly received.
When a test failed, re-check the set items following the error message.
Sending test A mail sending test is made on the SMTP server. A test mail is sent to "E-
mail address of this copy machine" set in Step 6.
Receiving test A receiving test is made on the receiving mail server. A test mail is received
from "E-mail address of this copy machine" set in Step 6.
98
4.3.5 Usage of the mail remote notification system
/C6501P/C65hc/C5501
For commands for communications with the main body and the details of options, see the table below.
bizhub PRO C6501

Command Option Description Minimum
letters
GETLOG Send back the information specified in [Option]. G
ModeMemory Send back [Mode memory list] by mail. M
UserSetting Send back by [User setting list] mail. U
FontPattern Send back [Font pattern list] by mail. F
Management Send back [Management list] by mail. Ma
Adjustment Sent back [Adjustment list] by mail. A
Parameter Send back [parameter list] by mail. P
UserManagement Send back [User management list] by mail. UseM
Counter Send back [Counter list] by mail. C
CoverageData Send back [CoverageData list] by mail. Cov
CommunicationLog Send back [Communication log list] by mail. Co
AuditLog Send back [Audit log report] by mail. Au
ALL Send back all of the above list prints by mail. AL
(Not specified) [Counter list] is edited so that it can be shown by cel-
lular phone. And this is sent back by mail.
CHPASS [OldPasswd][New- Change a password to be used for certification of a C
Passwd] mail.
[OldPasswd] Specify a password that is currently used.
[NewPasswd] Specify a new password.
HELP (Not specified) Send a help mail that describes the operating H
instructions of the commands above.
4.3.6 Mail sending

The command and option on the mail are recognized by the top letters without distinction between capital and
small letters. Accordingly, not all letters of the command must be typed. It is recognized by the minimum letters
in the above table.
Note
• Mail software can be used without discrimination by OS and a hand-held device or a free mail
using browser.
• Use the mail software in the text mode. A mail in the HTML mode cannot be used.
• For the mail software, as a condition for reception, 128 characters or more are recommended as
the maximum number of characters displayed in a line.
• There are 1 or more spaces or TAB required between a command and an option that are written in
the mail. However, a line feed is not allowed.
• Enter all the commands that are written in the mail in alphanumeric characters (ASCII characters).
When any other characters are used, an error message "Command Not Found" is sent back.
• Start a command written in the mail from the line head without space.
When there is a space or TAB found at the line head, the line is ignored.
• The maximum number of commands available in a mail is ten. Commands exceeding ten are
ignored.
• Do not paste an attached file to a mail sent to the main body. This may be treated as an illegal mail
according to the size of the attached file.
99 1
• Do not enter a signature to a mail sent to the main body. A signature may be treated as a com-
/C6501P/C65hc/C5501
mand and sent back as an error mail.

bizhub PRO C6501
• When the power is shut off while the main body is sending/receiving a mail or when the main body
is printing the list print, the same mail may be sent back twice.
• The maximum number of mails that can be received by the main body at a time is 5. When more
mails than 5 is being receive by the mail server, they will be handled while in the next reception.
100
4.4 Job history list
/C6501P/C65hc/C5501
bizhub PRO C6501
4.4.1 OUTLINE
"Job History List" is the function to refer to the output history of the copier by using Web browser. The job history
displayed on the operation panel is stored in the memory and deleted when the SW2 is turned OFF. However,
with this function, the job history is stored in the optional hard disk unit (HD-506) so that the users can refer it
even after the SW is turned OFF.
4.4.2 Major functions

The job history list allows you to use the following functions.
• Displaying and downloading of job history by 100 data.
• Saving of the job history up to 1 million. (The number of histories to save is selectable from 100, 500 thou-
sand or 1 million. Select 0 to turn OFF the job history utility.)
• Up to 10 types (A to J) of setting files can be imported from the CE page.
• The contents displayed can be changed for each of the 10 setting files (A to J).
Note
• The history data displayed on the output history list of the main body when the job is completed is
stored in HD-506. Therefore the data is not stored in case the job is stopped, proof is output or jam
is caused.
• Sending history of the scanned information (Scan to E-mail, Scan to FTP, Scan to SMB, and so on)
is not saved.
• The history data is stored only in Bk of HD-506. Therefore, the data can not recover if the hard
disk of Bk is damaged.
4.4.3 Setting method

When using the Job history list in default setting, the 4 items of job history are displayed. However by importing
the customized setting file, other items can be displayed. For the information about getting this setting file and
the editor commands, contact the Support section of the authorized distributor.
The following are the display items of job history in the initialization
• No
• JobId
• Mode
• Date
101 1
A. Setting from the touch panel

/C6501P/C65hc/C5501
Set the IP address of the copier from the touch panel to connect the copier to the network.
bizhub PRO C6501
When this setting has been already made, proceed to "B. Setting from the Web browser."
(1) Procedure
Proce- Operations
dure
1 Select [Utility/Counter] button on the touch panel.
2 Press [03 Machine Manager Setting].
3 Press [05 Network Setting].
4 Press [01 Machine NIC Setting].
5 Enter "IP address," "Subnet mask," and "Gateway Address."
Note
• The system administrator normally assigns the IP address of the copier. For details, contact the
system administrator.
B. Setting from the Web Utilities

Input the setting on the web browser to import the setting file to the copier. In order to use the Web browser,
make preparations of the PC that can be introduced into the network.
(1) Procedure
Proce- Operations
dure
1 Start up the Web browser.
• When the proxy is set on the Web browser, it becomes unavailable to access the main body
Web. For particulars, contact the network administrator. For Web browser, Internet Explorer or
Netscape Navigator is recommended. However, be sure to avoid setting from 2 or more browsers
at a time.
102
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bizhub PRO C6501
2 Specify the IP address of the copier main body that is entered thorough "A. Setting from the opera-
tion panel".
When you access the Web Utilities of the copier main body, "Main page" is displayed.
Copyright c 2000 GoAhead Software, Inc. All Rights Reserved.

4 Enter the user name or the CE password in "Extension for maintenance" and press "OK."
Password: CE Enter the password. (Default:"9279272")
5 Enter the service mode.
Note
• When the copier is not in service mode, the setting of [Machine setting data Import/
Export] is unavailable.
103
bizhub PRO C6501

Click [Machine setting data Import/Export].
7 "Machine setting data Import/Export screen"

Click each symbol (A to J) displayed on [Import datatype change] - [Web setting].
Note
• The setting file imported to A is displayed on "Machine Admin. Setting screen" in default
setting, therefore selecting A is recommended.
When the preparation of the setting file is completed, the following message is displayed. Click
[Browse] key, and specify the setting file.
Note
• The setting file does not need to be named [joblogA.html]. The settings are saved in the
main body with names of joblogA.html to joblogJ.html.
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Click [OK].

When the import is completed correctly, the following message is displayed. Turn on and off the sub
power switch (SW2) of the main body.
Note
• To enable the setting data, turn the SW2 OFF and ON again and initialize the HDD-506.
• Access the Web Utility after the initialization of main body/options is completed. The
imported setting files may not take effect when accessing the Web Utility soon after the
OFF/ON of SW2.
Click [Administrator Setting].
12 Enter the user name and the administrator password on "administrator setting log in" page, and click
"OK".
User name: admin (small letter, cannot be changed)

Password: Enter the administrator password of the main body.
Note
• They differ from the login user name and the password for the Extension for mainte-
nance
13 "Machine Admin. Setting screen"
Click [Job History List].
105 1
14 "Job History List screen"

Change the URL in the address bar to the letter from A to J that has imported the customized file to
bizhub PRO C6501
update the page.

Example
Before: http://X.X.X.X/goform/joblog.cgi?viw=A
After: http://X.X.X.X/goform/joblog.cgi?viw=B
Note
• In case the customized file is imported to "B".
15 "Job History List screen"
Click [JobHistory list].
Note
• This operation sets the customized item number in order.
• The address bar displays "http://X.X.X.X/goform/joblog.cgi" after the click.
(2) In case the writing of the setting file fails

When the writing of the setting file fails, the following message is displayed, In this case, conduct the following
procedure to see if the hard disk HD-506 has malfunction and requires the replacement or not.
1 Conduct the step1 to step10 of the procedure (1) to see if the import of the setting file is normally
completed. When the import of the setting file fails after conducting these processes, conduct the
step4 and the following steps.
2 Enter the Service mode.
[Service mode menu screen]
[05 State Confirmation]
Press [01. I/O check mode].
3 [I/O check mode screen]
Enter "99" with the numeric keys. Confirm that "99-00" is displayed on the message display area.
4 Press the Access button.
5 Enter "03" with the numeric keys. Confirm that "99-03" is displayed on the message display area.
6 Press the Start button.
Press the Start button to perform the HDD bad sectors check and recovery again when "NG" is dis-
played.
When "OK" appears, conduct the step1 - step10 of the procedure (1) to see if the import of the set-
ting file is normally completed. If the writing of the setting file fails after conducting these processes,
the trouble of the HD-506 is considerable. Replace it with new one.
Note
• Perform "99-04" Hard disk recovery in the output check of the I/O check mode when
HD-506 is replaced.
1 106
Field Service Ver.3.0 Jul. 2009 5. FIRMWARE VERSION UP
5. FIRMWARE VERSION UP
/C6501P/C65hc/C5501
bizhub PRO C6501
5.1 ISW
5.1.1 Types of ISW
A. ISWTrns
This is a software for Windows to rewrite the firmware, it rewrites firmware with the main body and the PC locally
connected with a parallel cable or a UBS cable.
Note
• When upgrading the ISWTrns version, be sure to uninstall the old version of ISWTrns before install-
ing the new version. When installed by overwriting, the USB driver may not be installed.
• When the main body uses the USB cable to conduct the ISW, it is necessary to install the USB
driver of the ISWTrns. For procedure for installation, Refer to "5.2.3 Usage of the ISWTrns" "A.
Installation of the USB driver (Windows2000/XP)".
B. USB memory ISW

Directly connect the USB memory to the service port of the main body, and use the program stored in the USB
memory to rewrite the firmware.
C. Internet ISW
Use the main body NIC to connect the main body to network environment, and use the FTP or the HTTP proto-
col to rewrite firmware via the program server on the Internet.
For the Internet ISW, the following methods are available.
• Internet ISW using Web Utilities
Rewrite the firmware by accessing the Web Utilities of the main body from the Web browser of the PC.
However, a network connected PC with the main body is required.
• Internet ISW using the operation panel
Rewrite the firmware using the operation panel.
• Internet ISW using mail remote notification system
Rewrite the firmware by sending mail to the main body and giving ISW instructions.
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5. FIRMWARE VERSION UP Field Service Ver.3.0 Jul. 2009
5.1.2 Firmware data flow

/C6501P/C65hc/C5501
The following shows the flow of the ISW data.

bizhub PRO C6501
PC Overall control board Image memory control I/F board Printer control FNS control board (FNSCB)
(OACB) board (IMCB) (IFB) board (PRCB) FD control board (FDCB)
SD control board (SDCB)
LS control board (LSCB)
RU control board (RUCB)
PB control board (PBCB)
GP controller PCB
DF control board (DFCB)
When executing the ISW over the entire system, be sure to execute it in the order given below. (To minimize the
occurrence of malfunction resulting from the mismatch of the firmware version)
Step Type of programs

1 FD (H), FS-521 (N1), FS-607, FS-520 (N2), SD (B), LS (S), RU-504 (R1), RU-506 (R2), PB (J), DF (F),
GP (G)
2 Printer control (c)
3 Overall control (I)
Note
• After replacing the OACB, be sure to conduct the ISW of the image control (Collective (I0)) first.
The main body power will not turn on if the overall control firmware is not in the OACB.
• Whenever the FDCB, FNSCB (FS-521), SDCB, LSCB, or PBCB is replaced, be sure to make the
main body model setting using the DIPSW (FD, FS, SD, PB) (Refer to P.782 ,P.788, P.794, P.805), or
using the LS toggle SW (Refer to Theory of Operation of the LS-505 P.46) before conducting the
ISW.
5.1.3 Settings on the main body side while in ISW

There are the following 2 ways for settings on the main body side.
A. Types of the setting

• Power ON mode
This mode is used when the firmware is not installed to the overall control board (OACB) or when it is dam-
aged. In this condition, ISW of the OACB is possible when sub power switch (SW2) is turned ON.
• Service mode
This mode is used when the firmware of the OACB is installed properly.
B. When upgrading the firmware
Target board Display when the power is turned ON Mode

Overall control board Normal Service mode
Other boards Normal Service mode
2 108
C. When writing the firmware newly (When replacing the board or when failed in rewriting the firm-
/C6501P/C65hc/C5501
ware)
bizhub PRO C6501

Target board Display when the power is turned ON Mode
Overall control board Power save LED blinks in red Power ON mode
No display on touch panel
Other boards Malfunction code display Service mode
(1) 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 this condition, the power save LED blinks in
red when power switch is turned ON and placed in the ISW stand-by mode.
In this status, write the OACB firmware (I1 to I5 all) in ISWTrns using a PC.
Note
• Firmware can only be written in ISWTrns.
(2) For other boards, when the firmware of the overall controller is normal and something is wrong
with other firmware, a malfunction code is shown on the touch panel when the power is turned
ON. In that case, enter the service mode and perform ISW normally.
109 1
5.2 ISWTrns
/C6501P/C65hc/C5501
bizhub PRO C6501
5.2.1 Specifications
A. ISWTrns (PC software)
(1) Operating environment of the software
• OS: Windows95/98/98SE/Me/NT4.0/2000/XP/
Vista Home Basic/Home Premium/Business/Enterprise
• CPU: Pentium 75MHz or above
• Memory: 32MB or more
• Free space in hard disk: 100MB or more
• Others: PC provided with parallel (printer) or USB interface (type A)
The operation environment of the hardware is pursuant to the specification of
each OS.
(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), DF control
board (DFCB), FNS control board (FNSCB), FD control board (FDCB),
SD control board (SDCB), LS control board (LSCB), RU control board
(RUCB), PB control board (PBCB), GP controller PCB
Rewritable firmware Image control Collective (I0), I1 to I5
Printer control C
ADF F
Stapler (FS-521) N1
Stapler (FS-520/607) N2
Multi-folder (FD-503) H
Saddle stitcher (SD-506) B
Stacker (LS-505) S
RU (RU-504) R1
RU (RU-506) R2
Perfect Binder (PB-501/502) J
Multi puncher (GP-501) G
Note
• For boards other than the above, ROM replacement is required.
2 110
5.2.2 Installation of the ISWTrns
/C6501P/C65hc/C5501
Install the ISWTrns program to the PC.
bizhub PRO C6501

(1) Procedure
Step Operation
1 Start the PC.
2 Copy the setup files to the PC and double click the [Setup.exe] file to start the install program.
Note
• When the old version of the ISWTrns remains, uninstall the old version first, and then
install the new version.
3 "ISWTrns setup screen"
Following the instructions on the screen, check the folder to which an installation is made, and then
click [Next].
Note
• For default, "C: \ Program Files \ KONICA MINOLTA
\ ISWTrns" is set as a folder to which an installation is made.
• When changing the folder to which an installation is made, click [Browse] and specify
the folder.
4 Following the instructions on the screen, check the folder to which the ISWTrns program is stored
and then click [Next].
Note
• For default, "ISWTrns" is set as a folder to which an installation is made.
• When changing the folder to which an installation is made, enter the folder name
directly, or select one from the existing folder displayed.
5 Following the instructions on the screen, click [Finish].
6 The installation of the ISWTrns program is automatically completed.
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/C6501P/C65hc/C5501 5. FIRMWARE VERSION UP Field Service Ver.3.0 Jul. 2009
Step Operation
bizhub PRO C6501
7 Select [ISWTrns] from the start menu or double-click the [ISWTrns] icon on the desk top to start up
the ISWTrns program.
8 "ISWTrns dialogue 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.
112
5.2.3 Usage of the ISWTrns
/C6501P/C65hc/C5501
A. Installation of the USB driver (Windows2000/XP)
bizhub PRO C6501

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), be sure to set the USB driver following the steps given below.
(1) Procedure
Step Operation
1 Connect one end of the USB cable to the main body.
2 Connect the other end of the USB cable to the USB connector of the PC.
3 From the screen below, select "Install from a list or specific location," and then click [Next].
The driver is stored in C:\WINDOWS\Drivers\Usb.
4 In the "Please choose your search and installation options" screen, select "Don't search. I will choose
the driver to install," and then click [Next].
5 Select USB driver in the driver selection screen and click [Next] to start the installation.
Driver name: KONICA MINOLTA Pro_C6500/C5500 USB Driver for ISW
6 When the "Completing the Found New Hardware Wizard" screen is displayed, click [Finish] to exit the
installation.
113
Step Operation
bizhub PRO C6501
7 Check the "Device Manager screen" to see if the USB driver has been correctly installed.
Driver name: KONICA MINOLTA Pro_C6500/C5500 USB Driver for ISW
B. Setting the communication method

(1) Parallel port setup
When using ISWTrns program for parallel port data transfer, ECP mode settings of the PC parallel need to be
canceled. ISWTrns does not support parallel port data transfer in ECP mode. Because of the above, an error
occurs during transfer and cancels the transfer if it is done in ECP mode. Therefore using ISWTrns in a PC with
ECP settings, the ECP mode need to be canceled.
1) Cancelling procedure of the ECP port

Cancel the ECP mode following the procedure given below.
Step Operation
1 Start the PC.
2 Open "System" in the "Control panel" and select "Device manager" then look for LPT1 in the "Port
(COM and LPT)".
• ECP port when the LPT1 port is "ECP printer port (LPT1)"
• Normal parallel port when the LPT1 port is "Printer port (LPT1)"
3 When the printer port is set to ECP port, change the BIOS settings of the PC and cancel the ECP
port.
Note
• Contact the system administrator to cancel the ECP mode as it varies depending on the
PC to change the BIOS.
114
C. Firmware copy
/C6501P/C65hc/C5501
By using the ISWTrns, copy the firmware to be transferred to the main body and save it into the specified folder.
bizhub PRO C6501

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

Click [Browse].
Select the folder into which firmware is stored as a copied file.
Note
• The folder selected is shown in the upper display section of the "Original Files."
• In the lower display section of the "Original Files," the firmware related files stored in the
folder are shown.
6 Select a file you want to copy from the lower display section of the "Original Files."
Note
• The plural transferred files (rewritten data) can be selected.
• When copying all of the files that are displayed, skip this step and proceed to step 7.
115
Step Operation
bizhub PRO C6501
7 Clicking [Copy] automatically copies the selected file into the specified folder created by installing the
ISWTrns.
Note
• When copying all of the files that are displayed in the lower display section of the "Origi-
nal Files", click [Copy All] instead of [Copy].
• In the upper display section of the "Copied Files", a folder name created at the setup of
the ISWTrns is displayed.
• In the list shown in the lower display section of the "Copied Files," 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 consid-
ered.
A. There exists a file of the same name and "O/W" is not checked.
B. Cannot find the folder to be stored.
C. An overwrite is made on an overwrite-prohibited file.
• When changing a file that is currently stored into a new data, click the overwrite check
box to make a check mark.
8 After completion of copy, click [Refresh].
9 Click [Cancel] to get back to "option screen."
10 "Option screen"
Click [OK].
116
D. Preparation for transfer of the main body
/C6501P/C65hc/C5501
(1) Checking the firmware version
bizhub PRO C6501

Before rewriting firmware, be sure to check the current firmware version following the procedure given below.
Step Operation
2 Press the [08 Firmware Version] in "Service Mode Menu" screen.
3 Press the [01 ROM Version] in the sub menu shown to the right of the screen.
4 " ROM Version Indication screen"
117
(2) ISW transfer standby

/C6501P/C65hc/C5501
Open the Service mode of the main body to put the ISW transfer in the standby condition.
bizhub PRO C6501
Step Operation
2 Press the [12 ISW] in "Service Mode Menu" screen.
3 Press the [01 ISW] in the sub menu shown to the right of the screen.
4 "Board Type Selection" screen
5 Press the button corresponding to the firmware to be rewritten.

e.g.) <Image Control> Collective (I0)
"ISW Mode <Image Control: Collective (I0)> screen"
118
E. Connection to the main body
/C6501P/C65hc/C5501
(1) When using the parallel cable
bizhub PRO C6501

Prepare the followings before connecting to the main body.
• PC which firmware have been copied.
• Parallel cable
1) Procedure
Step Operation
1 Turn OFF the power of the main body.
2 Turn OFF the power of the PC.
3 Connect the parallel cable [2] to the IEEE1284 port [1] of the PC.
[1]
[2]
50gaf2c176na
4 Connect the parallel cable [1] of the PC to the ISW connector [2] of the main body.
[2]
[1]
a03uf2c132ca
119
(2) When using the USB cable

/C6501P/C65hc/C5501
Prepare the followings before connecting to the main body.

bizhub PRO C6501
• PC which firmware have been copied.

• USB cable
1) Procedure
Step Operation
1 Turn OFF the power of the main body.
2 Turn OFF the power of the PC.
3 Connect the UBS cable [2] to the USB port [1] of the PC.
[1]
[2]
50gaf2c178na
4 Connect the USB cable [1] of the PC to the ISW connector [2] of the main body.
[2]
[1]
a03uf2c133ca
120
F. Rewriting of firmware
/C6501P/C65hc/C5501
(1) Relationship between the ISW and the display of the operation panel
bizhub PRO C6501

When the ISWTrns starts up, the main screen is displayed. In the main screen, the transmission file (firmware) is
selected, the information is displayed, the checksum and the transmission file are sent out. For detailed informa-
tion of the functions, refer to the following.
[2] [3]
[1] [4]
[5]
[6]
[7]
[8] [9]
[10]
[1] File status information list

View detailed information about the version file when firmware is selected.
[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 displayed initially when started next time.
[3] Version selection frame
This frame let you select which version of a transfer file you want to be transmitted when more than one ver-
sion is stored in a folder.
[4] Version storage folder edit box
When the select type frame of [2] is decided, a folder name is displayed in full path from the information of
the data folder set in the option window and the INI file. When the firmware is in a folder other than the
specified data folder, this can be changed by clicking [Browse] [6] to specify the file location or entering
directly the file location. A firmware corresponding to the INI file conditions in the folder shown here is dis-
played in the list box of [5].
[5] Version file selection list box
Displays files that are in the folder selected at [4]. When more than 1 version files are stored in the same
folder, all versions are displayed in this list box. The list displayed here is sorted in the order of names, and
an item displayed last is selected when the list is displayed. Changing the selected item decides a firmware
version to be transmitted.
[6] Version file [Browse]
This key is used when the firmware is in a folder other than the specified data folder. Display the folder
selection screen to select the folder of [4].
[7] Send file information frame
Display the list of firmware to be actually transmitted based on the information selected in the frames [2] and
[3], and click [FileCheck] [9] to display the checksum of the file and the consistency (OK, NG, ??) of the
checksum.
[8] Send file information display list
When version files are selected at [5], files to be actually transmitted are displayed. The number of files actu-
ally transmitted is described in the checksum attached to the firmware. Click [FileCheck] at [9] to calculate
the checksum of the entire displayed files. And compare the obtained value with the checksum value stored
in the checksum file (*.sum) attached to the firmware to display the result.
121 1
[9] [FileCheck]
/C6501P/C65hc/C5501
With a transmission file displayed in "SendFile info" of [8], press this key to calculate the file checksum
bizhub PRO C6501
(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]
Starts the transmission of the transferred file.
(2) Procedure
e.g.) When the overall control program (ALL) is written.
Step Operation
1 Start the ISWTrns program.
2 Click [Set-up (S)] from the menu and then click [Communication setting (C)].
3 "Set Communication" screen
Select a port through which the transmission is made and click [OK].
Note
• When [Parallel] is selected, be sure to specify [Port] as well.
4 Select the machine type, the destination and the board types.
Machine type: Pro_C6501_C6501P, Pro_C5501 or Pro_C65hc, Country: EU, Board type: I1/I5 (ALL)
5 The data to be used is displayed in the version selection frame and the send file information frame.
1 122
/C6501P/C65hc/C5501
Step Operation
bizhub PRO C6501

6 Press the [FileCheck] to check if the file to be used has any problems.
Note
• The files (I1 to I5 all) of Pro_C5501 cannot be written in Pro_C6501 and vice versa. Doing
so will be detected as model name abnormality and the data won’t be written in.
7 Place the main body in the ISW standby condition.
8 First, press [Start] on the touch panel, then click [FileSend] in ISWTrns.
9 The following window is displayed on the PC while in the file transfer.
123 1
Step Operation
bizhub PRO C6501
10 The following screen is displayed when transmission of the file is complete.

"ISWTrns"
"Touch panel"
11 "ISWTrns"
Click [OK].
"Touch panel"
Press [Continue] when conducting the ISW successively.
To end ISW, press [End].
The main body automatically restarts when [End] is pressed.
12 Check the firmware version in the service mode to see if the ISW is completed successfully.
124
5.2.4 Error list
/C6501P/C65hc/C5501
A. Overall control board firmware abnormality
bizhub PRO C6501

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

1 CPU in initialization when the power is turned on OFF
2 Flash memory in checking OFF
3 An error is detected while in memory check (ISW standby status) Blinks in red
4 ISW processing (data being received from the PC and firmware being Blinks in green
written)
5 When abnormality is detected while in data transmission Blinks in red and green
alternately
6 When an error is detected while in writing firmware Blinks in red
7 Memory check completed successfully: During reboot OFF
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
file and a file in use.
Cannot read a checksum file Loading of a checksum file into memory failed. Possible causes include a
shortage of memory and an OS problem.
Cannot open a file Opening of a send file failed. Possible causes include a corrupted file and
a file in use.
Cannot open the LPT port Opening of the LPT port failed.
Communications port setup A call to GetCommState failed.
acquisition error
Communications port setup error A call to SetCommState failed.
Cannot open a send file Opening of a send file failed. Possible causes include a corrupted file and
a file in use.
Cannot send a Term Test file Transmission of a communications test block failed.
1. The main body is not ready to receive.
2. The cable is out of position.
3. Transmission of the wrong send file was attempted.
Unsuccessful file transmission The transmission of a send file failed. Possible causes include a cable
out of position.
Unsuccessful transmission to the Output to the LPT port failed. Possible causes include a cable out of
LPT port position.
Invalid folder name An invalid folder name was entered. Start a folder name with a drive
name, such as C:\.
Default data folder is not set. A data folder is not set in ISWTrns.INI.
Please select folder. This message is displayed when ISW Trns launches for the fist time.
Unsuccessful thread creation The creation of a thread failed.
125 1
Message Status of the ISWTrns

bizhub PRO C6501
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. When a file with an illegal name is in the data folder, or a file name that
seems to be illegal is displayed in the folder list.
2. The number of files in a divided file is wanting. Identify the wanting files
in the folder list and copy them again.
3. When the checksum file is damaged, copy it to the folder again.
C. Main body error list

The following shows the malfunction code.
Code Error Applicable program

41 Input data format abnormality Common
42 Input data model name abnormality
43 Input data board name abnormality
64 Rewritten address error F (DFCB)
81 Input device abnormality, such as input time-out Common
C1 Flash ROM deletion failure I (OACB)
C2 Flash ROM writing error
C3 Checksum abnormality
C4 Output device abnormality, such as output time-out Common
E0 Noncompletion of writing the Flush ROM F (DFCB)
E1 Program SUM check error
Flash ROM deletion failure C (PRCB) /H (FDCB)
E2 Flash ROM writing error /B (SDCB) /N (FNSCB)
/S (LSCB)
E3 Blank check error F (DFCB)
Communication error C (PRCB) /H (FDCB)
/B (SDCB) /N (FNSCB)
/S (LSCB)
100 Network, USB memory connection error Common
101 Network, USB memory file error
102 Communication error with the USB memory
4xx HTTP error (protocol regulations error, was able to connect to
network, but an error was returned from the server)
5xx FTP error (protocol regulations error, was able to connect to net-
work, but an error was returned from the server)
2 126
D. ISWTrms troubleshooting
/C6501P/C65hc/C5501
When an error occurs while in the execution of the ISWTrns program.
bizhub PRO C6501

Condition Causes Measure taken
1 The ISWTrns does not The ISWTrns.EXE file is damaged Set it up again.
start up. The setup files itself is damaged. Check the setup files and set it up
again.
2 When an item in the The transferred file is not stored in the Check to see if the firmware file is
combo box is selected, specified folder. stored in the folder displayed in the
the transferred file is "File" text box of "Version." Use the
not displayed. "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. Use the "Data Copy" function if the file
storage location is unknown.
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.
3 "NG" is displayed while The transferred firmware is damaged. Copy the firmware and check it again.
in the file checksum. When "NG" still recurs, contact the
supplier of the firmware.
4 "??" is displayed while When the firmware was copied to the Copy the checksum file into the same
in the file checksum. PC, the copying of the checksum file folder as the 1 for the firmware at the
(*.sum) was forgotten. same time. (If you use the "Data
Copy" function, a copy is made auto-
matically.)
127
Condition Causes Measure taken

bizhub PRO C6501
5 An error "Cannot The file is being used by anther pro- Exit another program. The error still
The transfer of the file failed.

open a file" is dis- gram or system. recurs, reboot Windows.
played.
An error "Cannot The connection of the cable is loos- Check the cable to see if it is con-
send a Term Test ened. nected securely or if there is any prob-
file" is displayed. lem found with the cable itself.
The main body is not in the receiving Check the main body to see if it is in
condition. the receiving condition.
An error "Unsuc- The connection of the cable is loos- Check the cable to see if it is con-
cessful transmis- ened. nected securely or if there is any prob-
sion to the LPT lem found with the cable itself.
port" is displayed. Wrong data has been sent. Check the file status screen to see if
the receiving mode on the main body
side (type of receiving board) corre-
sponds with the transferred file on the
PC side.
The length of the cable is out of spec- Use a cable the length of which is less
ifications. than 2 m.
The parallel port of the PC is set to Cancel the ECP mode with reference
the ECP mode. to the PC manual.
There is a compatibility problem Conduct a test with a PC that has a
between the parallel port of the PC track record of transmitting, and
and the port on the main body side. check if there is any compatibility
problem found.
128
5.3 USB memory ISW
/C6501P/C65hc/C5501
bizhub PRO C6501
5.3.1 Usage of the USB memory ISW
Note
• The "Service Port Device" must be set to [On] in the settings menu mode of the "User Setting-Sys-
tem Setting-service Port Device", or the USB memory ISW cannot be used.
A. Procedure
Step Operation
1 Save the firmware to the USB memory in the folder structure described below.
PRO_C6500 PRO_C5500
I I
I0 I0
I1 I1
I2 I2
I3 I3
I4 I4
I5 I5
C C
H N
B N2
N F
N1
N2
Note
• Create the PRO_C6500 or PRO_C5500 folder directly under the USB memory route.
• Several firmware can be saved to a folder. However 24 files is the maximum it can dis-
play on the touch panel. Also, 2 byte font cannot be displayed.
• Maximum 40 letters for a file name.
129 2
Step Operation
bizhub PRO C6501
2 Connect the USB memory [1] to the main body service port [2].
[2] [1]
a03uf2c134ca

4 "Service Mode Menu screen"
Press [12 ISW].
5 "ISW Menu screen"
Press [01 ISW].
6 "Board Type Selection screen"
Press [USB Memory ISW], once the 1shot message "Connection of a USB memory has been rec-
ognized." is displayed, press the button that is applicable to the firmware be rewritten.
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9 e.g.) <Image Control> Collective (I0)
The file in the USB memory applicable folder will be displayed. (Maximum 24 files)
Select the version of the file you want to rewrite, and press [OK]
Note
• From the file name, the file availability is judged and the result is shown by text color.
White: File effective as ISW.
Yellow: Special ROM file.
Red: File other than ISW or file for different destination.
• Press [Limit] to display only the effective files, files can be sorted by pressing [File
Name], [Date], [Size (byte)].
10 "External Memory Device ISW Mode" screen

Check the type and name of file to conduct ISW, and press [Start].
Note
• Press [File Select] to return to the file name selection screen.
• Press [ROM Select] to return to the board type selection screen.
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Step Operation
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11 The following screen is displayed when ISW is complete.
12 Press [Continue] when conducting the ISW successively.

To end the ISW, pull out the USB memory from the service port, then press [End].
The main body automatically restarts when [End] is pressed.
5.3.2 Main body error list

When an error occurs during USB memory ISW operation, the malfunction code is displayed on the touch panel.
(Refer to P.126)
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5.4 Internet ISW
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5.4.1 OUTLINE
"Internet ISW" is a system to operate the ISW by the main body automatically receiving firmware from the pro-
gram server, using Web browser, main body operation panel, or Internet mail (E-mail) to direct the ISW. ISW can
be operated at the customer facility without carrying the program, if Internet ISW using main body operation
panel or Web browser is used. Also, with Internet ISW using mail remote notification system, ISW can be oper-
ated remotely.
5.4.2 Operating environment

To use the Internet ISW function, the following conditions must to be met.
• The main body must be connected to the network environment that allows the download of firmware from
the Internet by using ftp or http protocol.
The following 4 are status of "Internet ISW" not operating in the main unit.
• The main power switch (SW1) is OFF.
• The sub power switch (SW2) is OFF.
• The copier is in the auto shut-off mode.
• When the "Security Strengthen Set" is set to ON, the main body NIC other than the CS Remote Care can-
not be used.
• During print operation, or various JOB (including reserve JOB) exists, or suspended JOB exists during main
body idling.
• Using modes other than normal mode
• Paper jam has occurred
• Image file exists in the image memory
• Program type, board do not match
5.4.3 Initial settings

To use the Internet ISW, it is necessary to set in advance the network parameter, program server address and
the fire wall address etc. of the main body.
A. Settings from the operation panel

To introduce the main body into the network, set the IP address of the main body from the operation panel.
When this setting has been already made, proceed to "B. Settings from the Web browser" .
(1) Procedure
Step Operation
1 Press the [Utility Menu/Counter] key on the operation panel.
2 Press [03 Machine Admin. Setting].
3 Press [05 Network Setting].
4 Enter [01 Machine NIC Setting].
5 Type in [IP Address], [Subnet Mask], [Gateway Address].
6 Restart the main body by turning the sub power switch (SW2) OFF/ON.
Note
• The IP address etc. of the main body is normally assigned by the system administrator. For partic-
ulars, contact the system administrator.
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B. Settings from the Web browser

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Enter the setting of the program server from the Web browser. At this time, in order to use the Web browser,
bizhub PRO C6501
make preparations of the PC that can be introduced into the network.
Note
• For all the settings, "Space" cannot be set.
• When an incorrect setting is made on the Web browser, be sure to correct it following the error
message. Correcting no input error may result in the download error of the program.
(1) Procedure
Step Operation
1 Start up the Web browser.
When the proxy is set on the Web browser, the main body Web may not be accessed.
For particulars, contact the network administrator. For Web browser, Internet Explorer 6.02,
Netscape Navigator 7.1 or Firefox 1.0 is recommended. However, be sure to avoid setting from 2
or more browsers at a time.
2 Specify the IP address of the main body that is entered thorough "A. Settings from the operation
panel".
When you access the Web Utilities of the main body, "Main page screen" is displayed.
"Main page" screen
Copyright © 2000 GoAhead Software, Inc. All Rights Reserved.

4 Enter user name and CE password in the window and press [OK].
Password: Enter the CE password. (Default: "92729272")
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Step Operation
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Click [Internet ISW].
6 "Internet ISW screen"

Click [Initial Setting].
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Step Operation
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7 "Proxy Server Setting screen"

Set the proxy server settings.
When using no proxy server (fire wall), proceed to the step 9.
Enable proxy Select the following.

When not using proxy: "no."
When using ftp proxy: "Use ftp proxy."
When using http proxy: "Use http proxy."
Proxy Server Type When selecting "Use ftp proxy" in "Enable Proxy," then select a
proxy server type from among the below.
Type 1: "User user@host"
Type 2: "OPEN host"
Type 3: "FW user => FW password => SITE host"
Type 4: "FW user => FW password => User user@host"
Note
• Types 2, 3, and 4 are unsupported.
• For authentication of proxy server, refer to "5.4.8
Authentication of the proxy server in the Internet ISW" .
Proxy Server IP Address When using the proxy server, set the IP address of the proxy
server.
Port Number When using the proxy server, set the number of the port that
uses the proxy server.
User name on the proxy When selecting the type 1 or type 2 in "Proxy Server Type" above
server set the account of the proxy server.
Password for the proxy server When selecting the type 1 or type 2 in "Proxy Server Type" above
set the password of the proxy server.
8 After completion of entry, click [Next] and then after checking the set items in the setting check
screen, click [Next]. However, if there is an input error, click [Back] following the message shown in
red and then re-set the item.
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Step Operation
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9 "Program Server Setting screen"
Set the program server settings. (When using the proxy)
Program Server Address Set the address of the server into which the program to be down
loaded is stored. Select the protocol to be used from the pull-
down menu left and enter the address after that in the text box
on the right. In the case of ftp, it is a relative path from the home
directory.
User name on the program Enter the account name of the program server.
server
Password for the program Enter the password of the program server.
server
Receiving time out Set the receiving time out of the program. When the time is out,
the down load of the program forcibly comes to an end, and the
system returns to the normal mode without conducting the ISW.
10 After completion of entry, click [Next]. Then after checking the set items in the setting check screen,
click [Finish]. However, if there is an input error, click [Back] following the message shown in red and
then re-set the item.
11 Set the program server settings. (When not using the proxy)
Protocol Select the protocol that receives the program.

Program Server IP Address Set the IP address of the server that stores the firmware to be
downloaded.
Target directory With http, set the path after the host domain. Also, with ftp, set
the relative pass from the home directory.
User name on the program Enter the account name of the program server.
server
Password for the program Enter the password of the program server.
server
Receiving time out Set the receiving time out of the firmware. When the time is out,
the down load of the firmware forcibly comes to an end, and the
system returns to the normal mode without conducting the ISW.
12 After completion of entry, click [Next]. Then after checking the set items in the setting check screen,
click [Finish]. However, if there is an input error, click [Back] following the message shown in red and
then re-set the item.
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Step Operation
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13 Conduct the Download test.

• In the down load test, "test.dat" is down loaded from the program server set in the initial setting
to check the connection. When the down load test failed, re-check the set items following the
error message.
• When the down load test is successfully completed, the communication speed and the esti-
mated receiving time are displayed as shown below. Refer to the "Receiving time out" setting.
• When the down load test failed, the response malfunction code from the server is display as
shown below. Since there may be a setting error, re-check the initialization.
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5.4.4 Internet ISW using the Web Utilities
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Using the Web Utilities of the main body allows the customer engineer, by just making a click from the browser,
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to download the programs from the program server automatically for rewriting.
(1) Procedure
Step Operation
1 Proceed to "Internet ISW" on the Web Utilities.
"Internet ISW screen"
The firmware version of the board is displayed beside each of the board types.
2 Select 1 ISW intended board at the item of "ISW." When specifying a file name to be download,
enter it in the [File name] text box.
When firmware file name is not specified, it will be rewritten in the following files stored in the program
server.
I0 bootI0.bin C1 bootC1.bin N1 bootN1.bin J1 bootJ1.bin

I1 bootI1.bin N2 bootN2.bin G1 bootG1.bin
I2 bootI2.bin F1 bootF1.bin B1 bootB1.bin
I3 bootI3.bin S1 bootS1.bin
I4 bootI4.bin H1 bootH1.bin R1 bootR1.bin
I5 bootI5.bin R2 bootR2.bin
Note
• bootN1.bin is for FS-521, bootN2. bin is for FS-607, FS-520.
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Step Operation
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3 After completion of entry, click the [ISW].

If there is an input error, click [Back] following the message displayed in red and then enter the item
again.
4 ISW condition verification
Power save LED will blink green when downloading program. Also by the web screen, the present
operation status and errors can be checked.
• "ISW is downloading"
• "ISW is writing"
• "Finish"
• "ISW was canceled due to transferring problem"
• "ISW was canceled due to transferring overtime"
• "ISW was canceled due to writing proglem to flash memory"
5 The main unit will automatically restart and complete ISW when ISW is normally completed.
6 After the main unit has restarted, check that the firmware version has been updated successfully in
the "Internet ISW main screen".
5.4.5 Internet ISW using the mail remote notification system

When the customer engineer sends a mail that describes the key word briefly to the main body, the main body
that receives that mail can download the program from the program server to conduct the rewrite automatically.
For the operating environment and initial setting, refer to "4.3 Mail remote notification system".
(1) Usage of the Internet ISW using the mail remote notification system
For a command that is sent to the main body and its options, see the table given below.
Command Option Descriptions

ISW I0, I1, I2, I3, I4, I5 Specifies a board that execute ISW.
C1 I: Overall control board (OACB)
F1 C: Printer control board (PRCB)
H1 F: DF control board (DFCB)
N1 H: FD control board (FDCB)
N2 N1: FS-521 control board (FNSCB)
B1 N2: FS-607, FS-520 control board (FNSCB)
S1 B1: SD control board (SDCB)
R1 S1: LS control board (LSCB)
R2 R1: RU-504 control board (RUCB)
J1 R2: RU-506 control board (RUCB)
G1 J1: PB control board (PBCB)
G1: GP controller PCB
By specifying "= firmware file name" following the option name, the
specified file in the program server can be turned into ISW.
e.g.) ISW I0=A03U001_00I0_G00_1000.bin
5 (minimum) Specify the time of validity of the mail. (Unit: in minutes) When no
1440 (maximum) specification is made, 90 minutes are employed.
When the time period after CE sends out a mail until the main body
receive the mail exceeds the time specified here, ISW is not con-
ducted.
e.g.) ISW I0 5
ISWHELP (Not specified) A help mail that describes the usage of the commands above is
returned.
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When firmware file name is not specified, it will be rewritten in the following files saved in the program server.
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I0 bootI0.bin C1 bootC1.bin N1 bootN1.bin J1 bootJ1.bin
I1 bootI1.bin N2 bootN2.bin G1 bootG1.bin
I2 bootI2.bin F1 bootF1.bin B1 bootB1.bin
I3 bootI3.bin S1 bootS1.bin
I4 bootI4.bin H1 bootH1.bin R1 bootR1.bin
I5 bootI5.bin R2 bootR2.bin
Note
• bootN1.bin is for FS-521, bootN2.bin is for FS-607, FS-520.
• bootR1.bin is for RU-504, bootR2.bin is for RU-506.
(2) Mail sending

Refer to "4.3 Mail remote notification system" for sending mail.
Note
• The number of commands that can be written down on a mail is only 1. When 2 or more com-
mands are written down, the second and the succeeding commands are ignored.
(3) Return mail

In the following cases, a mail is returned from the main body.
• After receiving an ISW start mail, the main body starts ISW. (A command sent and the firmware version
before ISW are written down.)
• When the ISW completed (sent command and the firmware version after ISW will be listed)
• When the time of validity of the mail expires. (A command sent is written down.)
5.4.6 Notes for use

(1) Notice to the administrator
When conducting the Internet ISW, be sure to notify the administrator of it and get approval from administrator in
advance.
Be sure to execute ISW with the main body not used. However, when the main body is in use (jobs present), the
Internet ISW does not operate.
(2) Power cut while in the ISW

While in the ISW rewrite, the operation panel and the power switch (SW2) are locked. However, when the main
power source is turned off due to power cut etc., the main body cannot start up.
However, this is a problem encountered while in the overall control board (OACB) rewrite. As for other errors
while in the ISW, they can be rewritten by the Internet ISW again.
Should the main body be not able to start due to the reason above, go to the actual place and use ISWTrns to
conduct the rewrite of the program.
141 2
5.4.7 Internet ISW using the operation panel

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When the customer engineer uses the Internet ISW from the operation panel, with no PC brought with, the main
bizhub PRO C6501
body can download the program from the program server to conduct the rewrite automatically.
(1) Procedure
e.g.) When rewrite the overall control board (OACB) firmware (ALL).
Step Operation
1 Display "ISW Mode screen"
2 Press [Internet ISW] on the screen, then press [Collective (I0)] of the <Image Control>.
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Step Operation
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3 Press the [Start] and download the latest firmware to start the rewrite.
In a case in which the download of an old version firmware is required, press the [File Name Input]
key and enter the file name manually.
4 The following screen is displayed when ISW is complete.
5 Press [Continue] when conducting the ISW successively.

To end the ISW, press [End].
The main body will automatically restart when [End] is pressed.
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(2) Main body error list

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When an error occurs during Internet ISW operation, the malfunction code is displayed on the touch panel.
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(Refer to P.126)
5.4.8 Authentication of the proxy server in the Internet ISW

A. Proxy server
Proxy server which is provided on the inside of the fire wall is the generic name of a mail server that serves the
proxy of a client who receives an access demand (HTTP and FTP) from the client.
B. Authentication of the proxy server

There are 4 types of authentication methods for the proxy server.
The Internet ISW is corresponding to these 4 types.
C. Authentication type of the proxy server and the command list

(1) Type 1: User user@host
When accessing the outside through the proxy, authentication to the proxy server is not required.
When accessing the outside through the proxy server, the entry of the user name and password of the proxy
server is not required, this proxy authentication is likely to be used.
Command
Command Parameter Reply Code Description
USER User@host 331 Transmit the user name of the program server and the
program server address
PASS password 230 Transmit the password for the user name above
(2) Type 2: OPEN host

This is almost the same as the type 1, except for the exchange of commands while in authentication.
When all the settings are made correctly and no communication is available with type 1 authentication, apply this
type.
Command
OPEN host ftp expanded Transmit the program server address
function, defined
for each server
USER user 331 Transmit the user name of the program server
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(3) Type 3: FW user = > FW password = > SITE host
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This is a type that requires the authentication to the proxy server itself when accessing the outside.
bizhub PRO C6501

The information of the server you want to access, the user name and password of the proxy server (F/W) are
necessary.
In the case of the user name and the password of the proxy server are required when accessing the outside
through
the proxy server, this proxy authentication is likely to be used.
Command
USER FW user 331 Transmit the user name of the proxy server
PASS FW password 230 Transmit the password for the user name above
SITE host ftp expanded Transmit the program server address
function, defined
for each server
USER user 331 Transmit the user name of the program server
(4) Type 4: FW user = > FW password = > USER user @host

This is almost the same as the type 3, except for the exchange of commands while in authentication.
When all the settings are made correctly and no communication is available with type 3 authentication, apply this
type.
Command
USER FW user 331 Transmit the user name of the proxy server
PASS FW password 230 Transmit the password for the user name above
USER user@host name 331 Transmit the user name of the program server and the
program server address
D. Remark
For fwtk2.1 (for Unix) and Black Jumbo Dog (for Windows), the type 1 authentication is used. For most of the
proxy servers, the type 1 authentication is used. When the authentication type of the proxy server is not known,
you are recommended to make settings in type 1 authentication as a temporary measure.
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5.5 Counter list obtaining with USB memory

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5.5.1 Outline
By connecting a USB memory to the service port, the counter list information can be saved in the USB memory
in text file format.
5.5.2 List that can be obtained
(1) Counter list

(2) Mode memory list
(3) User setting list
(4) Use management list
(5) Audit log report
(6) Management list
(7) Adjustment list
(8) Coverage Data list
(9) Communication log list *
*Communication log list is output to the file when DIPSW30-1 is ON.
5.5.3 Obtaining method

A. Preparation
(1) Set the Service Port Device settings [On].
(2) Connect the USB memory to the Service Port.
B. Procedure
1 Press the [Utility Menu/Counter] key in the user mode.

2 Press [Details].
3 "Detail Counter List screen"
Press the key in the order of [Help] - [Utility Menu/Counter] - [Mode Check].
4 After the following message appears, remove the USB memory.
Note
• Do not remove the USB memory before the message disappears. The data is being output to the
file while the message is displayed.
• If the USB memory is removed while the message is displayed, the file cannot be saved properly.
C. File saving destination

The list print data file is saved to the root directory in the USB memory.
D. File name
The file name is defined as follows. When the same file name exists, it is overwritten with new data.
listprint + Machine type + Destination code + Serial No._Year_Date_Time.txt
e.g.) listprintA03U020000285_2007_0404_1749.txt
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Field Service Ver.3.0 Jul. 2009 6. HOW TO USE THE ADJUSTMENT/SETTING SECTION
ADJUSTMENT/SETTING
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6. HOW TO USE THE ADJUSTMENT/SETTING SECTION
6.1 Composition
This part "ADJUSTMENT/SETTING" describes items to be adjusted and the method of adjustment that is
required by this machine, it also gives detailed explanations.
A. Checking before starting work

When conducting claims in the field, it is necessary to check first the following:
1. Are the power supply and voltage secured in accordance with the specifications?
2. Is the power supply properly grounded?
3. Is any equipment that repeatedly consumes a lot of electricity connected to the same power supply? (e.g.:
Electric noise sources such as elevator and air conditioner)
4. Are environmental conditions suitable for the machine?
• High temperature and high humidity, direct sunlight, air ventilation, etc.
• Levelness of the location on which the machine is installed.
5. Does the cause of poor images lie in the original itself?
6. Is density selected properly?
7. Is the original glass stained?
8. Is proper paper used for copy?
9. Are copy consumable replaced with new ones at their life? (e.g.: Developer, drum, cleaning blade, etc)
10. Is toner filled?
B. Checkpoints when conductions on-site service

Due attention should be paid to the following when repairing the machine.
1. Be sure to unplug the power cord from the power outlet. Also, when operating the machine with the power
supplied, be careful of the scan of the exposure unit and be sure not to get caught by the gear.
2. The fusing section may be very hot. Be careful not to get burnt when handling it.
3. The developing unit is strongly magnetized. Be careful not to bring a watch and instrument near to the unit.
4. Be careful not to damage the drum with a tool.
5. Be careful not to touch IC directly with bare hands.
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7. UTILITY MENU Field Service Ver.3.0 Jul. 2009
7. UTILITY MENU
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7.1 List of utility mode
01 Scan Send 01 Address Edit

Address 02 E-mail Title Setting
03 E-Mail Text Setting
02 User Set- 01 System Set- 01 Language Setting
ting ting 02 Unit Setting
03 Feed Tray 01 Paper Setting
Setting 02 Feed Tray Auto Selection
03 ATS Permit Setting
04 Auto Paper Type
05 Dehumidification Fan
04 Reset Set- 01 Auto Reset Setting
ting 02 Mode Reset Setting
05 Default Screen Setting
06 Preset Zoom Setting
07 Power Save Setting
08 Time and Date Setting
09 Buzzer Set- 01 Buzzer Volume Regulation
ting
02 Buzzer for Job Stop Set
010 Key Response Time
011 Short cut 01 Application
Key Setting 02 Quality Adjust.(Copy)
03 Quality Adjust.(Scanner)
04 Quality Adjust. Area Set
012 Service Port Device
02 Initial Setting 01 Copy Initial setting
02 Scan Initial setting
03 Common Setting
04 Copy Setting
05 Scan Setting
06 Printer Set- 01 Gray Text Outline Enhance
ting 02 Thin Line Enhancement
03 Reversed Text Enhancement
04 Blur Prevention
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Field Service Ver.3.0 Jul. 2009 7. UTILITY MENU
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02 User Set- 07 Image Qual- 01 Screen
ting ity Setting
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02 Screen Initial setting
03 Original Density shift
04 ACS adjustment
05 Density Unevenness Adj.
08 Change Password
03 Machine 01 System Set- 01 Power Save Setting
Admin. Setting ting 02 Time and Date Setting
03 Weekly 01 Weekly Timer On/Off Set
Timer Setting 02 Timer Setting
03 Timer Action On/Off Set
04 Lunch Hour Off Setting
05 Timer Interrupt Password Set
04 Operation 01 Lock/Delete 01 Copy Mode Memory
Prohibit Set Mode Memory 02 Scan Mode Memory
02 Change Prohibit Setting
03 Scanner Prohibit Setting
05 Expert 01 AES Level Adjustment
Adjustment 02 Erase Adjust- 01 Non-Image Area Erase
ment 02 Erase Operating Setting
03 ADF Frame Erase
03 Printer Adjust- 01 Restart Timing Adjustment
ment 02 Centering Adjustment
03 FD-Mag. Adjustment
04 CD-Mag. Adjustment
05 Lead Edge Erase Adjustment
06 Registration Loop Adj.
07 Pre-registration Adj.
04 Finisher 01 Stapler Position Adj.
Adjustment *1 02 Multi Folder (Punch) Adj.
03 Multi Folder (Fold) Adj.
04 Multi Folder (PI) Adj.
05 Stacker Adjustment
06 Saddle Stitcher Adj.
07 RU Adjustment
08 Perfect Binder Adjustment
04 Finisher 01 Saddle Stitcher Stopper Adj.
Adjustment *2 02 Half Fold Stopper Adj.
03 Punch Adjustment
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/C6501P/C65hc/C5501 7. UTILITY MENU Field Service Ver.3.0 Jul. 2009
03 Machine 01 System Set- 05 Expert 04 Finisher 04 Tri-Fold Adjustment

Admin. Setting ting Adjustment Adjustment*2
bizhub PRO C6501
05 2 Pos. Staple Pitch Adj.

06 Paper Inserter Tray Size Adj.
07 Output quantity limit
08 Curl Adjustment
05 Scanner 01 Restart Timing Adjustment
Adjustment 02 Centering Adjustment
03 FD-Mag. Adjustment
06 Process 01 Front & Back Density
Adjustment 02 Toner Density Sensor
03 Toner Quantity/Exposure
07 Quality 01 Printer Gamma Offset Adj.
Adjustment 02 Printer Gamma Offset Auto Adj
03 Printer Gamma Sensor Adj.
04 Image Quality Stability
05 Custom Screen
08 Execute Adjust Operation
06 List/Count
07 Size Setting 01 Orig. Glass Size Detect
02 ADF Original Size Detect
03 Orig. Glass Minimum Detect
04 K size
05 ADF/Orig. Glass Priority
06 PI Size Priority
08 Perfect 01 Useful Paper Weight
Binding Setting 02 Paper Count Limit
03 Unfitting Cover Stop
02 Administrator Register
03 Scanner 01 Address Edit

Send Address 02 E-Mail Title Setting
03 E-Mail Text Setting
04 User Auth./ 01 Authentication Method
Account Track 02 User 01 Management Setting
Authentication 02 User Register
Set 03 User Counter
03 Account 01 Account Register
Track 02 Account Counter
04 Without Authentication
05 Network Set- 01 Machine NIC Setting
ting 02 E-Mail Initial Setting
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03 Machine 06 Common Setting
Admin. Setting
bizhub PRO C6501

07 Copy Setting
08 Scan Setting
09 System Con- 01 Administrator
nection
10 Security Set- 01 Administrator Password
ting 02 HDD Lock Password
03 Overwrite image data
04 Security Strengthen Set
04 Touch Screen Adjustment
*1 Depending on which options among the FS-521, FD, LS, SD, RU and PB-501/502 are installed, the enabled
adjustment items change.
*2 Depending on which option(s) among the FS-520, FS-607, PK, and PI is (are) installed, the enabled adjust-
ment items change.
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7. UTILITY MENU Field Service Ver.3.0 Jul. 2009
7.1.1 Density Unevenness Adj.

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Adjust the density unevenness in crosswise direction electrically.

bizhub PRO C6501
Note
• This adjustment is carried out as the finishing process for image stabilization control, screen pro-
cessing, for example. Therefore, there is a possibility that the appropriate adjustment value is mis-
aligned in case the adjustment is automatically carried out by image stabilization control or in
case the screen is changed. Set it again if necessary.
A. Procedure
1. Be sure that the ordinary copy screen is displayed.

2. Press [Utility/Counter] key.
3. "User Setting Menu Screen”
Press [02 User Setting].
4. “User Setting Menu Screen”
Press [07 Image Quality Setting].
5. “Image Quality Setting Menu”
Press [05 Density Unevenness Adj.].
6. “Density Unevenness Adjustment Setting Screen”
Press [COPY].
7. “COPY Screen”
Select a paper size to adjust the density unevenness, then press Start key.
8. Check the density unevenness in crosswise
direction. 8
Note
• Choose paper in the max. size, or not all
the range is printed.
• Printing up to 318mm is available. 4
• The scale No.4 on the actual print pattern
is set backward by about 10mm from the
center.
• The scale on the actual print pattern cor-
responds with the position to be adjusted. 0
a0u0f3c001ca
Therefore, the scale can be used in this
adjustment.
9. Press [Setting Menu].
1 152
10. “Density Unevenness Adjustment Setting Screen”
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Choose a color to adjust by pressing [Y] (Yellow), [M] (Mazenta), [C] (Cyan), or [K] (Black).
bizhub PRO C6501

Choose the position to be adjusted from [0] to [8], enter the adjusted value with the numeric keys,
and press [<<SET].
Setting range: -32 (lighten) to +31 (darken)
Note
• Be sure to take a memo about the present value before the adjustment.
• The setting of the color is stored by pressing [Invalid] but the value is not reflected.
• The value of all the positions to be adjusted of the color is cleared by pressing [Y Clear],
[M Clear], [C Clear], and [K Clear].
• The area between each divided arranging area comes to be like the following image by the
linear interpolation process. It makes the boundary between the arrangement smooth.
0 4 8
a0u0f3c002ca
11. Repeat the steps 6 - 9 until an appropriate value is obtained.

12. After the adjustment with the test pattern, check the actual print image that the density unevenness
is adjusted.
153
8. ADJUSTMENT LIST Field Service Ver.3.0 Jul. 2009
8. ADJUSTMENT LIST
/C6501P/C65hc/C5501
bizhub PRO C6501
Note
• This table shows the list of adjustment items when replacing a part. Items are numbered in a circle
by the priority if there is any.
• After replacing the developer, do NOT print until the toner density sensor initial automatic adjustment completes.
• When replacing the overall control board (OACB) due to damage of the board, be sure to remove
the NVRAM board (NRB) on the current OACB and install it to the new OACB.
Drum cartridge, Developer,

Replacement parts/Others
Transfer belt, Belt cleaner

Drum cartridge /Y,/M,/C,/K
Developer /Y,/M,/C,/K
Exposure of scanner/
After maintenance
Belt cleaner blade

implementation
Transfer belt
V mirror unit
CCD unit
Adjustment/setting items
blade
Machine Printer Adjustment Restart Timing Adjustment
Adjustment CD-Mag. Adjustment
Belt Line Speed Adjustment
Writing Init. Pos. Memory
Color Registration Adjustment
Color Registration/Manual
CD Skew Adjustment
Quality Adjustment Scanner smooth tone/color
Printer Gamma Offset Auto Adjustment
Printer gamma sensor adjustment
Printer Screen Gradation Adjustment
Process Drum Peculiarity Blade setting mode
Adjustment Adjustment Automatic gamma adjustment
LD bias adjustment
Automatic Developer Charge
TonerDensity Sensorunit
Initial drum rotation
System Setting Software SW Setting
Counter/Data Maintenance Counter
Parts Counter Count of special parts (reset)
State Confirmation I/O Check Mode
Finisher Stacker Adjustment Paper Width Adjustment
Adjustment Paper Length Adjustment
Punch Adjustment Paper Edge Detect Sensor Adj.
ISW ISW
Others Mirror unit positioning (require the jigs)
Dust-proof glass cleaning (Write unit)
Setting powder application
1st transfer roller installation direction (shaft groove
comes front side)
Transfer belt installation direction (UPSIDE mark comes rear)
2nd transfer rollers/Up and /Lw installation direction
(Concave at the shaft edge comes front)
Fusing belt installation direction (lot number comes rear)
Fusing heater lamp installation direction (colored wiring
comes front)
Thermostat/UC, /UF, /L positioning (require the jigs)
NVRAM board (NRB) replacement
Main body NIC setting
Board DIPSW setting
Toggle switch setting
EEPROM remove and install
Stapler positioning (require the jigs)
Grip conveyance home sensor adjustment
Density Unevenness Adj.
1 154
Exposure lamp (L1)
Original glass
Write unit /K
Write unit /Y,M,C
Dust-proof glass /Y,M,C,K
Charging corona /Y,M,C,K
1st transfer roller /Y,M,C,K
2nd transfer roller /Up, /Lw
Field Service Ver.3.0 Jul. 2009
Image correction unit

Color registration sensor
(PS8) /R (PS9)
Fusing belt
Fusing heater lamp /4
Thermostat /1 (TS1)
Thermostat /2 (TS2)
Thermostat /3 (TS3)
Stapler unit <FS-607>
Trimmer board assembly
Overall control board (OACB)
Printer control board (PRCB)
Image processingboard (IPB)
FNS control board (FNSCB)
FNS control board (FNSCB)
LS control board (LSCB)
FD control board (FDCB)
PI drive board (PIDB)
Multi feed detection board <FD>
Multi feed detection board <PF>
Multi feed detection board <PB>
Punch drive board (PDB) <PK>
Paper edge sensor (PESB) <PK>
Hard disk /Y,/M,/C,/K
8. ADJUSTMENT LIST
155
1
bizhub PRO C6501
/C6501P/C65hc/C5501
9. SERVICE MODE Field Service Ver.3.0 Jul. 2009
9. SERVICE MODE
/C6501P/C65hc/C5501
bizhub PRO C6501
9.1 List of service mode

Adjustment/Setting Item Page
01 Machine 01 Printer Adjust- 01 Restart Timing Adjustment P.161
Adjustment ment 02 Centering Adjustment P.162
03 FD-Mag. Adjustment P.163
04 CD-Mag. Adjustment P.164
05 Lead Edge Erase Adjustment P.165
06 Registration Loop Adj. P.166
07 Pre-registration Adj. P.167
08 Belt Line Speed Adj. P.168
09 Writing Init. Pos. Memory P.169
10 Color Registration Adj. P.169
11 Color Registration/Manual P.170
12 PFU Dfeed Detect Adj. P.172
13 CD Skew Adj. P.174
14 Recall Standard Data P.175
02 Scanner Adjust- 01 Restart Timing Adjustment P.176
ment 02 Centering Adjustment P.177
03 FD-Mag. Adjustment P.178
03 Quality Adjust- 01 Scanner smooth tone/color P.180
ment 02 Printer gamma 01 Printer Gamma Offset Adj. P.181
adjustment 02 Printer Gamma Offset Auto Adj. P.183
03 Printer gamma sensor adj. P.185
04 Printer Screen Gradation Adj. P.188
03 Sharpness adjustment P.189
04 Contrast adjustment P.189
05 Image Distinction 01 Dot detect adjustment P.190
Level 02 Color text adjustment P.191
03 Dot/Text area adjustment P.192
06 ACS adjustment P.193
07 Density adjustment 01 AES adjustment P.194
02 Copy density adjustment P.195
03 Adjust Background P.196
04 B-Side Prevent P.197
08 Tone adjustment 01 Red P.198
02 Green P.199
03 Blue P.199
09 Recall standard data P.200
04 Non-Image Area Erase Check P.201
156
Field Service Ver.3.0 Jul. 2009 9. SERVICE MODE
/C6501P/C65hc/C5501
bizhub PRO C6501

02 Process 01 High Voltage 01 1st transfer manual adj. P.203
Adjustment Adjustment 02 2nd transfer manual adj. P.203
03 HV adj. (separation AC) P.203
04 HV adj. (separation DC) P.203
05 Pre-transfer Guide HV check P.203
02 Drum Peculiar- 01 Blade setting mode P.203
ity Adj. 02 Automatic drum potential P.204
03 Auto gamma adjustment P.204
04 LD bias adjustment P.205
05 Automatic Developer Charge P.207
06 Toner Density SensorInit. P.210
07 Initial drum rotation P.210
03 Sensor output 01 Surface potential sensor P.211
check 02 Maximum density sensor P.211
03 Gamma sensor output P.211
04 Toner Density Sensor P.211
05 Drum Surface potential P.212
06 Humidity/Temperature P.212
07 Toner Density Return Mode P.213
04 Process Fine 01 Covered Margin Fine Adj. P.214
Adjustment 02 Develop Ac Bias Fine Adj. P.215
03 Develop AC Frequency P.216
04 Toner Density Fine Adj. P.217
05 Interval/Quan- 01 Drum TinyRotation Interval P.218
tity Adj. 02 Auto. Refresh Interval P.218
03 Toner Dens. Sensor Interval P.219
06 Recall standard data P.219
03 System Set- 01 Software SW Setting P.220
ting 02 Telephone Number Setting P.237
03 M/C Serial Number Setting P.237
04 Setup Date Input P.238
04 Counter/Data 01 Maintenance Counter P.239
02 Data Collection 01 Paper Size Counter(Total) P.242
02 Paper Size Counter(Copy) P.242
03 Paper Size Counter(Print) P.242
04 ADF Counter P.243
05 Coverage Data History P.244
06 Paper Jam History P.245
07 Jam Counter P.245
08 Copy Mode Counter(1) P.247
09 Copy Mode Counter(2) P.253
157
/C6501P/C65hc/C5501 9. SERVICE MODE Field Service Ver.3.0 Jul. 2009

bizhub PRO C6501
04 Counter/ 02 Data Collection 10 SC Counter P.257

Data 11 Paper Jam Sectional Counter P.245
12 Failure Sectional Counter P.257
13 SC data of time series P.262
03 Parts Counter 01 Count of special parts P.263
02 Count of each parts P.274
05 State Con- 01 I/O Check Mode P.277
firmation
06 ADF Adjust- 01 ADF Original Size Adj. P.332
ment 02 ADF Orig.Stop Position Adj. P.333
03 ADF Sensor Adjustment P.334
04 ADF Registration Loop Adj P.335
07 Finisher 01 Stapler Position 01 Staple Center Position P.336
Adjustment *1 Adj. 02 Paper Width (staple) P.337
03 Paper Width (straight) P.338
04 Exit Guide Center Adj. P.341
05 Exit Guide Paper Width P.342
02 Multi Folder 01 Paper Width Adjustment P.342
(Punch) Adj. 02 Hole-Punch Vertical 01 2-Hole Punch P.343
Pos. 02 3-Hole Punch P.343
03 4-Hole Punch P.343
03 Multi Folder 01 Half Fold Position Adj. P.344
(Fold) Adj. 02 Tri-Fold-in Pos. Adj. P.345
03 Tri-Fold-out Pos. Adj. P.346
04 Double Parallel Pos. Adj. P.347
05 Z-Fold Position Adj. P.348
06 Gate Fold Position Adj. P.349
07 Fold Regist Loop Adj. P.350
04 Multi Folder (PI) Adj. P.350
05 Stacker Adjust- 01 Paper Width Adjustment P.351
ment 02 Paper Length Adjustment P.351
06 Saddle Stitcher 01 Staple Center Adj. P.352
Adj.
02 Staple Paper Width Adj. P.353
03 Staple Pitch Adjustment P.354
04 Half Fold Position Adj. P.355
05 Tri-Fold Position Adj. P.356
06 Fold Paper Width Adj. P.357
07 Trimming Adjustment P.358
08 Trimmer Receiver Adj. P.359
07 RU Adjustment 01 Curl Reform Direction P.359
08 Perfect Binder 01 Cover Trimming Adjustment P.360
Adjustment 02 Cover Lead Edge Adj. P.361
158
/C6501P/C65hc/C5501
bizhub PRO C6501

07 Finisher 08 Perfect Binder 03 Spine Corner forming Pos. P.362
Adjustment *1 Adjustment 04 Pasting Start Postion P.363
05 Pasting Finish Position P.364
06 Paste Formation Finish Pos. P.365
07 Temperature Adjustment P.366
08 Sub Compile CD Width Adj. P.367
09 Clamp CD Width Adjustment P.368
10 Cover Up/Down CD Width P.369
11 Clamp FD Position Adj. P.370
09 Relay Stacker 01 Paper Width Adjustment P.371
Adjustment 02 Paper Length Adjustment P.372
10 Recall standard Data P.373
07 Finisher 01 Saddle Stitcher Stopper Adj. P.374
Adjustment *2 02 Half Fold Stopper Adj. P.375
03 Punch Adjust- 01 Vertical Position Adj. P.376
ment 02 Horizontal Position Adj. P.377
03 Registration Adjustment P.378
04 Paper Edge Detect Sensor Adj. P.378
04 Tri-Fold Adjustment P.379
05 2 Pos. Staple Pitch Adj. P.380
06 Paper Inserter Tray Size Adj. P.381
07 Output quantity limit P.381
08 Curl Adjustment P.359
08 Firmware 01 ROM Version P.383
Version
09 CS Remote 01 CS Remote 01 E-Mail P.384
Care Care 02 Modem P.384
10 List Output Machine Management List P.407
Adjustment Data List P.407
Coverage Data List P.407
Font Pattern P.407
Communication Log List P.407
Memory Dump List P.407
11 Test Mode 01 Running Test Mode P.408
02 Test Pattern Output Mode P.409
12 ISW 01 ISW P.420
*1 Depending on which options among the FS-521, FD, LS, SD, RU and PB are installed, the enabled adjust-
ment items change.
*2 Depending on which option(s) among the FS-520, FS-607, PK, and PI is (are) installed, the enabled
adjustment items change.
159 2
9.2 Setting method

/C6501P/C65hc/C5501
bizhub PRO C6501
Service mode allows you to adjust/set various settings on the machine. Data adjusted/set in this mode are
stored in NVRAM board (NRB).
9.2.1 Start and exit 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. Since starting up the service mode with the machine turned OFF skips the user mode, it is
preferred during machine setup before installing the consumables or when some malfunction code is occurring.
A. Starting and exiting service mode while the power is ON
1. Be sure that the ordinary copy screen is displayed.

2. Press [Utility Menu/Counter] key.
3. "Utility Menu screen"
Press the hard keys in the following order:
Stop → 0 → 0 → Stop → 0 → 1
Note
• If a CE Authentication is set, input the password to enter the service mode.
4. "Service Mode Menu screen"
Service mode is started.
5. Select the item you want to set.
A setting screen corresponding to each item appears.
6. Press [Exit] to exit the service mode.
7. The new settings will be effective after reboot.
B. Starting and exiting service mode while the power is OFF
1. While pressing [Utility Menu/Counter] key turn the sub power switch (SW2) ON.
Note
• If a CE Authentication is set, input the password to enter the service mode.
Service mode is started.
3. Select the item you want to set.
A setting screen corresponding to each item appears.
4. Press [Exit] to terminate the service mode.
5. The new settings will be effective after reboot.
160
9.3 Machine adjustment
/C6501P/C65hc/C5501
bizhub PRO C6501
9.3.1 Restart Timing Adjustment (Printer Adjustment)
Adjust the image leading edge timing.
This adjustment changes the restart timing of the registration roller to adjust the image position in sub-scanning
direction.
Note
• Be sure the "FD-mag. Adjustment (Printer Adjustment)" have been adjusted before performing this
adjustment.
(Refer to P.163)
A. Procedure

Press [01 Machine Adjustment].
2. "Machine Adjustment Menu screen"
Press [01 Printer Adjustment].
3. "Printer Adjustment Menu screen"
Press [01 Restart Timing Adjustment].
4. "Restart Timing Adjustment screen"
Press [T] or [S] to select the item you want to adjust, and press [COPY].This adjustment can be per-
formed for each feed tray (trays, ADU), paper size (large, small), and paper type (plain paper, thick paper).
Note
• Large size: 300 mm and more (sub-scanning direction)
• Small size: Less than 300 mm (sub-scanning direction)
• Thick paper: Paper weight 106 g/m2 and more
5. "Copy screen"
Set the copy according to the item that has been adjusted and press the Start key to output a test pattern
(No. 16).
6. Check the leading edge timing.
20
Standard value 20 ± 0.5mm
57gaf3c007na
7. When the value is not within the standard value, press the [SERVICE].
8. "Restart Timing Adjustment screen"
Enter a value through the numeric buttons and press [<<SET].
Setting range: -60 (shorter) to +60 (longer) 1 step = 0.1 mm
9. Repeat steps 4 to 8 until the standard value can be obtained.
161
9.3.2 Centering Adjustment (Printer Adjustment)

/C6501P/C65hc/C5501
Adjust the image mis-centering in main scanning direction on the printer.

bizhub PRO C6501
This adjustment changes the laser writing start timing.
Note
• Be sure the "CD-mag. Adjustment (Printer Adjustment)" have been adjusted before performing
this adjustment.
(Refer to P.164)
A. Procedure

Press [02 Centering Adjustment].
4. "Centering Adjustment screen"
Press [T] or [S] to select the item you want to adjust, and press [COPY].
This adjustment can be performed for each feed tray (trays, ADU), paper size (large, small, 81/2 x 51/2 (trays
1 to 5) ), and paper type (plain paper, thick paper).
Note
5. "Copy screen"
(No. 16).
6. Fold the output page in half in main scanning direction, and check the discrepancy from the center line of
the print.
Standard value 0 ± 1.5mm or less
7. When the value is not within the standard value, press [SERVICE].
8. "Centering Adjustment screen"
Setting range: -40 (image in back) to +40 (image in front) 1 step = 0.1 mm
162
9.3.3 FD-Mag. Adjustment (Printer Adjustment)
/C6501P/C65hc/C5501
Adjust the magnification in sub-scanning direction.
bizhub PRO C6501

This adjustment changes the speed of the polygon motor and adjusts the image magnification.
Note
• There are the following two methods to adjust the magnification of the printer in sub-scanning direction.
(1)FD-Mag. Adjustment (Printer Adjustment)
Perform this adjustment when the magnification in sub-scanning direction has changed because of the worn
registration roller or paper shrinkage by heat.
(2)Belt Line Speed Adj. (Printer Adjustment)
Perform this adjustment under the conditions not mentioned above.
• Magnification adjustment on back side in sub-scanning direction is not reflected to the image in default. WHEN
ADJUSTING the magnification on back side, enter "User Setting - Common Setting" and turn the "Side 2 Lens
Adjustment mode" [On]. However, since the polygon motor speed is switched for back side, the print speed is
reduced up to 3/4.
A. Procedure

Press [03 FD-Mag. Adjustment].
4. "FD-Mag. Adjustment screen"
Select the item you want to adjust, and press [COPY].
This adjustment can be performed for both sides at a time (all trays) or for back side (each tray).
5. "Copy screen"
Select A3 or 11 X 17 paper and press Start key to output the test pattern (No. 16).
6. Check the magnification in sub-scanning direction.
Standard value: 0.5% or less (when in life-size) 205.7 1
205.7 ± 1 mm or less
57gaf3c003na
Setting range • Printer FD-Mag. (both sides at a time): -100 (shorter) to +100 (longer)
• Other than the above: -80 (shorter) to +20 (longer)
1 step = 0.01%
9. Enter a value through the numeric buttons and press [<<SET].
163
9.3.4 CD-Mag. Adjustment (Printer Adjustment)

/C6501P/C65hc/C5501
Adjust the magnification in main scanning direction.

bizhub PRO C6501
This adjustment changes the magnification in image processing prior to the laser exposure.
A. Procedure

Press [04 CD-Mag. Adjustment].
4. "CD-Mag. Adjustment screen"
This adjustment can be performed for both sides at a time (all trays) or for back side (each tray).
5. "Copy screen"
6. Check the magnification in main scanning direction.
Standard value: ± 0.5% or less (when in life-size)
190 ± 1 mm or less
190
57gaf3c004na
Setting range: -100 (shorter) to +100 (longer) 1 step = 0.01%
164
9.3.5 Lead Edge Erase Adjustmet (Printer Adjustment)
/C6501P/C65hc/C5501
Adjust the image erasure amount of the leading edge.
bizhub PRO C6501

Note
• This adjustment is for C6501/C5501 (copier version) but not for C6501P/C65hc (printer version).
A. Procedure

Press [05 LeadEdge Erase Asjustment].
4. "Lead Edge Erase Adjustment screen"
Press [COPY].
5. "Copy screen"
Set the test chart to the original glass, choose a paper A3 or 11x17, and press Start key.
6. Check the leading edge erasure amount.
Standard value a: 4 mm or less a
57gaf3c029nb
8. "Lead Edge Erase Adjustment screen"
Setting range: -20 (narrower) to +40 (wider) 1 step = 0.1 mm
165 1
9.3.6 Registration Loop Adj. (Printer Adjustment)

/C6501P/C65hc/C5501
Adjust the paper loop amount in the registration roller section to remove paper skew and wrinkle, or paper jam-
bizhub PRO C6501
ming in the registration section.
A. Procedure

Press [06 Registration Loop Adj.].
4. "Registration Loop Adjustment screen"
This adjustment can be performed for feed tray (trays, ADU), paper size (large, small, 150 mm or less of
width), and paper type (plain paper, thick paper).
Note
5. "Copy screen"
(No. 16).
6. If the problem is not solved, press [SERVICE].
7. "Registration Loop Adjustment screen"
Setting range: -99 (smaller) to +99 (larger) 1 step = 0.1 mm
166
9.3.7 Pre-registration Adj. (Printer Adjustment)
/C6501P/C65hc/C5501
Adjust the paper loop amount in the pre-registration roller section to remove paper skew and wrinkle, or paper
bizhub PRO C6501

jamming in the pre-registration section.
A. Procedure

Press [07 Pre-registration Adj.].
4. "Pre-registration Adjustment screen"
This adjustment can be performed for feed tray (trays, ADU) and paper size (large, small).
Note
5. "Copy screen"
7. "Pre-registration Adjustment screen"
Setting range: -99 (smaller) to +99 (larger) 1 step = 0.1 mm
167
9.3.8 Belt Line Speed Adj. (Printer Adjustment)

/C6501P/C65hc/C5501
Adjust the magnification in sub-scanning direction.

bizhub PRO C6501
This adjustment charges line speed of the transfer belt.
Note
• There are the following two methods to adjust the magnification of the printer in sub-scanning
direction.
(1) FD-Mag. Adjustment (Printer Adjustment)
Perform this adjustment when the magnification in sub-scanning direction has changed because
of the worn registration roller or paper shrinkage by heat.
(2) Belt Line Speed Adjustment (Printer Adjustment)
Perform this adjustment under the conditions not mentioned above.
A. Procedure

Press [08 Belt Line Speed Adj.].
4. "Belt Line Speed Adjustment screen"
Press [COPY].
5. "Copy screen"
Standard value: ± 0.5% or less (when in life-size) 205.7 1
205.7 ± 1 mm or less
57gaf3c003na
8. "Belt Line Speed Adjustment screen"
Note
• Setting range is available from -100 to +100, but the optimum value is from -5 to -35. An error
code may occur by entering the value that is not within the optimum value.
168
9.3.9 Writing Init. Pos. Memory (Printer Adjustment)
/C6501P/C65hc/C5501
Perform this adjustment after replacing the write unit.
bizhub PRO C6501

A. Procedure

Press [09 Writing Init. Pos. Memory].
4. "Writing Init. Pos. Memory screen"
Select the color of the replaced write unit and press [Start].
9.3.10 Color Registration Adj. (Printer Adjustment)

Perform this adjustment when there is a color registration error. Main Scan, Sub Scan, Horizontal (main scanning
direction magnification), and skew of color registration misalignment of Y, M, and C are automatically adjusted
relative to K.
Note
• This adjustment has a large correction area than that of the color registration adjustment in the user
mode. If the malfunction code C-4520 appears, perform this adjustment.
A. Procedure

Press [10 Color Registration Adj.].
4. "Color Registration Adjustment screen"
Press [Start].
5. The color registration adjustment starts and a message "Completed" is shown in about 2 minutes.
If the error message appears, perform an error correction referring to the below.
• Error 1: It does not converge within the standard value.
The patch density may be too light. Check around the drum unit and perform the auto gamma
0. Then conduct this adjustment again.
• Error 2: The difference of the color registration is too much.
Check the installation position of the write unit.
• Error 3: Other
The other malfunction other than the auto color registration adjustment may occur. Restart the
main body in the normal mode to check for malfunction code.
6. "Color Registration Adjustment screen"
Misalignment amounts of Y, M, and C of "Main Scan", "Sub Scan", "Horizontal", and "Skew" relative to K
are displayed on the panel. (unit: pixel)
169 1
9.3.11 Color Registration/Manual (Printer Adjustment)

/C6501P/C65hc/C5501
Measure the misalignment amount of Y, M, and C relative to K of "Main Scan", Mag.(ALL) (whole magnification in
bizhub PRO C6501
main scanning), "Mag.(PART)" (partial magnification in main scanning), "Sub Scan", "Incline" (skew), and "Scan
Bend" (main scanning), and adjust Mag.(PART) manually.
Note
Adjust C6501P/C65hc (printer version) by "Color Registration Adj. (Printer Adjustment)”.
• Be sure the "FD-Mag. Adjustment (Printer Adjustment)" have been adjusted before performing
this adjustment.
(Refer to P.163)
• Be sure the "CD-Mag. Adjustment (Printer Adjustment)" have been adjusted before performing
this adjustment.
(Refer to P.164)
• Complete the "Color Registration Adj. (Printer Adjustment)" have been adjusted before performing
this adjustment.
(Refer to P.169)
A. Procedure

Press [11 Color Registration/Manual].
4. "Color Registration Manual Adjustment screen"
Press [COPY].
5. "Copy screen"
[3]
Select A3 or 11 X 17 paper and press Start to output
the test pattern. Place the outputted test pattern [1] [2]
on the original glass securely against the original
positioning plate /Lt [2] and the original positioning
plate /Rr [3], and close the DF or original cover.
Note
• When placing the test pattern onto the original
glass, be sure to take care of the setting direc-
tion (with printing face down) and position.
• Check that the settings for all colors (Y, M, C, K)
in the [Test Pattern Output Mode] is set to 255. If [1]
not, it will cause an error.
8050fs1011
1 170
6. Press [SERVICE].
/C6501P/C65hc/C5501
Press [Start] to scan the test pattern using the scanner.
bizhub PRO C6501

7. Shows the misalignment amount of Y, M, and C relative to K of "Main Scan", "Mag.(ALL)" (whole magnifi-
cation in main scanning), "Mag.(PART)" (partial magnification in main scanning), Sub Scan, "Incline"
(skew), and "Scan Bend" (main scanning) at "Rest" section on the touch panel. (unit: pixel).
8. Make sure that "OK" is displayed for all the items. If the value is out of standard, "NG" and an error code
will appear.
If "NG" appears for "Main Scan", "Mag.(ALL)", "Sub Scan", or "Incline", perform the Color registration
adjustment again.
Error code Descriptions Causes

Error 1 Cannot detect the chart pattern Chart misplacement
Error 2 The chart is placed upside down Chart misplacement
Error 3 Cannot detect the chart pattern Different chart is placed
Error 4 Adjustment impossible Software bug
Error 5 Value is out of standard Retry the adjustment
Error 6 Non-volatile data abnormality Check the installation position of
the NVRAM board
Error 7 Accessing to unassigned memory Software bug
Error 8 Memory-related abnormality Software bug
Error 9 Program error Software bug
Error 10 Chart is skewed Chart misplacement
Error 11 Image header information read error Software bug
Error 12 Arguments setting error Software bug
Error 13 Measurement error Chart misplacement or chart fail-
ure
9. If "NG" appears for "Main Scan", "Mag.(ALL)", or

"Mag.(PART)", open the toner supply section and
loosen 2 screws [1] located beside the developing unit
of a color from which an "NG" is displayed, and slide
the adjusting plate [2] up and down to adjust the
"Mag.(PART)" (partial magnification in main scanning).
Moving the adjusting plate [2] upward increases the
"Rest" of the "Mag.(PART)" (positive) and moving the
plate downward reduces the "Rest" (negative).
• Adjustment guideline
Move the adjusting plate [2] by referring to the "Rest"
of "Mag (PART)" (unit: pixel) displayed at the touch
panel. The scale of the adjusting plate [2] changes the [2]
"Rest" approx. 0.5 pixel per notch.
[1] a03uf3c007ca
171
10. Press [Return] to return to [Printer Adjustment Menu] screen.

/C6501P/C65hc/C5501
bizhub PRO C6501
11. Perform the Color registration adjustment (printer adjustment) with reference to "9.3.10 Color Registration
Adj. (Printer Adjustment)".
12. Repeat steps 3 to 11 until "OK" is displayed.
9.3.12 Adjustment when replacing multi feed detection board (PF)

Perform this adjustment when replacing the PF multi feed detection board (MFDTB) or the PF drive board
(PFDB), as well as when multi feeding is not detected properly for special papers (thin paper, thin coated paper,
thick paper, etc.).
Note
• The multi feed detection board/S and /R are adjusted in the manufacturing process as a pair of
upper and lower. Be sure to replace them as a pair.
• Be sure to perform the adjustment under normal room temperature (20 to 30 °C) that is similar
to the real environment where the machine is operated because the temperature sensor output
level varies with its surface temperature. (When you bring in a replacement part from a place
under a different temperature, leave the part and wait for the sensor surface temperature to reach
the room temperature before performing the adjustment.)
A. Procedure

Press [12 PFU DFeed Detect Adj.].
4. Open the front door [1] of the PF, and open the jam.
[1]
processing guides PF2 [2] and PF5 [3] in the horizon-
tal conveyance section.
[3] [2]
a03uf3c025ca
172
5. Insert a sheet of paper [1] (part No. 65AA-991#, fus-
/C6501P/C65hc/C5501
[4] [1]
ing adjustment paper, 16 sheets/A3) while turning the
bizhub PRO C6501

nkob PF4 [2], and close the jam processing guides
PF2 [3] and PF5 [4].
(When there isn’t paper [1], use 200 to 300 g/m2
paper.)
[3] [2]
a03uf3c026ca
6. "PFU DFeed Detect Adjustment screen"

Press "start"
7. If the multi feed detection adjustment is normally completed, "Completed" is displayed. If abnormally com-
pleted, "Error" is displayed. When the error message is is displayed, repeat steps 4 to 6.
Note
• When an error occurs, the adjustment data is not written but the data before the adjustment still
remains.
8. Remove the paper inserted in step 5.
9. Turn on the sub power switch and enter the I/O check mode.
10. Enter "18" with the numeric buttons. Confirm that "18-00" is displayed in the message display area.
11. Press Access button.
13. Insert a sheet of paper that the customer uses mainly (paper weight: 50 to 300 g/m2) and press Start key.
Make sure that "0" is displayed on the panel.
14. Insert one more sheet of paper (total: 2 sheets) that the customer uses mainly.
Make sure that "1" is displayed on the panel.
15. Remove the papers and install the removed parts.
173
9.3.13 CD Skew Adj. (Printer Adjustment)

/C6501P/C65hc/C5501
Adjust the CY2 lens in the write unit/K and corrects the image distortion of K in main scanning direction.
bizhub PRO C6501
Note
• Image distortion of K in main scanning direction cannot be corrected by the Color registration
adjustment. (Adjusts YMC only.)
• Image distortion of K in main scanning direction can also be changed by conducting [Chart
Adjustment] of [Both Side Adj.] in the user mode.
A. Procedure

Press [13 CD Skew Adj.].
4. "Crosswise Direction Skew Adjustment screen"
Press [COPY].
5. "Copy screen"
Note
• When the Start key is pressed, CY2 lenses of YMCK are adjusted and the Color registration
adjustment is automatically started. When the adjustment is complete (approx. 2 minutes), test
pattern (No. 16) will be printed.
6. Check the skew in main scanning direction.
Standard value: ± 0.3% or less (difference between
280mm diagonal lines "a. b" is 0.84 mm or less) b
a03uf3c001ca
7. If the value is out of spec, press [SERVICE].

8. "Crosswise Direction Skew Adjustment screen"
Setting range: -30 to +30 1 step = 0.01 mm
174
9.3.14 Recall Standard Data (Printer Adjustment)
/C6501P/C65hc/C5501
Restore the printer adjustment set values to factory initial data or installation initial data.
bizhub PRO C6501

Note
• Adjustment data of "Color Registration Adj.", "Color Registration/Manual", "PFU Dfeed detect
Adj.", and "CD Skew Ad." are not restored.
A. Procedure

Press [14 Recall Standard Data].
4. "Recall Standard Data screen"
Press [Factory Initial Data] or [Installation Initial Data].
Note
• Selecting [Factory Default Data] restores various set values to factory initial data.
• Selecting [Installation Initial Data] restores to the adjustment values stored when I/O check
mode (code "91-00") was conducted.
5. Press [Yes] to restore standard data.
Press [No] to cancel the operation.
175
9.3.15 Restart Timing Adjustment (Scanner Adjustment)

/C6501P/C65hc/C5501
Adjust the image leading edge timing when scanning in platen mode.
bizhub PRO C6501
This adjustment changes read start timing when scanning original in sub-scanning direction.
Note
• Be sure the "Restart Timing Adjustment (Printer Adjustment)" have been adjusted before perform-
ing this adjustment.
(Refer to P.161)
A. Procedure

Press [02 Scanner Adjustment].
3. "Scanner Adjustment Menu screen"
Press [01 Restart Timing Adjustment].
4. "Scanner Re-start Timing Adjustment screen"
Press [COPY].
5. "Copy screen"
Select A3 or 11 x 17 paper. Set the test chart to the original glass and press Start key.
8. "Scanner Re-start Timing Adjustment screen"
When the value is not within the standard value, press [SERVICE].
Setting range: -10 (image faster) to +20 (image slower) 1 step = 0.1 mm
1 176
9.3.16 Centering Adjustment (Scanner Adjustment)
/C6501P/C65hc/C5501
Adjust the image mis-centering of the main scan direction when scanning from the original glass and DF.
bizhub PRO C6501

Note
• Be sure the "Centering Adjustment (Printer Adjustment)" have been adjusted before performing
this adjustment.
(Refer to P.162)
A. Procedure

Press [02 Centering Adjustment].
4. "Scanner Centering Adjustment screen"
5. "Copy screen"
When you select [ADF Centering Adj-Front] or [ADF Centering Adj-Back], set the "Adjustment chart" on
the DF, select A3 or 11 X 17 paper and press Start key. When you select [Orig. Glass Left Image], set the
"Test chart" on the original glass, select A3 or 11 X 17 paper and press Start key.
6. Fold the output page in half in main scanning direction, and check the discrepancy from the center line of
the print.
Standard value (platen mode): 0 ± 1.5mm or less
Standard value (DF mode): 0 ± 2.0mm or less
8. "Scanner Centering Adjustment screen"
Setting range: -30 (image in front) to +30 (image in back) 1 step = 0.1 mm
177 1
9.3.17 FD-Mag. Adjustment (Scanner Adjustment)

/C6501P/C65hc/C5501
Adjust the magnification in sub-scanning direction in platen mode and DF mode.

bizhub PRO C6501
This adjustment changes scan speed.
Note
• Be sure the "FD-Mag. Adjustment (Printer Adjustment)" have been adjusted before performing
this adjustment.
(Refer to P.163)
A. Procedure

Press [03 FD-Mag. Adjustment].
4. "Scanner FD-Mag. Adjustment screen"
Press [COPY].
5. "Copy screen"
Place a test chart on the original glass, select A3 or 11 X 17 paper and press Start key.
Standard value: 0.5% or less (same size)
200 ± 1 mm or less
200
57gaf3c005na
8. "Scanner FD-Mag. Adjustment screen"
1 178
9.3.18 Recall Standard Data (Scanner Adjustment)
/C6501P/C65hc/C5501
Restore the scanner adjustment set values to factory initial data or installation initial data.
bizhub PRO C6501

Note
A. Procedure

Press [04 Recall Standard Data].
Note
179 1
9.3.19 Scanner smooth tone/color (Quality Adjustment)

/C6501P/C65hc/C5501
Conduct the gradation correction of the scanner. When color reproduction is a poor condition, usually conduct
bizhub PRO C6501
the "Auto gamma adjustment" of the "Process Adjustment".

Conduct this adjustment if color reproduction is a poor condition (especially in a high light area) after replacing
the CCD unit, exposure lamp (L1), original glass or each scanner mirror.
Caution:
• Scanner gradation (gamma) has been adjusted for each machine at factory. Please be noted that
the scanner gradation data is overwritten to the average value if the [Adj. data reset] in the "Scan-
ner Smooth Tone/Color Adjustment screen" is pressed.
• Once [Adj. data reset] is pressed, previous data cannot be restored.
Note
A. Procedure
1. After replacing the part(s), set a "Color chart" on the original glass, A3 or 11 X 17 paper and press Start
key.
Note
• Press the hard key on the operation panel, not the soft key on the touch panel.
2. Check if there is no image background or problem in color balance.
3. If there is abnormality, enter Service mode.
Press [03 Quality Adjustment].
6. "Quality Adjustment Menu screen"
Press [01 Scanner smooth tone/color].
7. "Scanner Smooth Tone/Color Adjustment screen"
Press [Adj. data reset].
Caution:
• Scanner gradation (gamma) has been adjusted for each machine at factory. Please be noted
that the scanner gradation data is overwritten to the average value if the [Adj. data reset] in
the "Scanner Smooth Tone/Color Adjustment screen" is pressed.
• Once [Adj. data reset] is pressed, previous data cannot be restored.
8. Press the [YES] key to overwrite the scanner gradation data to average value. Press [No] to cancel the
operation.
1 180
9.3.20 Printer gamma adjustment (Quality Adjustment)
/C6501P/C65hc/C5501
When the color reproduction is in poor condition, conduct this adjustment to correct the gradation.
bizhub PRO C6501

Note
• Be sure the "Auto gamma adjustment" have been adjusted before performing this adjustment.
(Refer to P.204)
(1) Printer Gamma Offset Adj.

Conduct this adjustment when the color reproduction varies with copy modes to adjust the gradation and the
background density in a high light area.
Note
• To adjust the printer gamma of C6501/C5501 (copier version), perform the "Printer Gamma Offset
Auto Adj." (Refer to P.183). Only perform this adjustment when you want to make fine adjustments
manually or for C6501P/C65hc (printer version).
a. Procedure

Press [02 Printer gamma adjustment].
4. "Printer Gamma Adjustment Menu screen"
Press [01 Printer Gamma Offset Adj.].
5. "Printer Gamma Offset Adjustment screen"
Press [Next] or [Previous] to select the screen you want to adjust.
Note
• Line1, Line2, Dot1 and Dot2 correspond to the screen names in user mode.
• Contone is a screen used in the character section of Line1, Line2, Dot1, and Dot2.
• ED is a screen used when "Compression" is selected in user mode.
• Contone does not require the adjustment.
6. Press [COPY].
7. Select A4 or 81/2 X 11 paper and press Start key to print a test pattern.
8. Check the printed test pattern.
[1]
• Make sure that the high light density starting section
of C and K is uniform, and even between the gray
Y
reference lines [1].
M
C
K
8050fs1015
181 1
9. If they are not even, press [SERVICE].

/C6501P/C65hc/C5501
bizhub PRO C6501
10. "Printer Gamma Offset Adjustment screen"

Press the button of a color (C or K) you want to adjust, enter a value through the numeric button and press
[<<SET].
Setting range: -128 (lighter) to +127 (darker)
12. Take notice of the gray gradation pattern [1] created
in C, M and Y, make sure that the gray balance at the Y
square marks line [2] and [3] is the same. M
C
K
[1]
[6] [5] [4] [2] [3] 8050fs1016
13. If the gray balance is not the same, press the color (Y or M) you want to adjust, enter a value through the
numeric buttons and press [<<SET].
Setting range: -128 (lighter) to +127 (darker)
• How to match the gray balance.
Take notice of the gray block [4] made up of 49 patches created in C, M and Y. In the 49 patches, M gets
darker toward right. And Y gets darker downward. C remains unchanged. The patch [5] at the center is
the same color as the gray [2]. The patches [6] positioned at the 4 corners of the patch [5] is the same
color as the gray [3]. Out of the 49 patches, select a gray of the same gray balance as the gray [6].
e.g.) When a patch on the lower right side is more suitable than the patch [5] at the center: Adjust M and
Y in the darker direction.
e.g.) When a patch on the upper left side is more suitable than the patch [5] at the center: Adjust M and Y
in the lighter direction.
14. Press [COPY].
15. Select A4 or 81/2 X 11 paper and press Start key to print a test pattern.
182
(2) Printer Gamma Offset Auto Adj.
/C6501P/C65hc/C5501
Conduct this adjustment when the color reproduction varies with copy modes to adjust the gradation and the
bizhub PRO C6501

background density in a high light area.
Note
• To adjust the printer gamma, perform this adjustment. Perform "Printer Gamma Offset Adj." (Refer
to P.181) when you want make fine adjustments manually.
• This adjustment is for C6501/C5501 but not for C6501P. Adjust C6501P by "Printer Gamma Offset
Adj.".
a. Procedure

Press [02 PrinterGammaOffsetAutoAdj.]
5. "Printer Gamma Offset Automatic Adj. screen"
Press [Next] or [Previous] to select the screen you want to adjust.
Note
• The adjustable screens are the same as the ones in Printer Gamma Offset Adjustment.
• The printer gamma offset value of each YMCK displayed are the current values, and they are
linked with the "Printer Gamma Offset Adj." values.
6. Press [Readjust].
To readjust press [Yes], and press [No] to cancel the operation.
Note
• When the gradation in high light area is way off, press [Adj. data reset] and reset the printer
gamma offset value to 0, then press [Readjust].
7. Press [COPY].
8. "Copy" screen
Select the A4 (for metric machine) or 81/2 x 11 (for inch machine) paper and press START key to print a test
pattern.
183

/C6501P/C65hc/C5501
[3] [4]
Returns to the adjustment screen automatically when
bizhub PRO C6501
test pattern is printed.

Place the outputted test pattern [1] on the original
glass securely against the original positioning plate/Lt
[3] and the original positioning plate/Rr [4].
[2]
Note
• Set the test pattern so that the green triangular
mark [2] comes to the left side.
(printed side face down)
[1]
a03uf3c030ca
10. Place 10 sheets of copy paper (white) on top of the test pattern and close the DF or the original cover.
Note
• Be sure to use white copy paper. Otherwise, the printer gamma cannot be corrected properly.
11. Press [Start].
12. The test pattern is scanned and the current YMCK values are updated.
Note
• Since the scanned result at the first scan is not examined, a "Completed" message does not
appear after the first scan.
• The quality judgement is made from the second scan. Make sure to repeat step 8 to 11 until the
"Completed" message appears.
Press [COPY].
14. Perform the steps 8 to 11.
15. Confirm that "Completed" is displayed. If message other than "Completed" is displayed, repeat steps 13
to 14.
184
(3) Printer gamma sensor adj.
/C6501P/C65hc/C5501
When a poor color reproduction results even after the "Auto gamma adjustment" of the "Process Adjustment",
bizhub PRO C6501

conduct this adjustment to correct gradation.
The printer gamma correction that is performed automatically on regular basis uses PGC sensor to read the pat-
tern on the transfer belt and there is a possibility that due to characteristic changes of PGC sensor, correction
may not be precise. This adjustment uses the scanner to correct the PGC sensor, enabling precise printer
gamma correction.
Note
• Use plain paper or color copy paper to carry out this adjustment. The color of test pattern
changes according to the colored paper, therefore precise adjustment cannot be gained.
• To reset the data to factory default, press [Adj. data reset]. Press [Yes] to reset the printer gamma
sensor adjustment to the factory default data, and [No] to keep the current data.
a. Procedure

Press [03 Printer gamma sensor adj.].
5. "Printer Gamma Sensor Adjustment screen"
Select the screen you want to adjust.
Note
• The adjustable screens are the same as the ones in Printer Gamma Offset Adjustment.
6. Press [COPY].
7. Select the A4 (for metric machine) or 81/2 x 11 (for inch machine) paper and press START key to print a test
pattern.
185 2
8. "Please load output paper...screen"

/C6501P/C65hc/C5501
[3] [4]
Returns to the adjustment screen automatically when
bizhub PRO C6501
test pattern is printed.

Place the outputted test pattern [1] on the original
glass securely against the original positioning plate /
Lt [3] and the original positioning plate /Rr [4].
[2]
Note
• Set the test pattern so that the green triangular
mark [2] comes to the left side. (printed side
face down)
[1]
8050fs1017
9. Place 10 sheets of copy paper (white) on top of the test pattern and close the DF or the original cover.
Note
• Be sure to use white copy paper. Otherwise, the printer gamma cannot be corrected properly.
10. Press [Start].
11. If the chart is scanned and it is normal, the gamma sensor adjustment will be carried out, printer gamma
correction is executed and "Completed" message will be displayed.
186
12. When an abnormality occurs, an error code is displayed for every cause. Correct the error referring to the
/C6501P/C65hc/C5501
following and repeat steps 6 to 11.
bizhub PRO C6501

Error code Descriptions Causes
Error 1 A crossmark cannot be detected Chart misplacement
Error 2 The chart is placed upside down Chart misplacement
Error 3 Cannot detect the chart pattern Different chart is placed
Error 4 Adjustment impossible Software bug
Error 5 Value is out of standard Retry the adjustment
Error 6 Non-volatile data abnormality Check the installation position of
the NVRAM board
Error 7 Accessing to unassigned memory Software bug
Error 8 Memory-related error Software bug
Error 9 Program error Software bug
Error 10 Chart is skewed Chart misplacement
Error 11 Image header information read error Software bug
Error 12 RBG data error Chart is different, or software bug
Error 13 Arguments setting error Software bug
Error 31 Sensor value error Retry the adjustment
Error 51 Regression calculation error Retry the adjustment
Error 52 Sequential number overflow Software bug
Error 53 Regression order error Software bug
Error 54 Select screen information error Software bug
Error 55 Color information error Software bug
187
(4) Printer Screen Gradation Adj

/C6501P/C65hc/C5501
Adjust tone jump (in which gradation is not continuous).

bizhub PRO C6501
Note
• Perform this adjustment after replacing the image processing board (IPB).
a. Procedure

Press [04 Printer Screen Gradation Adj.].
5. "Printer Screen Gradation Adjustment screen"
Press [COPY].
6. Select A4 or 81/2 X11 paper and press Start key to print a test pattern.
7. 5 sheets will be printed automatically so check that there are no tone jumps on the test patterns.
8. If tone jump has occurred, press [SERVICE].
9. "Printer Screen Gradation Adjustment screen"
Select the color that the tone jump has occurred in.
10. Enter the number subtracted one from the current value and press [<< SET].
Setting range: -3 to +1
11. Repeat steps 5 to 10 until there is no tone jump.
188
9.3.21 Sharpness adjustment (Quality Adjustment)
/C6501P/C65hc/C5501
Conduct the sharpness adjustment or, this is carried out when moire reproduced.
bizhub PRO C6501

Perform this adjustment to change the center value of the sharpness adjustment in user mode.
Note
• This adjustment is only effective for images scanned by the scanner.
A. Procedure

Press [03 Sharpness adjustment].
4. "Sharpness Adjustment screen"
Press [COPY].
5. "Copy screen"
Place a "Color chart" on the original glass, select A3 or 11 X 17 paper, and press Start.
6. Press [SERVICE].
Setting range: -5 (soft/less moire) to +5 (sharp/more moire)
8. Repeat steps 4 to 7 until the appropriate value can be obtained.
9.3.22 Contrast adjustment (Quality Adjustment)

Adjust the contrast.
Perform this adjustment to change the center value of the contrast adjustment in user mode.
Note
A. Procedure

Press [04 Contrast adjustment].
4. "Contrast Adjustment screen"
Press [COPY].
5. "Copy screen"
Place a "Color chart" on the original glass, select A3 or 11 X 17 paper, and press Start.
6. Press [SERVICE].
Setting range: -5 (contrast increase) to +5 (contrast decrease)
189 1
9.3.23 Image Distinction Level (Quality Adjustment)

/C6501P/C65hc/C5501
Adjust the threshold value of original image distinction.

bizhub PRO C6501
Note
• The scanned image is distinguished into text, photo, dot, and colored text areas in image process-
ing, and a screen to be used is determined according to the distinction.
• This adjustment is used to increase the distinction accuracy of the original that the areas are
incorrectly distinguished once.
• To increase the distinction range of photo, perform the adjustment in user mode.
(1) Dot detect adjustment

Adjust the dot distinction threshold value of the original image.
a. Procedure

Press [05 Image Distinction Level].
4. "Image Distinction Level Menu screen"
Press [01 Dot detect adjustment].
5. "Dot Detect Adjustment screen"
Press [COPY].
6. Place an original you want to adjust on the original glass, select A3 or 11 X 17 paper, and press Start key.
7. Dot detect pattern will be printed.
By this output pattern, you can find out what this image was distinguished into.
Cyan section: Distinguished as dot
White section: Distinguished as photo
Black section: Distinguished as black text
Magenta section: Distinguished as colored text
8. Press [SERVICE].
9. "Dot Detect Adjustment screen"
Select the color you wish to adjust, enter a value through the numeric buttons and press [<<SET].
Setting range: -5 (dot area decrease) to +5 (dot area increase)
1 190
(2) Color text adjustment
/C6501P/C65hc/C5501
Adjust the color text distinction threshold value of the original image.
bizhub PRO C6501

Perform this adjustment to change the center value of the color text distinction function in user mode.
a. Procedure

Press [02 Color text adjustment].
5. "Color Text Adjustment screen"
Press [COPY].
7. Color text detect pattern will be printed.
Magenta section: Distinguished as colored text
8. Press [SERVICE].
9. "Color Text Adjustment screen"
Setting range: -5 (color text area decrease) to +5 (color text area increase)
191
(3) Dot/Text area adjustment

/C6501P/C65hc/C5501
Adjust the dot distinction and text distinction threshold values of the original image.
bizhub PRO C6501
Perform this adjustment to change the center value of the text photo distinction function in user mode.
a. Procedure

Press [03 Dot/Text area adjustment].
5. "Dot/Text Area Adjustment screen"
Press [COPY].
7. Dot/text detect pattern will be printed.
Cyan section: Distinguished as dot
White section: Distinguished as photo
Magenta section: Distinguished as colored test
8. Press [SERVICE].
9. "Dot/Text Area Adjustment screen"
Setting range: -5 (dot area increase/text area decrease) to +5 (dot area decrease/text area increase)
192
9.3.24 ACS adjustment (Quality Adjustment)
/C6501P/C65hc/C5501
Perform this adjustment when ACS (Automatic color selection) function does not work properly.
bizhub PRO C6501

Note
A. Procedure

Press [06 ACS adjustment].
4. "Place original and touch [SCAN] screen"
Place an original that the ACS does not work properly on the original glass and press [Scan].
5. Next to the "JUDGE:", the result "COLOR" or "BLACK" will be displayed.
Setting range: -5 (black) to +5 (color)
193 1
9.3.25 Density adjustment (Quality Adjustment)

/C6501P/C65hc/C5501
Adjust the AES density, copy density, background density, and B-side (see-through image) density.
bizhub PRO C6501
This adjustment moves in parallel with shade direction without changing the printer gamma curve form and
adjusts the copy density.
Note
(1) AES adjustment

Adjust to change the center value selected in automatic copy density function in user mode.
a. Procedure

Press [07 Density adjustment].
4. "Density Adjustment Menu screen"
Press [01 AES adjustment].
5. "AES Adj. -Set value then touch [SCAN] screen"
Place an original that you want to change the AES density on the original glass and press [Scan].
6. Next to the "RESULT:", the numeric value will be displayed.
7. If the "RESULT" is other than 0, enter a value through the numeric buttons and press [<<SET].
(e.g.: If the "RESULT" is 2, input -2).
Setting range: -5 to +5
8. Repeat steps 5 to 7 until the "RESULT" becomes 0.
1 194
(2) Copy density adjustment
/C6501P/C65hc/C5501
Adjust the density for copying.
bizhub PRO C6501

Perform this adjustment to change the center value of the "Original Density Shift" in user mode.
a. Procedure

Press [02 Copy density adjustment].
5. "Copy Density Adjustment screen"
Press [T] or [S] to select the item you want to adjust.
6. Press [COPY].
7. "Copy screen"
Select the mode to adjust, select A3 or 11 X 17 paper, place a "Color chart" on the original glass, and
press Start key.
8. Press [SERVICE].
9. "Copy Density Adjustment screen"
Setting range: -5 (lighter) to 5 +(darker)
195
(3) Adjust Background

/C6501P/C65hc/C5501
Adjust the background density (density of highlighted area) for copying.

bizhub PRO C6501
In user mode only a batch adjustment is enabled. Therefore, it is impossible to perform individual adjustment for
original settings or color modes.
a. Procedure

Press [03 Adjust Background].
5. "Background Adjustment screen"
6. Press [COPY].
7. "Copy screen"
Select the mode to adjust, select A3 or 11 X 17 paper, place a "Test chart" on the original glass, and press
Start key.
8. Press [SERVICE].
9. "Background Adjustment screen"
196
(4) B-side Prevent
/C6501P/C65hc/C5501
Adjust the density of see-through image on back side of paper (density for shadow area) for copying.
bizhub PRO C6501

In user mode only a batch adjustment is enabled. Therefore, it is impossible to perform individual adjustment for
original settings or color modes.
a. Procedure

Press [04 B-Side Prevent].
5. "B-Side Prevent screen"
6. Press [COPY].
7. "Copy screen"
Select the mode to adjust, select A3 or 11 X 17 paper, place a text chart on the original glass, and press
Start key.
8. Press [SERVICE].
9. "B-Side Prevent screen"
Setting range: -5 (lighter) to 0
197
9.3.26 Tone adjustment (Quality Adjustment)

/C6501P/C65hc/C5501
Conduct the tone adjustment of red, green or blue.

bizhub PRO C6501
Perform this adjustment to change the center value for the "Hue-Fine Adjustment" in the user mode.
Note
(1) Red
Adjust the density of red.
a. Procedure

Press [08 Tone Adjustment].
4. "Tone Adjustment Menu screen"
Press [01 Red].
5. "Red screen"
Press [COPY].
6. Select A3 or 11 X 17 paper, place a "Color chart" on the original glass, and press Start key.
7. Press [SERVICE].
9. Repeat steps 5 to 8 until it is appropriate.
1 198
(2) Green
/C6501P/C65hc/C5501
Adjust the density of green.
bizhub PRO C6501

a. Procedure

Press [02 Green].
5. "Green screen"
Press [COPY].
7. Press [SERVICE].
(3) Blue
Adjust the density of blue.
a. Procedure

Press [03 Blue].
5. "Blue screen"
Press [COPY].
7. Press [SERVICE].
199
9.3.27 Recall standard data (Quality Adjustment)

/C6501P/C65hc/C5501
Restore the quality adjustment set values to factory initial data or installation initial data.
bizhub PRO C6501
Note
• Adjustment data of "Scanner smooth tone/color" is not restored.
A. Procedure

Press [09 Recall standard data].
Note
200
9.3.28 Non-Image Area Erase Check
/C6501P/C65hc/C5501
When installing the copier or moving its installation location, check to see if the "Non-Image Area Erase" of the
bizhub PRO C6501

application function works satisfactorily. This also automatically adjusts sensitivity to correctly detect the non-
image area.
Preparation
• Open the DF or the original cover fully.
• Do not put anything on the original glass.
• Clean the original glass.
A. Procedure

Press [04 Non-Image Area Erase Check].
3. "Non-Image Area Erase check screen"
Press [Start].
4. Check that the message below is displayed.
NORMAL adjustment selected.

The machine is set to appropriate parameters for Non-image Area Erase.
If any other message appears, refer to "B. Error message and Handling", and perform the Non-Iimage
Area Erase Check again.
201
B. Error message and Handling

/C6501P/C65hc/C5501
If an error is detected in the Non-Image Area Erase Check, error message as the following is displayed.
bizhub PRO C6501
(1) Error message -1
Adjust for Moderate Brightness.

The Non-image area erase function may not operate correctly with dark (density) originals.
Handling 1
When the "Non-image area erase" function is not used very frequently, or when copy originals that have a dark
background are not copied very frequently in non-image area erase, the copier can be used in the current instal-
lation location. However, when copy originals that have a dark background are frequently copied, install the
copier in a location where less external light gets in (darker) than the present location, and check the non-image
area erase check mode again.
(2) Error message -2
Adjust for Extreme Brightness.

In many case, the non-image area erase function will not operate correctly.
Handling 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.
202
9.4 Process Adjustment
/C6501P/C65hc/C5501
bizhub PRO C6501
9.4.1 1st transfer manual adj. (High Voltage Adjustment)
Do not conduct this adjustment in the field.
9.4.2 2nd transfer manual adj. (High Voltage Adjustment)

9.4.3 HV adj. (separation AC) (High Voltage Adjustment)

Must not be used during maintenance/repair.
9.4.4 HV adj. (sepration DC) (High Voltage Adjustment)

9.4.5 Pre-transfer Guide HV check (High Voltage Adjustment)

Do not use this adjustment in the field.
9.4.6 Blade setting mode (Drum Peculiarity Adj.)

Perform this adjustment when changing the belt cleaning blade or the transfer belt. In this mode, toner is applied
onto the transfer belt then cleaned with the belt cleaning blade. This prevents the damages of the transfer belt
and the belt cleaning blade.
A. Procedure

Press [02 Process Adjustment].
2. "Process Adjustment Menu screen"
Press [02 Drum Peculiarity Adj.].
3. "Drum Peculiarity Adjustment Menu screen"
Press [01 Blade setting mode].
4. "Blade Setting Mode screen"
Press [Start]. This process completes in about 15 seconds and complete message is shown on the
screen.
203
9.4.7 Automatic drum potential (Drum Peculiarity Adj.)

/C6501P/C65hc/C5501
Measure the charging potential of each drum of Y, M, C, and K to adjust the developing bias value and the
bizhub PRO C6501
charging voltage automatically. This adjustment is not necessary in the field. (Because this adjustment is
included in the "Auto gamma adjustment 0".)
A. Procedure
1. "Service Mode Menu" screen

2. "Process Adjustment Menu" screen
3. "Drum Peculiarity Adjustment Menu" screen
Press [02 Automatic drum potential].
4. "Automatic Drum Potential screen"
Press [Start]. This process completes in about 10 seconds and the charging potential is displayed for
each line speed (1/1 speed, 2/3 speed and 1/2 speed) and for each color (Y, M, C and K) on the screen,
then a completion message will appear.
9.4.8 Auto gamma adjustment (Drum Peculiarity Adj.)

Adjust image stabilization automatically.
A. Procedure

2. "Process Adjustment Menu" screen
3. "Drum Peculiarity Adjustment Menu" screen
Press [03 Auto gamma adjustment]].
4. "Automatic Gamma Adjustment screen"
Press [Start]. This process completes in about 3.5 minutes and the developing DC bias value is displayed
for each line speed (1/1 speed, 2/3 speed and 1/2 speed) and for each color (Y, M, C and K) on the
screen, then a completion message will appear.
Note
• There are 8 kinds of the "Auto gamma adjustment" (0 to 7), however, conduct "Auto gamma
adjustment 0" only in the field.
"Automatic gamma adjustment 0": Perform the Dmax density adjustment, dot diameter adjust-
ment, automatic drum potential adjustment, and the gamma adjustment for all screens.
"Automatic gamma adjustment 1 to 7": Performs the image stabilization adjustment by screen.
• When an abnormality occurs, an error code is displayed. Correct the error referring to the fol-
lowing.
Error 1: The gamma correction is unavailable due to the abnormal PGC sensor output.
When an error occurs, machine is controlled by using a correction value used
previously.
204
9.4.9 LD bias adjustment (Drum Peculiarity Adj.)
/C6501P/C65hc/C5501
Perform this adjustment after replacing the write unit.
bizhub PRO C6501

Note
• Do not perform this adjustment except when replacing the write unit.
A. Procedure
1. Check the number on the barcode [1] pasted on

the new write unit and replace it.
* A177 B174 *
a03uf0c000ca
2. Enter Service mode.

Press [04 LD bias adjustment].
6. "LD Bias Adjustment screen"
Press [T] or [S] and select the color of the replaced write unit.
e.g.) After exchanging write unit/Y, press [Y1 Adjustment Data].
7. Input the number written on the barcode of the replaced write unit and press [<< SET]
e.g.) Barcode shown in step 1 was attached to the write unit/Y,
[Y1 Adjustment Data]: Input A value, 177
[Y2 Adjustment Data]: Input B value, 174
8. Press [Return] and press [SERVICE].
Press [05 State Confirmation] and press [01 I/O Check Mode].
205
10. Execute LD1/2 alarm data clear of the color that corresponds the write unit you have replaced.
/C6501P/C65hc/C5501
"Output check"
bizhub PRO C6501
• 37-91: LD1/2 alarm data clear/Y

• 37-92: LD1/2 alarm data clear/M
• 37-93: LD1/2 alarm data clear/C
• 37-94: LD1/2 alarm data clear/K
11. Execute the LD alarm measurement in "Output check" 37-00.
• 37-00: LD alarm measurement
Note
• LD alarm data (laser power of the laser diode) can be checked using "Adjustment Data List" in "List
output".
• "Default" in "Adjustment Data List" shows first measurement data, which is the value obtained
when executing 37-00 after clearing the LD alarm data by "37-9*".
• "Setting" in "Adjustment data list normally shows "000". Measurement result of the LD alarm data
obtained by executing 37-00 will appear in the section, and the result will be overwritten each time
37-00 is executed.
• The value of the LD alarm level will decrease as the laser diode deteriorates.
• Steps 8 to 11 described above are the procedures to manage the history of the write unit replace-
ment.
12. Executing the LD1/2 Laser emission timing adjustment (main scanning) in "Output check" 46-00. (Adjust-
ment time: Max. 1 minute)
Note
• The adjustment is performed for all 4 colors at a time. "FIN" will appear in the "OUT" column dis-
played on the touch panel when the adjustment is completed successfully.
• If an abnormality is detected, an error code will be displayed
NG1 #: Deviation amount is larger than 70/100 pixel
NG2 #: Deviation amount is larger than 15/100 pixel
(Y, M, C, or K will appear at "#" to indicate which write unit is causing the error.)
13. Action when an error code displays
• When abnormality is found for 2 or more write units, only one error code of the color with a high priority
(priority order is YMCK) is displayed. Therefore, replace a damaged write unit according to the error code
and repeat 46-00 until "FIN" is displayed.
e.g.) When write unit/Y and /K are damaged.
"NG1Y" will displayed by the first execution of 46-00 → Replace the write unit/Y.
"NG1K" will displayed by the second execution of 46-00 → Replace the write unit/K.
"FIN" will displayed by the third execution of 46-00.
206
9.4.10 Automatic Developer Charge (Drum Peculiarity Adj.)
/C6501P/C65hc/C5501
In this mode, new developers are automatically charged after the current developers being discharged from the
bizhub PRO C6501

developing unit manually.
Note
• Always carry out the "Toner density sensor initial auto. adjustment" after replacing the developer.
If printing is started without performing the "Toner density sensor initial auto. adjustment", a
proper image density cannot be obtained, and the developers need to be replaced.
• Do not open the cover of the developing unit. Otherwise, dust gets in the unit causing image fail-
ure.
A. Procedure
1. Open the toner supply section. (Refer to Theory of Operation of the main body P.166)
2. Remove the 3 screws [1] and remove the upper
[2] [1]
cover/Fr [2].
a03uf3c012ca
3. Pull out the supporting shaft [1].

[2] [5] [1] [4]
4. Loosen the 2 screws [2] and remove the developer
charging plate [3].
5. Loosen the 2 screws [4] and remove the developer
charging funnel/Lw [5].
[3] a03uf3c013ca
207
6. Set the developer charging plate [2] to the shoulder

/C6501P/C65hc/C5501
[1] [2]
screws [1] provided above the developing unit of a
bizhub PRO C6501
color into which you are going to charge develop-

ers.
[1] [2]
a03uf3c014ca
208
7. Set the developer charging funnel /Lw [2] to the
/C6501P/C65hc/C5501
[3] [2] [1]
developer charging plate [1].
bizhub PRO C6501

Note
• Be sure to attach the tip of the developer
charging funnel/Lw [2] securely to the toner
supply opening [3].
a03uf3c015ca
8. Set the developer charging funnel/Up [2] packaged

[2] [1]
together with developer to the developer charging
funnel/Lw [1].
Note
• The developer charge funnel/Up [2] is pack-
aged together with each developer. Be sure not
to reuse the funnel.
a03uf3c016ca
9. Enter Service mode.

Press [05 Automatic Developer Charge].
13. "Automatic Developer Charge screen"
Select the color of developer.
14. Press the [Start], then pour a new developer into the developer charging funnel/Up.
15. Make sure that the developer has been charged successfully before pressing the [CANCEL].
16. When charging another developer, repeat steps 3 to 12.
17. Press [Return] to return to "Drum Peculiarity Adjustment Menu screen".
18. Put the installed parts back to their original positions.
19. Perform "Toner density sensor Init." adjustment.(Refer to P.210)
209
9.4.11 Toner density sensor Init. (Drum Peculiarity Adj.)

/C6501P/C65hc/C5501
Carry out this adjustment after new developers are charged, and adjust the standard toner concentration of the
bizhub PRO C6501
developer.
Measure developer permeability in the developing unit with TCR sensor, memorize the input voltage obtained
when the TCR sensor output voltage became the standard value to the NVRAM board (NRB).
Note
• After replaceing developer, do not execute printing without carrying out this adjustment. Other-
wise, a proper image density cannot be obtained, and the developers need to be replaced.
• The value displayed after the adjustment is a TCR sensor control voltage (input voltage) expressed
in 8 bit.
A. Procedure

Press [06 Toner Density Sensor Init.].
4. "Toner Density Sensor Initial Auto. Adj. screen"
Select the color of a developer that has been newly charged and then press the [Start].
5. A message "Completed" is displayed.
9.4.12 Initial drum rotation (Drum Peculiarity Adj.)

Conduct this operation after replacing the drum cartridge. This operation rotates the drum at low speed to lubri-
cate by the Lubricant applying roller it to protect the drum and the cleaning blade.
A. Procedure

Press [07 Initial drum rotation].
4. "Initial Drum Rotation screen"
Press [Start]. This process completes in about 10 seconds and complete message is shown on the
screen.
210
9.4.13 Surface potential sensor (Sensor output check)
/C6501P/C65hc/C5501
Measure uncharged potential of the drum before charging by the drum potential sensor (PRPS). (8 bit output)
bizhub PRO C6501

9.4.14 Maximum density sensor (Sensor output check)

Measure uncharged potential of the transfer belt by the PGC sensor (PS11) and checks the baseline controlled
voltage for the maximum density correction. (8 bit output)
9.4.15 Gamma sensor output (Sensor output check)

Measure uncharged potential of the transfer belt by the PGC sensor (PS11) and checks the baseline controlled
voltage for the gamma correction. (8 bit output)
9.4.16 Toner Density Sensor (Sensor output check)

Checks the output voltage of the TCR sensor. (8 bit output)
A. Procedure

Press [03 Sensor output check].
3. "Sensor Output Check Menu screen"
Press [04 Toner Density Sensor].
4. "Toner Density Sensor Output screen"
Press [Next] or [Previous] to select the process speed (Line Speed1: 1/1, Line Speed2: 2/3 and Line
Speed3: 1/2) to be checked.
5. Select the color(S) to be checked.
6. Press [Start] to display the output value of the selected items.
7. Press [STOP] to end the check.
8. When checking another line speed, repeat steps 4 to 7.
211
9.4.17 Drum Surfase potential (Sensor output check)

/C6501P/C65hc/C5501
Check the V0 (charging potential) and the Vi (exposure potential) of drums (The potential output value multiplied
bizhub PRO C6501
by 4 becomes voltage).
A. Procedure

Press [05 Drum Surface potential].
4. "Drum Surface Potential screen"
Press [Next] or [Previous] to select the process speed (Line Speed1: 1/1, Line Speed2: 2/3 and Line
Speed3: 1/2) to be checked.
5. Select the color(S) to be checked.
6. Press [Start] to display the V0 and Vi potential output value of selected items.
8. When checking another line speed, repeat steps 4 to 7.
9.4.18 Humidity/Temperature (Sensor output check)

Check the output of the temperature/humidity sensor.
A. Procedure

Press [06 Humidity/Temperature].
4. "Humidity/Temperature Output screen"
Press [Start] to display the humidity and temperature value of the items below.
Humidity/Temperature sensor 1: Temp/humidity sensor /1 (TEM/HUMS/1)*1
Humidity/Temperature sensor 2: Temp/humidity sensor /2 (TEM/HUMS/2)
Fixing Heat Roller Temp. (center): Temperature sensor/1 (TEMS/1)
Fixing Heat Roller Temp. (end): Temperature sensor/3 (TEMS/3)
Fixing Press Roller Temp. (center): Temperature sensor/2 (TEMS/2)
*1 When the PF is connected to: Temperature-humidity sensor (TEM/HUMS) of PF is used.

212
9.4.19 Toner Density Return Mode (Sensor output check)
/C6501P/C65hc/C5501
Supply toner automatically up to the standard value for the developing unit, whose output value of the TCR sen-
bizhub PRO C6501

sor is below the standard value (low toner concentration).
A. Procedure

Press [07 Toner Density Return Mode].
4. "Toner Density Recovery Mode screen"
Select the color(s) whose density needs to be recovered.
5. Press [Start] to supply toner to the developing unit with lower than the standard density value. When the
toner concentration reaches to the standard value, the main body stops.
Note
• The Output value and the State (ON/OFF) on the touch panel are corresponding to the TCR sen-
sor output value (8bits) and the state (ON/OFF) of toner supply operation.
213
9.4.20 Covered Margin Fine Adj. (Process Fine Adjustment)

/C6501P/C65hc/C5501
Change potential difference between the charging potential and the developing bias to prevent image back-
bizhub PRO C6501
ground, white spots image, and carrier scattering.
Note
• Do not perform this adjustment when there is no problem. Unnecessary adjustment may cause
image failure (image background, white spot image) or damages to the drum and the cleaning
blade.
• There are several adjustment to reduce the image background.
As a priority of adjustment, adjust in the following order.
1)Develop AC Frequency
2)Covered Margin Fine Adj.
3)Toner Density Fine Adj.
• After changing the set value, conduct the auto gamma adjustment.
(Refer to P.204)
A. Procedure

Press [04 Process Fine Adjustment].
3. "Process Fine Adjustment Menu screen"
Press [01 Covered Margin Fine Adj.].
4. "Covered Margin Fine Adjustment screen"
Select the color(S) to be adjusted and enter the adjustment value with the numeric buttons, and press [<<
SET].
Adjustment range: -5 (carrier scattering /white spot image caused by carrier prevention) to +5 (image back-
ground prevention) 1 step = 6V
Note
• Take care that carrier scattering/white spot image caused by carrier prevention and image back-
ground prevention are trade off. When either of them is improved, the other is worsened.
5. Press [default] to restore the default settings.
214
9.4.21 Develop AC Bias Fine Adj. (Process Fine Adjustment)
/C6501P/C65hc/C5501
Change the developing AC bias to reduce noisy image (roughness due to white spot), and improve developing
bizhub PRO C6501

ability (increase density in solid area).
Note
• After changing the set value, conduct the auto gamma adjustment. (Refer to P.204)
A. Procedure

Press [02 Develop AC Bias Fine Adj.].
4. "Develop AC Bias Fine Adjustment screen"
SET].
Adjustment range: -5 (noisy image prevention) to +5 (improve developing ability) 1 step = 0.1kV
215
9.4.22 Develop AC Frequency (Process Fine Adjustment)

/C6501P/C65hc/C5501
Change frequency of the developing AC bias to improve the image background and reproducibility of outline
bizhub PRO C6501
characters on a colored background.
Note
(Refer to P.204)
A. Procedure

Press [03 Develop AC Frequency].
4. "Develop AC Frequency Fine Adjustment screen"
SET].
Adjustment range: -5 (improve reproducibility of outline characters on a colored background.) to +5
(image background prevention) 1 step = 0.3kHz
216
9.4.23 Toner Density Fine Adj. (Process Fine Adjustment)
/C6501P/C65hc/C5501
Change the TCR sensor control voltage to prevent image background, toner scattering, carrier scattering, white
bizhub PRO C6501

spot caused by carrier.
Note
(Refer to P.204)
A. Procedure

Press [04 Toner Density Fine Adj.].
4. "Toner Density Fine Adjustment screen"
Select the colors to be adjusted and enter the adjustment value with the numeric buttons, and press [<<
SET].
Adjustment range: -5 (image background, toner scattering prevention) to +5 (carrier scattering, white spot
caused by carrier prevention) 1 step = 0.1%
217
9.4.24 Drum Tiny Rotation Interval (Interval/Quantity Adj.)

/C6501P/C65hc/C5501
Change interval of low humidity environment correction control (rotates drums periodically) to improve image fail-
bizhub PRO C6501
ures caused by a uneven drum charging potential (that occurs easily with low humidity).
A. Procedure

Press [05 Interval/Quantity Adj.].
3. "Interval/Quantity Adjustment Menu screen"
Press [01 Drum Tiny Rotation Interval].
4. "Drum Small Rotation Interval screen"
Enter the adjustment value with the numeric buttons and press [<<SET].
Adjustment range: +1 to +5 1 step = One minute
9.4.25 Auto. Refresh Interval (Interval/Quantity Adj.)

Select the execution intervals and the toner consumption amount of the toner refresh mode. (Checks the aver-
age of print coverage for each color with each specific drive distance of the developing roller/K, and consumes
a certain amount of toner for the color that the print coverage is lower than 5% converted in A4 size after com-
pletion of printing.)
A. Procedure

Press [02 Auto. Refresh Interval].
"Automatic Refresh Interval screen"
Specify the settings of each adjustment item, "Execution existence", "Execution frequency" and "Refresh
quantity", and press [OK] to enable the new settings.
• Execution existence: [OFF], [ON]
• Execution frequency: [small] - Equivalent to A4 continuous 1,000 prints
[middle] - Equivalent to A4 continuous 500 prints
[large] - Equivalent to A4 continuous 330 prints
• Refresh quantity: [small] - Equivalent to A3 solid 3 sheets
[middle] - Equivalent to A3 solid 5 sheets
[large] - Equivalent to A3 solid 8 sheets
Note
• Execution frequency varies depending on environmental temperature and print modes.
4. Press [Cancel] to cancel the operation.
218
9.4.26 Toner Dens. Sensor Interval (Interval/Quantity Adj.)
/C6501P/C65hc/C5501
Change correction interval of the TCR sensor control voltage at 2/3 speed and 1/2 speed.
bizhub PRO C6501

A. Procedure

Press [03 Toner Dens. Sensor Interval].
4. "Toner Density Sensor Line Speed screen"
Select an interval and press [OK].
5. Press [Cancel] to cancel the operation.
9.4.27 Recall standard data

Restore the process adjustment set values to factory initial data or installation initial data.
Note
• Adjustment data of "Automatic drum potential" and the "LD bias adjustment" can be restored.
A. Procedure

Press [06 Recall standard data].
Note
• Select [Installation Initial Data] to retrieve the values from a backup in I/O check mode (code:
"91-00").
219
9.5 System Setting

/C6501P/C65hc/C5501
bizhub PRO C6501
9.5.1 Software SW Setting

Set the software DIPSW.
Note
• Do not change any switch not described in the service manual.
A. Procedure

Press [03 System Setting].
2. "System Setting Menu screen"
Press [01 Software SW Setting].
3. "Software Switch Setting Mode screen"
Press [T] / [S] or numeric buttons after pressing the "DIPSW number" and "Bit number" buttons.
4. Press [On(1)] or [Off(0)] to specify ON/OFF of the selected bit numbers.
B. Software Switch Setting Mode screen
[1]
[2] [3] [4] [5] a03uf3e001ca
[1] DIPSW data (indicates the 8bit values of the selected DIPSW numbers in hexadecimals from 00 to FF.)
[2] DIPSW number [4] Bit data: 1:ON, 0:OFF
[3] Bit number (0 to 7) [5] Numeric buttons
220
C. Software DIPSW lists
/C6501P/C65hc/C5501
bizhub PRO C6501
DIPSW Bit Function 0 1 Default setting
Japan Inch Metric
1 0 Display of process adjustment on user Disabled Enabled 0 0 0
screen
1 — — — 0 0 0
2 Print stop method after displaying toner *1 *1 1 1 1
3 supply or waste toner full display *1 *1 0 0 0
4 Print when the maintenance count is reached Allowed Prohibited 0 0 0
5 Number of allowed print quantity after *2 *2 0 0 0
6 reaching the maintenance count *2 *2 0 0 0
7 *2 *2 0 0 0
2 0 Hard disk drive connection recognition Disabled Enabled 0 0 0
1 — — — 0 0 0
2 — — — 0 0 0
3 — — — 0 0 0
4 — — — 0 0 0
5 Line 1 screen switchover Previous screen New screen 1 1 1
6 — — — 1 1 1
7 Polygon motor rotation speed switchover Speed when 2/3 speed 0 0 0
print operation
is ended
3 0 — — — 1 1 1
1 Malfunction code latch (C1540~1562, Unlatched Latched 0 0 0
3501~3916)
2 Reverse decurler roller preliminary rotation Disabled Enabled 0 0 0
3 — — — 0 0 0
4 — — — 0 0 0
5 — — — 0 0 0
6 I/O check mode output 15 memory clear Disabled Enabled 0 0 0
7 The maximum stacking capacity selec- Stop at the Stop at the 0 0 0
tion in small-size (longer side 250mm to tray middle main tray
319mm) of FS-521 in shift mode position sen- lower limit
sor (PS6) sensor (PS3)
(equivalent to (equivalent to
stacking 1500 stacking 3000
sheets) sheets)
221 1

bizhub PRO C6501
Japan Inch Metric

4 0 Air assist shutter open/close control (PF) Enabled Disabled 0 0 0
1 Paper exit decurler roller pressure setting/1 Normal Moist paper sup- 0 0 0
port
2 — — — 0 1 0
3 — — — 0 0 1
4 Paper exit decurler roller pressure setting/2 Normal Prevention of 0 0 0
wrinkle at lead
edge of paper in
duplex mode
5 APS when magnification is changed Enabled Disabled 0 1 0
6 Large size paper counting method - B&W Count as 1 *3 Count as 2 *3 0 1 0
(other than maintenance counter)
7 Large size paper count method - Color Count as 1 *3 Count as 2 *3 1 1 0
(other than maintenance counter)
5 0 — — — 0 0 0
1 — — — 0 0 0
2 — — — 0 0 0
3 — — — 0 0 0
4 Fusing jam blank paper cleaning Enabled Disabled 0 0 0
5 Change of the size of the large size paper B4 / 81/2 X14 A3 / 11X17 0 0 0
(maintenance counter) (338mm) or (365mm) or
larger larger
6 Dust proof filter/1 life message display 180,000 prints: 200,000 prints: 0 0 0
timing near life end near life end
200,000 prints: 220,000 prints:
life end life end
7 Print when the dust proof filter/1 life Allowed Prohibited 0 0 0
count is reached
6 0 Faulty part isolation: FD fold and punch Normal Unavailable 0 0 0
function
1 Faulty part isolation: FD main tray paper Normal Unavailable 0 0 0
exit
2 Faulty part isolation: FD post insertion Normal Unavailable 0 0 0
function
3 Faulty part isolation: FS staple function Normal Unavailable 0 0 0
4 Faulty part isolation: FS main tray paper Normal Unavailable 0 0 0
exit
5 Faulty part isolation: FS Normal Unavailable 0 0 0
6 Faulty part isolation: LS main tray paper Normal Unavailable 0 0 0
exit (1st unit)
7 Faulty part isolation: LS main tray paper Normal Unavailable 0 0 0
exit (2nd unit)
222
/C6501P/C65hc/C5501
bizhub PRO C6501

Japan Inch Metric
7 0 Faulty part isolation: SD saddle stitching Normal Unavailable 0 0 0
1 Faulty part isolation: SD multi folding Normal Unavailable 0 0 0
2 Faulty part isolation: SD multi letter Normal Unavailable 0 0 0
3 Faulty part isolation: SD trimming Normal Unavailable 0 0 0
4 Faulty part isolation: SD coupling convey- Normal Unavailable 0 0 0
ance, sub tray paper exit
5 Faulty part isolation : PB cover paper Normal Unavailable 0 0 0
insertion
6 Faulty part isolation : PB binder function Normal Unavailable 0 0 0
7 Faulty part isolation : PB Normal Unavailable 0 0 0
8 0 — — — 0 0 0
1 — — — 0 0 0
2 — — — 0 0 0
3 — — — 0 0 0
4 — — — 0 0 0
5 Counter action for the jam in the *4 *4 0 0 0
reverse/exit section
6 Large size paper count method Count as 1 Count as 2 1 1 1
(maintenance counter)
7 Custom size paper count method *5 *5 1 0 0
9 0 — — — 0 0 0
1 — — — 0 0 0
2 — — — 0 0 0
3 — — — 0 0 0
4 Copy quantity limit *6 *6 0 0 0
5 *6 *6 0 0 0
6 *6 *6 0 0 0
7 *6 *6 0 0 0
10 0 — — — 0 0 0
1 Hard disk image memory Disabled Enabled 1 1 1
2 — — — 0 0 0
3 Change of the size of the large size paper *7 *7 0 0 0
4 (other than maintenance counter) *7 *7 1 0 1
5 Custom size tolerance setting Only with ATS : Tray selection 0 0 0
tolerance is ± and ATS : toler-
2mm ance is ±
10mm
6 Private MIB count method (large size) Count as 2 Count as 1 1 1 1
7 — — — 1 1 1
223 1

bizhub PRO C6501
Japan Inch Metric

11 0 — — — 0 0 0
1 — — — 0 0 0
2 SD multi center folding number limit Enabled Disabled 0 0 0
(Max. 50)
3 Automatic restart of the job under sus- Disabled Enabled 0 0 0
pension
4 Filter for jagged edges on slanting lines Disabled Enabled 0 0 0
5 Thick paper BK mode setting *8 *8 0 0 0
6 Automatic paper supply Disabled Enabled 0 0 0
7 Jam code display Disabled Enabled 0 0 0
12 0 — — — 0 0 0
1 OFF setting of auto low power and auto One is possible Both are possible 0 0 0
shut off
2 — — — 0 0 0
3 — — — 0 0 0
4 — — — 1 1 1
5 — — — 0 0 0
6 — — — 0 0 0
7 Konica Minolta logo when power switch Enabled Disabled 0 0 0
is turned ON
13 0 — — — 0 0 0
1 — — — 0 0 0
2 — — — 0 0 0
3 — — — 0 0 0
4 — — — 0 0 0
5 — — — 0 0 0
6 — — — 0 0 0
7 — — — 0 0 0
14 0 — — — 0 0 0
1 Switching of utility menu counter display Normal Counter 0 0 0
display display for each
size
2 — — — 0 0 0
3 — — — 0 0 0
4 — — — 0 0 0
5 — — — 0 0 0
6 — — — 0 0 0
7 CSRC connection selection *9 *9 0 0 0
1 224
/C6501P/C65hc/C5501
bizhub PRO C6501

Japan Inch Metric
15 0 CSRC connection selection *9 *9 1 1 1
1 CMS function screen display Disabled Enabled 0 0 0
2 Charging corona life display Enabled Disabled 0 0 0
3 FNS alarm stop method *10 *10 0 0 0
4 *10 *10 0 0 0
5 CS Remote Care connection recognition Disabled Enabled 0 0 0
6 Scan send address resetting after scan- Disabled Enabled 0 0 0
ning
7 LDAP function Disabled Enabled 0 0 0
16 0 Scanner magnification setting Disabled Enabled 0 0 0
1 Box name Japanese input Disabled Enabled 0 0 0
2 Coin vendor type Parallel Serial 0 0 0
3 Counting of the key counter in the printer Disabled Enabled 0 0 0
mode
4 Display of machine install date in Utility Enabled Disabled 0 0 0
menu mode
5 Dehumidifier heater temperature control *11 *11 0 0 0
6 (LU/PF) *11 *11 0 0 0
7 — — — 0 0 0
17 0 — — — 0 0 0
1 — — — 1 1 1
2 — — — 1 1 1
3 — — — 0 0 0
4 Density selection at scanning the tab *12 *12 0 0 0
5 paper *12 *12 0 0 0
6 *12 *12 0 0 0
7 — — — 0 0 0
18 0 Faulty part isolation: Tray 1 Normal Unavailable 0 0 0
1 Faulty part isolation: Tray 2 Normal Unavailable 0 0 0
2 Faulty part isolation: Tray 3 Normal Unavailable 0 0 0
3 Faulty part isolation: Tray 4 (LU) Normal Unavailable 0 0 0
4 Print during temperature control by dehu- Prohibited Allowed 0 0 0
midifier heater (LU/PF)
5 Faulty part isolation: FS center fold, sad- Normal Unavailable 0 0 0
dle stitch
6 Faulty part isolation: PI Normal Unavailable 0 0 0
7 Faulty part isolation: HDD Normal Unavailable 0 0 0
225

bizhub PRO C6501
Japan Inch Metric

19 0 — — — 0 0 0
1 Fusing upper and lower roller tempera- *13 *13 1 1 1
2 ture selection *13 *13 1 1 1
3 *13 *13 0 0 0
4 Multi feed detection (PF) Enabled Disabled 0 0 0
5 Faulty part isolation: PF Normal Unavailable 0 0 0
6 Developing motor stop control during *14 *14 0 0 0
7 printing *14 *14 0 0 0
20 0 Group stapling Disabled Enabled 0 0 0
1 Image scanning area with “Page Margin“ Normal Original priority 0 0 0
mode
2 Total page number standard in "Stamp" Based on origi- Based on print 0 0 0
mode nal paper
3 — — — 0 0 0
4 Periodical black toner band creation on Normal Increased at the 0 0 0
the transfer belt edges
5 — — — 0 0 0
6 — — — 0 0 0
7 — — — 0 0 0
21 0 PB perfect binding limit number High-quality Plain paper 0 0 0
switchover paper/color table
paper/coated
paper table
1 PB warm-up control switchover Warm up Not warm up 1 1 1
(effective by power OFF/ON after the set- when power when power
ting change) switch is turned switch is turned
ON ON
2 PB heater control switchover Turn OFF the Not turn OFF 0 0 0
(effective by power OFF/ON after the set- heater automati- the heater auto-
ting change) cally after com- matically after
pletion of completion of
perfect binding perfect binding
3 257-300g/m2 paper exit with its face up Not allowed Allowed 0 0 0
4 Faulty part isolation: Tray4 (PF) Normal Unavailable 0 0 0
5 Faulty part isolation: Tray5 (PF) Normal Unavailable 0 0 0
6 — — — 0 0 0
7 — — — 0 0 0
226
/C6501P/C65hc/C5501
bizhub PRO C6501

Japan Inch Metric
22 0 Machine NIC setting Disabled Enabled 1 1 1
1 Number of punch holes *15 *15 1 1 0
2 (effective by power OFF/ON after the set- *15 *15 0 0 1
ting change)
3 Image position for the custom size origi- Based on user Based on APS 0 0 0
nal (when using DF) selection at DF
4 Function of the power save key Enabled Disabled 0 0 0
5 SD trimming board adjustment display Disabled Enabled 0 0 0
6 Operation when FS runs out of staple Staple supply Selecting 0 0 0
request between staple
supply or staple
release
7 — — — 0 0 0
23 0 — — — 0 0 0
1 — — — 0 0 0
2 Precision of the color registration auto- Normal *16 Fine *16 0 0 0
matic correction (during printing)
3 Control of the color registration automatic Enabled *17 Disabled *17 0 0 0
correction (periodical correction)
4 The color registration automatic correc- Enabled *18 Disabled *18 0 0 0
tion in main scan direction (periodical cor-
rection)
5 Gamma correction (IC) Enabled Disabled 1 1 1
6 FS-521 far side staple angle 45 degree Parallel 0 0 0
(effective by power OFF/ON after the set- diagonal
ting change)
7 Punch auto switching (PK/FD) Disabled Enabled 1 1 1
(effective by power OFF/ON after the set-
ting change)
24 0 Simple-gamma correction counter reset Reset when Not reset when 0 0 0
print job is print job is
started started
1 — — — 0 0 0
2 Image stabilization control Enabled Disabled 0 0 0
3 — — — 1 1 1
4 — — — 0 0 0
5 — — — 0 0 0
6 — — — 0 0 0
7 — — — 0 0 0
227

bizhub PRO C6501
Japan Inch Metric

25 0 — — — 0 0 0
1 — — — 0 0 0
2 — — — 0 0 0
3 Color registration automatic correction *19 *19 0 0 0
4 control *19 *19 0 0 0
5 Precision of the color registration auto- Normal *20 Speed prefer- 0 0 0
matic correction ence *20
6 — — — 0 0 0
7 Dehumidifier heater (standard heater) Enabled Disabled 0 0 0
26 0 — — — 0 0 0
1 — — — 0 0 0
2 — — — 0 0 0
3 Multi feed detection (PI/PB) Enabled Disabled 0 0 0
(effective by power OFF/ON after the set-
ting change)
4 Printer auto centering correction (LU, PF) Enabled Disabled 0 0 0
5 Printer auto centering correction (ADU) Enabled Disabled 0 0 0
6 — — — 0 0 0
7 — — — 0 0 0
27 0 — — — 0 0 0
1 — — — 0 0 0
2 — — — 0 0 0
3 — — — 0 0 0
4 — — — 0 0 0
5 — — — 0 0 0
6 — — — 0 0 0
7 — — — 0 0 0
28 0 — — — 0 0 0
1 — — — 0 0 0
2 — — — 0 0 0
3 — — — 0 0 0
4 — — — 0 0 0
5 — — — 0 0 0
6 — — — 0 0 0
7 — — — 0 0 0
228
/C6501P/C65hc/C5501
bizhub PRO C6501

Japan Inch Metric
29 0 — — — 0 0 0
1 — — — 0 0 0
2 — — — 1 1 1
3 Inclusion of proof copy to the set copy Disabled Enabled 0 0 0
quantity
4 — — — 0 0 0
5 — — — 0 0 0
6 PB perfect binding minimum number of Follow the set- 6 sheets (81g/ 0 0 0
the inside paper ting of the Utility m2 or heavier)
menu
7 — — — 0 0 0
30 0 — — — 0 0 0
1 Restriction of the display of the service Disabled Enabled 0 0 0
mode "List output"
2 — — — 0 0 0
3 — — — 1 1 1
4 — — — 0 0 0
5 PB perfect binding limit (includes Z-fold) Enabled Disabled 0 0 0
6 — — — 0 0 0
7 — 0 0 0
31 0 — — — 1 1 1
1 SRA4,SRA3 main tray paper exit of FS- Disabled Enabled 0 0 0
607
2 Z-fold max paper exit capacity: FS-521 *21 *21 0 0 0
3 main tray *21 *21 0 0 0
Z-fold, center-fold max paper exit capac-
ity: FD main tray
4 FS-521 Z-fold + Staple output number *22 *22 0 0 0
limit
5 *22 *22 0 0 0
6 — — — 0 0 0
7 — — — 0 0 0
32 0 Default setting of gamma correction con- Other than For C65hc 0: Other than C65hc
trol C65hc 1: C65hc
1 Contone output of solid text (IC) Disabled Enabled 1 1 1
2 Internal trapping (IC) Disabled Enabled 1 1 1
3 — — — 0 0 0
4 — — — 0 0 0
5 — — — 0 0 0
6 — — — 0 0 0
7 — — — 0 0 0
229 1
Note
/C6501P/C65hc/C5501
• Bold boxes show default settings.

bizhub PRO C6501
*1 Print stop method after displaying toner supply Mode 1-3 1-2
or waste toner full display
Stops after ejecting paper 0 0
This switch is to select whether to display process
in the machine
adjustment button on the [Paper Setting] screen of
Stops at a break between 0 1
[MACHINE] screen.
copy set
Stops at the end of the 1 0
current job
Does not stop 1 1
*2 Number of allowed print quantity after reaching Mode 1-7 1-6 1-5
the maintenance count
1,000 prints 0 0 0
2,000 prints 0 0 1
3,000 prints 0 1 0
4,000 prints 0 1 1
5,000 prints 1 0 0
1,000 prints 1 0 1
1,000 prints 1 1 0
1,000 prints 1 1 1
230
*3 Large size paper counting method (other than
/C6501P/C65hc/C5501
maintenance counter)
bizhub PRO C6501

This switch is used to set count of large size paper
print as 1 or 2. It changes count method for other
than maintenance counter.
The related switches are DIPSW5-5, 8-6 and 10-3
through 4.
Default differs depending on the main body destina-
tion.
Refer to the following list for the default in each area.
Destination Counter Mode Large-size count number DIPSW default

A3/11 x 17 B4/8.5 x 14
Japan Maintenance Color 2 2 5-5-0
counter Black and White 2 2 8-6-1
Other than main- Color 2 2 4-6-0
tenance counter Black and White 1 1 4-7-1
10-3-0
10-4-1
Europe Maintenance Color 2 2 5-5-0
10-3-0
10-4-1
North America Maintenance Color 2 2 5-5-0
10-3-0
10-4-0
Others Maintenance Color 2 2 5-5-0
10-3-0
10-4-1
231
*4 Counter action for the jam in the reverse section

/C6501P/C65hc/C5501
Mode 8-5
When the jam occured with 8.5x11 thin-paper in the
bizhub PRO C6501
Disabled 0
reverse exit section, prevents the papers from attach-
Enabled (Counter action for 1
ing together by hastening the reversing speed.
the jam)
*5 Custom size paper count method Mode 8-7

This switch changes the standard of custom size Infinite 1: 196mm or shorter 0
paper used for Paper Size Counter. Infinite 2: 250mm or shorter
Infinite 3: 330mm or shorter
Infinite 5: 391mm to 456mm
Longpaper: 457mm or longer
Infinite 1: 196mm or shorter 1
Infinite 5: 900mm or longer
*6 Copy quantity limit Mode 9-7 9-6 9-5 9-4

No limit 0 0 0 0
1 print 0 0 0 1
3 prints 0 0 1 0
5 prints 0 0 1 1
9 prints 0 1 0 0
10 prints 0 1 0 1
20 prints 0 1 1 0
30 prints 0 1 1 1
50 prints 1 0 0 0
99 prints 1 0 0 1
No limit 1 0 1 0
No limit 1 0 1 1
No limit 1 1 0 0
No limit 1 1 0 1
No limit 1 1 1 0
No limit 1 1 1 1
*7 Change of the size of the large size paper (other Mode 10-4 10-3
than maintenance counter)
A3 / 11X17 or larger 0 0
This switch changes the standard of large size paper
All sizes are small 0 1
used for counter control other than maintenance
B4 / 81/2 X 14 / 8K or larger 1 0
counter.
81/2 X 13, 1 1
81/4 X 13, 81/8 X 131/4,
8 X 13 or larger
In the case of custom size
paper, 330mm or more in
sub scan direction.
2 232
*8 Thick paper BK mode setting
/C6501P/C65hc/C5501
Mode 11-5
This setting is for reducing the boundings which
bizhub PRO C6501

Disabled 0
occur to the area 230mm inner from paper edges
Enabled 1
when printing the halftone image with thick paper.
"Thick Paper BK Mode" is displayed on User Setting /
Machine Manager Setting by selecting "1" for this
setting and it enables users to turn ON/OFF the
bounding reducing mode.
In case it turns ON, it presses first transfer roller on
each YMC colors and operates in color mode during
printing in B/W mode.
NOTE
• Use only for thick paper on which the bound-
ing occurs.
• Since even the printing in B/W mode operates
in color mode, the total counter counts in B/
W and the maintenance counter counts in
color. (It does not develop YMC but the life of
the developer is shorten since it agitates the
developing unit.)
• In the case of the color printing after printing
more than 1000 sheets in a row in this mode,
it causes toner scattering or blurred color
image.
*9 CSRC function selection Mode 15-0 14-7

Setting to switch CSRC function.
Telephone 0 0
Mail 1 0
http 0 1
Disabled 1 1
*10 FS alarm stop method Mode 15-4 15-3

This switch is used to select alarm stop condition.
Stop immediately after 0 0
Alarm stop means detection of the following states.
detection
FD/FS/LS tray lower limit, FD/FS/LS/SD tray paper
Stops at a break between 0 1
full, FD/PK punch waste full, FS staple waste full, SD
print set after detection
trimming waste full
Does not stop while 1 0
printing
Does not stop while 1 1
printing
233
*11 Dehumidifier heater temperature control (LU/

/C6501P/C65hc/C5501
Mode 16-6 16-5

PF)
bizhub PRO C6501
Environment temperature 0 0
With LU, PF option dehumidifier heater is connected,
+6 °C
this switch is used to set control temperature when
dehumidifier fan heater control is set to [On (compul-
+8 °C
sory) ] in the Utility menu mode.
+10 °C
+6 °C
*12 Density selection at scanning tab paper Mode 17-6 17-5 17-4
This switch is used to select background density
Brightness level 80 0 0 0
when scanning tabed paper.
(Lightest)
Brightness level (Darkest) 1 1 1
*13 Fusing upper and lower roller temperature Mode 19-3 19-2 19-1
selection
-30 °C 0 0 0
This switch is used to change the fusing standard
-20 °C 0 0 1
control temperature. Decrease temperature against
-10 °C 0 1 0
paper curling or waving and increase temperature
against insufficient fusing or fusing winding jam. Standard 0 1 1
Upper roller: standard 1 0 0
Lower roller: +10 °C
Standard 1 0 1
Standard 1 1 0
Standard 1 1 1
*14 Developing motor stop control during printing Mode 19-7 19-6
Normal 0 0
(automatic switchover)
Rotation at 1/4 speed 0 1
when image is not devel-
oped
OFF when image is not 1 0
developed
Normal 1 1
(automatic switchover)
234
*15 Number of punch holes
/C6501P/C65hc/C5501
Mode 22-2 22-1
This switch changes prohibition control by paper size,
bizhub PRO C6501

2-hole 0 0
which differs depending on the number of punch
2/3-hole switchover 0 1
holes. It also changes the number of holes on the
punch hole select screen of user mode. 2/4-hole switchover 1 0
Swedish 4-hole
— 1 1
*16 Precision of the color registration automatic Mode 23-2

correction (during printing)
Normal 0
This switch changes accuracy of color registration
Fine 1
correction that is performed periodically during print-
ing. If fine is selected, the registration accuracy
improves by approx. 0.5 pixels, but the correction
time takes 2 minutes longer.
*17 Control of the color registration automatic cor- Mode 23-3

rection (periodical correction)
Enabled 0
Down time while in the continuous printing is reduced
Disabled 1
by disable the color registration correction that is per-
formed periodically. (Color registration correction
when the fusing temperature is lower than the speci-
fied temperature at power ON is not omitted.)
Mode 23-4
*18 The color registration automatic correction in
Enabled 0
main scan direction (periodical correction)
Disabled 1
The color registration correction that is performed
periodically can be disabled in the main scan direc-
tion only. This is used temporarily when there is a reg-
istration error along the main scan as a result of a
trouble around the transfer belt unit, or when isolating
faulty part.
*19 Color registration automatic correction control Mode 25-4 25-3

This switch is used to change the timing of periodical
Enabled 0 0
color registration correction control or disable the cor-
Disabled 0 1
rection.
No performed during 1 0
• Enable: Correction is performed by suspending
printing
print at specified print.
• Disable: Correction is omitted temporarily to — 1 1
reduce down time when the machine cannot be
used with malfunction code related to the drum
potential sensor or PGC sensor.
• No performed during printing: Correction that is
performed by suspending print at every specified
print is performed after the print job to reduce
down time.
235
*20 Precision of the color registration automatic

/C6501P/C65hc/C5501
Mode 25-5
correction
bizhub PRO C6501
Normal 0
This switch changes accuracy of color registration
Speed preference 1
correction that is performed automatically. If speed
preference is selected, the correction time can be
shorten. Correction time of "speed preference" is
approx. 30 seconds.
*21 Z-fold max paper exit capacity: FS-521 main Mode 31-3 31-2
tray
50 sheets 0 0
Z-fold,center-fold max paper exit capacity: FD
40 sheets 0 1
main tray
30 sheets 1 0
This switch is used to select the max stacking capac-
ity of paper which is Z-folded or center-folded by FD 20 sheets 1 1
on the FS or FD main tray during continuous printing.
If folding performance is poor and causing paper jam
or dropping from tray, reduce the max stacking
capacity of folded paper using this switch.
(effective by power OFF/ON after the setting change)
*22 FS-521 Z-fold + Staple number limit Mode 31-5 31-4

5 sheets 0 0
This switch is used to set the max number of FS-521
8 sheets 0 1
Staple Z-folded papers included in 50 sheets (A3
10 sheets 1 0
size).
3 sheets 1 1
236
9.5.2 Telephone Number Setting
/C6501P/C65hc/C5501
Register telephone and fax numbers of a service center that will be displayed in help information or when a mal-
bizhub PRO C6501

function occurs.
A. Procedure

Press [02 Telephone Number Setting].
3. "Customer Support TEL/FAX Setting screen"
Press either of [Service Center Tel (16)] or [Service Center Fax (16)] that you want to set.
4. Enter telephone number or fax number to be registered with the numeric buttons.
Note
• When a number is less than 16 digits, be sure to use hyphens or etc to fill up the blanks.
5. Press [OK] to register the data.
Press [Cancel] to cancel the operation.
9.5.3 M/C Serial Number Setting

Set and display the serial numbers of the main body and options.
Note
• The serial number of the main body cannot be changed.
A. Procedure

Press [03 M/C Serial Number Setting].
3. "Serial Number Setting Mode screen"
Select the option, then a keyboard screen appears. Enter a serial number using the alphanumeric buttons.
4. Press [OK] to register the data.
237
9.5.4 Setup Date Input

/C6501P/C65hc/C5501
Set the starting date of the total counter that is displayed on the screen in the utility menu mode.
bizhub PRO C6501
When the DIPSW 16-4 is set to "1", the starting date of the total counter is not displayed.
A. Procedure

Press [04 Setup Date Input].
3. "Setup Date Input screen"
Enter an installation date with the numeric buttons. Press [Set] to highlight the Year/Month/Date to be
entered.
4. Press [OK] to update the data.
238
9.6 Counter/data
/C6501P/C65hc/C5501
bizhub PRO C6501
9.6.1 Maintenance Counter
Set or reset the maintenance counter cycle.
Note
• The maintenance cycle can be set either paper count (Quantity) or travel distance (m) of the devel-
oping roller/K (Distance). "Quantity" is selected by default.
• The count condition of the maintenance counter varies depending on the DIPSW8-6 settings.
0: 1 count for a single side of each paper exit, and 2 counts for a double side.
1: 2 counts for a single side of each large size paper exit (the definition of large size paper is set by
DIPSW10-3 and 4), and 4 counts for a double side. For those other than the large size, the count
is same as when set to "0."
A. Counter reset
After the maintenance is completed, reset the maintenance count using this mode.
Note
• Be sure to reset the maintenance counter after the periodic maintenance (every 200,000 prints
(PRO C6501)/every 150,000 prints (PRO C5501)).
If it is not reset, the warning message and icon for periodic maintenance will not be disappeared.
(1) Procedure

Press [04 Counter/Data]
2. "Counter/Data Menu screen"
Press [01 Maintenance Counter].
3. "Maintenance Counter screen"
Press [Count Reset] to reset the maintenance counter.
4. "Reset confirmation screen"
Press [Yes] to reset.
The count is reset and the starting date is automatically entered.
Press [No] to cancel.
239
B. Maintenance cycle setting

/C6501P/C65hc/C5501
Set the maintenance cycle counter.

bizhub PRO C6501
Note
• The maintenance counter is predetermined. Be sure not to change the count value normally. Default setting
is set to 200,000 (PRO C6501)/150,000 (PRO C5501) prints and 130,000 m (PRO C6501/C5501).
(1) Procedure

Press [04 Counter/Data]
Press [01 Maintenance Counter].
Enter high digits of the cycle with the numeric buttons.
Press [OK] to register the data. Press [Cancel] to cancel the opreration.
240
9.6.2 Data Collection
/C6501P/C65hc/C5501
Display the counter/data of the main body shown below on the touch panel.
bizhub PRO C6501

Counter/data can also be checked in the CS Remote Care, List Output and Mail Remote Notification System.
• Paper Size Counter (Total)

• Paper Size Counter (Copy)
• Paper Size Counter (Print)
• ADF Counter
• Coverage Data History
• Paper Jam History
• Jam Counter
• Copy Mode Counter (1)
• Copy Mode Counter (2)
• SC Counter
• Paper Jam Sectional Counter
• Failure Sectional Counter
• SC data of time series
A. Procedure

Press [04 Counter/Data].
Press [02 Data Collection].
3. "Parts Counter Menu screen"
Press the counter/data item you want to check.
4. "Collecting Data screen"
Press [Next] or [Previous] to scroll the pages.
Note
• [Count Reset] is displayed on each screen of [Paper Jam Sectional Counter] and [SC data of
time series]
"Count Reset confirmation screen" appears when [Count Reset] is pressed. Press [Yes] to reset
the sectional count. Press [No] to cancel the count reset.
By resetting these data when you visit the customer of the maintenance implementation etc. you
can check the jam and malfunction occurrence count after it was visited last time.
241
B. Paper Size Counter (Total/Copy/Print)

/C6501P/C65hc/C5501
Confirm the number of print of each paper size.

bizhub PRO C6501
Note
• Maximum count number is 99,999,999.
• Count value is one count each for all kinds of paper size.
No. CSRC parameter Size Remarks

(B1,B6,B8,
BD,BE,BF)
01 00 Others
02 01 A3
03 02 A4
04 03 A5
05 04 A6
06 05 B4
07 06 B5
08 07 B6
09 08 12 x 18
10 09 11 x 17
11 0A 8.5 x 14
12 0B 8.5 x 11
13 0C 7.25 x 10.5
14 0D 5.5 x 8.5
15 0E F4
16 0F Post card
17 10 4x6
18 11 8K
19 12 16K
20 13 Long paper
21 14 A2
22 15 SRA3
23 16 SRA4
24 17 13 x 19
25 18 Infinite 1 Custom size: 196 mm or shorter in sub-scan direc-
tion. (When DIPSW 8-7 is 0)
Custom size: 196 mm or shorter in sub-scan direc-
26 19 Infinite 2 Custom size: 250 mm or shorter in sub-scan direc-
2 242
/C6501P/C65hc/C5501
27 1A Infinite 3 Custom size: 330 mm or shorter in sub-scan direc-
bizhub PRO C6501

28 1B Infinite 4 Custom size: 390 mm or shorter in sub-scan direc-
29 1C Infinite 5 Custom size: 391 mm to 456 mm in sub-scan direc-
Custom size: 900 mm or longer in sub-scan direc-
C. ADF Counter
Confirm the number of originals fed in each DF mode.
Note
• Maximum count number is 99,999,999.
• No.01 and No.02 counter do not double count with other counters.
• One count for single-sided, 2 counts for double-sided.
No. CSRC parameter Item Remarks

(F0)
01 00 N of originals fed in ADF mode/1 side
02 01 N of originals fed in ADF mode/2 side
03 02 N of originals fed in RDH mode Reserved
04 03 N of originals fed in RRDH mode Reserved
05 04 N of originals fed in LDF mode Reserved
06 05 N of originals fed in CFF mode Reserved
07 06 N of 1-sided SDF original fed Reserved
08 07 N of mix originals fed in ADF/1 side
09 08 N of mix originals fed in ADF/2 side
10 09 N of originals fed in 2in1 mode Reserved
11 0A N of 1-sided Z-folded original fed
12 0B N of 2-sided Z-folded original fed
13 0C N of 2-sided SDF original fed Reserved
243 2
D. Coverage Data History

/C6501P/C65hc/C5501
Confirm the average coverage of 5,000 print sheets of the latest 30 data for each of Y, M, C and K.
bizhub PRO C6501
Note
• The coverage data is a calculated value based on the colored area and the transfer paper area of
the image data. Therefore, it is different from the toner consumption when actually printed.
• Up to 30 latest coverage data are maintained with the older ones deleted in sequence.
No. CSRC parameter Print count Coverage

(V0) (%)
01 00 Total (00.0 to 99.9)
02 01 Print count 1
03 02 Print count 2
04 03 Print count 3
05 04 Print count 4
06 05 Print count 5
07 06 Print count 6
08 07 Print count 7
09 08 Print count 8
10 09 Print count 9
11 0A Print count 10
12 0B Print count 11
13 0C Print count 12
14 0D Print count 13
15 0E Print count 14
16 0F Print count 15
17 10 Print count 16
27 1A Print count 26
28 1B Print count 27
29 1C Print count 28
30 1D Print count 29
31 1E Print count 30
244
E. Paper Jam History
/C6501P/C65hc/C5501
Confirm the latest 100 jams, it is possible to confirm jam code, total count, date of occurrence, tray used, paper
bizhub PRO C6501

size, and magnification.
F. JAM/Paper Jam Sectional Counter

Confirm the number of jam occurrences for each jam code.
Note
• Maximum count is 999,999.
• The stationary jam is not included in the count.
• Jam code is displayed on the user mode screen when changing the DIPSW11-7 to 1.
No. CSRC Item No. CSRC Item No. CSRC Item

parameter (Jam code) parameter (Jam code) parameter (Jam code)
(J0) (J0) (J0)
001 00 J-1001 031 1E J-1657 061 3C J-3254
002 01 J-1002 032 1F J-1658 062 3D J-5101
003 02 J-1003 033 20 J-1701 063 3E J-9201
004 03 J-1051 034 21 J-1702 064 3F J-9202
005 04 J-1101 035 22 J-1703 065 40 J-9251
006 05 J-1151 036 23 J-1704 066 41 J-9252
007 06 J-1201 037 24 J-1705 067 42 J-9301
008 07 J-1251 038 25 J-1706 068 43 J-9351
009 08 J-1301 039 26 J-1707 069 44 J-9401
010 09 J-1351 040 27 J-1708 070 45 J-9451
011 0A J-1501 041 28 J-1709 071 46 J-6101
012 0B J-1502 042 29 J-1710 072 47 J-6102
013 0C J-1551 043 2A J-1751 073 48 J-6103
014 0D J-1552 044 2B J-1752 074 49 J-6201
015 0E J-1601 045 2C J-1753 075 4A J-6203
016 0F J-1602 046 2D J-1754 076 4B J-6206
017 10 J-1603 047 2E J-1901 077 4C J-6209
018 11 J-1604 048 2F J-1902 078 4D J-6301
019 12 J-1605 049 30 J-1903 079 4E J-6304
020 13 J-1606 050 31 J-3201 080 4F J-6305
021 14 J-1607 051 32 J-3202 081 50 J-6501
022 15 J-1608 052 33 J-3203 082 51 J-6502
023 16 J-1609 053 34 J-3204 083 52 J-6504
024 17 J-1610 054 35 J-3205 084 53 J-6508
025 18 J-1651 055 36 J-3206 085 54 J-7101
026 19 J-1652 056 37 J-3207 086 55 J-7103
027 1A J-1653 057 38 J-3209 087 56 J-7105
028 1B J-1654 058 39 J-3251 088 57 J-7106
029 1C J-1655 059 3A J-3252 089 58 J-7107
030 1D J-1656 060 3B J-3253 090 59 J-7216
245

bizhub PRO C6501
(J0) (J0) (J0)

091 5A J-7217 132 83 J-7666 173 AC J-7510
092 5B J-7218 133 84 J-7667 174 AD J-7511
093 5C J-7219 134 85 J-7668 175 AE J-7512
094 5D J-7220 135 86 J-7669 176 AF J-7513
095 5E J-7221 136 87 J-7670 177 B0 J-7514
096 5F J-7222 137 88 J-7671 178 B1 J-7515
097 60 J-7223 138 89 J-7672 179 B2 J-7516
098 61 J-7224 139 8A J-7673 180 B3 J-7517
099 62 J-7225 140 8B J-7674 181 B4 J-7518
100 63 J-7226 141 8C - 182 B5 J-7519
101 64 J-7228 142 8D J-7676 183 B6 J-7520
102 65 J-7229 143 8E J-7677 184 B7 J-7521
103 66 J-7230 144 8F J-7678 185 B8 J-7522
104 67 J-7235 145 90 J-7679 186 B9 J-7523
105 68 J-7243 146 91 J-7680 187 BA J-7524
106 69 J-7248 147 92 J-7681 188 BB J-7540
107 6A J-7249 148 93 J-7682 189 BC J-7541
108 6B J-7250 149 94 J-7683 190 BD J-7542
109 6C J-7251 150 95 J-7684 191 BE J-7543
110 6D J-7281 151 96 J-7685 192 BF J-7561
111 6E J-7282 152 97 J-7686 193 C0 J-7562
112 6F J-7283 153 98 J-7687 194 C1 J-7563
113 70 J-7290 154 99 J-7688 195 C2 J-7564
114 71 J-7401 155 9A J-7689 196 C3 J-7565
115 72 J-7402 156 9B J-7690 197 C4 J-7566
116 73 J-7403 157 9C J-7691 198 C5 J-7567
117 74 J-7404 158 9D J-7692 199 C6 J-7568
118 75 J-7405 159 9E J-7693 200 C7 J-7569
119 76 J-7406 160 9F J-7696 201 C8 J-7570
120 77 J-7407 161 A0 J-7697 202 C9 J-7571
121 78 J-7408 162 A1 J-7698 203 CA J-7572
122 79 J-7409 163 A2 J-7108 204 CB J-7573
123 7A J-7410 164 A3 J-7501 205 CC J-7574
124 7B J-7411 165 A4 J-7502 206 CD J-7575
125 7C J-7412 166 A5 J-7503 207 CE J-7576
126 7D J-7660 167 A6 J-7504 208 CF J-7577
127 7E J-7661 168 A7 J-7505 209 D0 J-7578
128 7F J-7662 169 A8 J-7506 210 D1 J-7579
129 80 J-7663 170 A9 J-7507 211 D2 J-7580
130 81 J-7664 171 AA J-7508 212 D3 J-7581
131 82 J-7665 172 AB J-7509 213 D4 J-7582
1 246
/C6501P/C65hc/C5501
bizhub PRO C6501

(J0) (J0) (J0)
214 D5 J-7583 223 DE J-7592 232 E7 J-7532
215 D6 J-7584 224 DF J-7593 233 E8 J-7533
216 D7 J-7585 225 E0 J-7594 234 E9 J-7535
217 D8 J-3101 226 E1 J-7595 235 EA J-7102
218 D9 J-3102 227 E2 J-7596 236 EB J-7675
219 DA J-3151 228 E3 J-7597 237 EC J-7681
220 DB J-3152 229 E4 J-7109 238 ED J-7694
221 DC J-7590 230 E5 J-7530 239 EE J-7695
222 DD J-7591 231 E6 J-7531 240 EF J-1611
G. Copy Mode Counter (1)

Confirm the status of use of each copy mode.
Note
• Maximum count is 99,999,999.
No. CSRC Item Count condition

parameter
(F1)
001 00 1 → 1mode
002 01 1 → 2 mode
003 02 2 → 1 mode
004 03 2 → 2 mode
005 04 ADF 1>1 mode
006 05 ADF 2>2 mode
007 06 Mixed original mode
008 07 Tab original mode
009 08 Z-Folded original mode
010 09 LEF: Portrait/SEF: Landscape (Reg.)
011 0A LEF: Landscape/SEF: Portrait (Reg.)
012 0B LEF: Portrait/SEF: Landscape (Rev.)
013 0C LEF: Landscape/SEF: Portrait (Rev.)
014 0D Image: text/photo
015 0E Image: Text
016 0F Image: Photo
017 10 Image: Map
018 11 Custom Size
019 12 Corner Staple (Top Left)
020 13 Corner Staple (Top Right)
021 14 2 Positions Staple (Left Bind)
022 15 2 Positions Staple (Top Bind)
247 1

parameter
bizhub PRO C6501
(F1)
023 16 Right/Left binding
024 17 Right Bind Counts when the right binding booklet
is selected.
025 18 Top Bind
026 19 Triple-Fold
027 1A Fold & Staple
028 1B Stacker 5000-sheets loading alarm
029 1C Uncollate
030 1D Offset uncollate
031 1E Collate
032 1F Offset Collate
033 20 Face Down
034 21 Face Up
035 22 1 to N
036 23 N to 1
037 24 —
038 25 Paper Inserter
039 26 Trimmer
040 27 Real size copy
041 28 Preset magnification E4
042 29 Preset magnification E3
043 2A Preset magnification E2
044 2B Preset magnification E1
045 2C Preset magnification R4
046 2D Preset magnification R3
047 2E Preset magnification R2
048 2F Preset magnification R1
049 30 User lens mode 1
052 33 Zoom
053 34 Vertical/Horizontal zoom
054 35 Maximum zoom
055 36 Minimum zoom
056 37 APS
057 38 AMS
058 39 AES
059 3A User density level 1
060 3B User density level 2
061 3C Interrupted copy
062 3D Auto image rotation cancellation
248
/C6501P/C65hc/C5501
parameter
bizhub PRO C6501

(F1)
063 3E Insert Sheet
064 3F Chapters control
065 40 Combine Originals
066 41 Booklet Pagination
067 42 —
068 43 —
069 44 Insert Image
070 45 Book Copy
071 46 Program Job
072 47 Non-image Area Erase
073 48 Neg./Positive Reverse
074 49 Auto repeat
075 4A Manual repeat
076 4B Standard Size repeat
077 4C Frame erase
078 4D Center erase
079 4E Image centering
080 4F All-image Area
081 50 Shift
082 51 Reduce & Shift
083 52 Image Overlay
084 53 Watermark
085 54 Built-in Stamp
086 55 Date/Time
087 56 Page
088 57 Numbering
089 58 Set quantity 1
090 59 Set quantity 2 - 5
091 5A Set quantity 6 - 10
092 5B Set quantity 11 or more
093 5C Time while power remote 1 is On Accumulation of time during which the
overall control board is powered (main
power switch is ON). (unit: min.)
094 5D Time while power remote 2 is On Time during which the power control
signal (REM2) is ON. (unit: min.)
095 5E Time while power remote 3 is On Time during which the power control
096 5F Time while power remote 4 is On Time during which the power control
097 60 Time during Low Power mode Time in the LOW POWER mode. (unit:
min.)
249

parameter
bizhub PRO C6501
(F1)
098 61 Time during warm up time Time for warm-up, before ready to
print status. (unit: min.)
099 62 Time during front door open Time during which the front door is
open. (unit: min.)
100 63 Ope. time in 1 side straight exit Time from the start of print and the
101 64 Ope. time in 1 side reverse exit end of print. (unit: sec.) (Down time
102 65 Operation time in 2 side print due to jam omitted)
103 66 Operation time in ADF mode Time during which DF operates.(unit:

min.)
104 67 Morning Correction count Counts 1 per image stabilization con-
trol.
105 68 Time during APS sensor On Time during which the APS sensor is
ON. (unit: min.)
106 69 —
107 6A —
108 6B N of Fold & Staple used jobs
109 6C Fold & Staple Tri-Fold Full
110 6D N of ADF NF occured Number of DF no feed detection.
111 6E N of ADF special error1 occurred Number of original size miss-detection.
112 6F N of ADF special error2 occurred Number of next original information error.
113 70 N of ADF special error3 occurred Number of mixed size mode error
114 71 N of scanner scanned Counts 1 for pressing Start key in the
platen mode.
115 72 N of electrode cleaned
116 73 N of memory overflow Total count of No.124, 125, 126 and
the number of occurrences of HDD
reading over flow.
117 74 N of fusing alarm occurred
118 75 N of no toner stop occurred Total count of the 4 colors.
119 76 N of AGC retry
120 77 N of sub scan beam correct error
121 78 N of mis-centering correct error
122 79 N of ADF distortion adjust error
123 7A N of ADF distortion data error
124 7B Compression memory overflow
125 7C Page memory overflow (scan)
126 7D Page memory overflow (print)
127 7E FNS alarm (tray/trimming)
128 7F FNS alarm (staple)
129 80 Saddle Stitcher trimmer scraps box full alarm
130 81 N of ADF special error4 occurred Ready time out error
131 82 —
250
/C6501P/C65hc/C5501
parameter
bizhub PRO C6501

(F1)
132 83 —
133 84 —
134 85 —
135 86 —
136 87 —
137 88 Saddle Stitcher staple alarm
138 89 —
139 8A —
140 8B —
141 8C —
142 8D —
143 8E Punch
144 8F Z-Folding
145 90 Multi Folder Punch Waste Full
146 91 —
147 92 —
148 93 —
149 94 —
150 95 —
151 96 —
152 97 —
153 98 —
154 99 —
155 9A —
156 9B —
157 9C —
158 9D —
159 9E —
160 9F —
161 A0 —
162 A1 —
163 A2 —
164 A3 —
165 A4 —
166 A5 —
167 A6 —
168 A7 —
169 A8 —
170 A9 —
171 AA —
172 AB —
251

parameter
bizhub PRO C6501
(F1)
173 AC —
174 AD —
175 AE —
176 AF —
177 B0 —
178 B1 —
179 B2 —
180 B3 —
181 B4 —
182 B5 —
183 B6 —
184 B7 —
185 B8 —
186 B9 —
187 BA —
188 BB —
189 BC —
190 BD —
191 BE —
192 BF —
193 C0 PB cover paper tray mode
194 C1 —
195 C2 —
196 C3 —
197 C4 Number of ejected paper on the sub tray (per-
fect binding)
198 C5 Number of ejected paper on the SC cection
(perfect binding)
199 C6 Number of times PB tray is pulled
200 C7 Number of times PB front door is opened/closed
201 C8 Number of times PB book stock cover opened/closed
202 C9 Copy protection
203 CA Total number of PB perfect binding books
204 CB Total number of PB perfect binding books (0.0 to
10.0mm)
205 CC Total number of PB perfect binding books (10.1
to 20.0mm)
206 CD Total number of PB perfect binding books (20.1
to 30.0mm)
207 CE Number of PB total inside pages
208 CF PB total thickness
252
H. Copy Mode Counter (2)
/C6501P/C65hc/C5501
Confirm the status of use of each copy mode.
bizhub PRO C6501

Note

parameter
(F2)
001 00 ACS
002 01 Full color
003 02 Black
004 03 Single Color (Y)
005 04 Single Color (M)
006 05 Single Color (C)
007 06 Single Color (R)
008 07 Single Color (G)
009 08 Single Color (B)
010 09 DF Thick paper
011 0A DF Thin paper
012 0B Type: Printed paper
013 0C Type: Photo paper
014 0D Type: Copied paper
015 0E Type: Inkjet paper
016 0F B-side Prevent
017 10 Screen: Auto
018 11 Screen: Line1
019 12 Screen: Line2/Type1
020 13 Screen: Dot1
021 14 Screen: Dot2/Type1
022 15 Screen: Compression
023 16 Glossy
024 17 Density shift
025 18 Adjust Background
026 19 Red
027 1A Green
028 1B Blue
029 1C Hue adjustment
030 1D Saturation adjustment
031 1E Brightness adjustment
032 1F Color balance adjustment
033 20 Sharpness adjustment
034 21 Contrast adjustment
035 22 Image Distinction Level
036 23 Paper type: Plain
253

parameter
bizhub PRO C6501
(F2)
037 24 Paper type: Coated-ML
038 25 Paper type: Color paper
039 26 Paper type: High quality
040 27 Paper type: Coated-GL
041 28 Paper type: Tab paper
042 29 Paper type: Color specific paper
043 2A Paper type: Coated-GO
044 2B Paper type: Coated-MO
045 2C Paper weight: 1
046 2D Paper weight: 2
047 2E Paper weight: 3
048 2F Paper weight: 4
049 30 Paper weight: 5
053 34 Multi-page enlargement
054 35 Main tray: Face up
055 36 N of no toner stop occurred (Y)
056 37 N of no toner stop occurred (M)
057 38 N of no toner stop occurred (C)
058 39 N of no toner stop occurred (K)
059 3A N of toner recovery box is full
060 3B N of color registration adj.
061 3C N of auto stability control
062 3D —
063 3E —
064 3F —
065 40 Off mode time Time in OFF mode. (unit: min.)
066 41 —
067 42 —
068 43 Polygon motor ope. time Time during which the polygon motor
is ON. (unit: min.)
069 44 Develop motor ope. time (color) Time during which the color develop-
ing motor is ON. (unit: min.)
070 45 Develop motor ope. time (black) Time during which the black develop-
ing motor is ON. (unit: min.)
071 46 On time of PCL (color) Time during which the color erase
lamp is ON. (unit: min.)
072 47 On time of PCL (black) Time during which the black erase
lamp is ON. (unit: min.)
254
/C6501P/C65hc/C5501
parameter
bizhub PRO C6501

(F2)
073 48 Operation time in Scanner mode Time during which the scanner motor
is ON. (unit: min.)
074 49 Time while power (ADF) Time during which DF is energized at
24V. (unit: min.)
075 4A —
076 4B —
077 4C —
078 4D Auto Y toner refresh mode count Counts 1 per 1 operation.
079 4E Auto M toner refresh mode count
080 4F Auto C toner refresh mode count
081 50 Auto K toner refresh mode count
082 51 N of 4 toner refresh performed
083 52 N of MC toner refresh performed
084 53 —
085 54 —
086 55 —
087 56 —
088 57 Right & Left bind (originals)
089 58 Upper bind (originals)
090 59 Inside Print Multi Triple-Fold
091 5A Outside Print Multi Triple-Fold
092 5B Inside Print Triple-Fold-in
093 5C Outside Print Triple-Fold-in
094 5D Inside Print Triple-Fold-out
095 5E Outside Print Tri-Fold-out
096 5F Inside Print Double Parallel
097 60 Outside Print Double Parallel
098 61 Inside Print Gate Fold
099 62 Outside Print Gate Fold
100 63 Multi Half Fold
101 64 Inside Print Half Fold
102 65 Outside Print Half Fold
103 66 Main tray output
104 67 Stacker tray output
105 68 Stacker pile setting permit
106 69 Fold & Staple tray output
107 6A Tri-Fold tray output
108 6B Fold sub tray output
109 6C Stacker sub tray output
110 6D Fold & Staple sub tray output
111 6E Staple sub tray output
255

parameter
bizhub PRO C6501
(F2)
112 6F Main tray output JOB
113 70 Stacker tray output JOB
114 71 Fold & Staple output JOB No.
115 72 Tri-Fold tray output JOB No.
116 73 Fold sub tray JOB
117 74 Stacker sub tray JOB
118 75 Fold & Staple sub tray JOB
119 76 Staple sub tray JOB
120 77 Multi Half Fold JOB
121 78 Inside Print Half Fold JOB
122 79 Outside Print Half Fold JOB
123 7A S.M.A.R.T (Y) Start/Stop Count Rotation/Stop times of the HDD/Y
spindle motor.
124 7B S.M.A.R.T (Y) Load Cycle Count Count of load/unload cycles of the
magnetic head of HDD/Y into landing
zone position.
125 7C S.M.A.R.T (Y) Loaded Hours Data reading time of the HDD/Y
(unit: min.)
126 7D S.M.A.R.T (M) Start/Stop Count Rotation/Stop times of the HDD/M
spindle motor.
127 7E S.M.A.R.T (M) Load Cycle Count Count of load/unload cycles of the
magnetic head of HDD/M into landing
zone position.
128 7F S.M.A.R.T (M) Loaded Hours Data reading time of the HDD/M
(unit: min.)
129 80 S.M.A.R.T (C) Start/Stop Count Rotation/Stop times of the HDD/C
spindle motor.
130 81 S.M.A.R.T (C) Load Cycle Count Count of load/unload cycles of the
magnetic head of HDD/C into landing
zone position.
131 82 S.M.A.R.T (C) Loaded Hours Data reading time of the HDD/C
(unit: min.)
132 83 S.M.A.R.T (K) Start/Stop Count Rotation/Stop times of the HDD/K
spindle motor.
133 84 S.M.A.R.T (K) Load Cycle Count Count of load/unload cycles of the
magnetic head of HDD/K into landing
zone position.
134 85 S.M.A.R.T (K) Loaded Hours Data reading time of the HDD/K
(unit: min.)
135 86 Paper Inserter Count
136 87 Perfect Binding (Copier)
137 88 Perfect Binding (Printer)
138 89 Number of exited perfect Binding sets
256
/C6501P/C65hc/C5501
parameter
bizhub PRO C6501

(F2)
139 8A Number of exited perfect Binding sets (Cover
paper trimming mode)
140 8B Number of exited perfect Binding sets (Cover
paper Not trimming mode)
I. SC Counter/Failure Sectional Counter
Note
• The malfunction codes, C-35## to C-39##, are not counted when the DIPSW3-1 in service mode is
set to 1. (latched).

parameter (Code) parameter (Code) parameter (Code)
(E0) (E0) (E0)
001 00 C-0001 027 1A C-0311 053 34 C-0416
002 01 C-0002 028 1B C-0312 054 35 C-0417
003 02 C-0003 029 1C C-0313 055 36 C-0418
004 03 C-0101 030 1D C-0314 056 37 C-1005
005 04 C-0102 031 1E C-0315 057 38 C-1006
006 05 C-0103 032 1F C-0316 058 39 C-1007
007 06 C-0201 033 20 C-0317 059 3A C-1008
008 07 C-0202 034 21 C-0318 060 3B C-1101
009 08 C-0203 035 22 C-0319 061 3C C-1102
010 09 C-0204 036 23 C-0320 062 3D C-1103
011 0A C-0205 037 24 C-0321 063 3E C-1104
012 0B C-0208 038 25 C-0401 064 3F C-1105
013 0C C-0209 039 26 C-0402 065 40 C-1106
014 0D C-0211 040 27 C-0403 066 41 C-1107
015 0E C-0212 041 28 C-0404 067 42 C-1108
016 0F C-0213 042 29 C-0405 068 43 C-1109
017 10 C-0301 043 2A C-0406 069 44 C-1110
018 11 C-0302 044 2B C-0407 070 45 C-1111
019 12 C-0303 045 2C C-0408 071 46 C-1112
020 13 C-0304 046 2D C-0409 072 47 C-1113
021 14 C-0305 047 2E C-0410 073 48 C-1114
022 15 C-0306 048 2F C-0411 074 49 C-1115
023 16 C-0307 049 30 C-0412 075 4A C-1116
024 17 C-0308 050 31 C-0413 076 4B C-1124
025 18 C-0309 051 32 C-0414 077 4C C-1125
026 19 C-0310 052 33 C-0415 078 4D C-1126
257

bizhub PRO C6501
(E0) (E0) (E0)

079 4E C-1127 120 78 C-1247 161 A1 C-1402
080 4F C-1132 121 79 C-1248 162 A2 C-1403
081 50 C-1137 122 7A C-1249 163 A3 C-1404
082 51 C-1138 123 7B C-1250 164 A4 C-1405
083 53 C-1140 124 7C C-1251 165 A5 C-1411
084 54 C-1141 125 7D C-1252 166 A6 C-1431
085 55 C-1142 126 7E C-1253 167 A7 C-1432
086 56 C-1143 127 7F C-1254 168 A8 C-1433
087 57 C-1201 128 80 C-1255 169 A9 C-1434
088 58 C-1202 129 81 C-1256 170 AA C-1451
089 59 C-1203 130 82 C-1257 171 AB C-1452
090 5A C-1204 131 83 C-1258 172 AC C-1453
091 5B C-1205 132 84 C-1259 173 AD C-2001
092 5C C-1206 133 85 C-1260 174 AE C-2002
093 5D C-1211 134 86 C-1261 175 AF C-2003
094 5E C-1212 135 87 C-1262 176 B0 C-2004
095 5F C-1213 136 88 C-1263 177 B1 C-2005
096 60 C-1214 137 89 C-1264 178 B2 C-2006
097 61 C-1215 138 8A C-1265 179 B3 C-2201
098 62 C-1216 139 8B C-1266 180 B4 C-2202
099 63 C-1221 140 8C C-1267 181 B5 C-2203
100 64 C-1222 141 8D C-1268 182 B6 C-2204
101 65 C-1223 142 8E C-1269 183 B7 C-2211
102 66 C-1224 143 8F C-1270 184 B8 C-2212
103 67 C-1225 144 90 C-1271 185 B9 C-2213
104 68 C-1226 145 91 C-1301 186 BA C-2214
105 69 C-1227 146 92 C-1302 187 BB C-2220
106 6A C-1228 147 93 C-1303 188 BC C-2221
107 6B C-1229 148 94 C-1304 189 BD C-2222
108 6C C-1230 149 95 C-1305 190 BE C-2301
109 6D C-1231 150 96 C-1306 191 BF C-2302
110 6E C-1232 151 97 C-1307 192 C0 C-2303
111 6F C-1233 152 98 C-1308 193 C1 C-2304
112 70 C-1234 153 99 C-1309 194 C2 C-2401
113 71 C-1235 154 9A C-1310 195 C3 C-2402
114 72 C-1241 155 9B C-1311 196 C4 C-2403
115 73 C-1242 156 9C C-1321 197 C5 C-2404
116 74 C-1243 157 9D C-1322 198 C6 C-2411
117 75 C-1244 158 9E C-1323 199 C7 C-2412
118 76 C-1245 159 9F C-1324 200 C8 C-2413
119 77 C-1246 160 A0 C-1325 201 C9 C-2414
258
/C6501P/C65hc/C5501
bizhub PRO C6501

(E0) (E0, E1) (E1)
202 CA C-2421 243 F3 C-2823 284 1C C-3913
203 CB C-2422 244 F4 C-2824 285 1D C-3914
204 CC C-2423 245 F5 C-2831 286 1E C-3915
205 CD C-2424 246 F6 C-2832 287 1F C-3916
206 CE C-2431 247 F7 C-2833 288 20 C-4101
207 CF C-2432 248 F8 C-2834 289 21 C-4102
208 D0 C-2433 249 F9 C-2840 290 22 C-4103
209 D1 C-2434 250 FA C-2841 291 23 C-4104
210 D2 C-2441 251 FB C-3101 292 24 C-4111
211 D3 C-2442 252 FC C-3102 293 25 C-4112
212 D4 C-2443 253 FD C-3103 294 26 C-4113
213 D5 C-2444 254 FE C-3104 295 27 C-4114
214 D6 C-2451 255 FF C-3301 296 28 C-4120
215 D7 C-2452 256 00 C-3302 297 29 C-4301
216 D8 C-2453 257 01 C-3303 298 2A C-4501
217 D9 C-2454 258 02 C-3501 299 2B C-4502
218 DA C-2461 259 03 C-3502 300 2C C-4503
219 DB C-2462 260 04 C-3503 301 2D C-4504
220 DC C-2463 261 05 C-3504 302 2E C-4511
221 DD C-2464 262 06 C-3505 303 2F C-4512
222 DE C-2470 263 07 C-3506 304 30 C-4513
223 DF C-2701 264 08 C-3507 305 31 C-4514
224 E0 C-2702 265 09 C-3508 306 32 C-4520
225 E1 C-2703 266 0A C-3801 307 33 C-4521
226 E2 C-2704 267 0B C-3802 308 34 C-4522
227 E3 C-2711 268 0C C-3803 309 35 C-4701
228 E4 C-2712 269 0D C-3804 310 36 C-4702
229 E5 C-2713 270 0E C-3805 311 37 C-4703
230 E6 C-2714 271 0F C-3806 312 38 C-4705
231 E7 C-2720 272 10 C-3901 313 39 C-4706
232 E8 C-2721 273 11 C-3902 314 3A C-4708
233 E9 C-2801 274 12 C-3903 315 3B C-4709
234 EA C-2802 275 13 C-3904 316 3C C-4711
235 EB C-2803 276 14 C-3905 317 3D C-4712
236 EC C-2804 277 15 C-3906 318 3E C-4713
237 ED C-2811 278 16 C-3907 319 3F C-4714
238 EE C-2812 279 17 C-3908 320 40 C-4715
239 EF C-2813 280 18 C-3909 321 41 C-4716
240 F0 C-2814 281 19 C-3910 322 42 C-4717
241 F1 C-2821 282 1A C-3911 323 43 C-4718
242 F2 C-2822 283 1B C-3912 324 44 C-4719
259

bizhub PRO C6501
(E1) (E1) (E1)

325 45 C-4720 366 6E C-6721 407 97 C-D0E9
326 46 C-4721 367 6F C-6722 408 98 C-D0EA
327 47 C-4722 368 70 C-6723 409 99 C-D0EB
328 48 C-4723 369 71 C-6724 410 9A C-D0EC
329 49 C-4724 370 72 C-6725 411 9B C-D0ED
330 4A C-4725 371 73 C-6801 412 9C C-D0EE
331 4B C-4840 372 74 C-7001 413 9D C-D0EF
332 4C C-4850 373 75 C-8001 414 9E C-D0F0
333 4D C-5001 374 76 C-8101 415 9F C-E001
334 4E C-5002 375 77 C-8102 416 A0 C-E002
335 4F C-5003 376 78 C-8103 417 A1 C-E003
336 50 C-5004 377 79 C-8401 418 A2 C-E004
337 51 C-5005 378 7A C-8402 419 A3 C-E005
338 52 C-5010 379 7B C-8403 420 A4 C-E006
339 53 C-5011 380 7C C-8404 421 A5 C-E007
340 54 C-5301 380 7D C-8405 422 A6 C-0322
341 55 C-5302 382 7E C-8406 423 A7 C-2851
342 56 C-5303 383 7F C-8407 424 A8 C-2852
343 57 C-6101 384 80 C-C101 425 A9 C-2853
344 58 C-6102 385 81 C-C102 426 AA C-2861
345 59 C-6301 386 82 C-C103 427 AB C-2862
346 5A C-6701 387 83 C-C104 428 AC C-2863
347 5B C-6702 388 84 C-C106 429 AD C-2871
348 5C C-6703 389 85 C-C107 430 AE C-2872
349 5D C-6704 390 86 C-C108 431 AF C-2873
350 5E C-6705 391 87 C-C109 432 B0 C-1009
351 5F C-6706 392 88 C-C111 433 B1 C-1010
352 60 C-6707 393 89 C-C112 434 B2 C-1011
353 61 C-6708 394 8A C-C113 435 B3 C-1330
354 62 C-6709 395 8B C-C114 436 B4 C-1331
355 63 C-6710 396 8C C-C115 437 B5 C-1332
356 64 C-6711 397 8D C-C120 438 B6 C-1333
357 65 C-6712 398 8E C-D0E0 439 B7 C-1334
358 66 C-6713 399 8F C-D0E1 440 B8 C-1406
359 67 C-6714 400 90 C-D0E2 441 B9 C-1435
360 68 C-6715 401 91 C-D0E3 442 BA C-1436
361 69 C-6716 402 92 C-D0E4 443 BB C-1437
362 6A C-6717 403 93 C-D0E5 444 BC C-1454
363 6B C-6718 404 94 C-D0E6 445 BD C-1501
364 6C C-6719 405 95 C-D0E7 446 BE C-1502
365 6D C-6720 406 96 C-D0E8 447 BF C-1504
260
/C6501P/C65hc/C5501
bizhub PRO C6501

(E1) (E1) (E1)
448 C0 C-1505 470 D6 C-1527 492 EC C-1554
449 C1 C-1506 471 D7 C-1528 493 ED C-1555
450 C2 C-1507 472 D8 C-1530 494 EE C-1556
451 C3 C-1508 473 D9 C-1531 495 EF C-1557
452 C4 C-1509 474 DA C-1532 496 F0 C-1558
453 C5 C-1510 475 DB C-1534 497 F1 C-1559
454 C6 C-1511 476 DC C-1537 498 F2 C-1560
455 C7 C-1512 477 DD C-1538 499 F3 C-1561
456 C8 C-1513 478 DE C-1540 500 F4 C-1562
457 C9 C-1514 479 DF C-1541 501 F5 C-C116
458 CA C-1515 480 E0 C-1542 503 F6 C-C134
459 CB C-1516 481 E1 C-1543 504 F7 C-1144
460 CC C-1517 482 E2 C-1544 505 F8 C-1145
461 CD C-1518 483 E3 C-1545 506 F9 C-1146
462 CE C-1519 484 E4 C-1546 507 FA C-1147
463 CF C-1520 485 E5 C-1547 508 FB C-1148
464 D0 C-1521 486 E6 C-1548 509 FC C-1272
465 D1 C-1522 487 E7 C-1549 510 FD C-1273
466 D2 C-1523 488 E8 C-1550 511 FE C-1274
467 D3 C-1524 489 E9 C-1551 512 FF C-1275
468 D4 C-1525 490 EA C-1552
469 D5 C-1526 491 EB C-1553

parameter (SC Code) parameter (SC Code) parameter (SC Code)
(E2) (E2) (E2)
513 00 C-1012 519 06 C-1342 525 0C C-1565
514 01 C-C117 520 07 C-1408 526 0D C-1566
515 02 C-1014 521 08 C-1439 527 0E C-C118
516 03 C-1281 522 09 C-1456 528 0F -
517 04 C-1282 523 0A C-1499 529 10 -
518 05 C-1341 524 0B C-1601 530 11 -
261 1
J. SC data of time series

/C6501P/C65hc/C5501
Confirm the latest 20 malfunction code, it is possible to confirm SC code, total count, date of occurrence, time
bizhub PRO C6501
of occurrence and machine condition (00: Idling, 01: Scanner operating, 02: Printer operating, 03: Scanner and
printer operating).
262
9.6.3 Count of special parts (Parts Counter)
/C6501P/C65hc/C5501
Confirm and reset the parts life counter.
bizhub PRO C6501

When a part is replaced, reset the counter of the part that has been replaced to manage the service history.
A. Procedure for registration, confirmation and reset

Press [03 Parts Counter].a
Press [01 Count of special parts].
4. "Special Parts Count/Touch screen"
Press [Next] or [Previous] to scroll the pages and check the counts.
5. Press [T] or [S] to select the part name you want to reset.
6. Press [Count Reset].
Press [No] to cancel and return to "Special Parts Count/Touch screen".
8. To register the parts to CMS, press the buttons on the left side of the parts you want to register tick off.
Note
• To display the CMS screen on the user screen, set 1 in the DIPSW15-1 setting.
B. List of special parts counter
Note
• Be sure to reset the parts counter after replacing any parts listed below. Otherwise, image failure
or jam may occur.
1) Dust-proof filter /1 assy: No.002 Dust-proof filter /1 (Right side)
2) Charging coronas /Y, /M, /C, and /K: No. 006 to 013 Charging coronas /Y, /M, /C, and /K
3) Drum cartridges /Y, /M, /C, and /K: No. 014 to 021 Drum cartridges /Y, /M, /C, and /K
4) Developer /Y, /M, /C, and /K: No. 022 to 029 Enclosed developing /Y, /M, /C, and /K
5) Belt cleaner blade: No.037 and 038 Belt cleaning blade
6) 1st transfer rollers /Y, /M, /C, and /K: No. 039 to 042 1st transfer rollers /Y, /M, /C, and /K
• When the counter exceeds the limit, the color of the character changes into red.
263
No. CSRC Part name Part number Count condition

bizhub PRO C6501
parameter
(Z1)
001 00 Toner collection box A03UA365 *1
002 01 Dust-proof filter/1 (Right side) A03UA122 Counted with the combination of
003 02 Dust-proof filter/2 (Rear side) 65AA-142 print coverage, drive distance of the
developing roller, humidity, and so
on. Shows the count in percentage
with respect to the end of its parts
life.
Counter reset No.002 and 003 are
linked to each other.
004 03 — —
005 04 Charging dust proof filter 65AA-387 *1
006 05 Charging corona/Y (Page) A03UA460 *2 Resetting this counter also
resets No.007.
007 06 Charging corona/Y (Time %) A03UA460 Counts the charging time and
shows the count in percentage with
respect to the end of its parts life.
Resetting this counter also resets
No.006.
008 07 Charging corona/M (Page) A03UA460 *2 Resetting this counter also
resets No.009.
009 08 Charging corona/M (Time %) A03UA460 Counts the charging time and
No.008.
010 09 Charging corona/C (Page) A03UA460 *2 Resetting this counter also
resets No.011.
011 0A Charging corona/C (Time %) A03UA460 Counts the charging time and
No.010.
012 0B Charging corona/K (Page) A03UA460 *1 Resetting this counter also
resets No.013.
013 0C Charging corona/K (Time %) A03UA460 Counts the charging time and
No.012.
014 0D Drum cartridge/Y (Page) A03UA330 *2 Resetting this counter also
resets No.015.
264
/C6501P/C65hc/C5501
parameter
bizhub PRO C6501

(Z1)
015 0E Drum cartridge/Y (Distance %) A03UA330 Compares the drive distance of the
drum with that of the Lubricant
applying roller and shows the larger
count number in percentage with
No.014.
016 0F Drum cartridge/M (Page) A03UA330 *2 Resetting this counter also
resets No.017.
017 10 Drum cartridge/M (Distance %) A03UA330 Compares the drive distance of the
No.016.
018 11 Drum cartridge/C (Page) A03UA330 *2 Resetting this counter also
resets No.019.
019 12 Drum cartridge/C (Distance %) A03UA330 Compares the drive distance of the
No.018.
020 13 Drum cartridge/K (Page) A03UA331 *1 Resetting this counter also
resets No.021.
021 14 Drum cartridge/K (Distance %) A03UA331 Compares the drive distance of the
No.020.
022 15 Enclosed Developing /Y (Page) A04PT700 *2 Resetting this counter also
resets No.023.
023 16 Enclosed Developing /Y (Dis- A04PT700 Counts the drive distance of the devel-
tance %) oping roller and shows the count in
percentage with respect to the end
of its parts life.
No.022.
024 17 Enclosed Developing /M A04PT800 *2 Resetting this counter also
(Page) resets No.025.
265

parameter
bizhub PRO C6501
(Z1)
025 18 Enclosed Developing /M (Dis- A04PT800 Counts the drive distance of the devel-
of its parts life.
No.024.
026 19 Enclosed Developing /C (Page) A04PT900 *2 Resetting this counter also
resets No.027.
027 1A Enclosed Developing /C (Dis- A04PT900 Counts the drive distance of the devel-
of its parts life.
No.026.
028 1B Enclosed Developing /K (Page) A04PT600 *1 Resetting this counter also
resets No.029.
029 1C Enclosed Developing /K (Dis- A04PT600 Counts the drive distance of the devel-
of its parts life.
No.028.
030 1D Developing unit/Y A03UA370 *2
031 1E Developing unit/M A03UA370
032 1F Developing unit/C A03UA370
033 20 Developing unit/K A03UB390 *1
034 21 Transfer belt A03U5042
035 22 Transfer belt cleaning unit A03UA515 *1 Resetting this counter also
resets No.036 to No.038.
036 23 Toner collection sheet/1 65AA-293 *1
037 24 Belt cleaning blade (Page) A03U5530 *1 Resetting this counter also
resets No.038.
038 25 Belt cleaning blade (Distance A03U5530 Counts the drive distance of the transfer
%) belt and shows the count in percent-
age with respect to the end of its
parts life.
No.037.
039 26 1st transfer roller/Y A03U5012 *2
040 27 1st transfer roller/M A03U5012
041 28 1st transfer roller/C A03U5012
042 29 1st transfer roller/K A03U5004 *1
043 2A 2nd transfer roller/U 65AA2611
044 2B Transfer belt separation claw 65AA-287
266
/C6501P/C65hc/C5501
parameter
bizhub PRO C6501

(Z1)
045 2C Transfer roller bearing 65AA2638 *1
046 2D — —
047 2E Separation claw solenoid 26NA8251 1 count for each paper exit in the
single side mode, 2 counts in the
double side mode.
048 2F 2nd transfer roller/L 65AA4501 *1
049 30 Separation discharging unit A03UA522
050 31 Transfer earth plate unit 65AA-456 1 count for each paper exit in the
double side mode.
051 32 Fusing roller/2 A03U7202 *1
052 33 Fusing roller/L A03U7203
053 34 Fusing belt A03U7205
054 35 Belt regulating sleeve A03U7250
055 36 Paper exit roller/Up A03U7225 1 count for each paper exit in the
double side mode.
056 37 Fusing limiter 65AA5365 *1
057 38 Insulating sleeve/U A03U7295
058 39 Fusing bearing/L 26NA5371
059 3A Insulating sleeve/L A03U7227
060 3B Fusing roller/1 A03U7201
061 3C Fusing drive gear/B A03U8082
062 3D Fusing bearing/1 A03U8078
063 3E Fusing drive gear/O A03U8095
064 3F Fusing regulating gear 65AA7747
065 40 Fusing duct assy A03UA780
066 41 Fusing bearing/2 56UA7507
067 42 Fusing drive gear/M A03U8093
068 43 Fusing lamp/U A03UM31
(A) (E) (F)
069 44 Fusing lamp/L A03UM32
(A) (E) (F)
070 45 Fusing temp sensor assy/U A03UA768
071 46 Fusing temp sensor assy/L A03UA737
072 47 Center fusing temp. sensor/U 65AA8801
073 48 Center fusing temp. sensor/L 65AA8802
074 49 Feed-reverse rubber (Tray-1) 25SA4096 1 count for each paper exit from tray 1.
075 4A Feed-reverse rubber (Tray-2) 25SA4096 1 count for each paper exit from tray 2.
076 4B Feed/reverse rubber (Tray-3) 25SA4096 1 count for each paper exit from tray 3.
077 4C Feed/reverse rubber (By-pass) 25SA4096 1 count for each paper exit from by-
pass.
267

parameter
bizhub PRO C6501
(Z1)
078 4D Paper feed roller (Tray-1) 56AA-458 1 count for each paper exit from tray1.
079 4E Paper feed roller (Tray-2) 56AA-458 1 count for each paper exit from tray 2.
080 4F Paper feed roller (Tray-3) 56AA-458 1 count for each paper exit from tray 3.
081 50 Paper feed roller (By-pass) 65AA-520 1 count for each paper exit from by-
pass.
082 51 Paper feed clutch (Tray-1) 56AA8201 1 count for each paper exit from tray1.
083 52 Paper feed clutch (Tray-2) 56AA8201 1 count for each paper exit from tray 2.
084 53 Paper feed clutch (Tray-3) 56AA8201 1 count for each paper exit from tray 3.
085 54 Paper feed clutch (By-pass) 56AA8201 1 count for each paper exit from by-
pass.
086 55 Pre-regist. clutch (Tray-1) 56AA8201 1 count for each paper exit from tray1.
087 56 Pre-regist. clutch (Tray-2) 56AA8201 1 count for each paper exit from tray 2.
088 57 Pre-regist. clutch (Tray-3) 56AA8201 1 count for each paper exit from tray 3.
089 58 Intermediate convey. clutch/1 56AA8201 1 count for each paper exit from tray
2 and 3.
090 59 Intermediate convey. clutch/2 56AA8201 1 count for each paper exit in the
091 5A Intermediate convey. clutch/3 56AA8201 single side mode, 2 counts in the
double side mode.
092 5B Registration cleaning sheet 65AA-462 1 count for each paper exit in the
093 5C Registration roller 65LA-464 single side mode, 2 counts in the
094 5D Decurler roller A03U8605 double side mode.
095 5E Paper exit decurler roller A03U8926 1 count for each paper exit.
096 5F ADU conveyance clutch/1 A03UM201 0 count for each paper exit in the
097 60 ADU conveyance clutch/2 A03UM201 single side mode, 1 counts in the
098 61 ADU conveyance clutch/3 A03UM201 double side mode.
099 62 ADU pre-registration clutch A03UM201

100 63 Exposure ON time A03UM301 Accumulation of time lamp is on.
(unit: min.)
101 64 Main power switch 55GA8601 1 count each time the main power
switch turns ON the power.
102 65 Sub power switch A03UM601 1 count each time the sub power
switch turns ON the power.
103 66 Door switch 40AA8501 1 count each time the front door is
104 67 Toner supply door switch 13GG-802 opened.
105 68 — —
106 69 — —
107 6A — —
108 6B — —
109 6C — —
110 6D — —
268
/C6501P/C65hc/C5501
parameter
bizhub PRO C6501

(Z1)
111 6E Paper exit roller A0438907 1 count for each paper exit.
112 6F Paper exit guide roller/2 65AA4818 (with 0T-502 installed).
113 70 Paper holding roller 65AA4849
114 71 — —
115 72 — —
116 73 — —
117 74 — —
118 75 LCT paper feed roller A03X5652 1 count for each paper exit from tray
119 76 LCT feed/reverse roller A03X5653/5654 4 (LU).
120 77 LCT feed clutch 56AA8201
121 78 LCT pre-registration clutch 56AA8201
122 79 — —
123 7A — —
124 7B — —
125 7C — —
126 7D PFU paper feed rubber (Tray 4) A03X5652 1 count for each paper exit from tray
127 7E PFU feed/rev roller (Tray 4) A03X5653/5654 4 (PF).
128 7F PFU feed clutch (Tray 4) 56AA8201
129 80 PFU reverse clutch (Tray 4) 56AA8201
130 81 PFU paper feed rubber (Tray 5) A03X5652 1 count for each paper exit from tray
131 82 PFU feed/rev roller (Tray 5) A03X5653/5654 5 (PF).
132 83 PFU feed/reverse roller (Tray 5) 56AA8201
133 84 PFU reverse clutch (Tray 5) 56AA8201
134 85 PFU Intermediate Convery. 56AA8201 1 count for each paper exit from tray
clutch/1 4 (PF).
135 86 PFU Intermediate Convery. 56AA8201
clutch/2
136 87 PFU Intermediate Convery. 56AA8201 1 count for each paper exit from tray
clutch/3 5 (PF).
137 88 PFU Pre-registration clutch 56AA8201
138 89 PFU Horizontal convery. 56AA8201
clutch/1
139 8A PFU Horizontal convery. 56AA8201
clutch/2
140 8B — —
141 8C — —
142 8D — —
143 8E — —
144 8F FS Staple/Front A0GYA735 1 count for each paper exit in the
145 90 FS Staple/Back A0GYA736 staple mode.
269 2

parameter
bizhub PRO C6501
(Z1)
146 91 FS Solenoid/A 56QA8251 1 count for each paper exit in the
147 92 FS Paper exit roller/A 122H4825 sort, non-sort or staple mode.
148 93 — —
149 94 — —
150 95 — —
151 96 — —
152 97 FD Feed roller/A Top 50BA-574 1 count for each PI /Up paper feed.
153 98 FD Reverse rubber/Top 13QN-443
154 99 FD Feed roller/B Top 50BA-575
155 9A FD Feed roller/A Low 50BA-574 1 count for each PI /Lw paper feed.
156 9B FD Reverse rubber/Low 13QN-443
157 9C FD Feed roller/B Low 56BA-575
158 9D FD Punch motor assy 15AG-573 1 count for each paper exit in the
punch mode.
159 9E FD Solenoid/A (release 1) 56QA8251 1 count for each paper exit in the
punch or the folding mode for all
size.
160 9F FD Solenoid/A (release 2) 56QA8251 1.1 count for each paper exit in the
folding mode for all size.
2. 1 count for each paper exit in the
punch mode with 220mm or longer
size.
161 A0 FD Motor assy 129U-108 1 count for each paper exit to the
main tray.
162 A1 — —
163 A2 — —
164 A3 — —
165 A4 — —
166 A5 LS Solenoid (Lead) 15AV8252 1 count for each paper exit in the
sort and the non-sort mode of all
size.
167 A6 LS Solenoid (Rear) 15AV8253 1 count for each paper exit in the
size.
168 A7 LS Solenoid (Center) 15AV8251 1 count for each paper exit in the
sort and the non-sort mode with
226 (W) X 295 (L) mm or larger size.
169 A8 LS Solenoid (Curl) 15AV8255 1 count for each paper exit in the
size.
170 A9 LS Up/Down motor 15AV8003 Count operation times of the stacker
tray operate up/down.
2 270
/C6501P/C65hc/C5501
parameter
bizhub PRO C6501

(Z1)
171 AA SD Trimmer edge A0H2R901 1 count for each paper set exit in the
172 AB SD Trimmer receiver A0H2B622 trimmer mode. (New type)
173 AC SD Trimmer press drive motor A0H2M101
174 AD SD Trimmer edge drive motor A0H2M102
175 AE SD Paper Cutter Unit A0H2A620
176 AF SD Staple/Right 15AN-550 1 count for each paper set exit in the
177 B0 SD Staple/Left 15AN-550 saddle stitch mode. (New/Old type)
178 B1 SD Trimmer edge 15AN-570 1 count for each paper set exit in the
179 B2 SD Trimmer receiver 15AN5282 trimmer mode. (Old type)
180 B3 SD Trimmer edge drive motor 15AN8002
181 B4 SD Convey solenoid 15AN8251 1 count for each paper conveyance
182 B5 SD Solenoid 13QE8251 to the folding section. (New/Old
type)
183 B6 SD FNS solenoid 12QR8252 1 count for each paper conveyance
to the right angle conveyance sec-
tion. (New/Old type)
184 B7 SD Gear/B 15AN7719 1 count for each paper set exit to
the bundle exit tray. (New/Old type)
185 B8 SD Paper adjusting unit 15AN5092 1 count for each paper set exit in the
trimmer mode. (Old type)
186 B9 — —
187 BA — —
188 BB — —
189 BC FNS stapler /F 15JM-501 1 count for each paper set exit in the
190 BD FNS stapler /R 15JM-501 1-staple, 2-staple or the saddle
stitching mode. (FS-607)
191 BE FNS shift motor 12QR-361 1 count each time an even number of
print is exited in the sort mode. (FS-520/
607).
192 BF FNS exit opening motor 12QR-361 1 count for each starting job for the size
A4S and 81/2 x 11S, and 1count at exit-
ing these size in staple mode. (FS-520/
607).
1 count at starting the fold and saddle
stitch mode. (FS-607).
193 C0 FNS folding knife motor 13QJ-502 1 count for each paper exit in the
folding, saddle stitching and tri-fold-
ing mode. (FS-607)
194 C1 By-pass gate solenoid 12QR-263 1 count for each paper exit for the A4,
B5, 81/2 x 11 and 16K sizes in the staple
mode. (FS-520/607).
195 C2 FNS tri-folding gate SD 12QR-263 1 count for each paper exit in the tri-
folding mode. (FS-607)
271 2

parameter
bizhub PRO C6501
(Z1)
196 C3 Paper exit roller /A 122H4825 1 count for each paper exit in the
197 C4 Paper exit roller /B A04D8904 main tray. (FS-520/FS-607)
198 C5 Conveyance exit roller /4 13QE4531 1 count for each paper exit in the
staple, folding and tri-folding mode.
(FS-520/FS-607)
199 C6 PI conveyance clutch/U 13QN8201 1 count for each PI/Up paper feed.
200 C7 PI feed roller /A/U 50BA-574 (PI)
201 C8 PI feed roller /B/U 13QN-446
202 C9 PI reverse roller /U 13QN-443
203 CA PI torque limiter /U 13QN4073
204 CB PI conveyance clutch/L 13QN8201 1 count for each PI/Lw paper feed.
205 CC PI feed roller /A/L 50BA-574 (PI)
206 CD PI feed roller /B/L 50BA-575
207 CE PI reverse roller /L 13QN-443
208 CF PI torque limiter /L 13QN4073
209 D0 Paper conveyance roller /A 20AK4210 1 count for each paper exit in the
staple, folding and tri-folding mode.
(FS-607)
210 D1 Staple Assy /Fr A07RA735 1 count for each paper set exit, in
either of the 1-staple at front or the
2-staple mode. (FS-520)
211 D2 Staple Assy /Rr A07RA736 1 count for each paper set exit, in
either of the 1-staple at rear or the
2-staple mode. (FS-520)
212 D3 Punching unit (2 hole) A04E0Y0 1 count for each punch operation.
213 D4 Punching unit (2/3hole,2/4hole) A04F0Y0 (PK)
214 D5 Punching unit (4hole) A04G0G0
215 D6 FNS cleaning plate assy A07RA741 1 count for each paper exit in the
staple mode. (FS-520)
216 D7 — —
217 D8 ADF paper feed roller 13YH4064 Original feed count in all modes. (DF)
218 D9 ADF feed roller 13YH4039 Original feed count in all modes. (DF)
219 DA ADF Dfeed prevention roller 20AJ4015
220 DB — —
221 DC — —
222 DD — —
223 DE — —
224 DF PB sub tray exit solenoid 56QA8251 1 count for each paper exit on the
sub tray.
225 E0 PB SC roller release motor 13GQ8005 1 count for each paper exit on the
226 E1 PB SC stopper solenoid 15AA8251 stacker.
227 E2 PB SC pressure arm solenoid 15AA8251
2 272
/C6501P/C65hc/C5501
parameter
bizhub PRO C6501

(Z1)
228 E3 PB switchback roller 13GQ4519 1 count for each paper exit
229 E4 PB pick-up roller 55VA-464 1 count for each book exit in PB tray
230 E5 PB paper feed roller, separa- 55VA-463 cover mode.
tion roller
231 E6 PB cover paper pick up clutch 56AA8201
232 E7 PB cover paper separation 56AA8201
clutch
233 E8 PB roller cutter blade assy A0756230 1 count for each book exit in cover
trimming mode.
234 E9 PB filter /1 A0753724 1 count for each paper exit
235 EA PB filter /2 A0753724
236 EB PB straight gate solenoid 56QA8251 1 count for each book exit except in
PB tray cover mode.
237 EC PB Melt tank ASSY A075A39 1 count for each hour of the glue
(A) (E) (F) apply roller rotation.
238 ED — —
239 EE — —
240 EF GP Aligner idler roller assembly A0N9PA01 1 count for each paper exit in the
punch mode.
241 F0 GP Bypass assembly A0N9PA02 1 count for each paper exit.
242 F1 GP Roller energy drive A0N9PA03 1 count for each paper exit in the
punch mode.
243 F2 GP Belt, aligner (Green) A0N9PA04 1 count for each paper exit in the
punch mode.
244 F3 GP Back gauge mechanism A0N9PA05 1 count for each paper exit in the
punch mode.
*1 Count in all color modes

DIPSW 8-6 = 0: 1 count for each paper exit in the single side mode, 2 counts in the double side mode.
= 1: For large size, 2 counts for each paper exit in the single side mode, 4 counts for double.
*2 Count only in the full color or mono color mode

DIPSW 8-6 = 0: 1 count for each paper exit in the single side mode, 2 counts in the double side mode.
= 1: For large size, 2 counts for each paper exit in the single side mode, 4 counts for double.
273 2
9.6.4 Count of each parts (Parts Counter)

/C6501P/C65hc/C5501
This is used when you want to manage the service history of parts that are not registered in the "Count of spe-
bizhub PRO C6501
cial parts".
For 30 data from No. 01 up to 30, confirm and reset of the name, P/N (parts number), limit value and print
count.
• 1 count for each paper exit exits of all sizes.
• When the counter exceeds the limit, the color of the character changes into red.
A. Procedure for registration and confirmation

(1) Procedure
1. "Sservice Mode Menu screen"

2. "Ccounter/Data Menu screen"
Press [03 Parts Counter].
Press [02 Count of each parts].
4. "Each Part Count/Touch screen"
Press [Next] or [Previous] to scroll the pages, and press [T] or [S] to select the data number.
5. Select either [Name Setting], [P/N Setting], or [Limit Setting].
6. Enter the data you want to set or change.
[Parts Name]: Enter the part name. (8 digits)
[P/N] Enter the part number. (9 digits)
[Limit]: Enter the limit value. (8 digits)
7. Press [OK] to update the data.
Press [Cancel] to cancel updating.
8. To register the parts to CMS, press the buttons on the left side of the parts you want to register to tick off.
Note
• To display the CMS screen on the user screen, set 1 in the DIPSW15-1 setting.
274
B. Procedure of reset
/C6501P/C65hc/C5501
(1) Procedure
bizhub PRO C6501

Press [03 Parts Counter].
Press [02 Count of each parts].
4. "Each Part Count/Touch screen"
Press [Next] or [Previous] to scroll the pages, and press [T] or [S] to select the items you want to set or
check.
5. Press [Count Reset].
Press [No] to cancel and return to "Each Part Count/Touch screen".
275
C. The relation ship between the data No. and the CSRC parameter
/C6501P/C65hc/C5501
bizhub PRO C6501
No. Part name P/N Count Limit Start date

CSRC CSRC CSRC CSRC CSRC
parameter parameter parameter parameter parameter
(Z4) (Z3) (G0) (H0) (H3)
001 00 00 00 00 00
002 01 01 01 01 01
003 02 02 02 02 02
004 03 03 03 03 03
005 04 04 04 04 04
006 05 05 05 05 05
007 06 06 06 06 06
008 07 07 07 07 07
009 08 08 08 08 08
010 09 09 09 09 09
011 0A 0A 0A 0A 0A
012 0B 0B 0B 0B 0B
013 0C 0C 0C 0C 0C
014 0D 0D 0D 0D 0D
015 0E 0E 0E 0E 0E
016 0F 0F 0F 0F 0F
017 10 10 10 10 10
018 11 11 11 11 11
019 12 12 12 12 12
020 13 13 13 13 13
021 14 14 14 14 14
022 15 15 15 15 15
023 16 16 16 16 16
024 17 17 17 17 17
025 18 18 18 18 18
026 19 19 19 19 19
027 1A 1A 1A 1A 1A
028 1B 1B 1B 1B 1B
029 1C 1C 1C 1C 1C
030 1D 1D 1D 1D 1D
276
9.7 State Confirmation
/C6501P/C65hc/C5501
bizhub PRO C6501
9.7.1 I/O Check Mode
This mode provide self-diagnostic functions (input/output check function) to check the condition of input (check-
ing the each signal to sensors) and output (checking and adjustment of the load operation).
A. I/O Check Mode screen
[1] [2] [3] [4]

a03uf3e002ca
[1] I/O Check code [3] Input check

[2] Multi code [4] Output check
277
9.7.2 Input check

/C6501P/C65hc/C5501
Check input condition of each signal to the sensors.

bizhub PRO C6501
A. Procedure

Press [05 State Confirmation].
2. "State Confirmation Menu screen"
Press [01 I/O Check Mode].
3. "I/O Check Mode screen"
Enter an input check code with the numeric buttons.
4. Press Access button to switch to the multi mode.
5. Enter the multi code with the numeric buttons.
6. The condition of the sensor (000/001 etc.) is displayed in the message box "IN".
7. When executing another input check, repeat steps 3 to 6.
B. List of sensors
Name Display and signal source

Multi code
High voltage, analog signal Classification
Symbol
Code
001 (High) 000 (Low)
0 0 TEM/ Temperature-humidity sensor (machine inner Display of humidity (%)

HUMS humidity)
1 TEM/ Temperature-humidity sensor (machine inner Display of temperature (°C)
HUMS temperature)
3 TEMSB Temperature sensor board Display of temperature (°C)
5 TEM/ Temp/humidity sensor /2 (machine inner Display of humidity (%)
HUMS/2 humidity)
6 TEM/ Temp/humidity sensor /2 (machine inner Display of temperature (°C)
HUMS/2 temperature)
7 TEMS1 Registration temperature sensor
1 4 PZS/Y Piezoelectric sensor /Y Toner No toner
5 PZS/M Piezoelectric sensor /M
6 PZS/C Piezoelectric sensor /C
7 PZS/K Piezoelectric sensor /K
8 PS60 Waste toner door sensor Box No box
9 PS52 Waste toner full sensor Full Empty
11 0 PS31 Paper empty sensor /1 Paper No paper
Paper feed conveyance
1 PS37 Paper empty sensor /2

2 PS43 Paper empty sensor /3
3 PS47 Paper empty sensor /PB
4 PS108 Paper empty sensor (LU)
5 PS3 Paper empty sensor /1 (PF)
6 PS11 Paper empty sensor /2 (PF)
12 0 PS32 Paper near empty sensor /1
1 PS38 Paper near empty sensor /2
278
/C6501P/C65hc/C5501
Paper feed conveyance Classification
Multi code
Symbol
Code
bizhub PRO C6501

001 (High) 000 (Low)
12 2 PS44 Paper near empty sensor /3 Paper No paper

3 PS102/ Remaining paper sensor /1 to 4 (LU) Paper level indication (0 to 100
PS103/ (%)
PS104/
PS105
4 VR2 Remaining paper VR/1 (PF)
5 VR4 Remaining paper VR/2 (PF)
13 0 PS33 Paper size sensor /Fr1 OFF ON
1 PS34 Paper size sensor /Rr1
2 PS39 Paper size sensor /Fr2
4 PS45 Paper size sensor /Fr3
6 PS48 Paper size sensor /BP1
7 PS49 Paper size sensor /BP2
8 PS5 Paper size sensor /Rt1 (PF)
9 PS6 Paper size sensor /Lt1 (PF)
10 PS13 Paper size sensor /Rt2 (PF)
11 PS14 Paper size sensor /Lt2 (PF)
12 PS110 Paper size sensor /Rr (LU)
13 PS111 Paper size sensor /Fr (LU)
14 0 VR1 Paper size VR/1 Display of AD value
1 VR2 Paper size VR/2
2 VR3 Paper size VR/3
3 VR4 Paper size VR/BP
4 VR1 Paper size VR/1 (PF)
5 VR3 Paper size VR/2 (PF)
6 VR1 Paper size VR (LU)
16 0 PS30 Upper limit sensor /1 Upper limit Not at upper
1 PS36 Upper limit sensor /2 limit
2 PS42 Upper limit sensor /3
3 PS25 Upper limit sensor /BP
4 PS109/ Upper limit sensor/Lower limit sensor (LU)
PS101
5 PS1 Upper limit sensor /1 (PF)
6 PS9 Upper limit sensor /2 (PF)
18 1 PS65 ADU centering sensor Display top 8 bit out of 16bit
2 PS1 Centering sensor (LU)
3 PS25 Centering sensor (PF) Multi feed Other than
multi feed
19 0 PS29 Paper feed sensor /1 Paper No paper
1 PS35 Paper feed sensor /2
279

Multi code
Symbol
Code
bizhub PRO C6501
001 (High) 000 (Low)
19 2 PS41 Paper feed sensor /3 Paper No paper

3 PS26 Paper feed sensor /BP
4 PS106 Pre-registration sensor (LU)
20 0 PS107 LU exit sensor (LU)
1 PS23 ADU pre-registration sensor
2 PS61 ADU conveyance sensor
3 PS27 Intermediate conveyance sensor /1
4 PS28 Intermediate conveyance sensor /2
6 PS22 Registration sensor
7 PS50 Vertical conveyance sensor
8 PS13 Paper exit sensor
9 PS19 Reverse/exit sensor
10 PS21 ADU reverse sensor
11 PS12 Paper exit full sensor Full Other than full
12 PS20 ADU stop sensor Paper No paper
13 PS62 Decurler sensor
23 5 PS109/ Upper limit sensor/Lower limit sensor (LU) Upper limit Not at upper
6 PS101 limit
24 0 PS24 2nd transfer HP sensor Home posi- Other than
tion home posi-
tion
25 0 PS18 Front door open/close sensor Open Close
1 PS51 Vertical conveyance door sensor
2 PS54 Toner supply door open/close sensor
3 PS14 Toner supply unit open/close sensor
5 MS2 Interlock switch /2 (LU) ON OFF
6 MS1 Interlock switch /1 (LU)
7 SW100 Tray down switch (LU)
8 PS22 Registration sensor Paper No paper
9 PS23 Front door open/close sensor Open Close
10 PS21 Horizontal conveyance door sensor /1 (PF)
11 PS24 Vertical door sensor (PF)
12 PS22 Horizontal conveyance door sensor /2 (PF)
280
/C6501P/C65hc/C5501
Multi code
Symbol
Code
bizhub PRO C6501

001 (High) 000 (Low)
27 25 PS10 Paper exit pressure home sensor Home posi- Other than
tion home posi-
tion
29 3 SD1 Belt separation claw solenoid Set Not set
11 PS20 Pre-registration sensor (PF) Paper No paper
12 PS18 Horizontal conveyance sensor/1
13 PS17 Vertical conveyance sensor/1 (PF)
16 PS18 Horizontal conveyance sensor/1 (PF)
26 TEMS/1 Temperature sensor /1 (in tray) Display of temperature (°C)
28 TEMS/2 Temperature sensor /2 (in tray)
30 TEMS1 Temperature sensor /1 (in tray) (LU)
30 0 PS1 Scanner HP sensor Home posi- Other than
Optical device
tion home posi-

tion
1 PS3 APS sensor /1 Paper No paper
2 PS4 APS sensor /2
3 PS2 APS timing sensor Open Close
33 0 INDEXB/ INDEVB/C Abnormal Normal
C
1 INDEXB/ INDEVB/M
M
2 INDEXB/ INDEVB/Y
Y
3 INDEXB/ INDEVB/K
K
4 INDEXB INDEVB /C, /M, /Y, /K It is abnormal
/C, /M, / if there is any
Y, /K of one or
more color.
38 5 PS1 Scanner HP sensor Home posi- Other than
tion home posi-
tion
281

Main body Classification
Multi code
Symbol
Code
bizhub PRO C6501
001 (High) 000 (Low)
45 0 TEMS/1 Temperature sensor /1 (Fusing upper heating Display of temperature (°C)

roller center)
1 TEMS/3 Temperature sensor /3 (Fusing upper heating
roller edge)
2 TEMS/2 Temperature sensor /2 (Fusing lower pres-
sure roller center)
3 TEMS/4 Temperature sensor /4 (Fusing lower pres-
sure roller edge)
4 TEMS/1 Temperature sensor /1 (Fusing upper roller
non-contact sensor correction)
5 TEMS/2 Temperature sensor /2 (Fusing lower roller
non-contact sensor correction)
8 TEMS/1 Fusing upper heating roller center detection
temperature (idling)
11 TEMS/1 Fusing upper heating roller center detection
temperature (when pressure release opera-
tion is powered ON)
12 TEMS/3 Fusing upper heating roller edge detection
tion is powered ON)
14 TEMS/2 Fusing lower pressure roller center detection
tion is powered ON)
47 3 PS16 Fusing release home sensor (when pressure Home posi- Other than
release operation is powered ON) tion home posi-
tion
4 Fusing release home sensor (at pressure
position move)
5 Fusing release home sensor (at release posi-
tion move)
6 PS64 Fusing loop sensor Paper No paper
48 0 PS15 1st transfer HP sensor Home posi- Other than
tion home posi-
tion
50 12 TCRS/Y TCR sensor /Y output value (1/1 speed) 0 to 255
Specific function
13 TCRS/M TCR sensor /M output value (1/1 speed)

14 TCRS/C TCR sensor /C output value (1/1 speed)
15 TCRS/K TCR sensor /K output value (1/1 speed)
58 0 TCRS/Y TCR sensor /Y control voltage (1/1 speed)
1 TCRS/M TCR sensor /M control voltage (1/1 speed)
2 TCRS/C TCR sensor /C control voltage (1/1 speed)
3 TCRS/K TCR sensor /K control voltage (1/1 speed)
59 3 PS17 Fusing paper exit detection sensor Paper No paper
282
/C6501P/C65hc/C5501
DF Classification
Multi code
Symbol
Code
bizhub PRO C6501

001 (High) 000 (Low)
60 1 PS304 Original empty sensor Original No original

2 PS301 Original registration sensor
3 PS302 Timing sensor
4 PS305 Original reverse sensor
5 PS306 Original exit sensor
6 PS303 Original paper feed cover sensor Open Close
7 PS308 Conveyance cover sensor Close Open
8 PS307 Paper exit cover sensor Open Close
9 RS Tray open/close sensor
70 1 PS1 FD entrance sensor No paper Paper
FD
2 PS4 PI exit sensor Paper No paper

3 PS5 Punch conveyance sensor No paper Paper
4 PS7 Main tray folding paper full sensor Other than full Full
5 PS8 2-holes punch home sensor Home posi- Other than
6 PS9 3 holes/4 holes home sensor tion home posi-
7 PS10 Alignment plate home sensor tion
8 PS11 Punch registration home sensor

9 PS12 Punch scraps box set sensor Set Not set
10 PS13 Intermediate conveyance sensor Paper No paper
11 PS16 Sub tray exit sensor
12 PS17 Sub tray paper full sensor Other than full Full
13 PS18 Main tray paper exit sensor Paper No paper
14 PS20 Main tray upper limit sensor Upper limit Other than
upper limit
15 PS22 Main tray lower limit sensor Lower limit Other than
lower limit
16 PS23 Main tray empty sensor No paper Paper
17 PS26 Punch scraps full sensor Other than full Full
22 PS2 Folding exit sensor Paper No paper
23 CN90 Main tray connection recognition (CN90 con- Unconnected Connected
nection)
24 PS51 1st folding conveyance sensor No paper Paper
25 PS52 Folding entrance sensor
26 PS53 2nd folding conveyance sensor
27 PS54 3rd folding conveyance sensor
28 PS55 1st folding cam home sensor Non-pressure Pressure
29 PS56 2nd folding cam home sensor
30 PS57 3rd folding cam home sensor
31 PS58 S size conveyance sensor Paper No paper
32 PS6 Punch registration sensor
283

FD Classification
Multi code
Symbol
Code
bizhub PRO C6501
001 (High) 000 (Low)
70 33 FDOB Staple selection switch OFF ON

34 Punch selection switch
35 Folding selection switch
36 Start/Stop switch
37 Multi feed function select switch
39 PS46 Sub tray folding paper full sensor Full Other than full
40 PS31 PI conveyance sensor /Up Paper No paper
41 PS37 PI conveyance sensor /Lw
42 PS32 PI upper limit sensor /Up Upper limit Other than
upper limit
43 PS33 PI paper empty sensor /Up Full Other than full
44 PS34 PI lift plate home sensor /Up Home posi- Other than
tion home posi-
tion
45 PS35 L size sensor /Up No paper Paper
46 PS36 S size sensor /Up
48 PS38 PI upper limit sensor /Lw Upper limit Other than
upper limit
49 PS39 PI paper empty sensor /Lw Full Other than full
50 PS40 PI lift plate home sensor /Lw Home posi- Other than
tion home posi-
tion
51 PS41 L size sensor /Lw No paper Paper
52 PS42 S size sensor /Lw
53 PS43 PI cover open/close sensor Close Open
54 PS44 PI paper set sensor /Up No paper Paper
55 PS45 PI paper set sensor /Lw
61 PS47 PI max paper size sensor /Up
62 PS48 PI max paper size sensor /Lw
64 - FD connection detection signal Connected Not con-
nected
71 1 PS1 Entrance sensor Paper No paper
SD
2 PS2 Horizontal conveyance sensor /1

3 PS3 Horizontal conveyance sensor /2
4 PS4 Horizontal conveyance exit sensor
5 PS5 Right angle conveyance sensor /1 No paper Paper
6 PS6 Right angle conveyance sensor /2
7 PS7 Folding sensor /1
8 PS8 Folding passage sensor Paper No paper
9 PS17 Overlap home sensor Home posi- Other than
tion home posi-
tion
2 284
/C6501P/C65hc/C5501
SD Classification
Multi code
Symbol
Code
bizhub PRO C6501

001 (High) 000 (Low)
71 10 PS18 Folding main scan alignment home sensor / Other than Home posi-
Fr1 home position
11 PS49 Folding main scan alignment home sensor / tion
Fr2
12 PS20 1st folding blade home sensor /1
13 PS21 1st folding blade home sensor /2 Home posi- Other than
tion home posi-
tion
14 PS22 2nd folding blade home sensor /1 Other than Home posi-
home position
tion
15 PS23 2nd folding blade home sensor /2 Home posi- Other than
16 PS24 Folding exit home sensor tion home posi-
tion
17 PS9 Tri-folding exit sensor Paper No paper
18 PS10 Tri-folding paper full sensor Other than full Full
19 PS11 Sub tray exit sensor Paper No paper
21 PS44 Folding sensor /2 No paper Paper
22 PS19 Folding main scan alignment home sensor / Home posi- Other than
Rr tion home posi-
23 PS46 Guide shaft home sensor tion
24 HS2/ Clincher start sensors /Rt and /Lt No clinch Clinch
HS4
33 PS13 Saddle stitching paper sensor No paper Paper
34 PS14 Bundle sensor /1
35 PS15 Bundle sensor /2
36 PS16 Bundle registration plate home sensor Other than Home posi-
home position
tion
37 PS25 Stapler movement home sensor Home posi- Other than
tion home posi-
tion
38 PS26 Clincher up down home sensor Other than Home posi-
home position
tion
39 PS27 Saddle stitching press home sensor Home posi- Other than
40 PS28 Saddle stitching alignment home sensor /Rt tion home posi-
41 PS29 Saddle stitching alignment home sensor /Lt tion
42 PS33 Bundle clip upper limit sensor Upper limit Other than
upper limit
43 PS30 Bundle clip lower limit sensor Lower limit Other than
lower limit
285

SD Classification
Multi code
Symbol
Code
bizhub PRO C6501
001 (High) 000 (Low)
71 44 PS32 Bundle arm home sensor Home posi- Other than

45 PS31 Bundle arm rotation home sensor tion home posi-
46 PS34 Bundle registration home sensor tion
47 PS35 Bundle press stage up down home sensor

48 PS45 Bundle press stage up down limit sensor Upper limit Other than
upper limit
49 PS37 Bundle press home sensor Other than Home posi-
home position
tion
50 PS47 Bundle press lower limit sensor Other than Lower limit
lower limit
51 PS48 Scraps press home sensor Other than Home posi-
home position
tion
52 PS40 Scraps box set sensor Set Not set
53 PS41 Trimmer scraps full sensor Other than full Full
54 PS36 Bundle press movement home sensor Home posi- Other than
55 PS38 Bundle arm assist home sensor tion home posi-
tion
56 PS39 Bundle arm assist upper limit sensor Other than Upper limit
upper limit
57 SW1 Staple empty switch /Rt No staple Staple
58 SW2 Staple empty switch /Lt
59 HS1 Stapler home sensor /Rt Other than Home posi-
60 HS3 Stapler home sensor /Lt home position
tion
61 PS50 Trimmer blade home sensor Home posi- Other than
tion home posi-
tion
62 PS51 Trimmer blade upper limit sensor Other than Upper limit
upper limit
63 PS52 Trimmer press upper limit sensor Upper limit Other than
upper limit
64 PS53 Trimmer press home sensor Lower limit Other than
lower limit
65 PS42 Front door sensor /Rt Open Close
66 PS43 Front door sensor /Lt
67 PS54 Bundle sensor /4 Paper No paper
68 PS55 Trimmer registration sensor Registration Other than
position registration
position
2 286
/C6501P/C65hc/C5501
SD Classification
Multi code
Symbol
Code
bizhub PRO C6501

001 (High) 000 (Low)
71 69 PS56 Folding sub scan alignment home sensor Home posi- Other than
tion home posi-
tion
70 PS57 Bundle exit sensor /2 No paper Paper
71 PS58 Bundle tray set sensor Not set Set
72 PS59 Trimmer board replacement sensor Replace Not replace
75 PS61 Bundle tray paper full sensor Full Other than full
77 PS60 Folding entrance sensor No paper Paper
81 PS62 Trimmer completion sensor Complete Other than
complete
83 PS66 Wire slack prevention sensor With slack Without slack
84 New trimming unit connection detection Not con- Connected
nected
88 - FNS connection detection signal Connected Not con-
nected
72 1 PS35 Rear stopper home sensor Home posi- Other than
FS-521
2 PS33 Intermediate roller home sensor tion home posi-

3 PS32 Stack assist home sensor tion
4 PS14 Stapler rotation home sensor Other than Home posi-

home position
tion
5 PS11 Stapler movement home sensor Home posi- Other than
tion home posi-
tion
6 PS34 Staple scraps box set sensor Set Not set
8 PS1 Sub tray exit sensor Paper No paper
9 PS5 Stacker entrance sensor
10 PS4 FNS entrance sensor No paper Paper
11 PS15 Counter reset sensor Reset Other than
reset
12 PS12 Paper exit opening sensor Other than Home posi-
home position
tion
13 PS10 Main tray paper exit sensor No paper Paper
14 PS3 Tray lower limit sensor Lower limit Other than
lower limit
15 PS39 Paper empty sensor No paper Paper
21 PS47 Staple ready sensor /Fr Other than Ready
ready
22 PS43 Cartridge set sensor /Fr No cartridge Cartridge
23 PS45 Staple empty sensor /Fr No staple Staple
287 2

FS -521 Classification
Multi code
Symbol
Code
bizhub PRO C6501
001 (High) 000 (Low)
72 24 PS41 Stapler home sensor /Fr Other than Home posi-

home position
tion
25 PS46 Staple ready sensor /Rr Other than Ready
ready
26 PS42 Cartridge set sensor /Rr No cartridge Cartridge
27 PS44 Staple empty sensor /Rr No staple Staple
28 PS40 Stapler home sensor /Rr Other than Home posi-
home position
tion
30 PS20 Stacker empty sensor No paper Paper
31 PS9 Paper exit arm home sensor Other than Home posi-
home position
tion
32 MS1 Door switch Open Close
33 PS31 Alignment home sensor /Fr Home posi- Other than
34 PS8 Alignment home sensor /Rr tion home posi-
tion
35 PS6 Tray middle position sensor With tray Without tray
36 PS13 Bypass roller release home sensor Other than Home posi-
home position
tion
37 PS16 Tray upper limit sensor Without tray With tray
38 PS19 Paper exit alignment plate home sensor /Rr Home posi- Other than
39 PS18 Paper exit alignment plate home sensor /Fr tion home posi-
tion
40 - FNS connection detection signal Connected Not con-
nected
41 OB Operation board (Pause button) OFF ON
42 PS24 Paper exit alignment plate retraction home Home posi- Other than
sensor tion home posi-
tion
43 PS17 Tray quarter position sensor With tray Without tray
44 PS23 Stacker entrance roller release home sensor Home posi- Other than
tion home posi-
tion
98 — FS connection detection signal Connected Not
connected
72 1 PS1 Sub tray paper exit sensor Paper No paper
FS-520/607
2 PS4 FNS Entrance sensor No paper Paper

3 PS19 Sub tray full sensor Full Other than full
2 288
/C6501P/C65hc/C5501
FS-520/607 Classification
Multi code
Symbol
Code
bizhub PRO C6501

001 (High) 000 (Low)
72 4 PS12 Paper exit opening home sensor Other than Closed

the closed position
position
5 PS16 Gate home sensor Other than Home posi-

home position
tion
6 PS6 Main tray paper exit sensor Paper No paper
7 PS18 Shift roller home sensor Other than Home posi-
home position
tion
10 PS3 Main tray lower limit sensor Lower limit Not at lower
limit
12 PS2 Main tray upper limit sensor Upper limit Not at upper
limit
13 PS7 Stapler paper exit upper limit sensor Other than Stand-by
the stand-by position
position
14 PS15 Counter reset sensor Paper No paper
17 PS5 Stacker entrance sensor
18 PS8 Alignment home sensor /Up Home posi- Other than
19 PS9 Paper exit belt home sensor tion home posi-
20 PS11 Stapler movement home sensor tion
21 PS13 Stapler rotation home sensor (FS-607 only)

22 PS14 Clincher rotation home sensor (FS-607 only)
23 PS20 Stacker empty sensor Paper No paper
24 MS1 Door switch Open Close
25 PS31 Stapler motor home sensor /Fr Other than Home posi-
26 PS30 Stapler motor home sensor /Rr home position
tion
27 SW4 Staple empty switch /Fr No staple Staple
28 SW2 Staple empty switch /Rr
29 SW4 Staple empty switch /Fr (crown staple)
30 SW2 Staple empty switch /Rr (crown staple)
31 SW3 Cartridge switch /Fr No cartridge Cartridge
32 SW1 Cartridge switch /Rr
35 PS33 Clincher motor home sensor /Fr (FS-607 Other than Home posi-
only) home position
36 PS32 Clincher motor home sensor /Rr (FS-607 tion
only)
41 PS22 Folding knife home sensor (FS-607 only)
289

Multi code
Symbol
Code
bizhub PRO C6501
001 (High) 000 (Low)
72 42 PS23 Saddle stitching stopper home sensor (FS- Home posi- Other than
607 only) tion home posi-
43 PS24 Alignment home sensor /Lw (FS-607 only) tion
44 PS25 Folding paper exit sensor (FS-607 only) Paper No paper
45 PS26 Folding pass-through sensor (FS-607 only)
46 PS29 Folding full sensor (FS-607 only) Full Other than full
49 PS201 Paper pass-through sensor /Up (PI) Paper No paper
50 PS206 Paper pass-through sensor /Lw (PI)
57 PS301 Punch home sensor (PK) Other than Home posi-
home position tion
58 PS306 Punch encoder sensor (PK) Light blocking Exposure
59 PS302 Punch scraps box full sensor (PK) Other than full Full
60 PS304 Punch scraps box set sensor (PK) set Not set
61 PS303 Punch shift home sensor (PK) Home posi- Other than
tion home position
62 PS305 Swing edge face detection 5 (PK) Paper No paper
63 Swing edge face detection 4 (PK)
73 PS202 Paper empty sensor /Up (PI) No paper Paper
74 PS203 Paper set sensor /Up (PI)
75 PS205 Tray upper limit sensor /Up (Upper stage) (PI) Not at upper Upper limit
limit
76 PS204 Tray lower limit sensor /Up (Upper stage) (PI) Not at lower Lower limit
limit
77 PIOB Sheet feeder manual start/clear SW (PI) OFF ON
78 Sheet feeder manual punch button SW (PI)
79 Sheet feeder manual function selection but-
ton SW (PI)
80 MS201 Cover sheet open/close detection (PI) Open Close
81 PS207 Paper empty sensor /Lw (PI) No paper Paper
82 PS212 Paper set sensor /Lw (PI)
83 PS209 Tray upper limit sensor /Lw (lower stage tray) Upper limit Not at upper
(PI) limit
84 PS210 Tray lower limit sensor /Lw (lower stage tray) Lower limit Not at lower
(PI) limit
86 PS208 L sizesensor /Lw (PI) No paper Paper
96 — FNS connection detection signal Connected Not
connected
73 1 PS4 Entrance sensor Paper No paper
LS
2 290
/C6501P/C65hc/C5501
LS Classification
Multi code
Symbol
Code
bizhub PRO C6501

001 (High) 000 (Low)
73 3 PS7 Conveyance sensor /1 Paper No paper

4 PS16 Conveyance sensor /2
5 PS17 Conveyance sensor /3
6 PS18 Coupling exit sensor
7 PS3 Stacker tray upper limit sensor Upper limit Other than
upper limit
8 PS6 Paper empty sensor Other than full Full
9 PS13 2,000 sheets stacked sensor ON OFF
10 PS19 Paper detection sensor
11 PS14 5,000 sheets stacked sensor
12 PS9 Sub tray full sensor Full Other than full
13 PS1 Stacker tray set sensor Set Not set
14 RS1 Hand cart reset switch
15 PS15 Stacker tray arm release sensor ON OFF
16 TOB Paper exit switch
17 MS1 Front door switch Open Close
18 RS2 JAM door switch
19 PS8 Sub tray door sensor
20 MS2 Stacker tray upper limit switch Upper limit Other than
upper limit
21 MS3 Stacker tray lower limit switch Lower limit Other than
lower limit
22 PS12 Alignment home sensor Home posi- Other than
23 PS11 Shift unit home sensor tion home posi-
tion
24 PS5 Grip conveyance home sensor
32 - FNS connection detection signal Connected Not connected
75 41 PS2 Intermediate sensor No paper Paper
RU-504
42 MS1 Interlock switch OFF ON

46 PS1 Entrance sensor No paper Paper
48 PS3 Paper exit sensor
56 — FNS connection detection signal Connected Not connected
75 07 PS5 Stacker jam sensor No paper Paper
RU -506
29 PS1 Entrance sensor

40 - FNS connection detection Connected Not con-
nected
42 PS4 CD alignment plate home sensor Home posi- Other than
tion home position
43 PS2 Paper exit sensor No paper Paper
44 PS6 Entrance jam sensor
46 PS3 FD alignment plate home sensor Home posi- Other than
tion home position
49 MS1 Interlock switch OFF ON
291 2

PB Classification
Multi code
Symbol
Code
bizhub PRO C6501
001 (High) 000 (Low)
77 01 PS1 Entrance sensor No paper Paper

02 PS2 SC entrance sensor
03 PS3 Cover paper entrance sensor
05 PS5 Sub tray full sensor Other than full Full
08 PS12 SC switchback arm pressure detection sensor OFF ON
09 PS13 SC switchback spring pressure detection sensor ON OFF
10 PS14 SC alignment HP sensor Home posi- Other than
tion home position
11 PS16 SC paper detection sensor No paper Paper
12 PS17 SC roller release sensor ON Release
13 PS18 Clamp entrance movement HP sensor Home posi- Other than
tion home position
14 PS19 Clamp entrance roller release sensor ON Release
15 PS21 Clamp alignment HP sensor Home posi- Other than
16 PS22 Clamp HP sensor tion home position
17 PS23 Clamp pressure sensor ON OFF

18 PS24 Clamp rotation HP sensor Home posi- Other than
tion home position
19 PS25 Clamp rotation pressure sensor Pressurize Not pressurize
20 PS26 Cover paper table upper limit sensor /Fr Upper limit Other than
21 PS27 Cover paper table upper limit sensor /Rr upper limit
22 PS28 Clamp paper sensor No paper Paper

23 PS29 Book thickness sensor Detection No detection
24 PS31 Glue tank movement limit sensor Upper limit is Other than
reached limit
25 PS32 Glue apply position detection sensor No paper Paper
26 PS33 Glue tank HP sensor Home posi- Other than
tion home position
27 PS36 Pellet remain sensor No Pellet Pellet
28 PS37 Pellet count sensor No detection Detection
29 PS38 Pellet supply arm upper limit sensor Upper limit Other than
upper limit
30 PS39 Pellet supply arm lower limit sensor Lower limit Other than
lower limit
31 M32 Glue apply roller motor Normal Abnormal
32 PS3 Paper exit sensor No paper Paper
33 PS41 Cover paper alignment HP sensor Home posi- Other than
34 PS42 Cover paper conveyance arm HP sensor /Rt tion home posi-
tion
35 PS43 Cover paper conveyance arm HP sensor /Lt
36 PS44 Cover paper switchback sensor No paper Paper
37 PS45 Cover paper sensor /Rt
292
/C6501P/C65hc/C5501
PB Classification
Multi code
Symbol
Code
bizhub PRO C6501

001 (High) 000 (Low)
77 38 PS46 Cover paper sensor /Lt No paper Paper

39 PS47 Cover paper table HP sensor /Fr Other than Home posi-
40 PS53 Cover paper table HP sensor /Rr home position tion
41 PS48 Cover paper folding plate HP sensor /Rt Home posi- Other than
42 PS49 Cover paper folding plate HP sensor /Lt tion home position
43 PS50 Cover paper folding plate encoder sensor Detection No detection

44 PS51 Cover paper folding plate position sensor At the refer- Not at the
ence position position
45 PS52 Cover paper folding pressure sensor Pressurize Not pressurize
46 SW41 Cutter HP sensor Other than Home posi-
47 SW42 Cutter HP sensor home position tion
48 MS2 Front door switch Close Open

49 PS57 Stacker door sensor
50 PS61 Book end sensor Detection No detection
51 PS62 Cover paper conveyance belt movement HP Home posi- Other than
sensor tion home posi-
52 PS63 Cover paper belt HP sensor tion
53 PS64 Cover paper belt lower limit sensor Lower limit Other than
lower limit
54 PS65 Book load limit sensor Other than Upper limit
upper limit
55 PS66 booklet sensor /1 No paper Paper
56 PS67 Book sensor /2
57 PS68 Book stopper HP sensor Home posi- Other than
tion home position
58 PS69 Cart set sensor Set Not set
59 OB/2 Book stock operation board SW OFF SW ON
60 - - - -
61 SW1 Upper door switch Open Close
64 PBCB FNS connection detection signal Connected Not con-
nected
65 - Cover paper tray set detection signal Not set Set
66 PS71 Cover paper empty sensor No paper Paper
67 - Power plug connection detection signal Connected Not con-
nected
68 PS74 Cover paper tray upper limit sensor Upper limit Other than
upper limit
69 PS75 Cover paper conveyance sensor /1 No paper Paper
70 PS76 Cover paper conveyance sensor /2
293

PB Classification
Multi code
Symbol
Code
bizhub PRO C6501
001 (High) 000 (Low)
77 74 PS80 Waste box full sensor Other than full Full

75 PS81 Waste box set sensor Set Not set
80 PS82 Cover paper tray knob sensor Locked Release
81 TH2 Glue tank temperature sensor /up 0 to 255
82 TH3 Glue tank temperature sensor /Md
83 TH4 Glue tank temperature sensor /Lw
84 TH1 Glue apply roller temperature sensor
85 OB/1 Manual operation board Glue apply Glue apply
SW OFF SW ON
86 OB/1 Manual operation board Alignment Alignment
SW OFF SW ON
87 OB/1 Manual operation board Start SW OFF Start SW ON
88 MS1 Pellet supply door switch Close Open
89 TH1 Glue apply roller temperature sensor (high Abnormal Normal
temperature abnormality)
90 TH1 Glue apply roller temperature sensor (low-
temperature abnormality)
91 TH2 Glue tank temperature sensor /up (high tem-
perature abnormality)
92 TH2 Glue tank temperature sensor /up (low-tem-
93 TH3 Glue tank temperature sensor /Md (high tem-
94 Glue tank temperature sensor /Md (low-tem-
95 TH Glue tank temperature sensor /Lw (high tem-
96 Glue tank temperature sensor /Lw (low-tem-
78 01 S1 Enter sensor Paper No Paper
GP
02 S2 Stepper 1 speed sensor

03 S3 Punch module sensor
04 S5 Back Gauge sensor
05 S6 Stepper 2 speed sensor
06 S7 Exit sensor
07 S8 Bypass sensor
08 S9 Punch flag sensor Punch operation Home position
09 - Chip tray switch Not set Set
10 - Die set swtich
11 - Door switch Open Close
13 S4 U-channel sensor Paper No paper
16 - GP connection detected Connected Not connected
2 294
9.7.3 Output check
/C6501P/C65hc/C5501
Load operations can be checked and adjusted (output check) using this output check.
bizhub PRO C6501

A. Procedure

Press [05 State Confirmation].
2. "State Confirmation Menu screen"
Press [01 I/O Check Mode].
3. "I/O Check Mode screen"
Enter an output check code with the fine numeric keys.
4. Press [Access] key to switch to the multi mode.
5. Enter the multi code with the fine numeric buttons.
6. Press the Start key.
The specified loading operates.
7. Press the Stop key.
The specified loading stops.
8. When executing another output check of the signal or loading operation, repeat steps 3 to 7.
B. List of loads
Multi code
Symbol
Code
Name Restrictive conditions
0 0 L1 Exposure lamp
1 0 M53, Toner bottle motor, toner bottle clutch /Y
MC14
3 M53, Toner bottle motor, toner bottle clutch /M
MC15
6 M53, Toner bottle motor, toner bottle clutch /C
MC16
9 M53, Toner bottle motor, toner bottle clutch /K
MC17
2 0 HV/1 High voltage unit /1 (charging/Y) No use allowed in the
1 High voltage unit /1 (charging/M) field.
2 High voltage unit /1(charging/C)
3 High voltage unit /1 (charging/K)
3 0 HV/2 High voltage unit /2 (1st transfer/Y)
1 High voltage unit /2 (1st transfer/M)
2 High voltage unit /2 (1st transfer/C)
3 High voltage unit /2 (1st transfer/K)
4 High voltage unit /2 (1st transfer/Y, /M, /C, /K)
7 High voltage unit /2 (1st transfer/K)
4 0 HV/2 High voltage unit /2 (separation)
1 High voltage unit /2 (separation: for measurement)
295
Multi code
Symbol
Code
bizhub PRO C6501
5 0 PS11 PGC sensor output voltage Number between 0 and

2 PS8, PS9 Color registration sensor output voltage 255 is displayed on [IN]
5 PS11 PGC sensor output voltage area of the screen
6 PS8, PS9 Color registration sensor

15 1 — CSRC, data collection counter clear When
2 Mode memory clear DIPSW3-6
98 CS Remote Care memory initialization Used in is OFF, these
CSRC function do
setting not work.
18 1 PS65 ADU centering sensor

2 PS1 Centering sensor (LU) Number between 0 and
3 PS25 Centering sensor (PF) 255 is displayed on [IN]
area of the screen
4 MFDT Multi feed detection board /S, /R (PF)
B/S, /R
20 0 SD7 Pick-up solenoid /1
Paper feed conveyance
1 SD8 Pick-up solenoid /2

2 SD9 Pick-up solenoid /3
4 SD5 Pick-up solenoid /BP
5 SD100 Pick-up solenoid (LU)
6 SD1 Pick-up solenoid /1 (PF)
7 SD5 Pick-up solenoid /1 (PF)
21 0 MC7 Paper feed clutch /1
1 MC9 Paper feed clutch /2
2 MC11 Paper feed clutch /3
4 MC6 Paper feed clutch /BP
5 MC101 Paper feed clutch (LU)
6 MC1 Paper feed clutch /1 (PF)
7 MC4 Paper feed clutch /1 (PF)
22 0 MC8 Pre-registration clutch /1
1 MC10 Pre-registration clutch /2
2 MC12 Pre-registration clutch /3
5 MC102 Pre-registration clutch (LU)
23 0 M38 Paper lift motor /1
1 M39 Paper lift motor /2
2 M40 Paper lift motor /3
3 M35 Paper lift motor /BP (down)
4 M35 Paper lift motor /BP (up)
5 M100 Paper lift motor (LU: down)
6 Paper lift motor (LU: up)
7 M2 Paper lift motor /1 (PF)
296
/C6501P/C65hc/C5501
Multi code
Symbol
Code
bizhub PRO C6501

23 8 M3 Paper lift motor /2 (PF)

24 0 M34 2nd transfer pressure/release motor
1 2nd transfer pressure (pressure position 1)
2 2nd transfer pressure (pressure position 2)
3 2nd transfer release
25 0 M30 Registration motor (1/2 speed)
1 Registration motor (2/3 speed)
2 Registration motor (1/1 speed)
3 Registration motor (paper feed line speed)
4 Registration motor (Hard timer ON: 1/1 speed)
26 0 M31 Loop motor (1/2 speed)
1 Loop motor (2/3 speed)
2 Loop motor (1/1 speed)
3 Loop motor (paper feed line speed)
27 0 M33 Reverse/exit motor (Forward rotation: 1/2 speed)
1 Reverse/exit motor (Forward rotation: 2/3 speed)
2 Reverse/exit motor (Forward rotation: 1/1 speed)
3 Reverse/exit motor (Forward rotation: Max. speed)
4 Reverse/exit motor (Reverse rotation: 1/2 speed)
7 Reverse/exit motor (Reverse rotation: Max. speed)
10 M55 Decurler motor (Forward rotation: 1/2 speed)
11 Decurler motor (Forward rotation: 2/3 speed)
12 Decurler motor (Forward rotation: 1/1 speed)
13 Decurler motor (Forward rotation: Max. speed)
14 Decurler motor (Reverse rotation: 1/2 speed)
15 Decurler motor (Reverse rotation: 2/3 speed)
16 M55 Decurler motor (Reverse rotation: 1/1 speed)
17 Decurler motor (Reverse rotation: Max. speed)
20 M54 Paper exit motor (Forward rotation: 1/2 speed)
21 Paper exit motor (Forward rotation: 2/3 speed)
22 Paper exit motor (Forward rotation: 1/1 speed)
23 Paper exit motor (Forward rotation: Max. speed)
25 Paper exit motor (Reverse rotation: continuous)
26 Paper exit motor (Reverse rotation: HP position)
27 Paper exit motor (Reverse rotation: high pressure
amount)
28 Paper exit motor (Reverse rotation: medium pres-
sure amount)
297
Multi code
Symbol
Code
bizhub PRO C6501
27 29 M54 Paper exit motor (Reverse rotation: low pressure

amount)
28 0 M41 Paper feed motor
1 M1 Paper feed motor (LU)
2 M1 Paper feed motor (PF)
29 0 MC13 Intermediate conveyance clutch /1
1 MC4 Intermediate conveyance clutch /2
2 MC5 Intermediate conveyance clutch /3
3 SD1 Belt separation claw solenoid
5 FM1, Paper feed assist fan /Fr, /Rr (LU)
FM2
6 SD4 Tray lock solenoid /1 (PF)
7 FM3, Paper feed assist fan /Fr12, /Rr12 (Tray 4) (PF)
FM4
FM2
FM8
FM6
11 MC12 Pre-registration clutch (PF)
12 MC7 Vertical conveyance clutch /1 (PF)
15 MC10 Horizontal conveyance clutch /1 (PF)
16 MC11 Horizontal conveyance clutch /2 (PF)
17 SD2, Shutter solenoid /Fr1, /Rr1 (PF)
SD3
19 SD6, Shutter solenoid /Fr2, /Rr2 (PF)
SD7
298
/C6501P/C65hc/C5501
Multi code
Symbol
Code
bizhub PRO C6501

29 21 SD4 Tray lock solenoid /1 (PF)

22 SD8 Tray lock solenoid /2 (PF)
23 MC2 Separation clutch /1 (PF)
24 MC5 Separation clutch /2 (PF)
25 FM9, Ventilation fan/1, /2 (PF)
FM10
26 HTR3, Fan heater /Up, Dehumidifier fan /1, /2 (HT)
FM11,
FM12
28 HTR4, Fan heater, Dehumidifier fan /3, /4 (HT)
FM13,
FM14
30 HTR1 Temperature adjustment tray 33°C, Heat pipe
70°C (tray 4) (LU)
32 0 M3 Polygon motor /Y (1/1 rotation)
1 M4 Polygon motor /M (1/1 rotation)
2 M5 Polygon motor /C (1/1 rotation)
3 M6 Polygon motor /K (1/1 rotation)
4 M3, Polygon motor /Y, /M, /C, /K (1/1 rotation)
M4,
M5,
M6
5 M3 Polygon motor /Y (rotates at adjustment value)
6 M4 Polygon motor /M (rotates at adjustment value)
7 M5 Polygon motor /C (rotates at adjustment value)
8 M6 Polygon motor /K (rotates at adjustment value)
9 M3, Polygon motor /Y, /M, /C, /K
M4, (rotates at adjustment value)
M5,
M6
33 0 INDEX INDEVB /Y
B/Y
1 INDEX INDEVB /M
B/M
2 INDEX INDEVB /C
B/C
3 INDEX INDEVB /K
B/K
4 INDEX INDEVB /Y, /M, /C, /K
B/Y, /
M, /C,
/K
34 0 — Shading correction operation
299
Multi code
Symbol
Code
bizhub PRO C6501
36 3 PS8 Color registration sensor /Fr Number between 0 and

4 PS9 Color registration sensor /Rr 255 is displayed on [IN]
area of the screen
37 0 — LD alarm measurement LD alarm value can be
91 LD1 /2 alarm data clear /Y checked on the adjust-
92 LD1 /2 alarm data clear /M ment list of list output.
93 LD1 /2 alarm data clear /C

94 LD1 /2 alarm data clear /K
99 LD1/2 alarm data clear /Y, /M, /C, /K
38 0 M1 Scanner motor (reciprocating driver 1) 11x17, magnification
100%, one scanning
1 Scanner motor (reciprocating driver 2) 11x17, magnification
100%, continuous scan-
ning
ning
ning
4 Scanner motor (reciprocating driver 5) 81/2 x11, magnification
ning
5 Scanner motor (home position search)
6 Scanner motor (back scan position move)
7 Scanner motor (back scan ACS operation + scan
operation)
41 0 M14 Drum motor /Y (1/2 speed)
Main body
1 Drum motor /Y (2/3 speed)

2 Drum motor /Y (1/1 speed)
3 M15 Drum motor /M (1/2 speed)
4 Drum motor /M (2/3 speed)
5 Drum motor /M (1/1 speed)
6 M16 Drum motor /C (2/3 speed)
7 Drum motor /C (1/2 speed)
8 Drum motor /C (1/1 speed)
9 M17 Drum motor /K (2/3 speed)
10 Drum motor /K (1/2 speed)
11 Drum motor /K (1/1 speed)
12 M18 Transfer belt motor (2/3 speed)
13 Transfer belt motor (1/2 speed)
14 Transfer belt motor (1/1 speed)
300
/C6501P/C65hc/C5501
Multi code
Symbol
Code
bizhub PRO C6501

42 0 M2 Scanner fan
1 M25 IPB fan/2
2 M42 DCPS fan
3 M37 Fusing ventilation fan
4 M48 Charge intake fan
5 M47 Main body fan
6 M43, Writing intake fan /1, /2
M44
7 M45, Developing fan /1, /2
M46
8 M26, Tucking fan /1, /2, /3
M27,
M28
9 M12 Drum fan /1
10 M13 Drum fan /2
11 M61, Paper exit fan /1, /2, /3
62, 63
12 M66 ADU fan /1
13 M36 Deodorization fan
14 M10 Fusing belt ventilation fan
15 M65 Fusing fan /Lw
16 FM3 Dehumidifier fan /1, /2 (LU)
17 FM4 Dehumidifier fan /3, /4 (LU)
18 FM11, Dehumidifier fan /1, /2 (PF)
FM12
19 FM13, Dehumidifier fan /3, /4 (PF)
FM14
20 M67 ADU fan /2
43 1 TCT/1 Total counter /1
2 TCT/2 Total counter /2
6 KCT Key counter
45 0 L2, L3, Fusing heater lamp /1, /2, /3, /4 (powered ON Temperature detection of
L4, L5 simultaneously) fusing upper heating roller
center
1 Temperature detection of
fusing upper heating roller
edge
fusing lower pressure
roller center
fusing lower pressure
roller edge
301
Multi code
Symbol
Code
bizhub PRO C6501
45 4 L2, L3, Fusing heater lamp/1, /2, /3, /4 (powered ON Non-contact sensor on
L4, L5 simultaneously) fusing lower roller
5 Non-contact sensor on
fusing lower roller
8 Proper temperature at idle
(at warming up)
11 L2, Fusing heater lamp/1 temperature control Number between 0 and
TEMS/1 255 is displayed on [IN]
12 L3, Fusing heater lamp/2 temperature control area of the screen
TEMS/3
13 L4, Fusing heater lamp/3 temperature control
TEMS/1
14 L5, Fusing heater lamp/4 temperature control
TEMS/2
46 0 — LD1/2 Laser emission timing adjustment (main
scanning)
47 0 M29 Fusing motor (Forward rotation: 1/2 speed)
1 Fusing motor (Forward rotation: 2/3 speed)
2 Fusing motor (Forward rotation: 1/1 speed)
3 Fusing motor (Reverse rotation: pressure release
operation ON, normal rotation)
4 Fusing motor (Reverse rotation: pressure position
move)
5 Fusing motor (Reverse rotation: release position
move)
9 Fusing roller press (continuous rotation 1/2
speed)
speed)
speed)
13 M29, Fusing roller press (ON all heaters at the same
L2, L3, time)
L4, L5
48 0 M19 1st transfer pressure/release motor (rotate con-
stantly)
1 1st transfer pressure/release motor (stop at
release position)
2 1st transfer pressure/release motor (stop at B&W
mode fusing position)
3 1st transfer pressure/release motor (stop at color
mode pressure position)
302
/C6501P/C65hc/C5501
Specific function Classification
Multi code
Symbol
Code
bizhub PRO C6501

50 0 M20 Developing motor/Y (1/1 speed)

1 Developing motor/Y (1/2 speed)
2 Developing motor/Y (1/3 speed)
3 M21 Developing motor/M (1/1 speed)
4 Developing motor/M (1/2 speed)
5 Developing motor/M (1/3 speed)
6 M22 Developing motor/C (1/1 speed)
7 Developing motor/C (1/2 speed)
8 Developing motor/C (1/3 speed)
9 M23 Developing motor/K (1/1 speed)
10 Developing motor/K (1/2 speed)
11 Developing motor/K (1/3 speed)
12 M20 Y color developing unit rotation
13 M21 M color developing unit rotation
14 M22 C color developing unit rotation
15 M23 BK color developing unit rotation
16 M20, YMC color developing unit rotation
M21,
M22
17 M20, All colors developing unit rotation
M21,
M22,
M23
51 0 EL/Y Eraser lamp/Y
1 EL/M Erasure lamp/M
2 EL/C Erasure lamp/C
3 EL/K Erasure lamp/K
54 0 M49 Toner supply motor /Y
3 M50 Toner supply motor /M
6 M51 Toner supply motor /C
9 M52 Toner supply motor /K
12 MC14 Toner bottle clutch /Y
13 MC15 Toner bottle clutch /M
14 MC16 Toner bottle clutch /C
15 MC17 Toner bottle clutch /K
55 0 SD2 Color registration shutter solenoid
1 SD3 PGC shutter solenoid
56 0 — Status indicator lamp (PAT1 lighting)
1 Status indicator lamp (PAT2 lighting)
303
Specific function Classification
Multi code
Symbol
Code
bizhub PRO C6501
58 0 TCRS /Y TCR sensor /Y

1 TCRS /M TCR sensor /M
2 TCRS /C TCR sensor /C
3 TCRS /K TCR sensor /K
60 1 M301 Original feed motor (Forward rotation: 300mm/
DF
sec)
2 Original feed motor (Forward rotation: 400mm/
sec)
sec)
4 Original feed motor (Reverse rotation: 300mm/
sec)
sec)
sec)
7 M302 Original feed motor (Forward rotation: 300mm/
sec)
sec)
sec)
sec)
sec)
sec)
13 M303 Original reverse/exit motor (Forward rotation:
300mm/sec)
14 Original reverse/exit motor (Forward rotation:
400mm/sec)
15 Original reverse/exit motor (Forward rotation:
900mm/sec)
16 Original reverse/exit motor (Reverse rotation:
300mm/sec)
400mm/sec)
900mm/sec)
19 SD302 Original reverse solenoid
20 SD301 Original paper exit solenoid
21 MC301 Original registration clutch
304
/C6501P/C65hc/C5501
FD Classification
Multi code
Symbol
Code
bizhub PRO C6501

70 1 M1 Entrance conveyance motor

2 M2 Punch conveyance motor
3 M3 Intermediate conveyance motor
4 M4 1st folding motor (F rotation)
5 M4 1st folding motor (R rotation)
6 M5 2nd folding motor (F rotation)
7 2nd folding motor (R rotation)
8 M6 3rd folding motor (F rotation)
9 3rd folding motor (R rotation)
10 M7 PI conveyance motor
11 M8 Paper lift motor /Up (down)
12 Paper lift motor /Up (up)
13 M9 Paper lift motor /Lw (down)
14 Paper lift motor /Lw (up)
15 M17 Main tray paper exit motor
21 M10 Punch motor (3 holes)
22 Punch motor (2 holes)
23 M11 Tray up down motor (home position search)
24 M12 Alignment motor (home position search)
26 M13 Punch registration motor
27 M14 1st folding release motor (conveyance position
move)
28 1st folding release motor (folding position move) ON: folding position OFF:
conveyance position
29 M15 2nd folding release motor (conveyance position
move)
30 2nd folding release motor (folding position move) ON: folding position OFF:
conveyance position
31 M16 3rd folding release motor (conveyance position
move)
32 3rd folding release motor (folding position move) ON: folding position OFF:
conveyance position
61 SD1 Entrance gate solenoid
62 SD3 S size gate solenoid
63 SD4 L size gate solenoid
64 SD5 Roller solenoid /1
68 SD9 Sub tray gate solenoid
69 SD12 Paper exit solenoid
305 2
FD Classification
Multi code
Symbol
Code
bizhub PRO C6501
70 70 SD13 PI pick-up solenoid /Up

71 SD14 PI pick-up solenoid /Lw
72 SD15 Folding gate solenoid
74 SD18 2nd folding roller solenoid
75 CL1 PI registration clutch /Up
76 CL2 PI registration clutch /Lw
82 MFDB1 Multi feed detection board /1 (CLK output)
89 FDOB FD operation board (lit all LEDs)
90 JAMIB Jam indicator board (lit all LEDs)
SD
2 M2 Horizontal conveyance motor

3 M3 Folding entrance motor
4 M4 Folding conveyance motor (F rotation)
5 Folding conveyance motor (R rotation)
6 M6 Right angle conveyance motor
7 M29 Stapler motor /Rt (1 staple)
8 M30 Stapler motor /Lt (1 staple)
9 M5 Bundle exit motor
10 M8 Folding sub scan alignment exit motor
21 M5 Bundle exit motor (home position search)
24 M7 Folding main scan alignment motor /Fr (home
position search)
25 Folding main scan alignment motor /Fr (alignment) Enabled after conducting
home position search (71-
24)
27 M8 Folding sub scan alignment motor (home position
search)
29 M9 Saddle stitching alignment motor /Rt (home posi-
tion search)
30 Saddle stitching alignment motor /Rt (inward Enabled after conducting
movement) home position search (71-
29)
31 M10 Bundle exit motor (home position search)
32 Bundle arm motor (inward movement) Enabled after conducting
home position search (71-31)
33 M11 Bundle clip motor (home position search)
34 M12 Bundle registration motor (home position search)
35 M13 Overlap motor (home position search)
36 M14 Folding main scan alignment motor /Rr (home
position search)
37 Folding main scan alignment motor /Rr (forward After conducting home
movement) position search (71-36)
2 306
/C6501P/C65hc/C5501
SD Classification
Multi code
Symbol
Code
bizhub PRO C6501

71 39 M15 Stapler movement motor (home position search)

40 Stapler movement motor (staple position move-
ment)
41 M16 Saddle stitching alignment motor /Lt (home posi-
tion search)
42 Saddle stitching alignment motor /Lt (inward
movement)
43 M17 Bundle press movement motor (home position
search)
44 M18 1st folding blade motor (home position search)
45 M19 2nd folding blade motor (home position search)
46 M20 Clincher up down motor (home position search)
47 Clincher up down motor (stapling)
48 M21 Saddle stitching press motor (home position
search)
49 M22 Bundle arm rotation motor (home position search)
50 M23 Bundle press motor (home position search)
51 M24 Bundle press stage up down motor (home posi-
tion search)
52 M25 Guide shaft motor (home position search)
53 M31 Trimmer blade motor (home position search)
54 Trimmer blade motor (trimming position)
55 M32 Trimmer press motor (home position search)
56 Trimmer press motor (upper limit search)
57 Trimmer press motor (pressing) Enabled after conducting
58 Trimmer press motor (movement to trimmer board home position search (71-
release position) 55)
59 M10 Bundle arm motor (inward movement)
60 M23 Bundle press motor (pressing)
61 M24 Bundle press stage up down motor (up)
62 Bundle press stage up down motor (home posi-
tion search for the bundle registration plate)
63 M26 Bundle arm assist motor (home position search)
65 M33 Trimmer paddle motor (forward rotation)
66 Trimmer paddle motor (reverse rotation)
72 SD2 Right angle conveyance gate solenoid
73 SD3 Horizontal conveyance gate solenoid
74 SD4 Roller release solenoid /4
75 SD5 Roller release solenoid /1 (roller press)
76 Roller release solenoid /1 (roller release)
307 2
SD Classification
Multi code
Symbol
Code
bizhub PRO C6501
71 77 SD6 Roller release solenoid /2

78 SD7 Roller release solenoid /3 (roller press)
79 Roller release solenoid /3 (roller release)
80 SD8 Folding unit lock solenoid (lock)
81 Folding unit lock solenoid (release)
82 SD11 Trimmer board solenoid (ON once)
83 Trimmer board solenoid (ON twice)
84 SD12 Brake solenoid
86 CL1 Tri-folding exit clutch
87 FM1 Scraps removal fan motor
90 JAMIB /2 Jam indicator board (LED ON)
95 - Trimmer board solenoid operation counter reset Reset after replace the
trimmer board
96 - Set of trimming operation
97 M32 Trimmer press motor (Move the trimmer board
replace position after home position search)
98 M32, Trimmer board forced movement (Turn ON SD11
SD11 after the trimmer press motor home position
movement)
72 1 M1 Conveyance motor (1000mm/sec)
FS -521
6 M3 Tray up down motor (home position search)

7 Tray up down motor (lower limit move)
11 M22 Alignment motor /Fr (home position search)
12 Alignment motor /Fr (A4S standby position move) Available only from the
home position
13 Alignment motor /Fr (A4S position move) Available only from A4S
position
14 Alignment motor /Fr (A4S standby position move) Available only after the
alignment operation
16 M7 Main tray paper exit motor (800mm/sec)
17 Main tray paper exit motor i205mm/secj
21 M8 Paper exit opening motor (home position search)
22 Paper exit opening motor (full opening: approx. 55°) Available only from the
23 Paper exit opening motor (half opening: approx. 44°) home position
24 Paper exit opening motor (small opening: approx. 27°)
26 M31 Stapler motor /Fr (needles out, empty staple)
27 Stapler motor /Fr (staple) Available after initialization
28 M30 Stapler motor /Rr (needles out, empty staple)
29 Stapler motor /Rr (staple)
31 M4, Stapler rotation motor, Stapler movement motor
M11 (home position search)
2 308
/C6501P/C65hc/C5501
Multi code
Symbol
Code
bizhub PRO C6501

72 32 M4, Stapler rotation motor, Stapler movement motor (1

M11 stapling position movement in A4 size)
33 M16 Stacker entrance roller release motor (home posi-
tion search)
34 Stacker entrance roller release motor (pressing
release position move)
36 M13 Stacker entrance motor (1000mm/sec)
41 M26 Rear stopper motor (home position search)
42 Rear stopper motor (stopper release) Available only from the
home position
46 SD5 Bypass solenoid
47 SD2 Gate solenoid
48 SD9 Paper exit opening solenoid (ON/OFF)
49 SD7 Intermediate roller release solenoid
51 M24 Stack assist guide motor (home position search)
52 Stacker assist motor (assist position move) Available only from the
home position
56 M25 Intermediate roller open close motor (home posi-
tion search)
57 Intermediate roller open/close motor (reserve Available only from the
position move) home position
61 M23 Paper exit arm motor (home position search) Available after conducting
62 Paper exit arm motor (800mm/sec) intermediate roller open/
63 Paper exit arm motor (400mm/sec) close motor shelter posi-
tion (72-57)
66 M6 Sub tray paper exit motor (1000mm/sec)
67 M18 Paper exit alignment plate retraction motor
(home position search)
68 Paper exit alignment plate retraction motor (Align-
ment position move)
71 M5 Alignment motor /Rr (home position search)
72 Alignment motor /Rr (A4S standby position move) Available only from the
home position
73 Alignment motor /Rr (A4S position move) Available only from A4S
position
74 Alignment motor /Rr (A4S standby position move) Available only after the
alignment operation
75 OB Operation board (LED ON)
76 M2 Paddle motor (ON/OFF)
77 JAMIB Jam indicator board (illuminate all LEDs)
309 2
Multi code
Symbol
Code
bizhub PRO C6501
72 78 M5, Alignment motor /Rr, /Fr (home position search)

79 M22 Alignment motor /Rr, /Fr (A4S standby position Available only from the
move) home position
80 Alignment motor /Rr, /Fr (A4S position move) Available only from A4S
position
81 M12 Bypass roller release motor (home position
search)
82 Bypass roller release motor (strong pressing posi- (Available only from the
tion move) home position)
83 Bypass roller release motor (home position move) (Available only from strong
pressing position)
84 Bypass roller release motor (pressing release posi- (Available only from the
tion move) home position)
85 Bypass roller release motor (home position move) (Available only from press-
ing release position)
86 M14 Paper exit alignment motor /Rr (home position
search)
87 Paper exit alignment motor /Rr (A4S standby
position move)
88 Paper exit alignment motor /Rr (Move from A4S Available only from A4S
standby position to alignment position) standby position
89 Paper exit alignment motor /Rr (Move from A4S Available only from A4S
alignment position to standby position) alignment position
90 M15 Paper exit alignment motor /Fr (home position
search)
91 Paper exit alignment motor /Fr (A4S standby posi-
tion move)
92 Paper exit alignment motor /Fr (Move from A4S Available only from A4S
standby position to alignment position) standby position
93 Paper exit alignment motor /Fr (Move from A4S Available only from A4S
alignment position to standby position) alignment position
94 M8 Paper exit opening motor (home position move
(close))
M5 Alignment motor /Rr (home position move)
M22 Alignment motor /Fr (home position move)
M14 Paper exit alignment motor /Rr (home position
move)
M15 Paper exit alignment motor /Fr (home position
move)
M18 Paper exit alignment plate retraction motor
(alignment position move)
2 310
/C6501P/C65hc/C5501
Multi code
Symbol
Code
bizhub PRO C6501

72 95 M8 Paper exit opening motor (opening big)

M5 Alignment motor /Rr (A4 straight standby position
move)
M22 Alignment motor /Fr (A4 straight standby position
move)
M14 Paper exit alignment motor /Rr (A4 straight
standby position move)
M15 Paper exit alignment motor /Fr (A4 straight
standby position move)
M18 Paper exit alignment plate retraction motor (Move
from home position to alignment position)
M3 Tray up down motor (paper exit alignment plate
avoiding operation (from down to up))
SD9 Paper exit opening solenoid ON
96 M5 Alignment motor /Rr (A4 straight alignment posi-
tion move)
M22 Alignment motor /Fr (A4 straight alignment posi-
tion move)
M14 Paper exit alignment motor /Rr (A4 straight align-
ment position move)
M15 Paper exit alignment motor /Fr (A4 straight align-
ment position move)
72 1 M1 FNS conveyance motor (667mm/sec)
FS-520/607
3 M2 Shift roller motor (home position search)

6 M3 Main tray up down motor (home position search)
7 Main tray up down motor (lower limit movement)
8 Main tray up down motor (peration in the main tray
up/down motor staple mode)
10 M4 Clincher rotation motor (home position search) FS-607 only
11 M5 Alignment motor /Up (home position search)
12 Alignment motor /Up (A4S standby position move) Available after home posi-
tion search
13 M5 Alignment motor /Up (Alignment operation) Available from the A4
position
14 Alignment motor /Up (standby position move) Available after alignment
operation
16 M7 Paper exit roller motor (staple mode)
17 Paper exit roller motor (folding mode)
21 M8 Paper exit roller motor (home position search)
22 Paper exit roller motor (open angle: A4S in staple Available after home posi-
mode) tion search
26 M14 Stapler motor /Fr (initial operation conduct)
27 Stapler motor /Fr (staple operation conduct)
311 2
Multi code
Symbol
Code
bizhub PRO C6501
72 28 M9 Stapler motor /Rr (initial operation conduct)

29 Stapler motor /Rr (staple operation conduct)
31 M11, Stapler movement motor, Clincher rotation motor
M4 (home position search)
32 Stapler movement motor, Clincher rotation motor
(A4, 1-stapling position)
36 M13 Stacker entrance motor (670mm/sec)
38 M6 Stapler rotation motor (home position search) FS-607 only
39 M16 Alignment motor /Lw (home position search) FS-607 only
41 M18 Saddle stitching stopper motor (home position FS-607 only
search)
42 Saddle stitching stopper motor (release A4S stop- Available after home posi-
per) tion search (FS-607 only)
43 M19 Folding knife motor (1 cycle) FS-607 only
44 M20 Folding conveyance motor (Hi-speed) FS-607 only
45 SD4 Paper exit opening solenoid
46 SD5 Bypass gate solenoid
47 SD6 Tri-folding gate solenoid FS-607 only
48 SD51 Paper assist solenoid
49 SD7, Flat stitching stopper release solenoid /Fr, /Rr FS-607 only
SD8
53 M21 Sub tray exit motor (667mm/sec)
55 M12 Gate motor (home position search)
58 M51 Paper assist motor (Forward rotation)
65 M302 Punch shift motor (home position search) (PK)
66 Punch shift motor (PK)
69 M301 Punch motor (home position search) (PK)
70 Punch motor (punching) (PK)
83 M203 Conveyance motor (667mm/sec) (PI)
84 MC201 Conveyance clutch /Up (PI)
85 MC202 Conveyance clutch /Lw (PI)
86 M201 Tray lift motor /Up (down: home position search)
(PI)
87 Tray lift motor /Up (up) (PI)
88 M202 Tray lift motor /Lw (down: home position search)
(PI)
89 Tray lift motor /Lw (up) (PI)
90 SD201 Pick-up solenoid /Up (PI)
91 SD202 Pick-up solenoid /Lw (PI)
92 MC203 Registration clutch (PI)
99 — No paper running mode
312
/C6501P/C65hc/C5501
LS Classification
Multi code
Symbol
Code
bizhub PRO C6501

73 1 M2 Conveyance motor
2 Conveyance motor
3 M3 Sub tray exit motor
4 Sub tray exit motor
5 M6 Coupling conveyance motor
6 Coupling conveyance motor
7 M4 Grip conveyance motor
8 Grip conveyance motor
9 M7 Alignment motor (initial operation)
10 Alignment motor
11 M5 Shift unit motor (home position search)
12 Shift unit motor
13 M1 Stacker tray up down motor (down)
14 Stacker tray up down motor (up)
15 SD1 1st gate solenoid
16 SD10 2nd gate solenoid
17 SD9 Front stopper solenoid
18 SD3 Rear stopper solenoid
19 SD8 Paper press solenoid /3
21 SD4 Front door lock solenoid
22 SD11 Tandem conveyance lock solenoid
23 SD2 Job partition solenoid
25 FM1, FM2, Paper cooling fan motor /Fr, Paper cooling fan
FM3, FM6 motor /Mi, Paper cooling fan motor /1, /2
26 FM5 Paper cooling fan motor/Rr
RU-504
2 M5 Paper exit motor

7 M2, Paper fan /1, /2, /3,
M3, Exhaust assist fan /1, /2
M4,
M6,
M7
8 M2, Paper fan /1, /2, /3,
M4,
M6,
M7
313
RU-504 Classification
Multi code
Symbol
Code
bizhub PRO C6501
75 14 M2, Paper fan /1, /2, /3,

M4,
M6,
M7
15 M2, Paper fan /1, /2, /3,
M4,
M6,
M7
16 M2, Paper fan /1, /2, /3,
M4,
M6,
M7
31 SD2 Decurler gate solenoid /1 (SD2)
32 SD3 Decurler gate solenoid /2 (SD3)
75 21 SD1 Straight gate solenoid
RU-506
22 SD2 Stacker exit shutter solenoid

23 SD3 Stack switching solenoid
24 SD4 Stacker entrance guide plate solenoid
29 M1 Entrance conveyance motor
42 M4 CD alignment motor (home position move)
43 M2 Paper exit motor
46 M3 FD alignment motor (home position move)
47 FM2 Stack assist fan /Rr
52 FM1 Stack assist fan /Fr
90 JAMIB JAM indicator board (lit all LEDs)
PB
02 M2 Intermediate conveyance motor

04 SD2 Bypass gate solenoid
05 SD3 Sub tray gate solenoid
06 SD4 Sub tray exit solenoid
07 M11 SC entrance conveyance motor
08 M12 SC switchback conveyance motor (F rotation)
09 SC switchback conveyance motor (R rotation)
10 M13 SC switchback release motor (home position search)
11 SC switchback release motor (High pressing posi-
tion move)
12 SC switchback release motor (Low pressing position move)
2 314
/C6501P/C65hc/C5501
PB Classification
Multi code
Symbol
Code
bizhub PRO C6501

77 13 M15 SC alignment motor (home position search)

14 SC alignment motor (A4 standby position move) 77-13 must have been
performed in advance.
15 SC alignment motor (alignment)
16 M17 SC bundle conveyance motor
17 M18 SC roller release motor (home position search)
18 SC roller release motor (movement to the pressing
position)
19 M19 Clamp entrance movement motor (home position
search)
20 Clamp entrance movement motor (movement to The following adjust-
the entrance position) ments must have been
made in advance.
1. 77-96
2. 77-31
3. 77-32
4. 77-19
5. 77-29
21 M20 Clamp entrance roller separation motor (home
position search)
22 Clamp entrance roller separation motor (pressing
position move)
23 SD11 FD alignment solenoid
24 SD12 SC stopper solenoid
25 SD13 SC pressure arm solenoid
26 M21 Clamp alignment motor (home position search)
27 Clamp alignment motor (A4 standby position
move)
28 Clamp alignment motor (alignment)
29 M22 Clamp motor (home position search)
30 Clamp motor (movement to the clamp position)
31 M23 Clamp rotation motor (home position search) 77-19 must have been
32 Clamp rotation motor (movement to the compile 77-19 must have been
position) performed in advance.
33 SD91 Straight gate solenoid
34 M31 Glue tank movement motor (home position The following adjust-
search) ments must have been
made in advance.
1. 77-55
2. 77-29
315
PB Classification
Multi code
Symbol
Code
bizhub PRO C6501
77 35 M31 Glue tank movement motor (tank forward move- The following adjust-
ment) ments must have been
made in advance.
1. 77-55
2. 77-29
3. 77-34
4. 77-49
5. 77-51
36 Glue tank movement motor (tank backward The following adjust-
movement) ments must have been
made in advance.
1. 77-35
2. 77-29
3. 77-34
4. 77-49
5. 77-51
6. 77-35
37 M32 Glue apply roller motor Be sure that the warm-up
completes.
38 SD31 Glue tank up solenoid /1
39 SD32 Cover paper glue up solenoid
40 H1 Glue tank heater
41 H2 Glue apply roller heater
42 M33 Pellet supply motor The following adjust-
ments must have been
made in advance.
1. 77-55
2. 77-29
3. 77-34
4. 77-44
43 M34 Pellet supply arm motor (home position search)
44 Pellet supply arm motor (movement to the supply The following adjust-
position) ments must have been
made in advance.
1. 77-55
2. 77-29
3. 77-34
45 M41 Cover paper alignment motor (home position 77-55 must have been
search) performed in advance.
46 Cover paper alignment motor (A3 standby posi- The following adjust-
tion move) ments must have been
made in advance.
1. 77-55
2. 77-45
3. 77-57
4. 77-60
316
/C6501P/C65hc/C5501
PB Classification
Multi code
Symbol
Code
bizhub PRO C6501

77 47 M41 Cover paper alignment motor (alignment) The following adjust-

ments must have been
made in advance.
1. 77-55
2. 77-45
3. 77-57
4. 77-60
5. 77-46
48 M42 Book exit motor 77-55 must have been
49 M43 Cover paper conveyance arm motor /Rt (home The following adjust-
position search) ments must have been
made in advance.
1. 77-55
2. 77-29
3. 77-34
50 M43 Cover paper conveyance arm motor /Rt (roller The following adjust-
pressure) ments must have been
made in advance.
1. 77-55
2. 77-29
3. 77-34
4. 77-49
51 M44 Cover paper conveyance arm motor /Lt (home The following adjust-
position search) ments must have been
made in advance.
1. 77-55
2. 77-29
3. 77-34
52 Cover paper conveyance arm motor /Lt (roller The following adjust-
pressure) ments must have been
made in advance.
1. 77-55
2. 77-29
3. 77-34
4. 77-51
53 M45 Cover paper conveyance motor (F rotation) 77-55 must have been
54 Cover paper conveyance motor (R rotation) 77-55 must have been
317
PB Classification
Multi code
Symbol
Code
bizhub PRO C6501
77 55 M46 Cover paper table up down motor /Fr, /Rr (home

M47 position search)
56 Cover paper table up down motor /Fr, /Rr (book The following adjust-
spine corner creation) ments must have been
made in advance.
1. 77-55
2. 77-29
3. 77-34
4. 77-49
5. 77-50
6. 77-51
7. 77-52
8. 77-19
9. 77-31
10. 77-30
11. 77-32
12. 77-45
13. 77-58
14. 77-61
57 M48 Cover paper folding motor /Rt (home position 77-55 must have been
58 M48 Cover paper folding motor /Rt (movement to the The following adjust-
open position) ments must have been
made in advance.
1. 77-55
2. 77-45
59 Cover paper folding motor /Rt (movement to the The following adjust-
close position) ments must have been
made in advance.
1. 77-55
2. 77-45
3. 77-58
60 M49 Cover paper folding motor /Lt (home position 77-55 must have been
61 Cover paper folding motor /Lt (movement to the The following adjust-
open position) ments must have been
made in advance.
1. 77-55
2. 77-45
62 M50 Cutter motor (home position search) 77-55 must have been
63 Cutter motor (cut position movement) 77-55 must have been
64 SD41 Cover paper lift solenoid
67 M61 Cover paper belt motor
318
/C6501P/C65hc/C5501
PB Classification
Multi code
Symbol
Code
bizhub PRO C6501

77 68 M62 Cover paper belt movement motor (home position

search)
69 Cover paper belt movement motor (A4 standby 77-68 must have been
position move) performed in advance.
70 Cover paper belt movement motor (book stock
alignment)
71 M63 Cover paper belt up down motor (home position
search: upper limit)
72 Cover paper belt up down motor (movement to The following adjust-
the lower position) ments must have been
made in advance.
1. 77-68
2. 77-69
73 M64 Book movement motor
74 M65 Book stopper motor (home position search)
75 Book stopper motor (A4 standby position move) 77-55 must have been
76 M73 Cover paper tray lift motor
77 M74 Cover paper feed motor
78 SD71 Cover paper pick up solenoid
79 SD72 Cover paper tray solenoid
80 M71 Cover paper tray fan /1
81 M72 Cover paper tray fan /2
82 MC71 Cover paper pick up clutch
83 MC72 Cover paper separation clutch
84 SD80 Front door lock solenoid (locked)
85 Front door lock solenoid (released)
86 M80 Exhaust fan /1
87 - Multi feed clock output signal
88 JAMIB/1 Jam indicator board /1 /2 (all the lights on)
JAMIB/2
89 OB/1 Manual operation board (all the lights on)
90 M4 Exhaust fan /2
M81 Pellet supply cooling fan
91 SD61 Book door solenoid (lock)
92 Book door solenoid (release)
95 M71, Cover paper feed operation for the adjustment of 77-96 must have been
M72, the multi feed detection board performed in advance.
M73,
M74,
SD71,
SD72,
MC71,
MC72
96 - All initial operation
319 2
GP Classification
Multi code
Symbol
Code
bizhub PRO C6501
78 01 - Entrance stepper motor

02 - Exit stepper motor
03 - Transport motor
04 - Punch motor
05 - Divert solenoid
06 - Backstop solenoid
07 - Punch brake
08 - Punch clutch
09 - Punch stepper motor punch operation
80 0 SD4 Paper exit solenoid
ADU
81 0 MC1 ADU conveyance clutch /1

1 MC2 ADU conveyance clutch /2
2 MC18 ADU Pre-registration clutch
3 MC3 ADU conveyance clutch /3
82 0 SD10 ADU gate solenoid
84 0 M32 ADU reverse motor (1/2 speed) (Forward rotation)
1 ADU reverse motor (2/3 speed) (Forward rotation)
2 M32 ADU reverse motor (1/1 speed) (Forward rotation)
3 ADU reverse motor (470mm/s) (Forward rotation)
4 ADU reverse motor (1000mm/s) (Forward rotation)
5 ADU reverse motor (1/2 speed) (Reverse rotation)
8 ADU reverse motor (470mm/s) (Reverse rotation)
9 ADU reverse motor (1000mm/s) (Reverse rotation)
85 0 M57 ADU Loop motor (1/2 speed) (Forward rotation)
1 ADU Loop motor (2/3 speed) (Forward rotation)
2 ADU Loop motor (1/1 speed) (Forward rotation)
3 ADU Loop motor (470mm/s) (Forward rotation)
4 ADU Loop motor (1000mm/s) (Forward rotation)
5 ADU Loop motor (1/2 speed) (Reverse rotation)
8 ADU Loop motor (470mm/s) (Reverse rotation)
9 ADU Loop motor (1000mm/s) (Reverse rotation)
2 320
/C6501P/C65hc/C5501
Adjustment/special mode Classification
Multi code
Symbol
Code
bizhub PRO C6501

90 0 — Finishing option adjustment data EEPROM stor- Perform after adjustment

age FD/SD/FS (FS-521)
91 0 — Main body adjustment data NVRAM board stor- Perform after adjustment
age
92 0 — NVRAM board data reset Does not work in the field
93 0 — Finishing option adjustment data EEPROM stor- Does not work in the field
age (factory default) FD/SD/FS (FS-521)
94 0 — Display of adjustment data
1 — Operation panel all lighting (LED)
96 0 — Main body adjustment data NVRAM board stor- Does not work in the field
age (factory default)
97 0 — Image memory (DRAM) capacity check (1 color)
98 0 — Image memory (DRAM) /Y check
1 — Image memory (DRAM) /M check
2 — Image memory (DRAM) /C check
3 — Image memory (DRAM) /K check
4 — Image processing board line memory (SDRAM) /Y
check
5 — Image processing board line memory (SDRAM) /M
check
6 — Image processing board line memory (SDRAM) /C
check
7 — Image processing board line memory (SDRAM) /K
check
99 1 HDD/ HDD capacity check (1 color)
2 Y, /M, / HDD remaining capacity check
3 C, /K HDD bad sectors check and recovery
4 HDD data copy Perform after replacing the
HDD.
321
9.7.4 Adjustment when replacing multi feed detection board (PI)

/C6501P/C65hc/C5501
Perform this adjustment when replacing the PI multi feed detection board (MFDB) or the PI drive board (PIDB),
bizhub PRO C6501
as well as when multi feeding is not detected properly for special papers (thin paper, thin coated paper, thick
paper, etc.).
Note
• The multi feed detection board/S and /R are adjusted in the manufacturing process as a pair of
• Be sure to perform the adjustment under normal room temperature (20 to 30 °C) that is similar to
the real environment where the machine is operated because the temperature sensor output var-
ies with its surface temperature. ( When you bring in a replacement part from a place under a dif-
ferent temperature, leave the part and wait for the sensor surface temperature to reach the room
temperature before performing the adjustment.)
A. Procedure
1. Replace the multi feed detection boards /1 and /2. (Refer to “11.3.20 Multi feed detection board /1
(MFDB/1), /2 (MFDB/2)” in Theory of Operation for FD-503)
2. Check the alphabets on the multi feed detection
boards /1 and /2 [1] (Same alphabet should be
printed.), and turn the rotary switch [2] on the PI
drive board (PIDB) so that it points to the numbers
described in the following chart.
Alphabet Rotary switch

A 1
B 2
C 3
D 4 [1]
E 6
F 7
Note
• Rotary switch 5 is not used.
[2] a03uf3c027ca
3. Enter the I/O check mode.

4. Enter "70" with the setting buttons. Confirm that "70-00" is displayed in the message display area.
322
7. Open the upper door and the front door of the FD,
/C6501P/C65hc/C5501
[2]
turn the jam processing knob [1], and insert a sheet
bizhub PRO C6501

of paper [2] (part no. 65AA-991#, fusing adjustment
paper, 16 sheets/A3) into between the multi feed
detection boards /1 and /2 [3]. (If the paper is
unavailable, use 200 to 300 g/m2 paper).
Note
• Turn the jam processing knob until the paper
hits the roller [4], and confirm that the paper is
inserted in between the multi feed detection
boards /1 and /2.
[3]
[1] [4] a03uf3c028ca
8. Press Start button to enter the output check mode,

VR2
and connect the tester to the following pins on the
PIDB.
Positive terminal: Test pin No. TP51 (GAIN) [1]
Negative terminal: Test pin No. TP11 (SGND) [2]
Range: DC 20 V
Note
• Do not allow the tester pin to touch or connect
to metal parts on the board nor irrelevant termi-
nals as the FD is energized. It may cause short-
circuit and damage the board.
LED1
[1] [2] a03uf3c029ca
9. Turn the PIDB volume (VR2) so that the voltage falls within the standard value.
Standard value: 8.0 ± 0.2 V
10. Press Stop and remove the paper inserted in Step 4.
11. Insert a sheet of paper that the customer uses mainly (paper weight: 50 to 300 g/m2), and make sure that
the LED (LED1) of the PIDB turns on.
LED on: Multi feed not occurred (Number of paper: 0 or 1)
LED off: Multi feed occurred (Number of paper: 2)
12. Insert one more sheet of paper (total: 2 sheets) that the customer uses mainly, and make sure that the
LED turns off.
13. If the detection does not work properly, return to Step 7 and perform the adjustment again. Then, turn the
PIDB volume (VR2) so that the voltage becomes 1.0 V lower than that of acquired in Step 9.
14. Repeat steps 10 to 13 until the detection functions correctly.
15. Remove the papers and install the removed parts.
323
9.7.5 Adjustment when replacing multi feed detection board (PB)

/C6501P/C65hc/C5501
Adjust when replacing the multi feed detection board of the PB or the PB control board (PBCB). Also, perform
bizhub PRO C6501
this adjustment when multi feed of special paper (thin paper, coated paper with less stiffness, thick paper) can-
not be detected properly.
Note
• The multi feed detection board /1 and /2 are adjusted in the manufacturing process as a pair of
• Adjustment error may occur because of the temperature of the sensor surface. Make the adjust-
ment at a temperature close to that in which the copier is actually used (20 to 30 °C). (In case you
brought a new part from outdoors, make the adjustment after the temperature of the sensor sur-
face and the room temperature become the same)
A. Procedure
1. Replace the multi feed detection board /1, /2. (Refer to “14.2.29 Multi feed detection boards /1
(MFDTB71) and /2 (MFDTB72)“ in Theory of Operation for PB-501/502)
2. Check the stamp letter [1] placed on the multi feed
detection board /1, /2, and rotate the rotary switch
[2] on the PBCB as per following table.
Alphabet Rotary switch

A 1
B 2
C 3
D 4
E 5
[1]
[2]
564Af3c001cb
3. Insert one sheet of paper (P/N 65AA-9910, fusing adjustment paper, 16 sheets/A3) in the cover paper tray
of the PB (200 to 300 g/m2 paper can also be used).
4. Select the output check code "77-96" of the I/O check mode in the service mode.
5. Press the Start button to perform the all initializing operation.
6. After the operations, press the Stop button.
7. Select the output check code "77-95" of the I/O check mode in the service mode.
324
8. Press the Start button.
/C6501P/C65hc/C5501
The paper is fed from the PB cover paper tray and stops at the conveyance section.
bizhub PRO C6501

Note
• Confirm that the paper is between the multi feed detection board /1 and /2.
9. After the operation, press the Stop button.
10. Connect the tester (voltmeter) to the following posi-
tions of the PBCB. [1]
+ terminal : test pin No. TP28 (GAIN) [1]
- terminal : test pin No. TP24 (SGND) [2]
Range : DC 20 V
Note
• Because the PB is powered, do not drop any
metal material on the board, or do not connect
the tester pin to an irrelevant terminal.
It may cause the board to short circuit and be
damaged.
VR4 [2] 564Af3c002cd
11. In the PBCB volume (VR4), set power voltage to the standard value.
Standard value: 8.0 ± 0.1 V
12. Pull out the paper inserted in step 8.
13. Insert one sheet of paper that customer mainly use (paper weight 50 to 300 g/m2 ), and confirm that the
PBCB's LED (LED1) can be turned on.
LED on: no multi feed (0 or 1 sheet of paper)
LED off: multi feed (2 sheets of paper)
14. Insert another sheet of paper (2 sheets in all), that customer mainly use, and to see if the LED is turned off.
15. In the case of detection error, return to step 3 to conduct the adjustment again. In step 11, set power volt-
age to the value 1.0 V lower than the previous adjustment.
16. Repeat the steps 3 to 14 until detection error is resolved.
17. Pull out the inserted papers, and install the parts you removed.
325
9.7.6 Storing FD, SD, FS, PB adjustment data into EEPROM

/C6501P/C65hc/C5501
Backup adjustment data of the FD, SD, FS and PB which are adjusted in the field are stored in the non-volatile
bizhub PRO C6501
memory (EEPROM) of the FD control board (FDCB), SD control board (SDCD), FNCB (FNS control board) and
the PB control board (PBCB). When necessary, it can be recalled with "Installation Initial Data" of "Recall Stan-
dard Data" (Finisher Adjustment) in the service mode.
Note
• Only one data can be backed up. When back up again, data will be overwritten.
• The data is stored into the control boards of all the connected optional units; FS, SD, FD and PB.
Connect the optional units one-by-one if you want to save the data independently.
A. Procedure

3. Press Start key.
4. “NOW” is displayed while backing up, and “FIN” appears when completed. The current finisher adjust-
ment data are saved into the EEPROM.
326
9.7.7 Storing main body adjustment data into NVRAM board
/C6501P/C65hc/C5501
Backup adjustment data of the main body which are adjusted in the field are stored in the NVRAM board (NRB),
bizhub PRO C6501

it can be recalled with "Installation Initial Data" of "Recall Standard Data" (Machine adjustment, Process
adjustment) in the service mode.
Note
• Only one data can be backed up. When back up again, data will be overwritten.
A. Procedure

3. Press Start key.
4. “NOW” is displayed while backing up, and “FIN” appears when completed. The current machine adjust-
ment data and process adjustment data are saved into the NRB.
327
9.7.8 Line memory check on image processing board

/C6501P/C65hc/C5501
Perform this check to see if abnormality has occurred at line memory on the image processing board (IPB) when
bizhub PRO C6501
significant image trouble (irregular image in sub-scanning direction of the specific color) occurred.
A. Procedure

4. Enter one of the followings with the numeric buttons.
Confirm that “98-##” (## is a multi-code number) is displayed in the message display area.
Multi code 04: Image processing board line memory (SDRAM) /Y check
Multi code 05: Image processing board line memory (SDRAM) /M check
Multi code 06: Image processing board line memory (SDRAM) /C check
Multi code 07: Image processing board line memory (SDRAM) /K check
5. Press Start key.
During execution:—"NOW" appears.
When completed normally—"OK" appears.
When completed abnormally—"NG" appears.
If "NG" appears, replace the IPB.
328
9.7.9 Hard disk check
/C6501P/C65hc/C5501
Perform this operation if you want to check the capacity and remaining capacity of the image memory area on
bizhub PRO C6501

the copier hard disk /K (HDD/K).
A. Procedure

4. Enter one of the followings with the numeric buttons.
Confirm that “99-##” (## is a multi-code number) is displayed in the message display area.
Multi code 01: HDD capacity check (1 color)
Multi code 02: HDD remaining capacity check
5. Press Start key.
• Capacity check: Displays the capacity of the image memory area on the HDD/K.
• Remaining capacity: Displays the remaining space of image memory area on the HDD/K.
329
9.7.10 Replacement of the hard disks

/C6501P/C65hc/C5501
Perform this operation if a copier hard disk-related malfunction code (C-D0E0 to D0F0) appears.
bizhub PRO C6501
A. Procedure

5. Press Start key.
Check and recovery of defective sectors on the hard disk /Y, /M, /C and /K (HDD /Y, /M, /C and /K) are
carried out.
When completed normally: "OK" appears.
When completed abnormally: "NG" appears.
When "NG" appears, press [Start] key to run the check and recovery again.
6. If "NG" appears again, replace the defective hard disk(s) following the steps below.
7. Enter "04" with the numeric buttons.
Confirm that "99-04" is displayed in the message display area.
8. Press Start key.
The result (o: okay, x: no good, -: not HDD) of the HDD check appears in the input check field in the order
of Y, M, C and K.
Ex) oxox = The HDD/M and /K are defective.
Replace the defective HDDs with new ones.
Note
• If malfunction occur related to HDD under the Security Strengthen Mode, all of the 4 HDDs must
be replaced.
Replacement steps: Remove the 4 HDDs → deactivate the Security Strengthen Mode → install
the 4 HDDs.
9. While pressing [Utility/Counter] button, turn ON the sub power switch (SW2) and start up the service
mode.
Note
• C-D0E0 is displayed when the user mode is started. Turning OFF/ON the main power switch
(SW1) at that time causes HDD to malfunction. Be sure to switch to the service mode after turn-
ing OFF the sub power switch (SW2).
• Up to 3 HDDs can be copied at a time.
• Data copy takes about one hour at the maximum.
13. Enter "04" with the numeric buttons.
Confirm that "99-04" is displayed in the message display area.
14. Press Start.
During execution: The "x" displayed in the HDD input check field changes to "N".
When completed normally: The "N" displayed in the HDD input check field changes to "o", and "FIN"
appears in the output check field.
1 330
15. Turn OFF/ON the sub power switch (SW2).
/C6501P/C65hc/C5501
bizhub PRO C6501
Note
• C-D0E0 is displayed when the sub power switch (SW2) is not turned OFF/ON. Turning OFF/ON
the main power switch (SW1) at that time causes HDD to malfunction. Be sure to start the user
mode after tuning OFF/ON the sub power switch (SW2).
331 1
9.8 ADF adjustment

/C6501P/C65hc/C5501
bizhub PRO C6501
Adjust the DF operations; original size detection, original stop position, sensors sensibility, registration loop
amount.
Note
9.8.1 ADF Original Size Adj.

Adjust when the DF does not detect an original size correctly.
A. Procedure

Press [06 ADF Adjustment].
2. "ADF Adjustment Menu screen"
Press [01 ADF Original Size Adj.]
3. "ADF Original Size Adjustment screen"
Press [A4] (for metric destination) or [81/2 x 11] (for inch destination).
4. Load A4 (for metric destination) or 81/2 x 11 (for inch destination) paper on the DF and press [Start].
Press [B6S] (for metric destination) or [51/2 x 81/2S] (for inch destination).
7. Load B6S (for metric destination) or 51/2 x 81/2S (for inch destination) paper on the DF and press [Start].
Press [A4S] (for metric destination) or [81/2 x 11S] (for inch destination).
10. Load A4S (for metric destination) or 81/2 x 11S (for inch destination) paper on the DF and press [Start].
11. After a message "Completed" is displayed, press [COPY].
12. Check if the original size is correctly detected by the DF.
1 332
9.8.2 ADF Orig. Stop Position Adj.
/C6501P/C65hc/C5501
Adjust the image leading edge timing when scanning in DF mode.
bizhub PRO C6501

This adjusts the scanning start posiiton (in sub scanning direction).
Note
• Be sure the Restart Timing Adjustment (Printer Adjustment) have been adjusted before performing
this adjustment.
(Refer to P.161)
• Be sure the Restart Timing Adjustment (Scanner Adjustment) have been adjusted before perform-
(Refer to P.176)
A. Procedure

Press [02 ADF Orig.Stop Position Adj.].
3. "ADF Original Stopper Adjustment screen"
Select an item to be adjusted, and press [COPY].
4. "Copy screen"
Set the copy settings (original setting and mode) according to the item you selected, load an "Adjustment
chart" on the DF, select A3 or 11 X 17 paper, and press the Start key.
Standard value: 0 ± 2.0mm or less
7. "ADF Original Stopper Adjustment screen"
Setting range: -14 (image faster) to +14 (image slower), 1step = 0.5 mm
333
9.8.3 ADF Sensor Adjustment

/C6501P/C65hc/C5501
Conduct this adjustment when a malfunction (JAM display does not disappear despite no paper JAM) occurs in
bizhub PRO C6501
the reflective type sensors.
Preparation
• Clean each of the DF reflective sensors.
A. Procedure

Press [03 ADF Sensor Adjustment].
3. "ADF Sensor Adjustment screen"
Close the DF cover and press [Start].
Completion message appears after the DF sensor sensitivity is automatically adjusted.
4. Press [Copy] and check if the sensor is operating properly.
5. If the sensor still malfunctions, press [SERVICE] and repeat steps 3 to 5.
334
9.8.4 ADF Registration Loop Adj.
/C6501P/C65hc/C5501
Adjust the original loop amount at the DF registration roller section to correct paper skew and wrinkle, or original
bizhub PRO C6501

jamming in the registration section.
A. Procedure

Press [04 ADF Registration Loop Adj.].
3. "ADF Regist Loop Adjustment screen"
Press [COPY].
4. "Copy screen"
Set an "Adjustment chart" in the DF, select A3 or 11 X17 paper, and press the Start key.
6. "ADF Regist Loop Adjustment screen"
Setting range: -7 (smaller) to +7 (larger), 1 step = 0.5 mm
7. Repeat steps 3 to 6 until an appropriate value is obtained.
335
9.9 Finisher Adjustment

/C6501P/C65hc/C5501
bizhub PRO C6501
9.9.1 Staple Center Position (Stapler Position Adj.)

Adjust the staple position of the main scanning direction made by the FS-521.
A. Procedure

Press [07 Finisher Adjustment].
2. "Finisher Adjustment Menu screen"
Press [01 Stapler Position Adj.].
3. "Staple Finisher Adjustment Menu screen"
Press [01 Staple Center Position].
4. "Staple Center Position Adjustment screen"
Press [COPY].
5. Select A3 or 11 X 17 paper and press Start key to output the test pattern (No. 16).
6. Fold the output page in half in main-scanning direc-
tion, and measure the gap "a" between the center
line of the print and the staple center. [1]
Standard value: "a" = ± 3 mm
[2]
a03uf3c018ca
[1] Paper center [2] Staple center
Setting range: -20 (in front) to +20 (in back), 1 step = 0.1mm
336
9.9.2 Paper Width (staple) (Stapler Position Adjustment)
/C6501P/C65hc/C5501
Adjust an uneven binding (main scanning direction) in a bundle of paper in staple mode by the FS-521.
bizhub PRO C6501

This adjustment adjusts the position of the alignment plate while in alignment.
A. Procedure

Press [02 Paper Width (staple)].
4. "Paper Width Adjustment (staple) screen"
Press [T] or [S] to select the paper size you want to adjust.
5. Press [COPY].
6. Select the paper size according to the item you want to adjusted and press the Start key to output a test
pattern (No. 16).
7. Open the front door of the FS and pull out the stacker.
Note
• If the length of the paper is longer than 239 mm in sub-scanning direction, the paper edge will
hanging out of the stacker. In that case, remove the paper through the paper opening section
before pulling out the stacker, and reload the paper in the stacker.
8. Measure the gap between the paper in the stacker and the alignment plate.
10. "Paper Width Adjustment (staple) screen"
Setting range: -20 (wider) to +20 (narrower), 1 step = 0.1 mm
337
9.9.3 Paper Width (straight) (Stapler Position Adj.)

/C6501P/C65hc/C5501
Adjust an uneven paper stack (main scanning direction) on the main tray in non-staple mode by the FS-521 .
bizhub PRO C6501
This adjustment adjusts the position of the stacker plate while in alignment.
A. Procedure

Press [03 Paper Width (straight)].
4. "Paper Width Adjustment (straight) screen"
Press [T] or [S] o select the paper size you want to adjust.
5. Press [COPY].
pattern (No. 16).
7. Open the front door of the FS and pull out the stacker.
Note
• If the length of the paper is longer than 239 mm in sub-scanning direction, the paper edge will
hanging out of the stacker. In that case, remove the paper through the paper opening section
before pulling out the stacker, and reload the paper in the stacker.
8. Measure the gap between the paper in the stacker and the alignment plate.
Standard value: 0.1 to 1 mm
10. "Paper Width Adjustment (straight) screen"
Enter the adjustment value with the setting buttons and press [<<SET].
12. To continue the adjustment for other sizes of paper, repeat steps from 4 to 11.
338
9.9.4 Exit Guide Center Adj. (Stapler Position Adj.)
/C6501P/C65hc/C5501
Adjust an uneven paper stack (main scanning direction) on the main tray in non-staple mode by the FS-521.
bizhub PRO C6501

This adjustment adjusts the center position of the paper exit alignment plate while in paper exit alignment.
Note
• This adjustment is effective only for paper more than 182mm width (B5S) in the main scan direc-
tion in straight exit, or paper more than 210mm width (A4) in shift exit. This adjustment is invalid
for paper of minimum size (A5S, B6S, 51/2 x 81/2S) since it does not operate the paper exit alignment.
• "Paper Width (straight) (Stapler Position Adj.)" must have been done in advance.
• Adjust in conjunction with "Exit Guide Paper Width (Stapler Position Adj.)" since the misalignment
of the paper width causes uneven paper stack.

2. "Finiher Adjustment Menu screen"
Press [04 Exit Guide Center Adj.].
4. "Exit Guide Center Adjustment screen"
Select the item to be adjusted of small-size or large-size.
The following items are selectable for each small-size and large-size.
Straight : Adjust the center position of the paper exit alignment plate in straight mode.
Shift in front : Adjust the center position of the paper exit alignment plate in shifting in front
Shift in back : Adjust the center position of the paper exit alignment plate in shifting in back
Note
• Large size: Sub scan direction of paper is more than 298mm
• Small size: Sub scan direction of paper is less than 297mm
5. Press [COPY].
6. Select the paper size according to the item you want to adjusted and press the Start key to output some
test pattern (No. 16).
339
7. Check the misalignment "a" of the stacked paper

/C6501P/C65hc/C5501
bizhub PRO C6501
a0u0f3c003ca
Note
• Check the misalignment between exit paper and the exit alignment plate under the operation as
a reference for the adjustment.
• With too much adjustment, paper gets touch with the exit alignment plate in exiting paper, so be
sure to check the alignment operation.
• Be sure to adjust in the position where the fixed side of alignment plate has no improper gap
and no stress in the case of the shift adjustment.
8. Press [SERVICE] to adjust the center position of the paper exit alignment plate.
Setting range: -50 (to the front) to +50 (to the back), 1 step = 0.1mm
Note
• Enter a same value to both large size and small size for straight adjustment.
• The input value of the straight does not reflect the value of the shift.
10. Repeat the steps 4 to 9 until an appropriate value is obtained.
340
9.9.5 Exit Guide Paper Width (Stapler Position Adj.)
/C6501P/C65hc/C5501
Adjust an uneven paper stack (main scanning direction) on the main tray in non-staple mode by the FS-521.
bizhub PRO C6501

This adjustment adjusts the position of the exit alignment plate (in front and back) while in paper exit alignment.
Note
• This adjustment is effective only for paper more than 182mm width (B5S) in the main scan direc-
tion in straight exit, or paper more than 210mm width (A4) in shift exit. This adjustment is invalid
for paper of minimum size (A5S, B6S, 51/2 x 81/2S) since it does not operate the paper exit alignment.
• "Paper Width (straight) (Stapler Position Adj.)" must have been done in advance.
• Adjust in conjunction with "Exit Guide Paper Width (Stapler Position Adj.)" since the center mis-
alignment of the exit alignment plate causes uneven paper stack.
1. "Service ModeMenu screen"

2. "Finiher Adjustment Menu screen"
Press [05 Exit Guide Paper Width].
4. "Exit Guide Paper Width Adjustment screen"
Select the paper size to be adjusted by pressing [S] or [T].
5. Press [COPY].
6. Select the paper size according to the item you want to adjusted and press the Start key to output some
test pattern (No. 16).
7. Check the misalignment "a" of the stacked paper
a0u0f3c003ca
Note
• Check the misalignment between exit paper and the exit alignment plate under the operation as
a reference for the adjustment.
• Too narrow adjustment causes uneven paper exit in the sub scan direction.
8. Press [SERVICE] to adjust the position of the paper exit alignment plate.
Setting range: -50 (wider) to +50 (narrower), 1 step = 0.1mm
Adjustment standard value (at the alignment operation) : Paper width 0mm to +1mm
341
9.9.6 Paper Width Adjustment (Multi Folder (Punch) Adj.)

/C6501P/C65hc/C5501
Adjust the position of the punch holes made by the FD in main scanning direction.
bizhub PRO C6501
A. Procedure

Press [02 Multi Folder (Punch) Adj.].
3. "Multi Folder (Punch) Adjustment Menu screen"
Press [01 Paper Width Adjustment].
4. "Paper Width adjustment screen"
5. Press [COPY].
6. Select the paper size according to the item you want to adjusted, set the 10 sets of copies and press the
Start key to output a test pattern (No. 16).
7. Align the edges of the 10 sheets of the exited paper, and measure the diameter of the holes punched
through them.
Number of Standard value (mm)

holes
2 & 4 holes φ 5.0 or more
3 holes φ 6.5 or more
9. "Paper Width adjustment screen"
When the value is not within the standard value, press [SERVICE].
Setting range: -20 (narrower) to +20 (wider), 1 step = 0.1 mm
Note
• If the alignment plate is wider than an appropriate position, the punch centering is displaced,
and when too narrow, the punch holes are apt to disperse. On the other hand, the punch holes
may be misaligned if the alignment plate is positioned too narrow.
342
9.9.7 Hole-Punch Vertical Pos. (Multi Folder (Punch) Adj.)
/C6501P/C65hc/C5501
Adjust the position of the punch holes made by the FD in main scanning direction.
bizhub PRO C6501

A. Procedure

Press [02 Multi Folder (Punch) Adj.].
3. "Multi Folder (Punch) Adjustment Menu screen"
Press [02 Hole-Punch Vertical Pos.].
4. "Punch hole select Menu screen"
Select [01 2-Hole Punch] or [02 4-Hole Punch].
5. "Punch Vertical Position Adjustment screen"
Press [COPY].
pattern (No. 16).
7. Check the distance "a" from the leading edge to the
center of the punch holes. a
Number of Standard value "a"

holes (mm)
2 & 4 holes 10.5 ± 4.0
fs503fs3013c
9. "Punch Vertical Position Adjustment screen"
Press [T] or [S] o select the paper size you want to adjust.
12. To continue the adjustment for other sizes of paper or the other number of holes, repeat steps from 4 to
11.
343
9.9.8 Half Fold Position Adj. (Multi Folder (Fold) Adj.)

/C6501P/C65hc/C5501
Adjust the fold position on the half fold mode by the FD.
bizhub PRO C6501
This adjustment changes the paper stop position when folding papers.
A. Procedure

Press [03 Multi Folder (Fold) Adj.].
3. "Multi Folder (Fold) Adjustment Menu screen"
Press [01 Half Fold Position Adj.].
4. "Half Fold Position Adjustment screen"
5. Press [COPY].
pattern (No. 16).
7. Check the misalignment "a" on the edge of the out-
a
putted paper.
Standard value "a": = ± 1.5 mm
fs503fs3014c
Setting range: -50 to +50, 1 step = 0.1 mm
• In the case of the mis-alignment given in the step 7, enter a set value on the positive side.
344
9.9.9 Tri-Fold-in Pos. Adj. (Multi Folder (Fold) Adj.)
/C6501P/C65hc/C5501
Adjust the fold positions on the tri-fold-in mode by the FD.
bizhub PRO C6501

A. Procedure

Press [02 Tri-Fold-in Pos. Adj.].
4. "Tri-Fold-in Position Adjustment screen"
5. Press [COPY].
pattern (No. 16).
7. Check the length of the 2 places indicated with "a"
and "b". b
Paper size Standard value (mm) [1]

a
a ± 1.5 b ± 1.5
A3 139.0 142.0 [2]
B4 120.3 123.3
a03uf3c019ca
A4S 98.0 101.0
SRA4 105.7 108.7 [1] Single fold [2] Double fold
12 x 18 151.4 154.4
11 x 17 142.9 145.9
81/2 x 14 117.5 120.5
81/2 x 11S 92.1 95.1
8K 129.0 132.0
9. "Tri-Fold-in Position Adjustment screen"
Press [Single Fold].
Setting range: -50 (shorter) to +50 (longer), 1 step = 0.1 mm
• The dimension "a" in the step 6 gets larger when the set value is moved to the positive side and gets
smaller when moved to the negative side.
11. Press [Double Fold].
• The dimension "b" in the step 6 gets larger when the set value is moved to the positive side and gets
345 2
9.9.10 Tri-Fold-out Pos. adj. (Multi Folder (Fold) Adjustment)

/C6501P/C65hc/C5501
Adjusts the fold positions on the tri-fold-out mode by the FD.

bizhub PRO C6501
A. Procedure

Press [03 Tri-Fold-out Pos. Adj.].
4. "Tri-Fold-out Position Adjustment screen"
5. Press [COPY].
pattern (No. 16).
and "b". b
Paper size Standard value (mm)

a ± 1.5 b ± 1.5 a [1]
A3 282.0 144.0 [2]
B4 243.7 123.3 a03uf3c020ca
A4S 199.0 101.0 [1] Single fold [2] Double fold

SRA4S 214.3 108.7
12 x 18 306.8 156.4
11 x 17 289.9 147.9
81/2 x 14 238.1 120.5
81/2 x 11S 187.3 95.1
8K 262.0 134.0
9. "Tri-Fold-out Position Adjustment screen"
2 346
9.9.11 Double Parallel Folds Pos. Adj. (Multi Folder (Fold) Adj.)
/C6501P/C65hc/C5501
Adjust the fold positions on the double parallel mode by the FD.
bizhub PRO C6501

Note
• When adjusting both the single and the double folds, be sure to adjust the single fold first.
A. Procedure

Press [04 Double Parallel Pos. Adj.].
4. "Double Parallel Position Adjustment screen"
5. Press [COPY].
pattern (No. 16).
and "b". b
[1]
a ± 1.5 b ± 1.5 a
A3 208.5 103.8 [2]
B4 180.5 89.8
a03uf3c021ca
A4S 147.0 73.0
SRA4S 158.5 78.8 [1] Single fold [2] Double fold
12 x 18 227.1 113.1
11 x 17 214.4 106.7
81/2 x 14 176.3 87.7
81/2 x 11S 138.2 68.6
8K 193.5 96.3
• The dimension "a" in the step 6 gets larger the set value is moved to the positive side and gets smaller
when moved to the negative side.
347 2
9.9.12 Z-Fold Position Adj. (Multi Folder (Fold) Adj.)

/C6501P/C65hc/C5501
Adjust the fold positions on the z-fold mode by the FD.

bizhub PRO C6501
Note
• When adjusting both the single and the double folds, be sure to adjust the first fold first.
A. Procedure

Press [05 Z-Fold Position Adj.].
4. "Z-Fold Position Adjustment screen"
5. Press [COPY].
pattern (No. 16).
and "b". b

[2] a [1]
a ± 1.5 b ± 1.5
A3 105.5 108.5 a03uf3c022ca
B4 91.5 94.5 [1] Single fold [2] Double fold

A4S 74.8 77.8
SRA4S 80.5 83.5
12 x 18 114.8 117.8
11 x 17 108.5 111.5
81/2 x 14 94.0 —
81/2 x 11S 70.4 73.4
8K 98.0 101.0
2 348
9.9.13 Gate Fold Position Adj. (Multi Folder (Fold) Adj.)
/C6501P/C65hc/C5501
Adjusts the fold position on the gate fold mode by the FD.
bizhub PRO C6501

Note
• When adjusting the single, the double, and the triple folds, be sure to perform the adjustment in
the order of first, second, and third.
A. Procedure

Press [06 Gate Fold Position Adj.].
4. "Gate Fold Position Adjustment screen"
5. Press [COPY].
pattern (No. 16).
7. Check the length of the 2 places indicated with "a",
"b" and "c". b
Paper size Standard value (mm) a
a ± 1.5 b ± 1.5 c ± 1.5 [1]
A3 103.5 213.0 106.5
c [2]
B4 89.5 185.0 92.5 [3]
A4S 72.8 151.5 75.8
a03uf3c023ca
SRA4S 78.5 163.0 81.5
12 x 18 112.8 231.6 115.8 [1] Single fold
[2] Double fold
11x 17 106.5 218.9 109.5
[3] Triple fold
8 / x 14
12
87.4 180.8 90.4
81/2 x 11S 68.4 142.7 71.4
8K 96.0 198.0 99.0
9. "Gate Fold Position Adjustment screen"
13. Press [Triple Fold].
349 2
/C6501P/C65hc/C5501

bizhub PRO C6501
• The dimension "c" in the step 6 gets larger when the set value is moved to the positive side and gets
9.9.14 Fold Regist Loop Adj. (Multi Folder (Fold) Adj.)

Adjust paper loop amount at the FD registration roller to correct paper skew, wrinkle, or paper jam at the roller.
A. Procedure

2. "Finisher Adjustment Menu" screen
3. "Multi Folder (Fold) Adjustment Menu" screen
Press [07 Fold Regist Loop Adj.].
4. "Fold Resist Loop Adjustment" screen
Press [COPY].
5. Select A3 or 11 X 17 paper and press Start key to output the test pattern (No.16).
7. "Fold Resist Loop Adjustment" screen
Setting range: -50 (smaller) to +50 (larger), 1 step = 0.1mm
9.9.15 Multi Folder (PI) Adj.
350
9.9.16 Stacker Adjustment
/C6501P/C65hc/C5501
Ajust the various adjustments concerning the LS.
bizhub PRO C6501

(1) Paper Width Adjustment
Adjust an uneven paper stack (main scanning direction) on the stacker tray.
a. Procedure

Press [05 Stacker Adjustment].
3. "Stacker Adjustment Menu screen"
4. "Paper Width Adjustment screen"
Press [COPY].
6. If the paper edges are not aligned, press [SERVICE].
(2) Paper Length Adjustment

Adjust an uneven paper stack (sub- scanning direction) on the stacker tray.
This adjustment adjusts the position of the leading edge stopper while in alignment.
a. Procedure

Press [05 Stacker Adjustment].
3. "Stacker Adjustment Menu screen"
Press [02 Paper Length Adjustment].
4. "Paper Length Adjustment screen"
Press [COPY].
6. If the paper edges are not aligned, press [SERVICE].
351
9.9.17 Staple Center Adj. (Saddle Stitcher Adj.)

/C6501P/C65hc/C5501
Adjust the center position of the staple on the saddle stitching mode by the SD.
bizhub PRO C6501
This adjustment changes the position of the alignment plate while in alignment.
A. Procedure

Press [06 Saddle Stitcher Adj.].
3. "Saddle Stitcher Adjustment Menu screen"
Press [01 Staple Center Adj.].
Press [COPY].
6. Fold the output page in half in main scanning direc-
tion, and measure the gap "a" between the center
line of the print.
Standard value "a": = ± 2mm
a
fs503fs3300c
7. If the value is out of spec, press [SERVICE].

Setting range: -20 (right) to +20 (left), 1 step = 0.1mm
352
9.9.18 Staple Paper Width Adj. (Saddle Stitcher Adj.)
/C6501P/C65hc/C5501
Adjust an uneven binding (main scanning direction) in a bundle of paper in saddle stitch mode by the SD.
bizhub PRO C6501

This adjustment adjusts the position of the saddle stitching alignment plate while in alignment.
Note
• Be sure the folding skew adjustment (mechanical adjustment) have been adjusted before perform-
A. Procedure

Press [02 Staple Paper Width Adj.].
4. "Staple Paper Width Adjustment screen"
5. Press [COPY].
pattern (No. 16).
7. Check the bundle of papers is misaligned (a: a mis-
alignment occurs when the paper width setting is a
larger than the paper width) and if the bundle is
curved (b: the curve occurs when the paper width
setting is smaller than the paper width).
Standard value "a": 1.0mm or less
b
fs503fs3012c
9. "Staple Paper Width Adjustment screen"
11. To continue the adjustment for other sizes of paper, repeat steps from 4 to10.
353
9.9.19 Staple Pitch Adjustment (Saddle Stitcher Adj.)

/C6501P/C65hc/C5501
Adjust the staple intervals for the saddle stitch mode by the SD.
bizhub PRO C6501
A. Procedure

Press [03 Staple Pitch Adjustment].
4. "Staple Pitch Adjustment screen"
5. Press [COPY].
pattern (No. 16).
7. Check the interval "a" between the staples against
the paper size "b".
Standard value: a = (b/2) ± 2 mm
a
b
fs503fs3011c
9. "Staple Pitch Adjustment screen"
• Setting range is restricted by the paper size.
Minimum value is determined based on the stapler movable range and the maximum value is determined
so that the saddle stitching alignment plate and stapler do not interfere with each other.
B5S: Setting is not possible (fixed to 91 mm)
B4: -20 to +20 mm (108.5 to 148.5 mm)
A4S: -14 to +14 mm (91 to 119 mm)
A3: -20 to +16.5 mm (128.5 to 165 mm)
81/2 x 14, 81/2 x 11S: -16.95 to +16.95 mm (91 to 124.9 mm)
11 x 17, 81/2 x 11: -20 to +20 mm (119.7 to 159.7 mm)
11. To continue the adjustment for other sizes of paper, repeat steps from 4 to10.
2 354
9.9.20 Half Fold Position Adj. (Saddle Stitcher Adj.)
/C6501P/C65hc/C5501
Adjust the fold position on the multi half fold mode by the SD.
bizhub PRO C6501

A. Procedure

Press [04 Half Fold Position Adj.].
5. Press [COPY].
pattern (No. 16).
7. Check the misalignment "a" on the edge of the out-
a
putted paper.
Standard value "a": 1.5 mm or less
fs503fs3014c
• In the case of the mis-alignment given in the step 7, enter a set value on the positive side.
355
9.9.21 Tri-Fold Position Adj. (Saddle Stitcher Adj.)

/C6501P/C65hc/C5501
Adjust the fold positions on the multi tri-fold-in mode by SD.

bizhub PRO C6501
Note
• When adjusting both the single and the double folds, be sure to adjust the double fold first.
• The position of the single fold is based on the leading edge of paper and the position of the double
fold is based on the position of the single fold. So, the dimension "b" in the step 6 varies when
either position of the single fold and the double fold is changed.
A. Procedure

Press [05 Tri-Fold Position Adj.].
4. "Tri-Fold Position Adjustment screen"
Press [COPY].
pattern (No. 16).
and "b". a

a ± 2.0 b ± 2.0
A4S 97.5 102.0 [2] b [1]
81/2 x 11S 91.6 96.1
fs503fs3015c
[1] Single fold [2] Double fold
8. "Tri-Fold Position Adjustment screen"
Select the paper size you want to adjust.
9. Press [Double Fold]. (the second fold)
Setting range: -100 (longer) to +100 (shorter), 1 step = 0.1 mm
• The dimension "a" in the step 6 gets smaller when the set value is moved to the positive side and gets
larger when moved to the negative side.
11. Press [Single Fold]. (the first fold)
Setting range: -100 (longer) to +100 (shorter), 1 step = 0.1 mm
2 356
9.9.22 Fold Paper Width Adj. (Saddle Stitcher Adj.)
/C6501P/C65hc/C5501
Adjust an uneven edge with the bundle paper at the multi half folding or multi tri-folding mode, conduct this
bizhub PRO C6501

adjustment.
This adjustment changes the alignment width when aligning in sub-scanning direction.
A. Procedure

Press [06 Fold Paper Width Adj.].
4. "Fold Paper Width Adjustment screen"
5. Press [COPY].
pattern (No. 16).
7. Check to if the bundle of papers is misaligned.
a: If the set value is wider than the paper width, fold
line skewed various direction.
b: If the set value is narrower than the paper width, a
fold line skewed same direction.
fs503fs3302c
9. "Fold Paper Width Adjustment screen"
357
9.9.23 Trimming Adjustment (Saddle Stitcher Adj.)

/C6501P/C65hc/C5501
When there is misalignment in the trimmed fore-edge or the trimming is too much by the SD, conduct this
bizhub PRO C6501
adjustment.
A. Procedure

Press [07 Trimming Adjustment].
4. "Trimming Adjustment screen"
5. Press [COPY].
pattern (No. 16).
7. Check the trimmed length "a" of the cover paper.
Standard value "a" : 2 mm or more a
Note
• When the trimmed length less than 2mm may
fs503fs3301c
cause trimming fault.
9. "Trimming Adjustment screen"
Setting range: -400 (smaller) to +400 (larger), 1 step = 0.1mm
358
9.9.24 Trimmer Receiver Adj. (Saddle Stitcher Adj.)
/C6501P/C65hc/C5501
Perform this adjustment when poor trimming (e.g. fluff on the cut end) occurs at the trimming by the SD.
bizhub PRO C6501

This adjustment changes the shift interval and the move pitch of the trimmer board.
A. Procedure

Press [08 Trimmer Receiver Adj.].
4. "Trimmer Receiver Adjustment screen"
Select the options for "Trimmer Count" (number of cuts counted until the trimmer board moves) and
"Move Pitch" (travel distance of the trimmer board when it moves).
5. Press [Execute Compulsive Movement] to move the trimmer board manually.
9.9.25 Curl Reform Direction (RU Adjustment)

Perform this adjustment if paper jam or other problems occur when feeding curled papers.
A. Procedure

Press [07 RU Adjustment].
3. "RU Adjustment Menu screen"
Press [01 Curl Reform Direction].
4. "Curl Reform Direction screen"
Select the option from [OFF], [Upper], or [Lower].
Note
• [Upper]: Corrects the convex curl.
• [Lower]: Corrects the concave curl.
• [Off]: Deactivates curl correction.
• Select [Upper] or [Lower] to correct paper curl at all times.
359
9.9.26 Cover Trimming Adjustment (Perfect Binder Adjustment)

/C6501P/C65hc/C5501
Adjusts the trimming position of the right side edge of the cover paper.
bizhub PRO C6501
Note
• In order to align the leading edges on the left and right covers, perform the adjustments in the
order shown below:
1. 10.9.25 Cover Lead Edge Adj.
2. 10.9.24 Cover Trimming Adjustment
A. Procedure

Press [08 Perfect Binder Adjustment].
3. "Perfect Binder Adjustment Menu screen"
Press [01 Cover Trimming Adjustment].
4. "Cover Trimming Adjustment screen"
Press the [Perfect Binder Tray] or [Except PB Tray] to select the tray you want to adjust.
5. Press [COPY].
6. Select the paper type and press the Start key to make test prints and carry out perfect binding.
7. Check the cover of the created book if its right side
[3]
edge and left side edge align with each other.
[1] Trimming position
[2] Right cover paper
[3] Left cover paper
[2] [1] 1050fs3357c
8. Press [SERVICE] to change the trimming position of the right cover paper.
9. "Cover Trimming Adjustment screen"
Setting range: -128 (reduces the trimming amount) to +127 (enlarges the trimming amount), 1 step =
0.1mm
360
9.9.27 Cover Lead Edge Adj. (Perfect Binder Adjustment)
/C6501P/C65hc/C5501
Sets the length that the left side of cover paper exceeds the length (width) of inside pages.
bizhub PRO C6501

A. Procedure

Press [02 Cover Lead Edge Adj.]
4. "Cover Lead Edge Adjustment screen"
Press [PB Tray] or [Except PB Tray] to select the tray you want to adjust.
5. Press [T] or [S] to select the paper size from the following options.
Full Area
A4
B5
A5
8.5 x 11
16K
A5S
5.5 x 8.5S
Custom (220mm to 379mm)
Note
• Above paper sizes are book (the inside pages) finished sizes.
6. Press [COPY].
8. Check that the width of the left cover paper is
[3] [4]
longer than that of the inside pages by specified
amount. [5]
[1] Inside pages [2] Right cover paper
[1]
[3] Left cover paper [4] Length differential
[5] Edge of the left cover paper
[2] 1050fs3358c
9. To change the width of the left cover paper, press [SERVICE].

10. "Cover Lead Edge Adjustment screen"
Setting range: -128 (short) to +127 (long), 1 step = 0.1mm
361
9.9.28 Spine Corner forming Pos. (Perfect Binder Adjustment)

/C6501P/C65hc/C5501
Adjusts the corner folding position of the cover paper.

bizhub PRO C6501
A. Procedure

Press [03 Spine Corner forming Pos.].
4. "Spine Corner forming Position Adjustment screen"
Press [COPY].
6. Check that the corner edges of the cover paper are
[4]
created uniformly in the main scan direction.
[1] Right cover paper
[1]
[2] Main scanning direction
[3] Cover paper
[4] Left cover paper
[2]
[3]
1050fs3359c
7. When the corner edges of the cover paper are not created uniformly, press [SERVICE].
8. "Spine Corner forming Position Adjustment"
Select [Up/Down (Forward) Adj.] or [Up/Down (Rear) Adj.].
Setting range: -128 (down) to +127(up), 1 step = 0.1mm
362
9.9.29 Pasting Start Postion (Perfect Binder Adjustment)
/C6501P/C65hc/C5501
Adjusts the start position for applying glue to inside pages.
bizhub PRO C6501

A. Procedure

Press [04 Pasting Start Postion].
4. "Pasting Start Position Adjustment screen"
Press [Ahead] or [Back] to select which start position, for applying during frontward movement or back-
ward movement, to be adjusted.
Full Area
A4
B5
A5
8.5 x 11
16K
A5S
5.5 x 8.5S
Note
6. Press [COPY].
8. Check that the glue applying start position to the
[3]
inside pages is appropriate.
[1] Start position for frontward applying
[2] Start position for backward applying
[3] Inside pages
[1]
[2] 1050fs3360c
9. To adjust the start position, press [SERVICE].

10. "Pasting Start Position Adjustment screen"
Setting range: -128 (earlier) to +127 (later), 1 step = 0.1mm
363
9.9.30 Pasting Finish Position (Perfect Binder Adjustment)

/C6501P/C65hc/C5501
Adjusts the position to finish applying glue.

bizhub PRO C6501
A. Procedure

Press [05 Pasting Finish Position].
4. "Pasting Finish Position Adjustment screen"
Press [Ahead] or [Back] to select which finish position, for applying during frontward movement or back-
ward movement, to be adjusted.
Full Area
A4
B5
A5
8.5 x 11
16K
A5S
5.5 x 8.5S
Note
6. Press [COPY].
8. Check that the glue applying finish position to the
[3]
inside pages is appropriate.
[1] Finish position for frontward applying
[2] Finish position for backward applying
[3] Inside pages
[1]
[2] 1050fs3361c
9. To adjust the finish position, press [SERVICE].

10. "Pasting Finish Position Adjustment screen"
364
9.9.31 Paste Formation Finish Pos. (Perfect Binder Adjustment)
/C6501P/C65hc/C5501
Adjusts the finish position of the process to make a uniform layer of glue applied on the inside pages spine.
bizhub PRO C6501

A. Procedure

Press [06 Paste Formation Finish Pos.].
4. "Paste Formation Finish Position Adjustment screen"
Press [T] or [S] to select the paper size from the following options.
Full Area
A4
B5
A5
8.5 x 11
16K
A5S
5.5 x 8.5S
Note
5. Press [COPY].
7. Check that the finish position of the process to make a uniform layer of glue on the inside pages spine is
appropriate.
8. When adjusting the the finish position of the process to make a uniform layer of glue,
press [SERVICE].
9. "Paste Formation Finish Position Adjustment screen"
365
9.9.32 Temperature Adjustment (Perfect Binder Adjustment)

/C6501P/C65hc/C5501
Sets the temperatures to be detected by the glue apply roller temperature sensor (TH1), the glue tank tempera-
bizhub PRO C6501
ture sensor/Up (TH2), the glue tank temperature sensor/Md (TH3), and the glue tank temperature sensor/Lw
(TH4) provided in the glue tank.
A. Procedure

Press [07 Temperature Adjustment].
4. "Temperature Adjustment screen"
Press [COPY].
6. Check that the glue applied has dried appropriately.
7. To adjust the dryness of the glue, press [SERVICE].
8. "Temperature Adjustment screen"
Select the option of which the temperature is set.
The following options are provided.
Melt Tank - Top
Melt Tank - Mid
Melt Tank - Low
Pasting Roller
• Melt Tank - Top
Setting range: 128 °C to 136°C
Default: 132 °C
• Melt Tank - Mid
Setting range: 140 °C to 145 °C
Default: 145 °C
• Melt Tank - Low
Setting range: 180 °C to 190°C
Default: 185 °C
• Pasting Roller
Setting range: 160 °C to 170 °C
Default: 165 °C
2 366
9.9.33 Sub Compile CD Width Adj. (Perfect Binder Adjustment)
/C6501P/C65hc/C5501
Adjusts the alignment width of the inside pages when aligning in the main scan direction.
bizhub PRO C6501

A. Procedure

Press [08 Sub Compile CD Width Adj.].
4. "Sub Compile CD Width Adjustment screen"
Full Area
A4
B5
A5
8.5 x 11
16K
A5S
5.5 x 8.5S
Note
5. "Sub Compile CD Width Adjustment screen"
Setting range:-20 (wider) to +20 (narrower), 1 step = 0.1mm
6. Create multiple books in normal copy mode, and check the alignment of the second and later book.
Change set value set in Step 5 until an properly aligned book is created.
367
9.9.34 Clamp CD Width Adjustment (Perfect Binder Adjustment)

/C6501P/C65hc/C5501
Adjusts the alignment width of the inside pages when aligning in the main scanning direction.
bizhub PRO C6501
A. Procedure

Press [09 Clamp CD Width Adjustment].
4. "Clamp CD Width Adjustment screen"
Full Area
A4
B5
A5
8.5 x 11
16K
A5S
5.5 x 8.5S
Note
5. "Clamp CD Width Adjustment screen"
6. Create multiple books in normal copy mode, and check the alignment of the second and later book.
Change set value set in Step 5 until an properly aligned book is created.
368
9.9.35 Cover Up/Down CD Width Adj. (Perfect Binder Adjustment)
/C6501P/C65hc/C5501
Adjusts the positional relation in the main scan direction between the cover paper and the inside pages.
bizhub PRO C6501

A. Procedure

Press [10 Cover Up/Down CD Width Adj.].
4. "Cover Up/Down CD Width Adjustment screen"
Press [Perfect Binder Tray] or [Except PB Tray] to select the tray you want to adjust.
5. Press [COPY].
7. Check if the relation between the main-scanning position of the cover and that of the inside pages are
appropriate.
8. To adjust the relation of their main-scanning positions, press [SERVICE].
9. "Cover Up/Down CD Width Adjustment screen"
369
9.9.36 Clamp FD Position Adj. (Perfect Binder Adjustment)

/C6501P/C65hc/C5501
Adjusts the alignment width of the inside pages when aligning in the sub scan direction.
bizhub PRO C6501
A. Procedure

Press [11 Clamp FD Position Adj.].
4. "Clamp FD Position Adjustment screen"
Full Area
A4
B5
A5
8.5 x 11
16K
A5S
5.5 x 8.5S
Note
5. Press [COPY].
7. Check if the sub-scanning direction of all the inside pages are properly aligned.
8. To adjust the alignment width in sub-scanning direction of the inside pages, press [SERVICE].
9. "Clamp FD Position Adjustment screen"
Setting range: -20 (wider) to +20 (narrower), 1 step = 0.1mm
Note
• If the setting is too wide, pages are misplaced in sub-scanning direction.
• If the setting is too narrow, mark of the FD alignment plate may appear.
370
9.9.37 Paper Width Adjustment (Relay Stacker Adjustment)
/C6501P/C65hc/C5501
A. Functions
bizhub PRO C6501

• Adjust the position of the alignment plate operates in the main scan direction on the relay stacker (RU-506).
B. Usage
• Adjust it when the punch holes are misarranged in the main scan direction.
C. Procedure
1. "Service mode menu screen"
2. [Finisher adjsutment menu screen]
Press [09 Relay Stacker Adjustment].
3. "Relay Stacker Adjustment Menu screen"
Press [COPY].
5. Set 10 sheets of paper with a size to be adjusted.
Set the setting to "10" to set the punch.
Press the start button.
6. Check the diameter of the through-hole when the ejected paper is stacked.
Holes Standard value (mm)

2/4 holes φ5.0 or larger
3 holes φ6.5 or larger
Setting range: -20 (narrower) to + 20 (wider), 1step = 0.1mm
Note
• For adjusting it, be sure to find the alignment point where the punch holes are not misarranged
by setting the value to the maximum (wide) first and then changing it to narrower.
371 2
9.9.38 Paper Length Adjustment (Relay Stacker Adjustment)

/C6501P/C65hc/C5501
A. Functions
bizhub PRO C6501
• Adjust the position of the alignment plate operates in the sub scan direction on the relay stacker (RU-506).
B. Usage
• Adjust it when the punch holes are misarranged in the paper path direction.
C. Procedure
1. "Service mode menu screen"
2. [Finisher adjsutment menu screen]
Press [09 Relay Stacker Adjustment].
3. "Relay Stacker Adjustment Menu screen"
Press [02 Paper Length Adjustment].
Press [COPY].
5. Set 10 sheets of paper with a size to be adjusted.
Set the setting to "10" to set the punch.
Press the start button.
6. Check the diameter of the through-hole when the ejected paper is stacked.
Holes Standard value (mm)

2/4 holes φ5.0 or larger
3 holes φ6.5 or larger
Setting range: -50 (narrower) to + 50 (wider), 1step = 0.1mm
Note
• For adjusting it, be sure to find the alignment point where the punch holes are not misarranged
by setting the value to the maximum (wide) first and then changing it to narrower.
2 372
9.9.39 Recall Standard Data (Finisher Adjustment)
/C6501P/C65hc/C5501
Restore the finisher adjustment set values to factory initial data or installation initial data.
bizhub PRO C6501

Note
• Adjustment data of "Stacker Adjustment (LS)", "Trimmer Receiver Adj. (SD)", "Curl Reform Direc-
tion (RU)", "Paper Edge Detect Sensor Adj. (PK)", and "Paper Inserter Tray Size Adj. (PI)" are not
restored.
A. Procedure

Press [09/10 Recall Standard Data].
Note
373 2
9.9.40 Saddle Stitcher Stopper Adj.

/C6501P/C65hc/C5501
Adjust the staple position in the sub scan direction while in the saddle stitching by the FS-607.
bizhub PRO C6501
This adjustment changes the position of the saddle stitching stopper.
Note
• Be sure the " Half Fold Stopper Adj. " have been adjusted before performing this adjustment.
A. Procedure

Press [01 Saddle Stitcher Stopper Adj.].
3. "Fold & Staple Stopper Adjustment screen"
4. Press [COPY].
pattern (No. 16).
6. Check the saddle stitching staple position of the
outputted paper.
Standard value "a": ± 1 mm
15sjf3c100na
8. "Fold & Staple Stopper Adjustment screen"
Setting range: -128 (lower) to +127 (upper), 1 step = 0.1 mm
374
9.9.41 Half Fold Stopper Adj.
/C6501P/C65hc/C5501
Adjust the folding position while in the multi center folding and saddle stitching by the FS-607.
bizhub PRO C6501

This adjustment changes the position of the saddle stitching stopper.
A. Procedure

Press [02 Half Fold Stopper Adj.].
3. "Half Fold Stopper Adjustment screen"
4. Press [COPY].
pattern (No. 16).
6. Check the misalignment "a" on the edge of the
outputted paper. a
15sjf3c101na
8. "Half Fold Stopper Adjustment screen"
Setting range: -128 to +127, 1 step = 0.1 mm
• In the case of the misalignment given in the step 6, enter a set value to the negative side.
375
9.9.42 Vertical Position Adj. (Punch Adjustment)

/C6501P/C65hc/C5501
Adjust the punch position of the punch kit (PK) in the main scan direction.
bizhub PRO C6501
A. Procedure

Press [03 Punch Adjustment].
3. "Punch Adjustment Menu screen"
Press [01 Vertical Position Adj.].
4. "Vertical position adjustment screen"
5. Press [COPY].
6. Select the paper size according to the item you want to adjusted, set the 10 sets of copies and press the
Start key to output a test pattern (No. 16).
7. Fold the output paper in half in the main scan
direction, and measure the gap "a" between the
center line of the print and the center of the punch
hole. [1]
a
[2]
15knf3c002nb
[1] Center of the paper

[2] Center of the punch hole
9. "Vertical position adjustment screen"
Setting range: -50 (in front) to +50 (in back), 1 step = 0.1 mm
376
9.9.43 Horizontal Position Adj. (Punch Adjustment)
/C6501P/C65hc/C5501
Adjust the punch position of the punch kit (PK) in the sub scan direction.
bizhub PRO C6501

A. Procedure

Press [02 Horizontal Position Adj.].
4. "Horizontal position adjustment screen"
Select [PI tray] or [Main tray], and press [COPY].
5. Set paper in the tray or PI, and press Start to print the test pattern (No. 16).
6. Check the punch position "a" of the output paper
in the sub scan direction. a
Paper size Standard value "a" (mm)
metric area 10.5 ± 5.0
inch area 9.5 ± 5.0
15knf3c001nb
7. When the value is not within the standard value, press the [Service].
8. "Horizontal position adjustment screen"
377
9.9.44 Registration Adjustment (Punch Adjustment)

/C6501P/C65hc/C5501
Adjust the registration loop amount of the punch kit (PK) while in the punch to remove punch skew, paper wrin-
bizhub PRO C6501
kles, or a jam at the punch registration section.
A. Procedure

Press [03 Registration Adjustment].
4. "Registration adjustment screen"
5. Set paper in the tray or PI, and press Start to print the test pattern (No. 16).
7. "Registration adjustment screen"
Setting range: -20 (larger) to +20 (smaller), 1 step = 0.8 mm
9.9.45 Paper Edge Detect Sensor Adj. (Punch Adjustment)

Adjust the sensitivity of the sensor after replacing the punch drive board (PKDB) or the paper edge detect sensor
board (PESB) of PK.
A. Procedure

Press [04 Paper Edge Detect Sensor Adj.].
4. "Paper Edge Detect Sensor Adjustment screen"
Press [Start].
5. A message "Completed" is displayed when the adjustment is finished successfully.
378
9.9.46 Tri-Fold Adjustment
/C6501P/C65hc/C5501
Adjust the 1st folding position of the multi tri-folding mode by the FS-607.
bizhub PRO C6501

Note
• The 2nd folding position (dimension "b") is mechanically adjusted. (Refer to "10.9.14 Adjusting the
tri-folding position (FS-607)" .)
A. Procedure

Press [04 Tri-Fold Adjustment].
3. "Tri-Fold Adjustment screen"
Select the paper size you want to adjust, and press [COPY].
pattern (No. 16).
5. Check "a" on the outputted paper.

a b c
A4S 95 ± 2 101 ± 2 101 ± 2
81/2 x 11S 89 ± 2 95 ± 2 95 ± 2
c
a
[1]
b 15sjf3c102na
[1] First fold
6. When the value is not within the standard value, press the [Service].
7. "Tri-Fold Adjustment screen"
Setting range: -128 (larger) to +127 (smaller), 1 step = 0.1 mm
379
9.9.47 2 Pos. Staple Pitch Adj.

/C6501P/C65hc/C5501
Adjust the staple intervals for the staple or saddle stitch mode by the FS-607.
bizhub PRO C6501
A. Procedure

Press [05 2 Pos. Staple Pitch Adj.].
3. "2 Position Staple Pitch Adjustment screen"
Press [Fold & Staple] or [Staple].
4. Press [COPY].
6. Press Start to print the test pattern (No. 16).
Standard value "a": 128 ± 6 mm
a 15sjf3c103na
[1]
a
15sjf3c104na
[2]
[1] Staple
[2] Fold & Staple
8. "2 Position Staple Pitch Adjustment screen"
Setting range: +128 (narrower) to +160 (wider), 1 step = 1 mm
380
9.9.48 Paper Inserter Tray Size Adj.
/C6501P/C65hc/C5501
This adjustment should be performed when the paper size is not correctly detected at the cover sheet tray of the
bizhub PRO C6501

PI.
A. Procedure

Press [06 Paper Inserter Tray Size Adj].
3. "PI1/PI2 Tray Size Adjustment screen"
Press [Next] or [Previous] and select the upper or lower tray, and press [A4S] or [8.5 x 11S].
4. Load A4S paper in the selected tray of PI and press [Start].
(When you selected [8.5 x 11S] in step 3, load 81/2 x 11S paper in the tray.)
6. When another tray needs to be adjusted, repeat steps 3 to 5.
7. Exit out of the service mode, and check if paper size set in the PI is correctly detected.
9.9.49 Output quantity limit

Set the maximum number of sheets for stapling, saddle stitching, multi half fold, and multi tri-fold of the FS-607.
Change the max. setting when the staples are buckled or paper folded is not enough.
A. Procedure

Press [07 Output quantity limit].
3. "Finisher Output Limit Setting screen"
Enter the maximum number of sheets for each item with the numeric buttons and press [<<SET].
381
9.9.50 Curl adjustment

/C6501P/C65hc/C5501
Set the adjustment for the paper curl amount on FS-607 or FS-520. Depending on the paper type, adjust this
bizhub PRO C6501
setting when the leading edge of paper is buckled at 1st folding in the Tri-fold mode or an uneven paper exit
occurs due to the paper curl.
A. Procedure

Press [08 Curl adjustment].
3. "Curl Adjustment Setting screen"
Select the pressure for the paper exit decurler roller among "High, Middle, Low".
Note
• The paper curl direction varies depending on the paper type, weight, moisture condition, tray load-
ing direction, etc. Adjust this setting after checking the condition of exit papers.
• Adjust the setting according to the following.
a. Exit with its face down

"Simplex (Print Side : Front)" : With the default setting "High", the paper tends to have a concave
curl. When the concave curl amount is large on the main tray, set
to "Middle" or "Low".
"Duplex" : With the default setting "Middle", set to "Low" when the concave
curl amount is large on the main tray, and set to "High" when the
convex curl amount is large on the main tray.
b. Exit with its face up

"Simplex (Print Side : Back)" : The paper tends to have a convex curl. When the
convex curl amount is large on the main tray, set
to "Middle" or "High".
"Simplex (Tri-folding 64-80g/m2 Inside print)" : With the default setting "High", when the leading
edge of paper is buckled at 1st folding, set to
"Middle" or "Low".
"Simplex (Tri-folding 81-105g/m2 Inside print)" : With the default setting "Low", when the leading
edge of paper is buckled at 1st folding, set to
"Middle" or "High".
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9.10 Firmware version
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Display the firmware version of the main body and options.
Note
• The [Image control] that is displayed on the screen represents the firmware version of the overall
control board (OACB).
A. Procedure

Press [08 Firmware Version].
2. "Firmware Version Menu screen"
Press [01 ROM Version].
3. "ROM Version Indication screen"
Each firmware version is displayed.
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9.11 CS Remote Care

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9.11.1 Outline
The CS Remote Care is a system that manages the main body by sending and receiving various kinds of the
management data of the main body between the main body and the CS Remote Care center computer through
the phone line, E-mail or WebDAV server.
It enables the main body to call the center computer, and the center computer to inquire regularly the main body
for various data.
The data handled by the CS Remote Care can be classified into the 3 following groups.
a. Data that allow you to grasp the use conditions of the main body, such as the total count and the PM count.
b. Data that give us the general information of when and how often an abnormality occurred with the main body.
c. All sorts of adjustment data
Note
• When the security enhanced mode is set to ON, the use of the main body NIC is not allowed.
9.11.2 Setup procedure of the CS Remote Care (When using the E-mail)
When the E-mail is used for the CS Remote Care system, make settings following the procedure as shown
below.
Note
• Be sure to use the NIC of the Copier. The use of the CSRC is not available for the controller NIC.
• Make settings of the mail address of the copier and the mail server by pressing the buttons [Util-
ity/Counter] - [Machine Admin. Setting] - [Network Setting] - [E-Mail Initial Setting] in this order.
(Refer to P.394)
• When the E-mail CS Remote Care is used jointly with the mail remote communication system, it is
necessary to take notice of the mail account and the DIPSW setting. For details, refer to “9.11.5
List of combinations of E-Mail CS Remote Care and Mail remote notification system”.
• When setting up once again a copier the CS Remote Care of which has been once set up, be sure
to set it up again after clearing the RAM for the CS Remote Care. For details, (Refer to P.404).
When using E-mail (Duplex) When using E-mail (Simplex (from machine to center))
Step Operation Step Operation
1 Registered the Device ID in the application on 1 Registered the Device ID in the application on
the CS Remote Care center side. the CS Remote Care center side.
When the Device ID is not registered, no initial When the Device ID is not registered, no initial
connection cannot be made. connection cannot be made.
2 E-Mail Initial Setting 2 E-Mail Initial Setting
Make settings of the mail address and the mail Make settings of the mail address and the mail
server of the copier by pressing the buttons server of the copier by pressing the buttons
[Utility/Counter] - [Machine Admin. Setting] - [Utility/Counter] - [Machine Admin. Setting] -
[Network Setting] - [E-Mail Initial Setting] in this [Network Setting] - [E-Mail Initial Setting] in this
order. (Refer to P.394) order. (Refer to P.394)
Note Note
• The E-Mail Initial Setting can also be • The E-Mail Initial Setting can also be
made with the "Extension for mainte- made with the "Extension for mainte-
nance" of the Web Utilities. nance" of the Web Utilities.
3 CS Remote Care Function ON 3 CS Remote Care Function ON
Set [15-5] to "On (1)" by pressing the buttons Set [15-5] to "On (1)" by pressing the buttons
[System Setting] - [Software SW Setting] in the [System Setting] - [Software SW Setting] in the
Service Mode. Service Mode.
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4 CS Remote Care setting 4 CS Remote Care setting
Select [CS Remote Care] - [CS Remote Care] Select [CS Remote Care] - [CS Remote Care]
in Service Mode and press [E-Mail]. in Service Mode and press [E-Mail].
5 Communication method selection 5 Communication method selection
Press [Duplex] on [CS Remote Care setting] Press [Simplex] on [CS Remote Care setting]
screen. screen.
6 Entering ID Code 6 Entering ID Code
1. Press [ID Code]. 1. Press [ID Code].
2. Enter the 7-digit service ID through the key- 2. Enter the 7-digit service ID through the key-
pad and then press [ID Code] again. pad and then press [ID Code] again.
7 Press [Detail Setting] to display the [E-mail 7 Press [Detail Setting] to display the [E-mail
(Duplex) setting menu] screen. (Simplex) setting menu] screen.
8 Basic setting 8 Basic setting
1. Press [Basic Setting] on [E-mail (Duplex) 1. Press [Basic Setting] on [E-mail (Simplex)
setting menu] screen. setting menu] screen.
2. Press [Center ID] and enter the center ID (5 2. Press [Center ID] and enter the center ID (5
digit). digit).
• The serial number that is input from [Serv- • The serial number that is input from [Serv-
ice mode] → [System Setting] → [Serial ice mode] → [System Setting] → [Serial
Number Setting] appears on [Device ID]. Number Setting] appears on [Device ID].
3. Press [Cryptogram] to make a selection to 3. Press [E-mail] and enter the mail address of
decide whether it is encrypted or not. the center.
(Default: Use Encryptogram). 4. Press [Cryptogram] to make a selection to
4. Press [OK]. decide whether it is encrypted or not.
(Default: Use Encryptogram).
5. Press [OK].
9 Date and Time Setting 9 Date and Time Setting
1. Press [Date and Time Setting] on the [E- 1. Press [Date and Time Setting] on the [E-
mail (Duplex) setting menu] screen. mail (Simplex) setting menu] screen.
2. Press [Setting Time] to enter the year, 2. Press [Setting Time] to enter the year,
month and the day. month and the day.
• Press [Set] to move the cursor among the • Press [Set] to move the cursor among the
year/month/day/hour/minute fields. year/month/day/hour/minute fields.
3. Press [Time Zone] to enter the time zone. 3. Press [Time Zone] to enter the time zone.
• Press [+ <-> -] in order to change over the • Press [+ <-> -] in order to change over the
time zone between the plus and the minus. time zone between the plus and the minus.
4. Press [OK]. 4. Press [OK].
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10 Response Timeout Setting 10 Periodical Transmission set
1. Press [Response Timeout Setting] on the 1. Press [Periodical Transmission set] on the
[E-mail (Duplex) setting menu] screen. [E-mail (Simplex) setting menu] screen.
2. Enter the response timeout time (10 to 2. Set the periodical transmission of the
1440 minutes, default: 30 minutes). schedule to the center.
3. Press [OK]. • Every month: Send it regularly to the center
on the same date. Sent date is set at the
end of the month by [EM].
• Every week: Send it regularly to the center
on the same time and the same day of the
week.
• Every day: Send it regularly to the center on
the same time everyday.
3. Press [OK].
11 Turn off and on the sub power switch (SW2) of 11 Fixed Date and Time Setting
the main body. 1. Press [Fixed Date and Time Setting] on the
[E-mail (Simplex) setting menu] screen.
2. Set the specified date and hour.
3. Press [OK].
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12 Initial connection 12 Data Collection setting
Send out a mail at the initial connection from 1. Press [Data Collection setting] on the [E-
the CS Remote Care center to the NIC mail mail (Simplex) setting menu] screen.
address of the copier. 2. Select data to be collected.
Note • Basic Data
• When any screen that is related to the • Account Track Data
CS Remote Care is displayed while in • Machine Adjustment Data
the reception of a mail sent at the initial • Coverage Data
connection from the CS Remote Care 3. Press [OK].
center, information being set is
destroyed with the CS Remote Care
Setting screen displayed.
• For details of the method for sending a
mail at the initial connection, refer to
the CS Remote Care center manual.
• The transmission and reception of a
mail is available only between the ini-
tially connected center and the copier.
• The initial connection is made from the
center, and the mail address of the
center that is sent out at this time is
saved in the copier.
• The center mail address, after comple-
tion of the initial registration, is dis-
played in [Service Mode] - [CS Remote
Care] - [CS Remote Care] - [Detail Set-
ting] - [Basic Setting] - [E-Mail].
• When an abnormal condition occurs
while in the communication with the
center, check the error code that is
being displayed. (Refer to P.405)
13 Turn off and on the sub power switch (SW2) of
the main body.
14 Initial connection
1. Press [Basic Setting] on the [E-mail (Sim-
plex) setting menu] screen.
2. Press [First Call] to send the initial connec-
tion mail to the center.
3. Once the mail is sent normally, CS Remote
Care setting screen appears.
Note
• The registration is done when the initial
connection mail is sent and the mail is
normally sent to SMTP server.
• When the transmission error occurs
against the center, check the error code
that appears. (Refer to P.405)
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9.11.3 Setup procedure of the CS Remote Care (When using the phone line modem)
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When a phone line modem is used for the CS Remote Care system, make settings following the procedure as
bizhub PRO C6501
shown below.
Note
• When setting up once again a copier the CS Remote Care of which has once been set up, be sure
to set it up again after clearing the RAM for the CS Remote Care.
• Be sure to use a Data modem compliant with the AT command, that is also compliant with ITU-T
V.34/V.32 bis/V.32.
When using the phone line modem

Step Operation
1 Registered the Device ID in the application on the CS Remote Care center side.
When the Device ID is not registered, no initial connection cannot be made.
2 Connecting the modem
With the power to the modem turned off, connect the copier and the modem with a modem cable and
also connect the modem and the wall plug socket with a modular cable.
• For details of the method for connecting the modular cable, refer to the instruction manual of the
modem used.
3 CS Remote Care Function ON
Set [15-5] to "On (1)" by pressing the buttons [System Setting] - [Software SW Setting] in the Service
Mode.
4 CS Remote Care setting
Select [CS Remote Care] - [CS Remote Care] in Service Mode and press [Modem].
5 Entering ID Code
1. Press [ID Code].
2. Enter the 7-digit service ID through the keypad and then press [ID Code] again.
6 Press [Detail Setting] to display the [Modem setting menu] screen.
7 Basic Setting
1. Press [Basic Setting] on the [Modem setting menu] screen.
2. Press [Center ID] to enter the Center ID (5 digits).
• For [Device ID], a serial number is displayed that has been entered by pressing the buttons [System
Setting] - [M/C Serial Number Setting] in the Service Mode.
3. Press [Center Telephone Number] to enter the center phone number.
• Use [P], [T], [W] or [-] as necessary.
4. Press [Machine Telephone Number] to enter the Machine Telephone Number.
• Use [P], [T], [W] or [-] as necessary.
5. Press [OK].
8 Date and Time Setting
1. Press [Date and Time Setting] on the [Modem Setting menu] screen.
2. Press [Setting Time] to enter the year, month and the day.
• Press [Set] to move the cursor among the year/month/day/hour/minute fields.
3. Press [Time Zone] to enter the time zone.
• Press [+ <-> -] in order to change over the time zone between the plus and the minus.
4. Press [OK].
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When using the phone line modem
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Step Operation
9 Entering the modem initialization AT command
Note
• Be sure to change the modem initialization AT command as necessary. (It is not necessary
to change it normally.)
• For details of the AT command, refer to the instruction manual of the modem used.
1. Press [AT Command] on the [Modem Setting menu] screen.
2. Press [First Command] to enter the AT command.
3. Press [OK].
10 Setting the DIPSW for the CS Remote Care
Note
• It is not necessary to set it normally. However, be sure to set it when required according to
the connection environment.
1. Press [Software SW Setting] on the [Modem Setting menu] screen.
2. Set the DIP-SW as necessary.
(Refer to P.395).
11 Turn off and on the sub power switch (SW2) of the main body.
12 Executing the initial transmission
1. Press [Basic Setting] on the [Modem Setting menu] screen.
2. Press [First Call] to start the initial transmission.
• When the connection to the center comes to a normal termination, the CS Remote Care setting
screen is displayed.
• When an abnormal condition occurs while in the communication with the center, check the error
code that is being displayed. (Refer to P.405).
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9.11.4 Setup procedure of the CS Remote Care (When using the WebDAV server)
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When the http communication is used for the CS Remote Care system, make settings following the procedure
bizhub PRO C6501
as shown below.
Note
• Be sure to use the NIC of the Copier. The use of the CSRC is not available for the controller NIC.
• When setting up once again a copier the CS Remote Care of which has once been set up, be sure
to set it up again after clearing the RAM for the CS Remote Care. (Refer to P.404).
• When the http proxy server is used, be sure to make settings of the proxy by pressing the buttons
[Utility/Counter] - [Machine Admin. Setting] - [Network Setting] - [http communication Setting] in
this order. (Refer to P.394).
In the case of http (Duplex) In the case of http (Simplex)

1 Registered the Device ID in the application on 1 Registered the Device ID in the application on
the CS Remote Care center side. the CS Remote Care center side.
When the Device ID is not registered, no initial When the Device ID is not registered, no initial
connection cannot be made. connection cannot be made.
2 http communication Setting (Arbitrary setting) 2 http communication Setting (Arbitrary setting)
When the http proxy server is used, be sure to When the http proxy server is used, be sure to
make settings of the proxy by pressing the but- make settings of the proxy by pressing the but-
tons [Utility/Counter] - [Machine Admin. Set- tons [Utility/Counter] - [Machine Admin. Set-
ting] - [Network Setting] - [http communication ting] - [Network Setting] - [http communication
Setting] in this order. (Refer to P.394). Setting] in this order. (Refer to P.394).
Note Note
• The http communication Setting can also • The http communication Setting can also
be made with the "Extension for mainte- be made with the "Extension for mainte-
nance" of the Web Utilities. nance" of the Web Utilities.
3 CS Remote Care Function ON 3 CS Remote Care Function ON
Set [15-5] to "On (1)" by pressing the buttons Set [15-5] to "On (1)" by pressing the buttons
[System Setting] - [Software SW Setting] in the [System Setting] - [Software SW Setting] in the
Service Mode. Service Mode.
4 CS Remote Care setting 4 CS Remote Care setting
Select [CS Remote Care] - [CS Remote Care] Select [CS Remote Care] - [CS Remote Care]
in Service Mode and press [http]. in Service Mode and press [http].
5 Selecting the communication method 5 Selecting the communication method
Press [Duplex] on the [CS Remote Care setting] Press [Simplex] on the [CS Remote Care set-
screen. ting] screen.
6 Entering ID Code 6 Entering ID Code
1. Press [ID Code]. 1. Press [ID Code].
2. Enter the 7-digit service ID through the key- 2. Enter the 7-digit service ID through the key-
pad and then press [ID Code] again. pad and then press [ID Code] again.
7 Press [Detail Setting] to display the [http 7 Press [Detail Setting] to display the [http (Sim-
(Duplex) setting menu] screen. plex) setting menu] screen.
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8 Basic Setting 8 Basic Setting
1. Press [Basic Setting] on the [http (Duplex) 1. Press [Basic Setting] on the [http (Simplex)
setting menu] screen. setting menu] screen.
2. Press [Center ID] to enter the Center ID (5 2. Press [Center ID] to enter the Center ID (5
digits). digits).
• For [Device ID], a serial number is displayed • For [Device ID], a serial number is displayed
that has been entered by pressing the but- that has been entered by pressing the but-
tons [System Setting] - [M/C Serial Number tons [System Setting] - [M/C Serial Number
Setting] in the Service Mode. Setting] in the Service Mode.
3. Press [Web Server] to enter the URL of the 3. Press [Web Server] to enter the URL of the
Web server (up to 255 characters). Web server (up to 255 characters).
4. Press [Cryptogram] to make a selection to 4. Press [Cryptogram] to make a selection to
decide whether it is encrypted or not. decide whether it is encrypted or not.
(Default: Use Encryptogram). (Default: Use Encryptogram).
9 Setting the Heart Beat *1 9 Setting the Heart Beat *1
1. Press [Heart Beat setting] on the [http 1. Press [Heart Beat setting] on the [http (Sim-
(Duplex) Setting menu] screen. plex) Setting menu] screen.
2. Press [Heart Beat Setting] to make a selec- 2. Press [Heart Beat Setting] to make a selec-
tion to decide whether the Heart Beat function to decide whether the Heart Beat func-
tion is made valid or invalid. tion is made valid or invalid. (Default:
(Default: Enable) Enable)
3. Press [Heart Beat Interval] to enter the 3. Press [Heart Beat Interval] to enter the
transmission interval of the Heart Beats (1 transmission interval of the Heart Beats (1
to 256 minutes, default: 30 minutes). to 256 minutes, default: 30 minutes).
4. Press [Heart Beat Send] to make a selec- 4. Press [Heart Beat Send] to make a selec-
tion to decide whether the fixed time trans- tion to decide whether the fixed time trans-
mission of the Heart Beat is made valid or mission of the Heart Beat is made valid or
invalid. (Default: Disable) invalid. (Default: Disable)
5. Press [Heart Bear Fixed Send Time] to 5. Press [Heart Bear Fixed Send Time] to
enter the time for the Heart Beat transmis- enter the time for the Heart Beat transmis-
sion at the fixed time. sion at the fixed time.
10 Date and Time Setting 10 Date and Time Setting
1. Press [Date and Time Setting] on the [http 1. Press [Date and Time Setting] on the [http
(Duplex) Setting menu] screen. (Simplex) Setting menu] screen.
2. Press [Setting Time] to enter the year, 2. Press [Setting Time] to enter the year,
month and the day. month and the day.
• Press [Set] to move the cursor among the • Press [Set] to move the cursor among the
year/month/day/hour/minute fields. year/month/day/hour/minute fields.
3. Press [Time Zone] to enter the time zone. 3. Press [Time Zone] to enter the time zone.
• Press [+ <-> -] in order to change over the • Press [+ <-> -] in order to change over the
time zone between the plus and the minus. time zone between the plus and the minus.
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11 Turn off and on the sub power switch (SW2) of 11 Periodical Transmission set
the main body. 1. Press [Periodical Transmission set] on the
[http (Simplex) Setting menu] screen.
2. Set the periodical transmission of the
schedule to the center.
3. Press [OK].
12 Executing the initial transmission 12 Fixed Date and Time Setting
1. Press [Basic Setting] on the [http (Duplex) 1. Press [Fixed Date and Time Setting] on the
Setting menu] screen. [http (Simplex) Setting menu] screen.
2. Press [First Call] to start the initial transmis- 2. Set the specified date and hour.
sion. 3. Press [OK].
• When the connection to the center comes
to a normal termination, the CS Remote
Care setting screen is displayed.
• When an abnormal condition occurs while
in the communication with the center,
check the error code that is being dis-
played. (Refer to P.405).
13 Data Collection setting
1. Press [Data Collection setting] on the [http
(Simplex) Setting menu] screen.
2. Select data to be collected.
• Basic Data
• Account Track Data
• Machine Adjustment Data
• Coverage Data
3. Press [OK].
14 4. Turn off and on the sub power switch
(SW2) of the main body.
15 Executing the initial transmission
1. Press [Basic Setting] on the [http (Simplex)
Setting menu] screen.
2. Press [First Call] to start the initial transmis-
sion.
• When the connection to the center comes
to a normal termination, the CS Remote
Care setting screen is displayed.
• When an abnormal condition occurs while
in the communication with the center,
check the error code that is being dis-
played. (Refer to P.405).
*1 The Heart Beat function is a function to give notice of the equipment being in operation by uploading the
Heart Beat file periodically to the registered Web server. In the Heart Beat file, information of the total counter
and the status is included.
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9.11.5 List of combinations of E-Mail CS Remote Care and Mail remote notification system
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To change a combination of E-Mail CS Remote Care and Mail remote notification system, refer to this table to
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configure the software switch setting or the mail account setting.
Case Mail remote E-Mail CS Setting item Value Remark

notification Remote Care
system using the main
body NIC
"Use the mail remote notification Use
system" of the main body NIC’s
1 Web utility (*2)
"Tech. Rep. mode - Software 1
Switch Setting": 15-5 (*1)
"Use the mail remote notification Use
system" of the main body NIC
2 — Web utility —
"Use the mail remote notification Use *3
system" of the main body NIC
3 — Web utility —
*1 Tech. Rep. mode - Software Switch Setting: 15-5 (CS Remote Care function ON, 0=OFF,
1=ON)
*2 Mail remote notification system and CS Remote Care using the main body NIC share the same mail
account
*3 To use E-mail CS Remote Care, set mail remote notification system "On" even you do not use that
system, and initialize the mail setting.
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9.11.6 E-Mail Initial Setting

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Settings are made of the mail address and the mail server for the copier.
bizhub PRO C6501
Note
• The E-Mail Initial Setting can also be made with the "Extension for maintenance" of the Web Util-
ities.
1. Press [Utility/Counter].
2. Press [Machine Admin. Setting] - [Network Setting] - [E-Mail Initial Setting].
3. Make the following settings.
• [Use E-mail system] : Select [On].
• [Time zone] : Set the time zone.
• [Trans(SMTP) mail server] : Set the host name or IP address of the SMTP server. When the host name is
entered, be sure to set the DNS server.
• [SMTP Port number] : Set the port number of the SMTP server.
• [Trans mail server timeout] : Set the timeout time (in seconds).
• [New-arrival check interval] : Set the intervals (in minutes) in which newly received mails are checked.
• Receive mail server : Set the host name or IP address of the incoming mail server. When the host name is
• Receive mail server type : Set the type (POP3/IMAP) of the incoming mail server.
• POP3/IMAP Port number : Set the port number of the incoming mail server.
• Receive mail account : Set the account name.
• Receive mail password : Set the password of the account.
• E-mail address for machine : Set the mail address of the copier.
• POP(IMAP) before SMTP Auth. : Make a setting to decide whether or not the POP(IMAP) before SMTP
Auth. is used.
4. Press [Test] and then press [Yes] on the confirmation screen displayed to make a transmission/reception
test.
5. Press [OK].
9.11.7 http communication Setting

When the http proxy server is used, be sure to make the following settings.
Note
• The http communication Setting can also be made with the "Extension for maintenance" of the
Web Utilities.
1. Press [Utility/Counter].
2. Press [Machine Admin. Setting] - [Network Setting] - [http communication Setting].
3. Make the following settings.
• [Enable Proxy Server] : Select [On].
• [Proxy Server Address Set] : Set the host name or IP address of the proxy server. When the host name is
• [Proxy Server Port] : Set the port number of the proxy server.
• [Enable SSL] : Make a setting to decide whether or not the SSL is used.
• [Enable Authentication] : Make a setting to decide whether or not the Authentication is used.
• Authentication User Name : Set the Authentication User Name.
• Authentication Password : Set the Authentication Password.
4. Press [OK].
394
9.11.8 Software SW setting for CS Remote Care
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Note
• Software SW bits data are written into the NVRAM board (NRB) 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. Enter the Tech. Rep. mode.

2. "Tech. Rep. mode menu screen"
Press the [CS Remote Care] key.
3. "Sub menu screen"
Press the [CS Remote Care] key
4. "CS Remote Care setting screen"
Press [ID Code] and enter the 7-digit ID Code.
5. Press the [ID Code] key.
6. Press the [Detail Setting] key.
7. "Setting menu screen"
Press the [Software SW Setting] key.
8. "Software SW Setting screen"
Select the DIPSW number.
Use the left arrow key or the numeric keys.
9. Select the DIPSW bit number.
Use the right arrow key or the numeric keys.
10. Select DIPSW On (1), Off (0).
Use the [On (1)], [Off (0)] key.
11. Press the [Return] key to return to the "Setting menu screen."
Note
• About functions of each switch, refer to “B. List of software SW for CS Remote Care.”
395
B. List of software SW for CS Remote Care

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Note
• Do not change any bit not described on this table
DIPSW Functions Bit Data Default

No. Bit 0 1
1 0 Dial mode Pulse dial Tone dial 1
1 Modem reception Receive*1 Do not receive*1 0
2 — — — 0
3 — — — 0
4 Baud rate *2 *2 0
5 *2 *2 0
6 *2 *2 0
7 *2 *2 1
2 0 Auto call on SC occurrence Do not call Call 1
1 Auto call on date specification Do not call Call 1
2 Auto call on the part replacement Do not call Call 1
3 Auto call on the drum replacement Do not call Call 1
4 Auto call on the periodic maintenance (PM) Do not call Call 1
5 — — — 0
6 — — — 0
7 Auto call when resetting the fixed replacement Do not call Call 0
parts
3 0 — — — 0
1 Auto call on the toner supply Do not call Call 1
2 Auto call on frequent JAM occurrence Do not call Call 1
3 Report on the waste toner box full Do not call Call 1
4 to 7 — — — 0
4 0 CS Remote Care communication mode *3 *3 0
1 *3 *3 1
2 to 7 — — — 0
5 0 Modem redial interval *4 *4 1
1 *4 *4 1
2 *4 *4 0
3 *4 *4 0
4 to 7 — — — 0
6 0 Modem redial times *5 *5 0
1 *5 *5 1
2 *5 *5 0
3 *5 *5 1
4 *5 *5 0
5 *5 *5 0
6 *5 *5 0
7 — — — 0
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bizhub PRO C6501

No. Bit 0 1
7 0 Redial for response time out Do not redial Redial 1
1 to 7 — — — 0
8 0 Retransmission interval on E-Mail delivery error *6 *6 0
1 *6 *6 1
2 *6 *6 1
3 *6 *6 0
4 to 7 — — — 0
9 0 Retransmission times on E-Mail delivery error *7 *7 0
1 *7 *7 1
2 *7 *7 0
3 *7 *7 1
4 *7 *7 0
5 *7 *7 0
6 *7 *7 0
7 — — — 0
10 0 Time zone setting *8 *8 0
1 *8 *8 0
2 *8 *8 0
3 *8 *8 0
4 *8 *8 0
5 *8 *8 0
6 *8 *8 0
7 *8 *8 0
11 0 Timer 1 *9 *9 0
1 RING reception → CONNECT reception *9 *9 0
2 *9 *9 0
3 *9 *9 0
4 *9 *9 0
5 *9 *9 1
6 *9 *9 0
7 *9 *9 0
12 0 Timer 2 *10 *10 0
1 Dial request completed → CONNECT reception *10 *10 0
2 *10 *10 0
3 *10 *10 0
4 *10 *10 0
5 *10 *10 0
6 *10 *10 1
7 *10 *10 0
13 0 Timer 3 — — 0
1 Not used — — 1
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bizhub PRO C6501
No. Bit 0 1
13 2 Timer 3 — — 0
3 Not used — — 1
4 — — 0
5 — — 0
6 — — 0
7 — — 0
14 0 Timer 4 *11 *11 0
1 Line connection → Start request telegram deliv- *11 *11 0
2 ery *11 *11 0
3 *11 *11 0
4 *11 *11 0
5 *11 *11 1
6 *11 *11 0
7 *11 *11 0
15 0 Timer 5 *12 *12 0
1 Wait time for other side's response *12 *12 1
2 *12 *12 1
3 *12 *12 1
4 *12 *12 1
5 *12 *12 0
6 *12 *12 0
7 *12 *12 0
16 0 Retry data, timer 6 *13 *13 1
1 Initialization OK → Dial request *13 *13 1
2 *13 *13 1
3 *13 *13 1
4 *13 *13 1
5 *13 *13 1
6 *13 *13 1
7 *13 *13 1
17 0 Call JAM date (main body) *14 *14 1
1 Valid copy quantity *14 *14 0
2 Call ADF JAM date *15 *15 1
3 Valid original feed quantity *15 *15 0
4 Call JAM date *16 *16 1
5 MCBJ setting *16 *16 0
6 Call ADF JAM date *17 *17 1
7 MOBJ setting *17 *17 0
18 0 Attention display Do not call Call 1
1 to 7 — — — 0
19 to 40 0 to 7 — — — 0
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*1 Modem reception
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Mode DIPSW No.1
bizhub PRO C6501

1
Receive 0
Issue ATA by RING delivery
Do not receive 1
Do not issue ATA by RING delivery
*2 Baud rate Mode DIPSW No.1

7 6 5 4
1200 bps 0 0 1 1
2400 bps 0 1 0 0
4800 bps 0 1 0 1
9600 bps 0 1 1 0
19200 bps 0 1 1 1
38400 bps 1 0 0 0
57600 bps 1 0 0 1
*3 CS Remote Care communication mode Mode DIPSW No.4

1 0
Data modem 0 0
FAX (not used) 0 1
E-Mail 1 0
http 1 1
*4 Modem redial interval Mode DIPSW No.5

3 2 1 0
1 minute 0 0 0 1
2 minutes 0 0 1 0
3 minutes 0 0 1 1
4 minutes 0 1 0 0
5 minutes 0 1 0 1
6 minutes 0 1 1 0
7 minutes 0 1 1 1
8 minutes 1 0 0 0
9 minutes 1 0 0 1
10 minutes 1 0 1 0
*5 Modem redial times Mode DIPSW No.06

6 5 4 3 2 1 0
0 to 9 times 000 0000 to 000 1001
10 times 0 0 0 1 0 1 0
11 to 99 times 000 1011 to 110 0011
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*6 Retransmission interval on E-Mail delivery error

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Mode DIPSW No.08

bizhub PRO C6501
3 2 1 0
0 minute 0 0 0 0
10 minutes 0 0 0 1
20 minutes 0 0 1 0
30 minutes 0 0 1 1
40 minutes 0 1 0 0
50 minutes 0 1 0 1
60 minutes 0 1 1 0
70 minutes 0 1 1 1
80 minutes 1 0 0 0
90 minutes 1 0 0 1
100 minutes 1 0 1 0
110 minutes 1 0 1 1
120 minutes 1 1 0 0
*7 Retransmission times on E-Mail delivery error Mode DIPSW No.09

6 5 4 3 2 1 0
0 to 9 times 000 0000 to 000 1001
10 times 0 0 0 1 0 1 0
11 to 99 times 000 1011 to 110 0011
*8 Time zone setting Mode DIPSW No.10

7 6 5 4 3 2 1 0
-12 to -1 1111 0100 to 1111 1111
0 0 0 0 0 0 0 0 0
1 to 12 0000 0001 to 0001100
*9 Timer 1 (RING reception → CONNECT recep- Mode DIPSW No.11

tion)
7 6 5 4 3 2 1 0
0 to 31 sec 0000 0000 to 0001 1111
32 sec 0 0 1 0 0 0 0 0
33 to 255 sec 0010 0001 to 1111 1111
*10 Timer 2 (Dial request completed → CONNECT Mode DIPSW No.12

reception)
7 6 5 4 3 2 1 0
0 to 63 sec 0000 0000 to 0011 1111
64 sec 0 1 0 0 0 0 0 0
65 to 255 sec 0100 0001 to 1111 1111
400
*11 Timer 4 (Line connection → Start request tele-
/C6501P/C65hc/C5501
Mode DIPSW No.14
gram delivery)
bizhub PRO C6501

7 6 5 4 3 2 1 0
0 to 31 (x 100 msec) 0000 0000 to 0001 1111
32 (x 100 msec) 0 0 1 0 0 0 0 0
33 to 255 0010 0001 to 1111 1111
(x 100 msec)
*12 Timer 5 (Wait time for other side's response) Mode DIPSW No.15
7 6 5 4 3 2 1 0
0 to 29 sec 0000 0000 to 0001 1101
30 sec 0 0 0 1 1 1 1 0
31 to 255 sec 0001 1111 to 1111 1111
*13 Retry data, timer 6 (Initialization OK → Dial Mode DIPSW No.16

request)
7 6 5 4 3 2 1 0
0 to 254 (x 5 msec) 0000 0000 to 1111 1110
255 (x 5 msec) 1 1 1 1 1 1 1 1
*14 Call JAM date (main body) Valid copy quantity Mode DIPSW No.17
1 0
3000 copies 0 0
6000 copies 0 1
9000 copies 1 0
12000 copies 1 1
*15 Call ADF JAM date Valid original feed quantity Mode DIPSW No.17
3 2
600 sheets 0 0
1200 sheets 0 1
1800 sheets 1 0
2400 sheets 1 1
*16 Call JAM date MCBJ setting Mode DIPSW No.17

5 4
500 0 0
1000 0 1
2000 1 0
3000 1 1
401
*17 Call ADF JAM date MOBJ setting

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Mode DIPSW No.17

bizhub PRO C6501
7 6
100 0 0
200 0 1
400 1 0
600 1 1
402
9.11.9 Setup confirmation
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bizhub PRO C6501
Make sure that only selected items for "E-Mail", "Modem" or "http" are displayed.
9.11.10 Maintenance call

As the CE starts the maintenance, enter the ID code of CE (7-digit number with which each CE is identified,
managed by a distributor.) to notify the center the start of maintenance. After the maintenance, pressing the
[Maintenance comp] notifies the center the completion of maintenance.
<At the start of maintenance>

Press the [CS Remote Care].
5. Press the [ID Code].
* During the maintenance, the [Start] button blinks until the completion of the maintenance.
<At the end of maintenance>

Press the [Maintenance comp].
9.11.11 Center call from manager

If the setup of CS Remote Care is completed, the manager can call the center of CS Remote Care.
1. Press [Utility /Counter].

2. "Utility Menu screen"
Press the [Machine Admin. Setting].
3. "Machine Administrator Setting screen"
Press the [System Connection].
4. "System Connection menu screen"
Press the [Administrator].
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5. "Administrator Call screen"

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Press the [Start].

bizhub PRO C6501
If the setup is not completed, or if other call is made, the [Start] is grayed out, disabling to make a call.
About how to call the center and send various data of the main body on the specified date and time, refer to the
CS Remote Care center's manual.
9.11.12 Confirm communication log

You can output and confirm the communication log.

Press the [List Output].
3. "List output screen"
Press the [Communication Log List] .
4. Press the [COPY] .
5. Press Start key to output the list.
For details of logs, refer to "9.12 List output."
9.11.13 Initialization of RAM for CS Remote Care

Initializing the RAM for CS Remote Care enables you to perform the setup again.

3. "CS Remote Care menu screen"
5. Press the [ID Code].
6. Press the [Detail Setting].
7. "Setting menu screen"
Press the [RAM Clear].
8. "RAM Clear setting screen"
Press [Execute].
9. The confirmation screen appears.
Press the [Yes].
10. The RAM is cleared, and the "CS Remote Care setting screen" appears.
11. Perform the setup again if necessary.
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9.11.14 Error code list
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In the case of modem
bizhub PRO C6501

Error code Error Solution
K00_00 Connection NG (Cannot connect from the modem, Redial and wait for re-reception.
timed out).
K00_01 No response (After connection, no start telegram Redial and wait for re-reception.
from the center detected).
K00_02 Copying. Could not be written in non-volatile mem-
ory, and line disconnected.
K00_03 Center ID mismatch. Confirm the center ID.
K00_04 Serial number mismatch. Confirm the serial number.
K00_05 Syntax error (when receiving undefined commands Redial.
or parameters).
K00_06 Received a write order for an unwritable item.
K00_07 Unread item error.
K00_08 Signal reception time out after a response detection Redial.
(after the start telegram shuttled).
K00_09 Already registered serial number.
K00_10 Communication error occurred because of the car- Redial.
rier OFF (NO CARRIER detected in the modem).
K00_11 Dialtone (NO DIALTONE) detected in the modem. Redial.
K00_12 Busy signal (BUSY) detected in the modem. Redial.
K00_13 NO ANSWER detected in the modem. Redial.
K00_14 Telegram error (irregular telegram received in Retry standard times, and redial.
response to the telegram you sent).
K00_15 Serial number not registered in the center (4 x 40
telegrams received).
K00_16 Errors not defined in the above -00 to 15 (last 2 dig- Redial.
its).
K00_17 Telephone number you must call was not registered.
K01_00 DSR turned OFF or remains turned OFF.
K01_01 Error on creating a message queue.
K01_02 Error on generating a task.
K01_03 Error on sending a message.
K01_04 Error on receiving a message.
K01_05 Received an error (NG) from the timer task.
K02_01 Modem initialization NG.
K03_00 Center call evacuation buffer is full. Cannot evacuate
any more.
*
The shaded error codes are the ones that may occur when a transmission is made from the main body to
the center.
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In the case of E-mail/http

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bizhub PRO C6501
Error code Error Solution

K05_90 Because of memory shortage, unable to secure
enough area for sending a mail.
K05_93 Mail sending error: an error was returned on sending In the auto transmission, an auto-
a mail. matic retry is performed after the
specified time. Check if there is no
fault in the network environment and
the network settings.
K05_94 Machine in operation: unable to send a mail because In the manual transmission, retry
the machine is in operation. when the machine is idling. In the
auto transmission, an automatic retry
is performed after 1 minute.
9.11.15 Troubleshooting
Check the followings when the main body neither receives the initial connection mail nor returns a response.
1) The center ID or the machine ID are not set in the main body.
2) The center ID or the machine ID are different (A machine ID error is not returned at the initial connection).
3) CS Remote Care function is disabled, or the phone line is selected in the CS Remote Care function selection.
4) Communication between the main body and the mail server is not proper (Check this with a transmission
test).
406
9.12 List output
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bizhub PRO C6501
9.12.1 List Output
Outputs various lists.
A. Procedure

Press [10 List Output].
2. "List Output screen"
The following lists can be printed from the list output menu:
• Machine Management List
• Adjustment Data List
• Coverage Data List
• Parameter List
• Font Pattern
• Communication Log List *1
• Memory Dump List
Note
• If you set DIPSW30-1 to 1, the parameter list and after are displayed.
• Memory Dump List is for development use only. Must not be used during maintenance/repair.
3. Press [COPY].
4. Press the Start key to output the selected list.
5. Press [SERVICE].
6. "List Output" screen
To print another list, repeat steps 2 to 5.
*1 Prints out the latest 30 items of the sending and receiving history of the CS Remote Care. The start time of
communications, the time period of communications (modem only), the communication modes, the
results of communications, and the senders (mail only) are printed. The communication modes and the
results of communications are displayed in the numbers of 4 digit number. For the meaning of them, refer
to the following table.
Communication mode Communication result Communication mode Communication result
0000 — Transmitted success- 0040 Maintenance com- —
fully pletion transmis-
sion
0001 Initial transmission Connection time out 0080 Administrator —
when transmitting transmission
0002 Emergency trans- — 0100 Fixed date trans- —
mission mission
0004 Emergency recov- Received successfully 0200 Response trans- —
ery transmission mission
0005 — Reception failed 0*** — Transmission failed
0008 Transmission for — 1000 Enquiry —

warning
0010 Warning recovery — 2000 Data rewrite —
transmission
0020 Maintenance start — 4000 Response recep- —
transmission tion
8000 Test mail —
The SMTP reply codes (200 to 554) prescribed in the RFC1846, 2554 and 2821 are displayed in this place of
***.
407 1
9.13 Test Mode

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bizhub PRO C6501
9.13.1 Running Test Mode

Performs continuous print operation test.
The following tests can be selected from this mode.
Note
• Any operation related with the scanner is not allowed in C6501P/C65hc (printer version).
• Intermittent copy mode

After completion of the printing operation for the set print count, the machine changes into the ready state
and waits for 0.5 sec. before resuming the same operation.
• Paperless running mode
Without detecting paper or jam, the printing operation is made nearly at the same timing as the normal
operation. In the same manner as the intermittent mode, after completion of the printing operation for the
set print count, the machine changes into the ready state and waits for 0.5 sec. before resuming the same
operation.
• Paperless mode
Without detecting paper or jam, the printing operation is made nearly at the same timing as the normal
operation.
• Paperless endless mode
The machine operates with the print count infinitely set automatically. In the same manner as the paperless
mode, without detecting paper or jam, the printing operation is made nearly at the same timing as the nor-
mal operation.
• Running mode
The printing operation is made in the paperless endless mode plus the scanning operation and the auto
paper feed tray switching.
• Measurement mode
Idles for 6 sec, keeps the fusing heater turned on (standby) for 9 sec, keeps the fusing heater turned on
(copy) for 9 sec, and performs scanning without feeding papers. The sequence is repeated 10 times and
stops.
A. Procedure

Press [11 Test Mode].
2. "Test Mode Menu screen"
Press [01 Running Test Mode]
3. "Running Test Mode screen"
Select the mode and press [COPY].
4. Press the Start key to start the running test.
5. Press the STOP key to stop the running test.
6. To exit the running test mode, turn the sub power switch (SW2) off and then on again.
1 408
9.13.2 Test Pattern Output Mode
/C6501P/C65hc/C5501
Prints various test patterns to be used for troubleshooting.
bizhub PRO C6501

Note
• Do not attempt to print the test pattern not described in this manual.
A. Procedure

Press [11 Test Mode].
2. "Test Mode Menu screen"
Press [02 Test Pattern Output Mode].
3. "Test Pattern Output Mode screen"
Press [Test Pattern], then enter the test pattern number through the numeric buttons and press [<<SET].
To select a screen, press one of the followings; [Line1], [Line2], [Dot1], [Dot2], [Compression], and [Con-
tone].To specify image density, select the color, enter adjustment value (0: lighter - 255: darker) using the
numeric buttons, and press [<<SET].
4. Press [COPY].
6. To print another test pattern, press [SERVICE] and repeat steps 3 to 5.
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bizhub PRO C6501
No.11 Beam check
[Check Item 1]
• Check the solid black pattern [1] to see if there is uneven density found in the main scanning and sub-
scanning directions.
[Recommended checkpoints]: Charging corona, developing unit, transfer belt unit, 2nd transfer unit, and
dust-proof glass
[Check Item 2]
• Check if there is any image repelling in the gradation pattern [2] at the leading/trailing edge of the test pat-
tern in sub-scanning direction.
[Recommended checkpoints]: 2nd transfer unit
Test Pattern
[1]
[2]
8050fs1020
[1] Solid black pattern [2] Gradation pattern
410
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bizhub PRO C6501
No.16 Linearity evaluation pattern
[Check Items]
This pattern is used to identify which of scanner system or printer system is causing the problem.
Items that can be checked include main scan magnification, sub scan magnification, image skew, and leading
edge timing, etc. of the printer system. If the copy image is defective despite no abnormality being visible on
the test pattern, the scanner system is defective.
Test Pattern
[1]
31mm 237mm
20mm
[1]
190mm
m
0m
28
205.7mm
28
0m
m
190mm
190mm 8050fs1021
[1] Edges of the image data
411
bizhub PRO C6501
No.51 Gradation evaluation pattern (main scan)
[Check Items]
• If there are image stripes or the uneven density, check if the write system or the process system operates
normally.
[Recommended checkpoints]: Developing unit, cleaning unit, charging corona, 2nd transfer unit, and
dust-proof glass
Test Pattern
a03uf3c002ca
412
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bizhub PRO C6501
No.52 Gradation evaluation pattern (sub scan)
[Check Items]
• If there are image stripes or the uneven density, check if the write system or the process system operates
normally.
[Recommended checkpoints]: Developing unit, cleaning unit, charging corona, 2nd transfer unit, and
dust-proof glass
Test Pattern
a03uf3c003ca
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bizhub PRO C6501
No.53 Overall halftone
[Check Items]
Check the image quality of each screen. (No.1 can print only with Contone)
• When the density is set to 70 (halftone)
If there are image stripes, determine whether the fault is with the scanner system or the process system.
[Recommended checkpoints]: Developing unit, cleaning unit, transfer belt unit, charging corona, 2nd
transfer unit, and dust-proof glass
• When the density is set to 0 (white)
If the test pattern is image foggy background image, determine whether the fault is with the process sys-
tem.
[Recommended checkpoints]: Charging corona, and high voltage contact.
• When the density is set to 255 (Y, M, C, K)
If the density is light, determine whether the fault is with the process system.
[Recommended checkpoints]: Write unit
*Refer to "9.13.2 Test Pattern Output Mode" for adjusting density.
Test Pattern
When the density is set to 70 When the density is set to 0 When the density is set to 255
8050fs1019
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bizhub PRO C6501
No.54 Gradation evaluation pattern
Check gradation reproducibility of each screen.

Refer to "9.13.2 Test Pattern Output Mode" for selecting screen.
Screen Purposes [Check Items]
Line1 Check the gradation reproduc- Make sure that the gradation of each color is smooth
Line2 ibility of each screen used by and even with no tone jump.
Dot1 the copier from primary color [Recommended checkpoint]: Conduct the adjust-
to secondary color. ment of the printer gamma sensor and the printer
Dot2
gamma offset.
Compression(ED)
Contone Check the gradation reproduc- Make sure that the density increases in incremental
ibility of the screen used in the step from the high light side, and the density in the
character area when the shadow section of each color is dark enough.
screen mentioned above is [Recommended checkpoint]: Conduct the adjust-
selected by the copier. ment of the printer gamma sensor.
Test Pattern
[2] [1]
a03uf3c004ca
[1] Primary color [2] Secondary color
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bizhub PRO C6501
No.55 5% Coverage
[Purpose]
When you need to make test prints continuously in order to check paper feed operation or etc., use this 5%
coverage test pattern to protect developer, drums, cleaners etc. from burden.
Test Pattern
a03uf3c005ca
416
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bizhub PRO C6501
No.58 Stripes checking pattern
[Purpose]
Use to locate the causes of sub-scan direction stripes which occur on the image.
[Checking procedure]
1. Select [Test Pattern] and set the density of each color M, C and K to "120".
2. Select [Dot1] for screen.
3. Press [COPY] tab and set a A3 paper.
4. Check whether the sub-scan direction stripes occur on area [1] or [2].
[Recommended checkpoints]
• In the case of [1] : Transfer belt unit/2nd transfer roller /Lw
• In the case of [2] : Drum cartridget
Test Pattern
[2] [1]
a03uf3c034ca
417
bizhub PRO C6501
No.62 Uneven density
[Purpose]
After the periodic maintenance, check uneven density and density defference between right and left side by
each gradation of YMCK, RBG and process Bk. Check uneven density with both edges [1] and [2] of Y, M, C
and process Bk.
[Checking procedure]
1. Select [Test Pattern] and set the density of YMCK to 255.
2. Select [Dot1] (default of controller) and [Line1] (default of copier) for screen.
3. Press [COPY] tab and set 8 A4 papers.
[Recommended checkpoints] : Charging unit, write unit
Test Pattern
[1]
[2]
a03uf3c035ca
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bizhub PRO C6501
No.80 Print characteristic evaluation pattern
Check gradation reproducibility of each screen.

Refer to "9.13.2 Test Pattern Output Mode" for selecting screen.
Screen Purposes [Check Item]
Line1 Check the gradation reproduc- Make sure that the gradation of each color is smooth
Line2 ibility of each screen used by and even with no tone jump.
Dot1 the copier from primary color [Recommended checkpoint]: Conduct the adjust-
to tertiary color. ment of the printer gamma sensor and the printer
Dot2
gamma offset.
Compression (ED)
Contone Check the gradation reproduc- Make sure that the density increases in incremental
ibility of the screen used in the step from the high light side, and the density in the
character area when the shadow section of each color is dark enough.
screen mentioned above is [Recommended checkpoint]: Conduct the adjust-
selected by the copier. ment of the printer gamma sensor.
Test Pattern
b
c
a
b
c
a03uf3c024ca
a: Primary color b: Secondary color c: Tertiary color
419
9.14 ISW
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Refer to "5. FIRMWARE VERSION UP" for details.

bizhub PRO C6501
(Refer to P.107)
420
9.15 CE/Administrator Security Setting
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bizhub PRO C6501
9.15.1 List of CE/Administrator Security Setting

CE/Administrator Security Setting 01 CE Authentication P.422
02 CE Auth. Password P.422
03 Admini. Authentication P.423
04 Administrator Password P.423
Important
• The use of the [Security Strengthen Set] in the [Machine Admin. Setting] in the utility mode is lim-
ited only when the [CE Authentication Setting] and [Admini. Authentication] are set to ON.
9.15.2 Start and exit CE/Administrator Security Mode

Set up the various settings concerning CE/Administrator security setting from the "CE/Administrator Security
Setting Menu screen".
A. Procedure

Before selecting any item in the service mode, press the hard keys in the order shown below.
Stop → 0 → C
2. "CE/Administrator Security Setting Menu screen"
CE/Administrator security mode is activated. And making CE/Administrator setting is enabled.
Press the item you want to set up, the setting screen of each item will be displayed.
Press [Close] to return to the "Service Mode Menu screen".
421
Important
bizhub PRO C6501
• The use of the [Security Strengthen Set] in the [Machine Admin. Setting] in the utility mode is lim-
ited only when the [CE Authentication Setting] and [Admini. Authentication] are set to ON.
9.15.3 CE Authentication
To enhance security of the service mode, configure the setting so that a password is required to enter the ser-
vice mode.
A. Procedure

Press [01 CE Authentication].
2. "CE Authentication On/Off Set screen"
Press [On] or [Off].
3. Press [OK] to activate the setting, and the "CE/Administrator Security Setting Menu screen" will be dis-
played.
Press [Cancel] to deactivate the new settings.
9.15.4 CE Auth. Password

Set a password for entering the service mode.
Note
• Do not use anything easily guessed by others such as your name, birthday.
• CE should not inform other people of the password.
• The selection of the [CE Auth. Password] is limited only when the [CE Authentication] is set to
[On].
A. Procedure

Press [02 CE Auth. Password].
2. "CE Authentication Password screen"
Press [Current Password] to display a keyboard, enter the current 8-digit password, and press [OK].
Default password: "92729272". "Incorrect password" appears when a wrong password is entered.
3. Press [New Password] to display a keyboard, enter new alphanumeric 8-digit password, and press [OK].
4. Press [Check Input] to display a keyboard, enter new 8-digit password again, and press [OK].
5. "CE Authentication Password screen"
Press [OK] to activate the setting, and the "CE/Administrator Security Setting Menu screen" will be dis-
played.
422
9.15.5 Admin. Authentication
/C6501P/C65hc/C5501
To enhance the security of the [Machine Admin. Setting] mode, configure the setting so that a password is
bizhub PRO C6501

required to enter the [Machine Admin. Setting] mode.
A. Procedure

Press [03 Admin. Authentication].
2. "Administrator Authentication On/Off set screen"
Press [On] or [Off].
3. Press [OK] to activate the setting, and the "CE/Administrator Security Setting Menu screen" will be dis-
played.
9.15.6 Administrator Password

Set a password to enter the [Machine Admin. Setting] mode.
Administrator password can also be set from the [Machine Admin. Setting] mode.
Note
• When the CE set or changed the [Administrator Password], CE must inform the user administrator
of that and ask for changing [Administrator Password].
• Do not use anything easily guessed by others such as your name, birthday.
• The selection of the [Administrator Password ] is limited only when the [Admin. Authentication] is
set to [On].
A. Procedure

Press [04 Administrator Password].
2. "Administrator Password screen"
3. Press [New Password] to display a keyboard, enter new alphanumeric 8-digit password, and press [OK].
4. Press [Check Input] to display a keyboard, enter new 8-digit password again, and press [OK].
5. "Administrator Password screen"
Press [OK] to activate the setting, and the "CE/Administrator Security Setting Menu screen" will be dis-
played.
423
9.16 Fee Collection Setting

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bizhub PRO C6501
9.16.1 List of Fee Collection Setting
Adjustment/Setting Item
Fee Collection Setting 01 Coin Vendor
02 Management Function
9.16.2 Start and exit Fee Collection Setting Mode

Set up the various settings concerning Fee collection setting from the "Fee Collection Menu" screen.
A. Procedure

Before selecting any item in the service mode, press the hard keys in the order shown below.
Stop → 9
2. "Fee Collection Menu screen"
Fee collection setting mode is activated. Set the various settings concerning fee collection setting.
Press the item you want to set up, the setting screen of each item will be displayed.
Press [Close] to return to the "Service Mode Menu screen".
9.16.3 Coin Vendor
Note
• This machine does not support the coin vendor function.
9.16.4 Management Function

Set the various settings concerning management equipment of the main body.
A. Procedure

Press [02 Management Function].
2. "Management Setting screen"
Select the options for each item of the management setting.
3. Press [OK] to activate the setting, and the "Fee Collection Menu screen" will be displayed.
1 424
Field Service Ver.3.0 Jul. 2009 10. MECHANICAL ADJUSTMENT
10. MECHANICAL ADJUSTMENT
/C6501P/C65hc/C5501
bizhub PRO C6501
10.1 Main body
10.1.1 Adjusting the paper feed roller/BP pressure
Perform this adjustment when no feed occurs in bypass feed.
A. Procedure
[1] [3] [2] (Refer to Theory of Operation of the main body
P.184)
2. Install a weight plate [3] to the paper feed roller/BP
upper part [2] with the 2 screws [1].
3. Put the ADU back in.
4. Make a print to confirm the paper feed.
5. If the no feed problem is not solved, increase the
number of weight plates and repeat steps 1 to 4.
Note
• Weight plate (P/N: 13FG4062*) is a supply
part. Purchase separately for use.
• The number of the weight plates to be
a052f3c003ca
installed should be 4 or less.
• When weight plate is added, ”10.1.3 Pick-up
movement amount adjustment (bypass)”
should be carried out.
(Refer to P.427)
425
10. MECHANICAL ADJUSTMENT Field Service Ver.3.0 Jul. 2009
10.1.2 (Maximum) paper feed (bypass) height adjustment

/C6501P/C65hc/C5501
bizhub PRO C6501
Conduct this adjustment when a no feed condition occurs or the paper edge is folded, or when feeding paper
with a large amount of curl.
Note
• As this adjustment effects the pick-up movement amount, carry out “10.1.3 Pick-up movement
amount adjustment (bypass)” after performing the adjustment. (Refer to P.427)
A. Procedure
(Refer to Theory of Operation of the main body
P.184)
P.172)
3. Loosen the screw [1], and adjust the installation
position of the tray limit sensor/BP (PS25) [2].
Note
• Keep a note of the primary value.
[2] (1) If the value is out of spec
Adjust the up/down position of the sensor installation

plate, so that the upper side height of the opening
guide and the up/down plate neutralize and become
within the standard value.
[1]
• When making the up/down plate higher:

lower the sensor installation plate.
8050fs1052
• When making the up/down plate lower:
higher the sensor installation plate.
(2) If some sort of error is occurring

• When the paper edge is folded:
• When feeding concave-curled paper:
• When feeding convex-curled paper:
lower the sensor installation plate.
4. Install the paper feed solenoid cover.

7. If there is no improvement, repeat steps 1 to 6
and readjust the installation of PS25.
426
10.1.3 Pick-up movement amount adjustment (bypass)
/C6501P/C65hc/C5501
bizhub PRO C6501
Perform this adjustment when no feed jam occurs frequently.
A. Procedure
P.184)
P.172)
3. Loosen the screw [1], and adjust the installation
position of the pick-up solenoid/BP (SD5) [2].
Note
• Keep a note of the primary value.
[2] 4. Install the paper feed solenoid cover.

7. If there is no improvement in the no feed, repeat
[1]
steps 1 to 6 for readjustment of the installation
position of PS25.
8050fs1054
427
10.1.4 Mis-centering adjustment of the paper feed tray /1, /2 and /3

/C6501P/C65hc/C5501
bizhub PRO C6501
Conduct this adjustment when a mis-centering occurs and cannot be adjusted in service mode.
A. Procedure
1. Pull out the paper supply tray.
[1] [2]
2. Loosen the 3 screws [2] located under the up/
down plate [1].
3. Move the guide plate [3], and adjust the center
position.
4. Tighten the 3 screws [2].
5. Print out the test pattern (No.16).
[3] a052f3c004ca
6. Fold the shorter side of the printed paper in half,

and check if the length between the center [3] of
[2] the image [2] and the center of the paper [1] is
[3] within the standard value.
Standard value: ± 3 mm or less
[1]
7. Repeat steps 1 to 6 until the mis-centering value
is within the standard.
8050fs1056
428
10.1.5 Separation pressure adjustment of the paper feed tray/1, /2 and /3
/C6501P/C65hc/C5501
bizhub PRO C6501
Conduct this adjustment when a no feed or a double feed condition occurs. Separation pressure is susceptible
to paper type or operating environment. No feed tends to occur in low temperature environment, whereas high
temperature environment results in a higher rate of double feed. Do not make an excessive adjustment. Doing
so may reverse the respective symptoms.
A. Procedure
1. Pull out the paper supply tray.
[1]
P.167)
3. Change the position of the hook of the Spring [1]
on the bottom part of the paper supply unit.
Reduced tension [2]:
Double feed jam condition improves.
Increased tension [3]:
No feed jam condition improves.
4. Install the paper supply unit, and set the paper
supply tray.
[3] [2] a03uf3c006ca
429
10.2 DF
/C6501P/C65hc/C5501
bizhub PRO C6501
10.2.1 Adjustment of the hinge opening/closing angle (70 degrees and 40 degrees)
A. Procedure
1. Remove the 4 screws [1] and the 2 hinge adjust-
[1]
ment brackets [2].
2. Install 2 new hinge adjustment brackets [2] and
tighten them with the 4 screws [1] securely.
[2] a052f3c001ca
10.2.2 Adjustment of the hinge opening/closing angle (90 degrees)

A. Procedure
Note
[2] [1]
• When removing the DF or removing any parts
from the scanner section with the DF opened,
be sure to secure the hinge adjustment
brackets at 90 degrees. Not doing so may
deform the metal frame in the DF installation
section.
1. To secure the hinge adjustment brackets at 90

degrees, follow either of the steps below.
[2] [1]
Brackets for 70 degrees: Loosen the 4 screws [1]
and slide the 2 brackets downward, and then
secure them with the 4 screws [1] again.
Brackets for 40 degrees: Remove the 4 screws
[1]. Turn the 2 brackets [2] upside down and rein-
stall them to DF and secure the 4 screw [1] again.
2. When completed, be sure to put the brackets
back to the original state.
a052f3c002ca
430
10.3 PF
/C6501P/C65hc/C5501
bizhub PRO C6501
10.3.1 Paper feed pick-up amount adjustment
Perform the adjustment when no feed occurs frequently.
A. Procedure
1. Pull out the tray.
2. If paper remains in the tray, remove it.
3. Turn to loosen the knob [1], slide the projection [2]
toward the rear side of the tray, and fasten the
knob [1] to secure the projection [2].
Note
• After the completion of the adjustment,
loosen the knob [1], put the projection [2]
back to the original position, and fasten the
4. Install the tray and pull out it again after the lift
[2] plate has been fully brought up, which can be
[1]
judged with the operating sound of the paper lift
motor.
5. Remove the rail stopper, and pull out the tray fur-
ther.
a03xf3c001ca (Refer to Theory of Operation of the PF P.52)
6. Remove the 2 screws [1], bend the stopper [2] in

[1] [3]
the direction of the arrow, and remove the paper
feed cover [3].
Note
• To easily remove the paper feed cover [3],
expand the metal plate [4] of the paper feed
cover in the direction of the arrow, and lift the
cover straight up.
the metal plate.
7. Put the tray back to the position where the stop-

[7]
per [2] is pushed in the paper feed cover [3], and
[2] [3] make the pick-up roller assy [7] placed horizon-
tally (paper feed position).
[6]
[4]
[5]
a03xf3c002ca
431
/C6501P/C65hc/C5501 10. MECHANICAL ADJUSTMENT Field Service Ver.3.0 Jul. 2009
8. Pull the plunger [2] of the pick-up solenoid [1] and

bizhub PRO C6501
[5] [1] [6] [2] measure the gap between the pick-up roller [3]
and the lift plate [4] with a feeler gauge.
Measured value A = 0.5 to 1.0 mm
If the measured value is not the specified value,
perform step 9 and the steps that follow.
Note
• Before loosening the screw, be sure to mark
off the position of the pick-up solenoid by
drawing a line [6].
10. With the plunger [2] pulled, adjust the position of

the pick-up solenoid [1] so that the gap between
the pick-up roller [3] and the lift plate [4] becomes
to the specified value.
11. Tighten the screw [5] and fasten the pick-up sole-
noid [1].
12. Put paper in the tray and close the tray.
13. Make a copy/print to check that papers are fed
properly.
[3]
steps in reverse.
A
[4]
a03xf3c003ca
432
10.3.2 Pick-up roller height adjustment
/C6501P/C65hc/C5501
bizhub PRO C6501
Perform the adjustment under the following conditions: no feed occurs frequently; printed page is often folded;
paper jam occurs at short intervals; feeding paper with a large amount of curl.
According to the pick-up roller height adjustment, the height of the upper most paper and the paper through
height of the paper feed roller are decided.
Note
• Pick-up roller height adjustment changes paper feed pick-up amount accordingly. When the
adjustment is completed, perform the paper feed pick-up amount adjustment to check the pick-
up amount.
A. Procedure
Note
[2]
motor.
5. Remove the rail stopper, and pull out the tray fur-
ther.
a03xf3c004ca
(Refer to Theory of Operation of the PF P.52)
433
6. Remove the 2 screws [1], and remove the paper

[1] [3]
bizhub PRO C6501
feed cover [3].
Note
• To easily remove the paper feed cover [3],
expand the metal plate [4] of the paper feed
cover in the direction of the arrow, and lift the
cover straight up.
the metal plate.
7. Put the tray back to the position where the stop-

per [2] is pushed in the paper feed cover [3], and
[7]
make the pick-up roller assy [7] placed horizon-
[2] [3]
tally (paper feed position).
[6]
[4]
[5]
a03xf3c005ca
8. Check if the actuator [1] of the pick-up roller assy

[2] [1] meets the center [3] of the upper limit sensor/1
(PS1) and /2 (PS9) [2].
[1]
[2]
[3] a03xf3c006ca
434
9. Mark off the position of the upper limit sensor
/C6501P/C65hc/C5501
[4] [3] [2] [1]
mounting plate [1] by drawing a line [2].
bizhub PRO C6501

10. Loosen the screw [3] to release the upper limit
mounting plate [1].
11. Loosen or tighten the screw [4] to adjust the
height of the upper limit sensor mounting plate [1].
Note
• The upper limit sensor mounting plate [1]
goes up by tightening the screw [4], and it
goes down by loosening the screw.
[6] [5]
Reference
• Raising the position of the upper limit sensor
brings down the pick-up roller [5] (resulting in
the increased difference [7] of elevation
[7] between the paper feed roller [6] and the
pick-up roller [5]).
• Lowering the position of the upper limit sen-
sor brings up the pick-up roller [5] (resulting
a03xf3c007ca
in the reduced difference [7] of elevation
between the paper feed roller [6] and the
pick-up roller [5]).
• When the printed page is folded, when paper
jam occurs frequently, or when feeding paper
with a large amount of curl, raise the upper
limit sensor mounting plate.
• When feeding convexly curled paper, lower
the upper limit sensor mounting plate.
12. After the completion of the adjustment, fasten the

screw [3] to secure the upper limit mounting plate
[1].
13. Put paper in the tray and close the tray.
14. Make a copy/print to confirm that papers are fed
properly. If the problem is not solved, repeat
steps 9 to 14.
15. Check the paper feed pick-up amount.
(Refer to P.431)
steps in reverse.
435
10.3.3 Separation pressure adjustment

/C6501P/C65hc/C5501
bizhub PRO C6501
Perform the adjustment when no feed or multi-feed occurs frequently.
Note
• The no-feed or multi-feed error is most likely to occur due to paper type or operating environment.
No feed tends to occur in low temperature environment, whereas high temperature environment
results in a higher rate of multi-feed.
• Do not make an excessive adjustment. Doing so may reverse the respective symptoms.
A. Procedure

2. Change the position of the spring adjustment
lever [1]. Slide the lever in the direction indicated
with [2] to increase the separation pressure. Slide
it in the direction indicated with [3] to reduce the
separation pressure.
Reduced pressure: lowers multi-feed rate.
Increased pressure: lowers no feed rate.
Reference
• The pressure applied to the spring increases/
[1] decreases by about 10% increment.
3. Close the tray and make a copy/print to confirm

that papers are fed properly.
4. If the problem is not solved, repeat steps 2 and 3.
[2] [3]
a03xf3c008ca
436
10.3.4 Lift plate horizontal adjustment
/C6501P/C65hc/C5501
bizhub PRO C6501
A. Procedure
Note
[2]
motor.
a03xf3c009ca
5. Check if the lift plate [3] is placed horizontally

[1] [3] using the engraved lines on the near side [1] and
the far side [2] of the tray. If the plate is not hori-
zontal, perform step 6 and the steps that follow.
6. Loosen the 2 screws [4] on the far side, and align
the lift plate [3] with the engraved lines on the front
side [1] and the far side [2] so that the lift plate is
placed horizontally.
Note
• Do not loosen the screws on the near side of
the tray.
7. After the completion of the adjustment, tighten the

[4] 2 screws [4].
[2]
a03xf3c010ca
437
10.3.5 Horizontal adjustment

/C6501P/C65hc/C5501
bizhub PRO C6501
Perform the adjustment when the unit is not placed horizontally, or when the height/tilt of the unit is different from
that of the main body.
Note
• Horizontal adjustment may displace the unit position relative to the main body. When the adjust-
ment is completed, be sure to make a test copy/print to see if papers are properly fed from the PF.
A. Procedure
1. Turn off the power switch (SW2) and the main
the power cord of the main body from the power
outlet.
2. Turn the 4 nuts [2] of the adjusters [1] with a
wrench to adjust the levelness of the unit.
Note
• Be sure to take the height against the main
body into account when making the adjust-
ment.
3. Turn the 4 nuts [2] of the adjusters [1] slightly to

see if there are any adjuster(s) that are off the
[1] [2] ground.
Note
• If there are adjuster(s) that are off the ground,
turn the nut [2] with a wrench to extend the
adjuster(s) until you feed the adjuster(s) are
securely grounded.
a03xf3c011ca
438
4. Pull out the tray/4, and make sure that the gap “A”
/C6501P/C65hc/C5501
between the PF plate [1] and the tray guide plate
bizhub PRO C6501

[2] is 3 ± 1 mm. Adjust it with the adjuster on the
right rear side of PF to move up when the clear-
ance is too tight, adjust it with the adjuster on the
right front side of PF to move up when the clear-
ance is too wide.
[1] A [2]
a03xf3c012ca
439
10.4 LU
/C6501P/C65hc/C5501
bizhub PRO C6501
10.4.1 Separation pressure adjustment
Conduct the separation pressure adjustment when there occurs a no feed or double feed condition repeatedly.
Note
• Do not make an excessive adjustment. Doing so may reverse the symptoms.
• Paper type and ambient temperature/humidity can be a major cause of the no-feed or multi-feed
jam. For example, no-feed jam tends to occur in low temperature, and multi-feed jam does in high
temperature. Make sure to carry out this adjustment with that in mind.
A. Procedure
1. Remove the LU from the main body.
2. Disconnect the hooked end [1] of the spring from
the tab, and attach it to another tab on the left [2]
or right [3] side of the center tab to raise or reduce
the separation pressure.
Note
• The 5 tabs correspond to 5 pressure levels.
Attach the hooked end of the spring to a tab
on the [2] side to raise the pressure, or attach
[1] it to a tab on the [3] side to reduce the pres-
sure.
Reducing pressure: lowers multi-feed jam
rate.
Raising pressure: lowers no-feed jam rate.
[2] [3] • The spring force changes in increments of
about 10%.
a03wf3c001ca
3. Reinstall the LU to the main body.
Note
• Make some test prints to check to see that
no-feed or multi-feed jam does not occur.
440
10.4.2 Paper lift plate horizontal adjustment
/C6501P/C65hc/C5501
bizhub PRO C6501
Conduct the paper lift plate horizontal adjustment when a paper feed jam occurs repeatedly or when the lift wire
has been changed.
A. Procedure
1. Remove the paper from the LU and close the
[2] [3] upper door.
2. Turn on the main power switch (SW1) and the sub
power switch (SW2) of the main body. After the
paper lift plate stops at its uppermost position (lis-
ten to the sound of the paper lift motor to figure
out the stop status), turn off the both switches.
(Refer to Theory of Operation of the LU P.36)
5. Remove the front cover.
6. Loosen the 2 screws on the front side [1].
7. Adjust the levelness of the paper lift plate [4] with
the adjustment screw [5] aligning its both end sur-
faces with the marking-off line [2] and [3].
Note
• Before adjusting with the screw [5], push
down the lift plate lightly to take up any slack
in the wires.
[5] [4]
8. Tighten the 2 screws [1].

steps in reverse.
Note
[1]
a03wf3c002ca
441
10.4.3 Paper centering adjustment

/C6501P/C65hc/C5501
bizhub PRO C6501
Perform this adjustment when images are not printed on the center of paper, which fed from LU, even after per-
forming the "Printer centering adjustment (tray4)" (adjustment range: ± 4 mm) in service mode.
A. Procedure
1. Load about 100 sheets of paper in the LU. (less
than 100 may cause the paper becoming warped
[2] [1] [3] [4]
when the guide plate is pressed against it.)
2. Feed paper from the tray4 (LU) and print the test
pattern No. 16.
3. Fold the printed sheet in half in main scan direc-
tion to see how much the printed pattern is off-
centered.
4. Close the upper door. And turn off the main power
switch (SW1) and the sub power switch (SW2)
after the paper lift plate stops at its uppermost
position (listen to the sound of the paper lift motor
to figure out the stop status).
5. Open the upper door and remove paper.
6. Loosen the 2 screws [2] of the guide plate /Fr [1]
and the 2 screws [4] of the guide plate /Rr [3].
7. Loosen the 2 screws [6] of the centering bracket
[5].
8. Slide the centering bracket [5] aligning the line on
[7] the both ends of the bracket with the marking-off
line [7], and tighten the 2 screws [6].
Note
• When sliding the centering bracket, make
sure to slide its both ends simultaneously (not
tilt it) so that the line on the both ends align
with one of the marking off lines at the same
position.
9. Load paper and press the guide plate /Fr [1] and /
Rr [3] against the paper, and tighten the 2 screws
[2] and the 2 screws [4].
Note
• When pressing the guide plates against
paper, make sure not to press them too much,
[6] [7] [5] or a paper jam may occur.
a03wf3c003ca
steps in reverse.
Note
the off-centered amount falls within the
allowable range.
442
10.4.4 Paper skew adjustment
/C6501P/C65hc/C5501
bizhub PRO C6501
Conduct this adjustment when there is a difference in the inclination found with the main body tray and the
paper skew. However, this method has a limited effect since all of the paper supplied is adjusted at the registra-
tion section.
An adjustment is made at a different place according to the case in which there occurs a skew of the same incli-
nation in all of the paper supplied from the LU or in which there occurs a skew at random for each sheet of
paper.
A. Preparation
1. Make the continuous print of the test pattern (No. 16) to check the skew.
2. Depending on the inclination of a skew, conduct either of the following adjustment B and C.
Skew in the same inclination for the entire LU: Adjustment procedure B
Skew at random: Adjustment procedure C
B. Adjustment procedure of all the paper skew regularly

3. Slide the positioning bracket [3] referring to the
marking-off line [2].
Note
• When sliding the positioning bracket [3],
move its both edges by the same amount so
that they align with the making-off line [2] at
the same position.
[1] [3] 4. Print the test pattern (No. 16) continuously to

check to see that no skew of paper occur.
[2] a03wf3c004ca
443
C. Adjustment procedure of each paper skew irregularly

/C6501P/C65hc/C5501
1. Load about 100 sheets of paper in the LU. (less

bizhub PRO C6501
[2] [1] [3] [4]

than 100 may cause the paper becoming warped
when the guide plate is pressed against it.)
Note
or a paper jam may occur.

3. Open the upper door and loosen the 2 screws [2]
of the guide plate /Fr [1], the 2 screws [4] of the
guide plate /Rr [3] and the 2 screws [6] of the
guide plate /Rt [5].
4. Press the guide plate /Fr [2], /Rr [4] and /Rt [6]
[5] [6] against the paper and tighten a total of 6 screws
a03wf3c005ca
[2], [4], and [6].
Note
• The paper size indications on the guide plates
are marked 2 mm larger than the actual size.
The 2 mm gap may cause the paper skew
depending on the paper type.
or a paper jam may occur.
5. Print the test pattern (No. 16) continuously to

check to see that no skew of paper occur.
444
10.4.5 (Maximum) Paper feed height adjustment
/C6501P/C65hc/C5501
bizhub PRO C6501
Conduct this adjustment when the following conditions occur.
• No-feed jam occurs
• Leading edge of printed page is folded
• No-feed jam of thick paper; it gets stuck with the entrance guide plate (the guide plate of the separation
roller section).
• Multi-feed jam occurs
• When feeding tightly curled papers
Note
• Be sure to carry out the pick-up roller separation adjustment after performing this adjustment,
since this adjustment changes the distance between the pick-up roller surface and paper when
the roller moved away from the paper. (Refer to P.446)
A. Procedure
[1] [3] [4]
upper door.
5. Loosen the screw [1] and adjust the position of
the mounting plate [3] of the upper limit sensor
[2]
a03wf3c006ca
(PS109) [2] while holding it horizontally referring to
the marking-off line [4], and tighten the screw [1].
Note
• Be sure to install the sensor mounting plate
[3] horizontally.
• Move the sensor mounting plate [3] down-
ward to raise the paper feed level, or move
the plate upward to lower the paper feed
level.
• When no-feed occurs or convexly curled
paper needs to be fed, move sensor mounting
plate [3] downward to raise the paper feed
level.
• When multi-feed occurs or the paper edge is
folded, or when convexly curled paper needs
to be fed, move sensor mounting plate [3]
upward to lower the paper feed height level.

steps in reverse.
445
10.4.6 Pick-up roller separation adjustment

/C6501P/C65hc/C5501
bizhub PRO C6501
Conduct this adjustment when there occurs a no feed jam repeatedly and when the paper feed height (upper
limit) adjustment is made.
A. Procedure
[2] [1] [6] upper door.
5. With the moving part [2] of the pick-up solenoid
(SD100) [1] pulled in the direction of the arrow,
measure the gap [5] between the pick-up roller [3]
and the paper lift plate [4].
[7] Standard value: 0.5mm or more (0.5 to 2.5 mm)
If the measured value is out of the specified range,
perform step 6 and the subsequent steps.
6. Loosen a screw [6] and move the SD100 [1] back
and forth reffering to the marking-off line [7] to
adjust its position, and tighten the screw [6].
steps in reverse.
Note
[3] [4] [5]
a03wf3c006ca
446
10.5 RU-506
/C6501P/C65hc/C5501
bizhub PRO C6501
10.5.1 Straight gate solenoid (SD1) position adjustment
Conduct this adjustment when replacing the straight gate solenoid (SD1).
A. Procedure
1. Turn OFF the straight gate solenoid (SD1) manu-
[1] [2] ally and check that its edge [1] is above the guide
plate [2]. At the same time turn ON the plunger
and check the edge [3] of the straight is below the
guide plate [4].
[3] [4] a0get3c021ca
447 2
2. When it is not within the adjustment range, loosen

/C6501P/C65hc/C5501
[1] [2] 2 fixing screws [2] and slide upward/downward

bizhub PRO C6501
the SD1 [1] to adjust the position.
a0gef3c001ca
2 448
10.5.2 Position adjustment of the stacker exit shutter solenoid (SD2)
/C6501P/C65hc/C5501
bizhub PRO C6501
Conduct this adjustment when replacing the stacker exit shutter solenoid (SD2).
A. Procedure
1. Turn ON the stacker exit shutter solenoid (SD2) [2]
[2] manually and check that its edge [3] is inside the
folded area [6] of the guide plate [5] of the paper
re-feed roller[4].
Note
[3] [6] [5] [4]
[1] [7] a0get3c024ca
449 2

/C6501P/C65hc/C5501
[1] 2 fixing screws [2] and slide SD2 [1] to left/right to

bizhub PRO C6501
adjust the position.
[2] a0gef3c002ca
2 450
10.5.3 Position adjustment of the stack switching solenoid (SD3)
/C6501P/C65hc/C5501
bizhub PRO C6501
Conduct this adjustment when replacing the stack switching solenoid (SD3).
A. Procedure
1. Turn OFF the plunger [1] of the stack switching
[2] [3] solenoid (SD3) manually and check that the driven
roller [2] is in contact with the paper re-feed roller
[3]. Then turn ON to check that the gap between
them is same as or lager than the standard value
"a".
Standard value "a": The gap between the driven

roller [2] and the re-feed roller
[3] is 2mm or more.
Note
a
[1] [4] a0get3c027ca
451 2

/C6501P/C65hc/C5501
[2] [1]
2 fixing screws [2] and slide SD3 [1] to left/right to
bizhub PRO C6501
adjust the position.
a0gef3c003ca
2 452
10.5.4 Position adjustment of the stacker entrance guide plate solenoid (SD4)
/C6501P/C65hc/C5501
bizhub PRO C6501
Conduct this adjustment when replacing the stacker entrance guide plate solenoid
A. Procedure
1. Be sure to fix the stacker entrance guide plate
[5] [4] solenoid assy at the position where the roller [4]
installed to the drive shaft [3] of the solenoid starts
pushing the mounting bracket [6] of the stacker
entrance roller [5] with the plunger [1] touching
with the mounting bracket [2].
Note
[6] [3]
[2] [1] [7] a0get3c030ca
453 2

/C6501P/C65hc/C5501
[2] 2 fixing screws [2] and slide upward/downward

bizhub PRO C6501
the SD4 [1] to adjust the position.
[1] a0gef3c004ca
2 454
10.6 FD
/C6501P/C65hc/C5501
bizhub PRO C6501
10.6.1 Roller solenoids /1 (SD5), /2 (SD6), /3 (SD7), /4 (SD8) position adjustment
When the roller solenoids /1 (SD5), /2 (SD6), /3 (SD7), /4 (SD8) are changed, be sure to conduct this adjust-
ment.
Note
• The following adjustment steps show the steps for the roller solenoid /2 (SD6). The steps for the
roller solenoids /1 (SD5), /3 (SD7) and /4 (SD8), are the same as the steps for the roller solenoid /2.
A. Procedure
1. Loosen 2 screws [2] of the roller solenoid /2 (SD6)
[1].
2. Measure the distance A [5] between the end face
of the vertical conveyance roller /Lt [3] and the
[1] right side (the opposite of the paper through side)
of the guide plate [4] when the roller solenoid /2
[4] (SD6) [1] is turned on, and then tighten the screw
[2] after adjusting the distance so that it becomes
[2]
the standard value.
[3] Standard value: A = 0mm to 1.5mm
[1]
[3]
A
[5]
[4] fd501fs3001c
455
10.6.2 2nd folding roller solenoid (SD18) position adjustment

/C6501P/C65hc/C5501
Conduct this adjustment when replacing the 2nd folding roller solenoid (SD18).
bizhub PRO C6501
A. Procedure
1. Loosen 3 screws [2] on the 2nd folding roller sole-
[1] noid mounting plate [1].
2. Measure the gap A which the vertical conveyance
roller /Lt [4] is out from the guide plate [5] when
the 2nd folding roller solenoid (SD18) [3] is ON.
[2] 3. Adjust the mounting position so that the gap A is
within the standard value shown in the following
table, and then loosen 3 screws [2].
Standard value: A = 4mm to 5mm
[3]
[4]
[4]
A
[5]
[4] a0h0f3c002ca
2 456
10.6.3 Punch centering adjustment
/C6501P/C65hc/C5501
bizhub PRO C6501
When the front to rear position of the punch holes cannot be adjusted up to the specification in the paper width
adjustment in the service mode, be sure to conduct this adjustment. (Refer to P.342)
A. Procedure
1. Remove the connector [1] and 4 screws [2], and
[3]
then remove the cord support board /A [3].
[1]
[2] fd501fs3002c
2. With the alignment plate /Fr [1] and the alignment

A [1] [2] B
plate /Rr [2] moved to the center, loosen the 2
screws [3].
3. Measure the distances A and B using a ruler and
adjust the positions of the alignment plate /Fr [1]
and the alignment plate /Rr [2] so that the dis-
tances A and B become equal, and then tighten 2
screws [3].
4. Reinstall the above-mentioned parts following the
[3] fd501fs3003c
457

/C6501P/C65hc/C5501
bizhub PRO C6501
A. Procedure
1. Conduct the horizontal adjustment by inserting
the driver to the holes [2] and [3] on each of 4
ratchet material [1] and moving it back and forth. It
goes up with the hole [2] and goes down with the
hole [3].
Note
• Be sure to make adjustments while consider-
ate the height between the main body and
other optional devices.
• Be sure not to go it up too much, otherwise
the bolt comes off. (max. ± 5mm)
• Be sure that the caster is contacting installa-
tion surface, otherwise the ratchet does not
work. In this case, adjust the casters which
are on the ground first to get the casters spin-
[1] [2] [3] ning to be on the ground.
a0h0f3c001ca
458
10.6.5 Paper feed control gear position adjustment (PI tray)
/C6501P/C65hc/C5501
bizhub PRO C6501
Note
• Be sure to conduct the gear position adjustment when disassembling the paper feed regulation
plate of the PI trays /Up and /Lw, the rack and the paper size VR section.
A. Procedure
1. Install the regulation plate rack A [1] and the regu-
[1]
lation rack B [2] so that they are aligned with the
reference hole of the detection gear [3].
[3] [2] fd501fs3008c
2. Check the paper size VR [2] to ensure that it is

[3] [1]
held by the 2 bosses on the paper size VR mount-
ing plate [1].
3. Install the paper size VR [2] so that the notch of its
center hole is set to the notch of the detection
gear [3].
[2] fd501fs3009c
459
4. Check to see if the regulation plate rack A [1], the

/C6501P/C65hc/C5501
[1] [2]
regulation plate rack B [2], the hole position of the
bizhub PRO C6501
detection gear [3] and the notch position of the

paper size VR [4] are in the correct position
respectively.
[3]
[4] fd501fs3010c
460
10.6.6 Paper feed pick-up volume adjustment (PI tray)
/C6501P/C65hc/C5501
bizhub PRO C6501
Perform this adjustment when multi-feed or paper jam occurs when feeding paper from the PI.
1. Slide 2 papers feed arm fixing levers [1] to inside,

[4] and insert the shafts [2] into the holes [3] in the
paper feed arm to secure the paper feed arm [4].
[3] [2]
[4]
[1]
fd501fs3011c
461
10.7 LS
/C6501P/C65hc/C5501
bizhub PRO C6501
10.7.1 Paper press solenoid /1 (SD6) adjustment
• Before starting this operation, be sure to bring the stacker tray down to the bottom in advance.
A. Procedure
1. With the paper press solenoid /1 (SD6) turned on
by hand, check to see if the A section in the draw-
ing left is 1.5mm to 3mm.
Rear end
retaining
part
Paper exit guide plate

ls502to3002c
2. When not in the range of adjustment, remove the

spring, loosen the fixing screw of the paper press
solenoid /1 (SD6), and make adjustment by mov-
ing it from side to side so that the range of the SD
stroke becomes 6 ± 0.5mm.
6 ± 0.5mm
ls502to3003c
462
10.7.2 Adjusting the paper press solenoid /2 (SD7)
/C6501P/C65hc/C5501
bizhub PRO C6501
A. Procedure
1. With the paper press solenoid /2 (SD7) turned off
ing left is 66 ± 2mm.
ls502to3004c
2. When not in the range of adjustment, loosen the

fixing screw of the paper press solenoid /2 (SD7)
and make adjustments by moving it up and down.
ls502to3005c
10.7.3 Adjusting the paper press solenoid /3 (SD8)
A. Procedure
1. With the paper press solenoid /3 (SD8) turned on
ing left is 50.1 ± 1mm.
ls502fs3006c
463

/C6501P/C65hc/C5501
fixing screw of the paper press solenoid /3 (SD8)

bizhub PRO C6501
and make adjustments by moving it from side to

side.
ls502fs3007c
10.7.4 Adjusting the job partition solenoid (SD2)
A. Procedure
1. With the job partition solenoid (SD2) turned on by
NG OK hand, check to see if the job partition blade [1] in
the drawing left does not protrude from the metal
frame [2].
[1]
[2]
ls502to3009c

fixing screw of the job partition solenoid (SD2) and
make adjustments by moving it from side to side.
ls502fs3008c
464
/C6501P/C65hc/C5501
bizhub PRO C6501
Adjustments are made when there is any discrepancy in height and slant found between the main body and
A. Procedure
hole [3].
Note
[1] [2] [3]
ning to be on the ground.
a0h1f3c001ca
465
10.7.6 Grip conveyance home sensor adjustment

/C6501P/C65hc/C5501
bizhub PRO C6501
Note
• When the shift unit drive abnormality (SC76-04) occurs after replacing the LS control board
(LSCB), conduct the following adjustment.
A. Procedure
1. Turn ON the power of the main body.
2. Move the grip belt by hand and stop it at the posi-
tion in which the leading edge of the grip [1] is
about 4mm from the stack exit guide plate [2].
a: approx. 4mm
[2]
[1] ls502fs3010c
3. Rotate VR1 [1] on the LS control board (LSCB)

fully to the left.
[1] ls502fs3011c
4. Rotate VR1 [1] to the right and stop it at the posi-

tion in which LED2 [2] turns on from flashing.
Note
• When LED2 is rotated too much from the
turn-on position to the flashing position,
repeat the procedure starting at Step2.
5. After completion of adjustment, turn off and on

the power of the main body and check if the grip
stops at the following position: Interval between
the edge of the grip and the stack exit guide plate:
[2] [1] ls502fs3012c
8 ± 2mm
466
10.8 FS-521
/C6501P/C65hc/C5501
bizhub PRO C6501
10.8.1 Adjusting the flat-stapling stopper position
In the flat-stapling mode, adjustments are made when the distance from the edge of paper to the stapling posi-
tion is not within the standard value, or when it is on a slant.
Note
• When making adjustments, be sure not to move the stapler by hand. (It causes the teeth of the belt
and the gear to jump.)
A. Procedure
1. Conduct the following in the output check of the I/
[2] [1]
O check mode in the service mode.
• 72-31 (Stapler movement motor home posi-
tion search)
• 72-78 (Alignment motors /Fr and /Rr home
position search)
• 72-42 (End stopper motor stopper release)
2. Turn OFF the power switch (SW2) and the main
the power plug from the power outlet.
3. Open the front door and remove the screw [1] of
the wire [2].
a0gyt3c015ca
467
4. Pull out the stacker unit, remove the rail stopper

/C6501P/C65hc/C5501
[1]
screws [1], 1 each, in front and rear and pull the
bizhub PRO C6501
stacker unit further out.
[1] fs503fs3002c
468
5. Loosen the screws [2], 1 each, of 4 flat-stapling
/C6501P/C65hc/C5501
stopper [1] and make adjustments of the positions
bizhub PRO C6501

of the 4 flat-stapling stoppers.
Note
• With the paper [3] inserted, be sure to check
[4] to see if the paper is on a slant and that all 4
flat-stapling stoppers are in contact with the
edge [4] of paper.
• When the stopper is not seen clearly, be sure
[3]
to adjust it after removing the guide plate
[1] assembly [5].
[5] [1] [3]
[2] fs503fs3009c
469
6. Conduct flat-stapling to check to see if it is within

/C6501P/C65hc/C5501
the standard value.

bizhub PRO C6501
• Standard value: a = 9.5 ± 2mm

• The line [1] connecting 2 staples is parallel to
the edge of paper.
• When the value is not within the standard
[1] value or the line is not parallel to the edge of
A
paper, repeat the above steps 1 to 6.
fs503fs3004c
10.8.2 Adjusting the alignment plate position
Conduct this adjustment operation when the slippage in the bundle of paper while in stapling and the uneven
paper exit while in non-stapling cannot be adjusted by conducting "Stapling center position adjustment" and
"Paper width adjustment" in the service mode.
Note
• After completion of this adjustment, be sure to conduct "Stapling center position adjustment" and
"Paper width adjustment" in the service mode.
A. Procedure
1. Conduct the alignment motors /Fr and /Rr home
[2] [1]
position movement in the output check 72-78 of
the I/O check mode in the service mode.
2. Turn OFF the main power switch (SW1) of the
main body, and unplug the power plug of the main
body from the power outlet.
3. Open the front door and remove the screw [1] of
the wire [2].
a0gyt3c015ca
470
4. Pull out the stacker unit, remove the rail stopper
/C6501P/C65hc/C5501
[1]
screws [1], 1 each, in front and rear and pull the
bizhub PRO C6501

stacker unit further out.
[1] fs503fs3005c
471
5. Loosen 2 screws [1] and check to see if the dis-

/C6501P/C65hc/C5501
B A [2]
tance from the front side of the side plate [2] in the
bizhub PRO C6501
rear to the paper side of the alignment plate /Rr [3]

is within the standard value A, and then tighten
the screws [1].
Standard value A = 17.9 + 1.0/ - 0.0mm
6. Loosen 2 screws [4] and check to see if the dis-

tance between the alignment plate /Rr [3] and the
inner face on the paper side of the alignment plate
/Fr [5] is within the standard value B, and then
tighten the screws [4].
[3]
Standard value: B = 376mm 0
[5] [4] [1] fs503fs3006c - 0.5
7. Move the staple home position using I/O check

mode 72-31 in service mode, insert a thick paper
or similar sheet, and check the angle of the rear
end stopper and the alignment plate.
Note
• Move the alignment plates with your hand
until the paper width space is created
between them, and make sure there is no
improper gap at the upper and lower side of
the alignment plates.

472
/C6501P/C65hc/C5501
bizhub PRO C6501
Adjustments are made when there is any discrepancy in height and slant found between the main body and
A. Procedure
hole [3].
Note
[1] [2] [3]
a0gyf3c001ca
473
10.9 FS-520/607
/C6501P/C65hc/C5501
bizhub PRO C6501
10.9.1 Adjusting the bypass gate
Conduct this adjustment when the paper gets jammed in the bypass gate.
A. Procedure
2. Pull out the stacker unit [1].
then pull out the stacker unit further.
[2]
Note
• Be sure to place a support [3] under the
[1]
[2]
[3] 15jkf3c001na
4. Open the bypass transfer guide plate [1].

[2]
5. Check to see if the clearance between the bypass
gate [2] and the bypass transfer plate [3] is within
[1] a standard value when the bypass gate solenoid
(SD5) turns OFF.
Standard value: A = 3.2 ± 0.5 mm
When the value is not within the standard value,
perform the following adjustment.
m
0 .5m [3]
3.2
A=
[2]
15jkf3c002na
474
6. Remove the rear cover
/C6501P/C65hc/C5501
[3] [2] [1]
(Refer to Theory of Operation of the FS-520/607 P.90)
bizhub PRO C6501

7. Disconnect all connectors [2] from the FNS con-
trol board (FNSCB) [1], and then remove the wir-
ing harnesses from the clamp [3].
8. Release 8 board supports [4] and remove FNSCB
[1] from the board mounting plate [5].
[4] [4] [5]

a04df2c002ca
9. Remove 6 screws [1], and then remove the board

[2]
mounting plate [2].
[1]
a04df2c003ca
10. Loosen 2 screws [2] on the bypass gate solenoid

[4] A= (SD5) [1], and then, by referring to the markings
3.2
[5], adjust the position of SD5 so that the clear-
0.5
mm ance between the bypass gate [3] and the bypass
[3] transfer plate [4] gets to the standard value when
SD5 turns OFF.
[2] Standard value: A = 3.2 ± 0.5 mm
steps in reverse.
[5]
[1] 15jkf3c005na
475
10.9.2 Shift position adjustment

/C6501P/C65hc/C5501
bizhub PRO C6501
Conduct this adjustment when the shift amount of the paper exited to the main tray is not within a standard
value (30 mm).
A. Procedure
• Remove the upper cover /1
(Refer to Theory of Operation of the FS-520/
607 P.89)
• Upper cover /2
607 P.89)
[4] [3] [5] [4] 2. Turn ON the main body. And then enter the serv-
ice mode and select [State Confirmation]- [I/O
Check Mode]. Perform the output code 72-03 :
Shift roller motor (M2) (home position search).
3. Turn OFF the main body.
4. Both in the home position and the shift position,
check to see if the edge of the actuator [5] of the
slide gear [4] is in the notch [3] of the slide stay [2]
of the shift unit [1].
When the edge of the actuator is in the notch of
the slide stay, perform the following adjustment.
[1] [2] 15jkf3c006na
5. Loosen the screw [2] on the mounting plate [4] of

[3] [2] [4] [1]
the shift roller home sensor (PS18) [1], and then
adjust the position of the mounting plate [4] by
referring to the markings [3].
6. After completing the adjustment, tighten the
screw [2].
steps in reverse.
15jkf3c007na
476
10.9.3 Adjusting the paper exit solenoid
/C6501P/C65hc/C5501
bizhub PRO C6501
Conduct this adjustment when the paper exited to the main tray is misaligned.
A. Procedure
• Remove the upper cover /1
[1]
607 P.89)
• Upper cover /2
A=6.5 0.5mm (Refer to Theory of Operation of the FS-520/
607 P.89)
[2] • Rear cover
607 P.90)
2. Turn ON the main body. And then enter the serv-
[3] 15jkf3c008na
Paper exit opening solenoid (SD4).
3. Turn OFF the main body.
4. Check to see if the clearance between the plunger
[2] of the solenoid and the stopper [3] of the
mounting plate is within a standard value when
SD4 [1] turns OFF.
5. Remove 2 screws [1] from the solenoid mounting

plate [3], and then remove the solenoid [2] with
[1]
[2]
[3] 15jkf3c009na
477
6. Loosen 2 screws [1] on the solenoid, and then

/C6501P/C65hc/C5501
[2]
adjust the position of the solenoid [2] and tighten
bizhub PRO C6501
the screws.
A=6.5 0.5mm
[1] 15jkf3c010na
478
7. Reinstall the solenoid and the mounting plate [1],
/C6501P/C65hc/C5501
[1] [5]
and then install the solenoid mounting plate at the
bizhub PRO C6501

position where the paper exit guide [2] contacts
[4] with the stopper (rubber) [4] of the paper exit
guide stay [3] with 2 screws [5].
[3]
Note
[2]
• There should be more than 1 mm of step
between the paper exit guide [2] and the
paper guide stay [3].

steps in reverse.
[4] [2]
[2] [3] 15jkf3c011na
479
10.9.4 Adjusting the mounting position of the paper exit arm

/C6501P/C65hc/C5501
bizhub PRO C6501
Conduct this adjustment when there is problem with the paper exit during the stapling operation.
A. Procedure
1. Open the front door, and then pull out the stacker
unit.
[3]
2. Rotate the belt detection gear to align the edge of
the actuator [2] of the belt detection gear [1] with
the notch [3] of the panel /Rr.
[2]
[1]
15jkf3c012na
480
For FS-520
/C6501P/C65hc/C5501
3. Check to see if the paper exit arm [1] is within the
bizhub PRO C6501

45 extent in the illustration [2].
When the position is not within the standard
extent, perform the following adjustment.
4. Remove 2 screws from the rail stopper, and then
pull out the stacker unit further. (Refer to P.474)
Note
• Be sure to place a support under the stacker
unit to prevent FS from falling down.
[2]
[1]
15jkf3c013nc
For FS-607
[2] [1]
15jmf3c001na
481
5. Remove the screw [2] from the belt detection gear

/C6501P/C65hc/C5501
[1] [1] and adjust the position of the paper exit arm to
bizhub PRO C6501
the standard position, and then adjust the position

of the belt detection gear [1] to the position in step
2 and secure it.
steps in reverse.
[2]
15jkf3c014na
482
10.9.5 Adjusting the mounting position of the alignment plate /Up (FS-520)
/C6501P/C65hc/C5501
bizhub PRO C6501
Conduct this adjustment when there is misalignment in the stapled paper bundle.
A. Procedure
1. Turn ON the main body, and then turn OFF the
main body after the FS initial operation.
unit.
NOTE
4. Check to see if the actuator [2] of the alignment

plate home sensor /Up (PS8) [1] is aligned with
the home position.
[2] [1] 15jkf3c015na
5. Check to see if the distance A between the align-

A 41.2 0.5mm ment plate /Up [1] and the panel /Rr [2] is within a
standard value.
Standard value: A = 41.2 ± 0.5 mm (inside to
inside)
[1] [2] 15jkf3c016nb
483
6. Loosen the screw [1] and adjust the distance

/C6501P/C65hc/C5501
[3]
between the alignment plate /UpRr [2] and the
bizhub PRO C6501
panel /Rr [3] in accordance with the standard

1.5 value, and the secure it.
A=335.5 0.5 mm
the alignment plate /UpFr [5] to make the distance
to the alignment plate /UpRr [2] be the standard
value.
+1.5
Standard value: A = 335.5 -0.5 mm (inside to
inside)
[5] [4] [1] [2] 15jkf3c017nb
10.9.6 Adjusting the mounting position of the alignment plate /Up (FS-607)
Conduct this adjustment when there is misalignment in the flat-stapled paper bundle.
A. Procedure
1. Turn ON the main body, and then turn OFF the
[1] main body after the FS initial operation.
[2] 2. Open the front door, and then pull out the stacker
unit.
Note

plate home sensor /Up (PS8) [2] is aligned with
the home position.
15jmf3c002na
484
5. Check to see if the distance A between the align-
/C6501P/C65hc/C5501
A=335.5 mm
ment plates /Up [1] is within a standard value.
bizhub PRO C6501

+0.5
Standard value: A = 335.5 -0 mm (inside to
inside)
[1] 15jmf3c003nb
6. Loosen 2 screws [1] and adjust the alignment

[4] [1] [2]
plate /UpRr [2] with the long center marking of the
marking lines [3], and then adjust the position of
the alignment plate /UpFr [4] by referring the back
side to make the distance be the standard value.
[2]
[1] [3]
15jmf3c004na
485
10.9.7 Adjusting the mounting position of the alignment plate /Lw (FS-607)
/C6501P/C65hc/C5501
bizhub PRO C6501
Conduct this adjustment when there is misalignment in the saddle stitched paper bundle.
A. Procedure
1. Check to see if "10.9.6 Adjusting the mounting
position of the alignment plate /Up (FS-607)" has
been completed.
Saddle stitching stopper motor (M18) (home posi-
tion search).
[1] 3. Turn OFF the main body.
unit.
[2]
[3] pull out the stacker unit further. (Refer to P.474)
15jmf3c005na
Note
6. Remove the stapler unit cover.

7. Check to see if the actuator of the alignment plate
home sensor /Up (PS8) is aligned with the home
position.
plate home sensor (PS24) [2] for the alignment
plate /Lw [1] is aligned with the home position.
9. Set the paper that is larger than A4S in the

[3]
[1] stacker section, and then make the alignment
plate /UpRr [1] and the alignment plate /LwRr [2]
contact with the paper [3] and check to see if the
they are aligned. Also, check to see if the distance
A between the alignment plate /LwRr [2] and the
alignment plate /LwFr [4] is within a standard
value.
+0.5
[4] [2] Standard value: A = 335.5 -0 mm (inside to
inside)
A=335.5 mm
15jmf3c006nb
486
/C6501P/C65hc/C5501
Note
bizhub PRO C6501

• When setting paper in the stacker, be sure to
press the flat-stapling stopper release lever
[2] with your finger to avoid the paper is
placed on the flat-stapling stopper [1].
[1] [2] 15jmf3c007na

[2]
the alignment plate /Lw [2] to make the distance
be the standard value.
[2]
[1]
[1]
15jmf3c008na
487
10.9.8 Adjusting the flat-stapling staple position (FS-520)

/C6501P/C65hc/C5501
Conduct this adjustment when the staple position is not within the standard value.
bizhub PRO C6501
NOTE
• Be sure not to move the stapler unit in the horizontal direction by hand. Otherwise, it may cause
the belt and gear tooth skipping.
A. Procedure
1. Perform the stapling operation and check to see if
[1] [2]
the staple position is within the standard value.
A=8.5 3mm
• The standard value in the 1 staple/one-cor-
ner stapling at rear [1]: A = 8.5 ± 3 mm
• The standard value in the 1 staple/front [2]:
B = 8.5 ± 3 mm
• The standard value in the flat-stapling [3]:
C = 8.5 ± 3 mm
B=8.5 3mm (In the flat-stapling, the edge of the paper and
the line connecting 2 staples [4] should be in
[3] parallel.)
C=8.5 3mm
Conduct the following adjustment when the value
is not within the standard value or when they are
not in parallel.
[4] 15jkf3c018na
488
/C6501P/C65hc/C5501
[2]
unit.
bizhub PRO C6501

NOTE
4. Loosen 2 adjusting screws [1] on each of the flat-

stapling stoppers /Fr and /Rr and 1 adjusting
screw [2] on each of the assist stoppers /Fr and /
[1] [3] [1] 15jkf3c019na
Rr, and then adjust the positions of the flat-sta-
pling stoppers /Fr and /Rr and the assist stoppers
/Fr and /Rr.
NOTE
• The heights of the 4 stoppers should be
same.
5. Loosen the adjusting screw [3] on the rigid stopper,

and then adjust the its position to make the height
difference with the other stoppers be 0 to -0.5 mm.
489
10.9.9 Adjusting the flat-stapling staple position (FS-607)

/C6501P/C65hc/C5501
Conduct this adjustment when the staple position is not within the standard value.
bizhub PRO C6501
Note
A. Procedure
[1] [2]
A=8.5 3mm
• The standard value in the 1 staple/one-cor-
ner stapling at rear [1]: A = 8.5 ± 3 mm
• The standard value in the 1 staple/front [2]:
B = 8.5 ± 3 mm
• The standard value in the flat-stapling [3]:
C = 8.5 ± 3 mm
B=8.5 3mm (In the flat-stapling, the edge of the paper and
the line connecting 2 staples [4] should be in
[3] parallel.)
C=8.5 3mm
Conduct the following adjustment when the value
is not within the standard value or when they are
not in parallel.
[4] 15jmf3c009na
490
/C6501P/C65hc/C5501
bizhub PRO C6501

Stapler movement motor (M11) (A4,1-stapling
position). Then turn OFF the main body.
unit.
NOTE

[1] 6. Loosen 2 adjusting screws [1] on the flat-stapling
stopper /Fr and 2 adjusting screw [2] on the flat-
stapling stopper /Rr, and then adjust the positions
of the flat-stapling stoppers /Fr and /Rr by refer-
ring to the markings [3] and [4].
[3]
[2]
[4] 15jmf3c010na
491
10.9.10 Staple position adjustment (flat-stapling) (FS-607)

/C6501P/C65hc/C5501
bizhub PRO C6501
Conduct this adjustment when the edge of the paper and the staple positions are not in parallel at the saddle
stitching.
A. Procedure
Note
1. Check to see if the edge of the paper and the line

[1]
[2] connecting 2 staples [1] should be in parallel [3]
and the misalignment L is within the standard
[2] value.
Standard value: misalignment L = 1 mm or less
When the misalignment is not within the standard
value, perform the following adjustment.
[3]
L
15jmf3c011na
492
2. Check to see if "10.9.6 Adjusting the mounting
/C6501P/C65hc/C5501
position of the alignment plate /Up (FS-607)" and
bizhub PRO C6501

[1]
"10.9.7 Adjusting the mounting position of the
alignment plate /Lw (FS-607)" have been com-
pleted.
unit.
Note
[2]

6. Loosen 3 screws [2] on the alignment plate /Lw
[3]
[1].
7. Adjust the position of the alignment plate /Lw to
the front and the rear if [4] and [5] are the cases
respectively.
[4] [5] 8. Tighten the 3 screws, and then perform the sta-
pling operation and check to see if the saddle
stitching position is within the standard value.
15jmf3c012na
493
10.9.11 Stapler vertical position adjustment (FS-607)

/C6501P/C65hc/C5501
bizhub PRO C6501
Conduct this adjustment when there is a problem in clinching of the stapler.
Note
A. Procedure
[1] there is one of the following clinching problems.
• There is the bucking [1] of the staple.
• The floating of the staple is more than the
L
[2] standard value (L = 1 mm).

L=1mm
• The bending height of the staple is more than
the standard value (L = 0.7 mm).
Conduct the following adjustment when one of
L
[3] L=0.7mm
the conditions is met.
15jmf3c014na
Check Mode]. Perform the output code 72-32.
Then move the stapler unit to the position for A4
and 1 staple in the service mode, and then turn
OFF the main body.
unit.
Note

[1] [2]
6. Remove the cartridge.
7. Remove the flat-stapling stopper release units /Fr
and /Rr.
8. Remove 4 screws [3] from each of the clincher /Fr
[1] and the clincher /Rr [2].
[3] [3] 15jmf3c015na
494
9. Install the stapler positioning jig [1] onto the car-
/C6501P/C65hc/C5501
tridge setting section.
bizhub PRO C6501

[1]
15jmf3c016na
495
10. Rotate the gears [1] of the staplers downward and

/C6501P/C65hc/C5501
adjust the clinchers to the positions where 2 pins

bizhub PRO C6501
[2] of the stapler positioning jigs are inserted into

the positioning holes [4] of the clinchers [3], and
then rotate the gears [1] downward further to fully
insert the pins into the positioning holes.
Note
• Be sure to rotate the gears of the staplers
carefully because the pins of the stapler posi-
tioning jigs may be clogged if they are
[1] [3] inserted forcedly.
11. Tighten 4 screws on each clinchers.

(Refer to step 8.)
12. Rotate the gears of the staplers upward to pull out
the pins of the jig from the positioning holes of the
clinchers, and then lift up and remove the jig.
13. Replace the cartridge.
14. Check the stapling operation.
[4]
[2] 15jmf3c017na
496
10.9.12 Folding stopper tilt adjustment (FS-607)
/C6501P/C65hc/C5501
bizhub PRO C6501
Conduct this adjustment when there is misalignment in the edges of the fold paper.
Note
• Be sure not to move the stapler unit in the
horizontal direction by hand. Otherwise, it
may cause the belt and gear tooth skipping.
• Never loosen the screw [1] of the folding
stopper. It is prohibited to be removed.
• For ease of understand, the position of the
folding stopper is shown lower than the
actual position in the illustration.
[1]
15jmf3c018na
A. Procedure
1. Perform the folding operation on A3 paper and
check to see if the misalignment is within the
standard value.
Standard value: A = 1 mm or less
A
When the misalignment is not within the standard
value, perform the following adjustment.
15jmf3c019na
497
/C6501P/C65hc/C5501
unit.
bizhub PRO C6501

Note

5. Loosen 5 screws [2] on the folding stopper [1],
[4] and then adjust the tilt of the folding stopper by
[2] referring to the markings [3].
[1] Note
[3]
• Never loosen the screw [4] of the folding
stopper. It is prohibited to be removed.
15jmf3c020na
• For ease of understand, the position of the
folding stopper is shown lower than the
actual position in the illustration.
6. Tighten 5 screws [2], and then perform the folding

operation and check to see if the misalignment is
within the standard value.
498
10.9.13 Adjusting the folding pressure (FS-607)
/C6501P/C65hc/C5501
bizhub PRO C6501
Conduct this adjustment if you want to change the power of the pressure of the folding roller.
A. Procedure
[1]
A (Refer to Theory of Operation of the FS-520/607 P.90)
[3] B 2. Open the front door.
3. Remove the stacker unit cover.
C
4. Change the mounting position of the each 2 pres-
sure springs [3] at both the front [1] and the rear
[2].
The folding pressure is:
C
A: weak B: normal C: strong
B
Note
A
• Hook the 4 pressure springs [3] on the hook
holes of the same mark.
C C
B B
A A
[3] [2] 15jmf3c021na
499
10.9.14 Adjusting the tri-folding position (FS-607)

/C6501P/C65hc/C5501
bizhub PRO C6501
Conduct this adjustment when the 1st folding position or the 2nd folding position is not within the standard
value.
A. Procedure
1. Check to see if "10.9.12 Folding stopper tilt
adjustment (FS-607)" has been completed.
2. Perform the tri-folding operation and check to see
if the tri-folding positions are within the standard
values.
When the tri-folding positions are not within the
standard values, perform the following adjust-
ment.
c
a Folding Standard value Standard
position A4S 81/2 x 11S
b
a 95 mm 89 mm ± 2 mm
15jmf3c022na
b 101 mm 95 mm ± 2 mm
c 101 mm 95 mm ± 2 mm
3. Turn ON the main body, adjust the 1st folding

position (standard a) with the "Try-folding position
adjustment" of "FNS adjustment" in the service
mode, and then perform the tri-folding operation.
4. If the 1st folding position a is within the standard,
open the front door, and then pull out the stacker
[3] unit.
5. Open the tri-folding guide plate [1] and loosen 2
screws [2] from the tri-folding stopper, and then
adjust the positions of the tri-folding stoppers [4]
by referring to the markings [3].
[2] 6. Tighten 2 screws [2], and then perform the tri-
[4] folding operation and check to see if the 2nd fold-
[2] [1] ing position b is within the standard.
15jmf3c023na
500
10.10 PI
/C6501P/C65hc/C5501
bizhub PRO C6501
10.10.1 PI tilt adjustment (with PK installed)
Conduct this adjustment if the edge of the paper and the punch hole position of the paper fed from PI is not in
parallel.
A. Procedure
1. Set 3 sheets of paper in the tray of the PI, and
[1] [2] then feed them in the punch mode as samples.
2. Fold the sheets in half and check the tilt of the
punch holes.
[1]: The front is wider
[2]: The back is wider
15jff3c004na
3. Open the front door of FS, and then loosen the

screw [2] of the guide plate [1].
4. Adjust the guide plate [1] in accordance with the
misalignment of the punch holes by referring to
the markings [3].
The back is wider: Move to [4]
The front is wider: Move to [5]
5. Tighten the screw [2].
6. Repeat step 1 to 5 until the tilt of the punch holes
is corrected.
[1]
[3]
[2]
[5] [4]
15jff3c005na
501
10.11 PK
/C6501P/C65hc/C5501
bizhub PRO C6501
10.11.1 Punch hole position tilt adjustment
Conduct this adjustment if the edge of the paper and the punch hole position on the paper are not in parallel.
A. Procedure
1. Align the paper on the main body tray with the
A side guide plate and the rear edge guide plate,
and then check the tilt with the platen copy or the
service mode (DF is unavailable).
2. Conduct the paper tilt adjustment if it is tilted sig-
nificantly.
C
3. Perform the punch mode printing for 3 sheets of
paper in each of the single sided mode and the
double sided mode as samples for checking the
tilt of the punch hole position.
B 4. Measure the tilt of the punch hole position for the
15kjf3c001na
3 sheets of paper.
Tilt of the punch hole position (%) = (A - B)/C
5. Open the front door of FS.

[1] 6. Remove 3 screws [2], and then remove the punch
unit cover [1].
[2]
15kjf3c002na
7. Loosen 4 adjustment screws [1] on PK.

[1]
8. Move the punch unit [3] in accordance with the tilt
[3]
of the punch hole position by referring to the
markings [2].
1 index: 0.5%
9. Tighten 4 adjustment screws [1].
10. Reinstall the punch unit cover.
11. Repeat step 3 to 10 until the tilt of the punch hole
position is corrected.
[1] [2] 15kjf3c003na
502
10.12 SD
/C6501P/C65hc/C5501
bizhub PRO C6501
Conduct this adjustment when SD is not in a horizontal position.
A. Procedure
hole [3].
Note
[1] [2] [3]
a0h2f3c001ca
503
10.12.2 Folding skew adjustment

/C6501P/C65hc/C5501
bizhub PRO C6501
Adjust the skew in the center folding.
A. Procedure
1. Perform the center folding operation for 5 sheets
of A3 or 11 x 17 paper and check their skew "a".
Standard value a = ± 1.5mm
perform the following procedure.
a 15anf3c002na
2. Open the front door /Rt and pull out the folding
[3] [6] [2] [1] [8]
unit.
3. Loosen the screw [1], adjust the alignment stop-
per /Rr2 [3] back and forth by sliding the adjusting
bracket [2] to right and left, and tighten the screw
[1].
Note
• If the folding pattern on paper exited to the
direction of bundle exit tray front side [4] is
[5], slide the adjusting bracket [2] in the
arrowed direction [6].
• If the folding pattern is [7], slide the adjusting
bracket [2] in the arrowed direction [8].
• By sliding the adjusting bracket [2] to 1mm
right and left, the alignment stopper /Rr2 [3]
moves 1/3mm back and forth.
4. Return the folding unit to the original position and

repeat the steps 1 through 3 until the standard
value can be obtained.
[5] [7]
[4] a0h2f3c002ca
504
10.12.3 Second folding position stabilization adjustment
/C6501P/C65hc/C5501
bizhub PRO C6501
This adjustment is for adjusting the misalignment of the second folding position in tri-folding.
Note
• This adjustment is to adjust the variation per each foldings. Adjust the second folding position by
following " Tri-Fold Position Adj. (Saddle Stitcher Adj.)" in the service mode. (Refer to P.356)
• Be sure that the adjusting position is vary from the number of folding sheets.
1. Conduct the tri-folding with A4S or 81/2 x 11S,

and check if the interval "A" between the first fold-
ing and the second folding is within the standard
value.
Standard value A = 102.0 ± 3mm (A4S)
A = 96.1 ± 3mm (81/2 x 11S)
a0h2f3c003ca
2. Open the front door /Rt and pull out the folding
[2] [1]
unit.
3. Loosen 2 screws [1] and move the stopper [2] in
parallel back and forth referring to the mark [3].
Note
• Moving to the front side [4] makes the length
between the foldings longer.
• Moving to the back side [5] makes the length
between the foldings shorter.
4. Repeat steps 1 to 3 until the standard value is

obtained.
[4] [3] [5] a0h2f3c004ca
505
10.12.4 Staple position adjustment

/C6501P/C65hc/C5501
bizhub PRO C6501
Adjust the misalignment between the staple position and the folding position.
A. Procedure
1. Perform the saddle stitching operation for 25 to
30 sheets of A3 or 11 x 17 paper and check the
misalignment "a" between the staple position and
the folding position.
Standard value a = ± 1mm
conduct "B. Adjustment Procedure /1" then "C.
Adjustment Procedure /2" in this order.
a
15anf3c005na
B. Adjustment procedure /1
Note
• Be sure not to adjust over the allowable value since only the saddle stitching hold /Up is adjusted
while the saddle stitching hold /Lw is not adjusted in this simple adjustment (fine adjustment).
• When it cannot be adjusted by this simple adjustment (fine adjustment), be sure to conduct C.
Adjustment procedure /2.
1. Open the front door /Lt.
2. Install the M4 screw [1] obtained from the exterior
[2] into the adjustment screw hole [3] of the saddle
[1]
stitching hold /Up [2] with your fingers and tighten
it slightly until it is contacted.
Note
[4]
[5] • Do not tighten the screw [1] too tight. Stop
tightening when it is contacted.

4. Rotate the screw [1] to move the position of the
saddle stitching hold /Up [2] on both of the stapler
/Rt and /Lt for the length of the misalignment "a".
Note
• Rotating the screw [1] 1 revolution moves the saddle
stitching hold /Up 0.7mm (same width with staple).
• When the screw [1] is tightened, the staple posi-
[3] a0h2f3c005ca
tion moves forward. When the screw [1] is loos-
ened, the staple position moves backward.
5. While pushing the saddle stitching hold /Up [2] to

the allowed direction [5] and contacting it to the
screw [1], tighten the screw [4].
6. Remove the screw [1] and return it to the original
position.
7. Conduct a test print in procedure A, and repeat
steps 2 to 6 until the standard value is obtained.
506
C. Adjustment procedure /2
/C6501P/C65hc/C5501
1. Pull out the saddle stitching unit. (Refer to Theory
bizhub PRO C6501

of Operation of SD P.126)

make the clinchers [2] contact with the staplers
and lock the clinchers [2].
[1] [2] 15anf3c006na
3. Install the M4 screw [1] obtained from the exterior

[10] [4] [2] [3] [1]
into the adjustment screw hole [3] of the saddle
stitching hold /Up [2] with your fingers and tighten
it slightly until it is contacted.
Note
• Do not tighten the screw [1] too tight. Stop
4. Loosen the screws [4], [5] and [6].

5. Rotate the screw [1] to move the position of the saddle
stitching hold /Up [2] for the length of the misalignment "a".
Note
• Rotating the screw [1] 1 revolution moves the
saddle stitching hold /Up 0.7mm (same width
with staple).
• When the screw [1] is tightened, the staple posi-
[9] [8] [7] [6] [5] a0h2f3c006ca tion moves forward. When the screw [1] is loos-
ened, the staple position moves backward.
6. While pushing the mounting plate [7] to the arrow-

marked direction [9] and contacting the saddle
stitching hold /Up [2] to the screw [1], tighten the
screws [5].
7. While pushing the saddle stitching hold /Up [2] to
the arrow-marked direction [10] and contacting the
saddle stitching hold /Up to the screw [1], tighten
the screw [4], and then tighten the screw [6].
8. Remove the screw [1] and return it to the original
position.
9. Return the saddle stitching unit, and then repeat
steps 2 to 8 until the standard value can be
obtained.
507
10.12.5 Stapler position adjustment

/C6501P/C65hc/C5501
bizhub PRO C6501
Conduct this adjustment when a broken staple, a bent staple, or a defective staple occurs in stapling.
This adjustment adjusts the phase lag with the clincher at front and rear.
A. Procedure
1. Carry out stapling operation to check that the bro-
[4] [6] [3] [1] [2]
ken staple, the bent staple, or the defective staple
does not occur. If the defective occurs, conduct
the following procedure.
3. Install the M3 screw about 20mm long [3] into the
adjustment screw hole [2] of the stapler mounting
bracket [1] with fingers and tighten it slightly until it
is contacted to the supporting bracket [4].
Note
• Do not tighten the screw [3] too tight but stop
[5] 4. Loosen a screw [5].
a0h2f3c007ca
5. Rotate the screw [3] and move the anteroposte-
rior position of the stapler to adjust the phase lag
with the clincher.
Note
• Rotating the screw [3] 1 revolution moves the
stapler 0.5mm.
• When the screw [3] is tightened, the staple
position moves forward. When the screw [3]
is loosened, the staple position moves back-
ward.
6. While pushing the stapler mounting bracket [1] to

the back side [6] and contacting the screw [3] to
the supporting bracket [4], tighten the screw [5].
8. Repeat steps 1 to 7 until the defective staple does
not occur.
508
10.12.6 Tilt/gap adjustment of the clincher
/C6501P/C65hc/C5501
bizhub PRO C6501
Perform this adjustment when the staple break through the paper by stapling a few pages of booklet.
A. Procedure
1. Carry out stapling operation with 2 sheets of
[3] [2]
papers, and check if the staple break through the
paper. If the paper is broken through, perform the
following steps.
2. Pull out the saddle stitching unit. (Refer to Theory
of Operation of SD P.126)
3. Tilt the bundle arm [1] to the front.
4. Remove the staple cartridges [2] to the front.
5. Rotate the stapler move gear [3] to move the sta-
pler assy inward, then move them outward by
approx. 30mm (the interval between the stapler
becomes approx. 60mm).
Note
[1] 15anf3c009na
• When moving the stapler assemblies, be sure
to move them by rotating the rotating knob [3]
to prevent the belt tooth from skipping. Oth-
erwise, it causes the belt tooth skipping.

[1] [2]
cover [2].
15anf3c010na
509

/C6501P/C65hc/C5501
[3]
bizhub PRO C6501
Note
• When reinstalling the saddle stitching unit, be
careful not to let the connector [1] make con-
tact with the main body.
8. Remove the 3 screws [2], and then remove the

saddle stitching guide plate [3].
[1]
[2] 15anf3c011na
510
/C6501P/C65hc/C5501
[3]
make the clinchers [2] contact with the staplers [3]
bizhub PRO C6501

and lock the clinchers [2]. At the moment the
clinchers are locked, check if the clinchers do not
roll from side to side and the gap between the sta-
a
plers and the clinchers equals to the standard
value.
Standard value "a": 0.3 ± 0.1mm (2 sheets of
80g/m2 papers can pass through the gap while 3
sheets cannot.)
10. When the gap is out of the standard value, loosen
the screw [1] counterclockwise and lower the
[2] clinchers once. Then perform the adjustment the
following procedure.
[1]
15anf3c012ca
511
11. Loosen 4 fixing screws [1].

/C6501P/C65hc/C5501
[3] [2] 12. Adjust the gap between the staplers and the
bizhub PRO C6501
clinchers so that the gap equals the standard

value while loosening (gap becomes narrower) /
tightening (gap becomes wider) the adjusting
screw/Rt [2] and /Lt [3] in the same manner.
Note
• Be sure to perform the adjustment for both
left and right side of each clincher/Rt [4] and /
Lt [5] so that the stapler and the clinchers are
parallel to each other.
[5] [4]
• When the adjustment is completed, be sure to
tighten the fixing screws [1].
13. Put the saddle stitching unit back. Then carry out
stapling operation with 2 sheets of papers, and
check if the staple does not break through the
paper.
[1] [2] ,[3]

15anf3c013ca
512
10.12.7 Trimming skew adjustment
/C6501P/C65hc/C5501
bizhub PRO C6501
Adjust the skew when it occurs at trimming.
A. Procedure
1. Check the trimming parallelism by trimming center
a folded or center stitched paper if it is within the
standard value.
Standard value a = 1.0mm or less
(2 sheets to 15 sheets)
a = 1.5mm or less
(16 sheets to 50 sheets)
Note
• Remove the staple to check it for 2 sheets to
15 sheets.
a0h2f3c008ca

[1] [2]
3. Loosen the screw [2] of the registration claw.
4. Turn the gear flange [4] with holding the shaft [3],
adjust the registration claw /Rt [1] back and forth,
and then tighten the screw [2].
[4]
[3]
a0h2f3c009ca
513
Note
bizhub PRO C6501
• Move the registration claw /Rt to the front

side in case the skew is [2] to the paper exit
direction [1], or move the claw to the rear side
in case the skew is [3].
[2]
5. Repeat steps 1 to 4 until the standard value is
obtained.
[1]
[3]
a0h2f3c010ca
514
10.12.8 Trimming adjustment
/C6501P/C65hc/C5501
bizhub PRO C6501
Adjust the gap when a large gap occurs at trimming thick books.
Note
• This adjustment is effective for the thick book more than 30 pages.
A. Procedure
1. Check the trimming gap "a" by trimming the
center folded or center stitched book which has
a 31 pages or more.
Conduct the following steps if the gap is large.
Note
• There is no standard value of trimming gap
a0h2f3c011ca for 31 pages or more. Refer to the standard
value for 16 pages to 30 pages, which is
1.5mm.

[3] [1] [2]
3. Remove the slope unit. (Refer to Theory of Opera-
tion of SD P.124)
4. Loosen the 2 screws [2] each of the registration

claw /Rt and /Lt [1], move the fold retaining
bracket [3] down to the bottom, and then tighten
the screws [2].
5. Repeat steps 1 to 4 until the allowable value can
be obtained.
a0h2f3c012ca
515

/C6501P/C65hc/C5501
bizhub PRO C6501
When the SD control board (SDCB) is replaced, be sure to replace the EEPROM (IC68).
A. Procedure
1. Remove the EEPROM (IC68) from the old SD con-
trol board (SDCB) [1] and install it into the new SD
control board (SDCB) [2].
Note
• Be sure to install the "A" sections of the EEP-
ROM (IC68) in the same direction.
• Be sure to set the SW3 [3] as the same as the
settings of the old SDCB. (Refer to P.794)
[1]
[2]
A
[3]
a0g6f3c053ca
2 516
10.13 PB
/C6501P/C65hc/C5501
bizhub PRO C6501
10.13.1 Clamp sub scan direction alignment adjustment
Carry out the adjustment when the following conditions occur.

• The fore edges near the top or the bottom of the book do not line up perfectly.
• The pages come off from the cover paper near the top or the bottom of the book due to insufficient gluing
to the spine of inside papers.
An improper gap between the reference plate and the sub scan alignment plate causes misalignment of the
pages in the sub scan direction. To correct the misalignment, perform " Clamp FD Position Adj. (Perfect
Binder Adjustment)" in Service Mode → Finisher Adjustment → Perfect Binding Machine Adjustment. (Refer
to P.370)
A. Procedure
1. Remove the SC cover/Fr. (Refer to Theory of
[2] [3] [1]
Operation of PB P.168)
3. Adjust the position of the sub scan alignment
plate by moving the clamp entrance assy [2] in the
direction of the arrow [4] or [5] to change the
installation position of the clamp entrance assy
against the coupling bracket [3].
Note
• Be sure to hold down the coupling bracket [3]
when moving the clamp entrance assy, as the
assy is heavy and hard to move.
• [6] shows the book exit direction;
a. To correct the misalignment near the bottom
[5] [4] side [7] (front side when inside papers alignment
is performed): Move the clamp entrance assy [2]
in the direction of the arrow [4] to make the gap
at the front side narrower.
b. To correct the misalignment near the top side [8]
(rear side when inside papers alignment is per-
formed): Move the clamp entrance assy [2] in
the direction of the arrow [5] to make the gap at
the front side wider.
• When moving the clamp entrance assy [2] in
the direction of the arrow [5], the misalign-
ment of the inside papers occurs at both the
[7] [8]
top and bottom sides. To correct the mis-
Top alignment, perform " Clamp FD Position Adj.
[6] (Perfect Binder Adjustment)" in Service Mode
→ Finisher Adjustment → Perfect Binding
Machine Adjustment after performing this
adjustment. (Refer to P.370)
Bot-
4. After performing the adjustment, make a test print
a075f3c014ca
and binding to check that the inside papers are
perfectly lined up in the sub scan direction.
steps in reverse.
517
10.13.2 Clamp main scan direction alignment adjustment

/C6501P/C65hc/C5501
bizhub PRO C6501

• The top and bottom edges of inside papers do not line up and it cannot be corrected even after performing
"Clamp section CD alignment width adjustment" and "SC section CD alignment width adjustment" in the
service mode.
• The cover and the inside papers are not aligned.
Note
• The misalignment of cover and inside papers can also be adjusted in "10.13.10 Cover paper align-
ment plate adjustment" and "10.13.12 Cover paper table positioning". (Refer to P.530, P.532)
A. Procedure
1. Pull out the clamp unit.
[2] [4] [1]
2. Move the clamp alignment plates/Fr [1] and /Rr [2]
inward as far as they go [3].
Note
• Be sure to hold both clamp alignment plates/
Fr [1] and /Rr [2], and move them slowly to
maintain the proper engagement of the belt
and the pulleys.
3. Loosen 2 screws [4] and adjust the position of the

clamp alignment plates/Fr [1] and /Rr [2] by mov-
ing them back and forth.
[3]
[6] [7] Note

Top
a. When top edge of cover paper runs off that of
[5] inside papers [6]: Move the clamp alignment
plates/Fr [1] and /Rr [2] backward by the same
distance.
b. When bottom edge of cover paper runs off that
Bot-
of inside papers [7]: Move the clamp alignment
a075f3c015ca
plates/Fr [1] and /Rr [2] forward by the same
distance.
• When moving 2 clamp alignment plates in the
same direction, always move them by the
same distance.

and binding to check that the top and bottom
edges of inside papers are perfectly lined up and
the cover edges neatly align with edges of inside
papers.
518
10.13.3 Pellet supply arm angle adjustment
/C6501P/C65hc/C5501
bizhub PRO C6501
• The pellet is supplied to the tank improperly and it spills out of the tank.
• The pellet supply arm contacts with the other parts when the arm is in its home position.
Note
• Be sure to turn Off the power switch (SW2) and the main power switch (SW1) of the main body in
advance.
A. Procedure
1. Remove the rear cover. (Refer to Theory of Opera-
[8] [3] [4] [2] [1] [5]
tion of PB P.165)
3. Adjust the home position of the pellet supply arm
by moving the mounting plate [3] of the pellet sup-
ply arm lower limit sensor (PS39) [2] referring to
the engraved lines [4] on the mounting plate.
a. Move the mounting plate in the direction of the
arrow [5] to make the pellet supply arm [6] home
position become closer to the glue tank [7].
b. Move the mounting plate in the direction of the
arrow [8] to make the pellet supply arm [6] home
position become further from the glue tank [7].
Note
• Adjust the position of the pellet supply arm so
that it stops in the center of the glue tank: A
when the arm comes to the supply position.
• Do not move the mounting plate excessively
or it contacts with the other parts.

[13][9] [10] [11] [8] [12] 5. Adjust the pellet supply position by moving the
mounting plate [10] of the pellet supply arm upper
limit sensor (PS38) [9] referring to the engraved
lines [11] on the mounting plate.
a. Move the mounting plate in the direction of the
arrow [12] to make the angle range of the pellet
supply arm [6] become narrower.
b. Move the mounting plate in the direction of the
arrow [13] to make the angle range of the pellet
supply arm [6] become wider.
Note
• Adjust the position of the pellet supply arm so
that the distance between the arm and the
[7] [6] edge of the metal frame is 10mm ± 2mm: B
a075f3c016ca
when the arm comes to the home position.
• Do not move the mounting plate excessively
or it contacts with the other parts.
6. Turn on the main power switch (SW1) and the

power switch (SW2).
519
7. Carry out the output check "77-43" of I/O check

bizhub PRO C6501
in the service mode to detect the home position of

the pellet supply arm and check if the home posi-
tion is appropriate.
8. Move the pellet supply arm to the pellet supply
position using the output check "77-44" of I/O
check in the service mode and check if the pellet
supply position is appropriate.
Note
• For restrictions or cautions of the output
check "77-44", refer to the I/O check mode.
A a075f2c089ca
(Refer to P.277)
9. When the test result is not good, turn off the sub
B= 10 0.2mm power switch (SW2) and the main power switch
(SW1) and repeat steps 2 to 8.
a075f2c090ca
520
10.13.4 Glue apply roller gap adjustment
/C6501P/C65hc/C5501
bizhub PRO C6501
This adjustment adjusts the gap between the metal surface of the glue apply roller and the spine of inside
papers.
Changing the gap allows you to adjust the amount of glue applied to the spine.
Note
• Reference values: The thickness of glue layer formed on the roller is about 1.5mm with the gap of
1mm.
CAUTION:
the power switch (SW2) of the main body.
• To prevent burn injuries, make sure to leave the unit until it cools enough before performing the
adjustment.
A. Procedure
[1]
tion of PB P.165)
2. Loosen 2 screws [1] and adjust the stopper [2]
position by moving it up and down referring to the
engraved lines [3].
Note
• Raising the stopper brings the glue apply
roller upward making the gap become
smaller, which decreases the amount of glue
applied.
• Lowering the stopper brings the glue apply
roller down making the gap become larger,
[2] [3]
which increases the amount of glue applied.
• Do not lower the stopper excessively. Too
much gap causes the glue application to fail.
• When raising or lowering the stopper, be sure
to maintain its horizontal state.

and binding to check that the amount of glue
applied to the book spine is appropriate.
a075f3c017ca
521
10.13.5 Cover paper glue roller gap adjustment

/C6501P/C65hc/C5501
bizhub PRO C6501
This adjustment is to adjust the gap between the surface of the cover paper glue roller (metal roller) and the
spine of inside papers.
Adjust the glue amount applied to the book spine by changing the gap.
Note
• The gap between the cover paper glue roller and the spine is about 1.5mm.
CAUTION:
the power switch (SW2) of the main body.
• To prevent burn injuries, make sure to leave the unit until it cools enough before performing the
adjustment.
A. Procedure
1. Open the front door and move the glue tank unit
[5]
[2] frontward.
Note
• Be sure to hold the right arm [1] of the glue
tank unit to move it.
2. Loosen 1 screw [3] and adjust the stopper [4]

position by moving it up and down referring to the
engraved lines [5].
Note
• The stopper has a scale marked at 1mm inter-
[4] [3]
val. The right and left scales shift 0.5mm verti-
cally. When adjusting it, be sure to move it by
1mm and check the position.
• When raising or lowering the stopper, be sure
to maintain its horizontal state.
• Raising the stopper brings the cover paper
glue roller closer to the book spine and it
makes the scraped-off glue amount larger,
which reduces the glue amount applied to the
book spine.
[2] [1] The applied glue is thin and the cover does
a075f3c029ca
not stick to the book body.
• Lowering the stopper increases the glue
amount applied to the book spine (the gap
between the cover paper glue roller and the
spine increases).
522
The applied glue is thick and makes extra glu-
/C6501P/C65hc/C5501
ing.
bizhub PRO C6501

• Raising the stopper reduces the glue amount
applied to the book spine (the gap between
the cover paper glue roller and the spine
decreases).

and binding to check that the glue amount
applied to the book spine is appropriate.
523
10.13.6 Glue tank movement rail tilt adjustment

/C6501P/C65hc/C5501
bizhub PRO C6501
This adjustment adjusts the parallelism between the glue tank movement rail and the spine of inside papers.
Perform this adjustment when glue is not applied uniformly on the spine, especially when amount of glue applied
is different between the top and bottom side of the book.
A. Procedure
1. Loosen 3 screws [2] of the bracket/Rt [1].
[1] 2. Loosen 2 screws [4] of the bracket/Lt [3].
3. Move the brackets/Rt [1] and /Lt [3] up and down
[5] by turning the screws [7] and [8] to adjust the
height of the glue tank movement rails/Rt [9] and /
Lt [10] referring to the engraved lines [5] and [6] on
[2] the brackets/Rt and /Lt.
Note
• Be sure to turn the screws [7] and [8] by the
[9] same amount so that the brackets/Rt [1] and /
Lt [2] move the same amount.
• When the glue applied to the spine gets lower
toward the bottom side, lower the brackets/
[7] Rt [1] and /Lt [2].
[3]

and binding to check that the glue is applied to
the book spine uniformly.
[10]
[4]
[6] [8]
a075f3c020ca
524
10.13.7 Cover paper folding plate nipping adjustment
/C6501P/C65hc/C5501
bizhub PRO C6501
This adjustment adjusts the position of the cover paper folding plate /Lt to apply pressure to the cover paper.
Perform this adjustment when the cover paper is not folded at the right angle (when the book spine inclines).
A. Procedure
1. Turn the knob [1] to move the cover paper align-
[3] [6] [4] ment plate /Fr [2] backward.
2. Loosen the screw [3] and adjust the actuator [6]
position of the cover paper folding plate HP sen-
sor/Lt (PS49) [5] by moving the actuator right and
left referring to the engraved lines [4].
Note
a. When the book spine inclines as [8]: Move the
actuator [6] to the left.
b. When the book spine inclines as [9]: Move the
[1] [2] [5]
actuator [6] to the right.

and binding to check that the book spine ends
form right angle and no inside papers come off
from the cover paper.
Note
• At the test print, print more than 50 sheets, or
you cannot check the book spine.
[8]
[7]
[9]
a075f3c021ca
525
10.13.8 Cover paper folding plate parallel adjustment

/C6501P/C65hc/C5501
bizhub PRO C6501
This adjustment adjusts the parallelism between the cover paper folding plate /Rt and /Lt.
Perform the adjustment when the book spine corners are not uniformly formed from the top and the bottom.
A. Procedure
1. Remove the cover paper tray. (Refer to Theory of
[1] [2]
Operation of PB P.203)
2. Remove 4 screws [1] and remove the cover /Rt
[2].
[1]
a075f3c022ca
526
/C6501P/C65hc/C5501
[9] [8] [1]
4. Put a hand from under the cover paper tray sec-
bizhub PRO C6501

tion and turn the knob [2] to move the cover paper
folding plate /Rt [3] and /Lt [4] so that the gap
between them becomes a few millimeters [5].
5. Slowly turn the knob [2] in reverse until the cover
paper folding plate /Rt [3] and /Lt [4] contact each
other without any gap at both front side [6] and
rear side [7].
[7]
Note
• Make sure that the pressure drive plate /Rt [8]
does not run on the pressure assist plate [9].
• Do not turn the knob [2] too much. Doing so
brings the plates into pressure-applying state
making the position adjustment impossible.

and binding to check that the book spine ends are
forming right angle from the top and the bottom.
[6] 8. Reinstall the above-mentioned parts following the
[2]
[3] [5] [4]
a075f3c023ca
527
10.13.9 Cover paper table up down belt adjustment

/C6501P/C65hc/C5501
bizhub PRO C6501
Perform the adjustment when the following conditions occur.

• The cover paper table up down drive system does not synchronize successfully.
• The front and rear cover paper table belts do not synchronize smoothly.
A. Check point
Check that the pin [1] is placed on the center of the
[2]
central sector of the gear [2].
When the pin is out of the center, perform the follow-
ing adjustment.
[1]
a075f3c030ca
528
B. Procedure
/C6501P/C65hc/C5501
bizhub PRO C6501

tion of PB P.165)
3. Move the gear [2] to the right [3] and remove the
pin [4].
5. Move the gear [2] to the left [6] and install the E-
ring [1].
6. Turn on the main power switch (SW1) and the
power switch (SW2) to let the system perform the
initial operation.
[5] [4] [2] [1] [3]
7. Insert the pin [4], adjust the gear [2] so that it
aligns with the gear inside, and slide the gear [2]
to the right.
8. Install the E-ring [5] Install the rear cover.
9. Install the rear cover.
[6] [2] [1]
a075f3c024cb
529
10.13.10 Cover paper alignment plate adjustment

/C6501P/C65hc/C5501
bizhub PRO C6501
This adjustment adjusts the position of the cover paper alignment plate /Fr in the main scan direction and its
perpendicularity against the main scan direction.
Perform the adjustment when the cover paper and the inside papers are vertically or relatively misaligned.
Note
• The misalignment of cover and inside papers can also be adjusted in "10.13.2 Clamp main scan direc-
tion alignment adjustment" and "10.13.12 Cover paper table positioning". (Refer to P.518, P.532)
A. Procedure
[8] [7]
1. Loosen the screw [1] and [2].
2. Adjust the position and angle of the cover paper
[1] alignment plate /Fr [9] by moving the mounting
brackets /Rt [5] and /Lt [6] to the front [7] and to
the back [8] referring to the engraved lines [3] and
[5]
[4].
[3]
Note
[2] [6] • Do not move the mounting bracket /Lt [6]
excessively, or the plate contacts with the
[4] gear [10].
a. When the cover paper runs off the top edge of
inside papers [12]: Move the mounting brackets
/Rt [5] and /Lt [6] forward [7] by the same dis-
tance.
[8]
b. When the cover paper runs off the bottom edge
[7] of inside papers [13]: Move the mounting brack-
ets /Rt [5] and /Lt [6] backward [8] by the same
distance.
c. When 3 edges of cover paper misalign with the
edges of inside papers [14]: Move the mounting
bracket /Rt [5] backward [8] and move the
mounting bracket /Lt [6] forward [7].
d. When 3 edges of cover paper misalign with the
[10] [9] edges of inside papers [15]: Move the mounting
[12] [13] bracket /Rt [5] forward [7] and move the mount-
Top ing bracket /Lt [6] backward [8].

and binding to check that the cover paper is
[11] Bot- neatly aligned with the inside papers.
[14] [15]
a075f3c025ca
530
10.13.11 Cover paper cutting skew adjustment
/C6501P/C65hc/C5501
bizhub PRO C6501
Perform the adjustment when the roller cutter trims the cover paper askew.
A. Procedure
1. Remove the cover paper waste box.
[2]
[2].
[1]
a075f3c026ca

[5] [4]
the roller cutter assy [3] by moving it to the right [4]
and the left [5] referring to the engraved lines [2].
Note
• When the length of the back cover is shorter
than the length of the front cover at the bot-
tom side: Move the roller cutter assy [3] to the
right side [4].
• When the length of the back cover is longer

than the length of the front cover at the bot-
[2] [1] [3] tom side: Move the roller cutter assy [3] to the
a075f3c027ca
left side [5].

trimmed correctly.
531
10.13.12 Cover paper table positioning

/C6501P/C65hc/C5501
bizhub PRO C6501
This adjustment adjusts the relative position between the clamp unit and the cover table unit in the main scan
direction.
Perform the adjustment when the cover paper is vertically misaligned with the inside papers.
Note
• The misalignment of cover and inside papers can also be adjusted in "10.13.2 Clamp main scan
direction alignment adjustment" and "10.13.10 Cover paper alignment plate adjustment". (Refer to
P.518, P.530)
A. Procedure
[3] [2] [5] [4]
2. Adjust the position of the positioning pin /Fr [3] by
moving it forward [4] and backward [5] referring to
the engraved lines [2].
Note
a. When the cover paper runs off the top edge of
inside papers [7]: Move the positioning pin /Fr
[3] to the back [5].
b. When the cover paper runs off the bottom edge
of inside papers [8]: Move the positioning pin /Fr
[3] to the front [4].
[1] 3. After performing the adjustment, make a test print

neatly aligned with the inside papers.
[7] [8]
Top
[6]
Bot-
a075f3c028ca
532
10.13.13 Cover paper tray pick-up adjustment
/C6501P/C65hc/C5501
bizhub PRO C6501
Perform the adjustment when no feed from the cover paper tray occurs frequently.
A. Procedure
1. Pull out the cover paper tray.
2. Remove all remaining cover papers from the cover
paper tray.
4. Push the stopper [3] in the direction of the arrow
with the release lever [2] retracted, and secure the
stopper [3] with the screw [1].
Note
• After performing the adjustment, loosen the
screw [1] and retighten it after releasing the
stopper [3].
5. Install the cover paper tray, and pull out the tray
again after the cover paper lift plate has lifted to
the upper limit, which can be judged by the oper-
ating sound of the cover paper lift motor.
the right and left rails and pull the cover paper tray
further out. (Refer to Theory of Operation of PB
P.203)
[2] [1] [3]

a075f3c001ca
7. Pull out the tray again. Remove 2 screws [1] to

[1] remove the paper feed cover [2].
[2] a075f3c002ca
533
8. Pull the plunger [2] of the pick-up solenoid [1] and

/C6501P/C65hc/C5501
[1] [2]
measure the gap between the pick-up roller [3]
bizhub PRO C6501
and the cover paper lift plate [4] with a thickness

gauge.
Measured value A = 0.1mm to 1.5mm
If it is not within the standard value, follow step 9
and after.
Note
• Before loosening the screw, be sure to mark
off the position of the pick-up solenoid [1] by
[5] [6] drawing a line [6].
10. With the plunger [2] pulled, adjust the position of

the pick-up solenoid [1] so that the gap between
the pick-up roller [3] and the cover paper lift plate
[4] falls into the specified range.
11. Tighten the screw [5] to fix the pick-up solenoid
[1].
12. Load cover papers on the cover paper tray and
close the tray.
13. Make a test print and binding selecting the perfect
binding as the binding method and the PB cover
[3] paper tray as the cover feeder. Check that the no
feed error does not occur.
A
[4]
a075f3c003ca
534
10.13.14 Cover paper tray pick-up roller height adjustment
/C6501P/C65hc/C5501
bizhub PRO C6501
Perform this adjustment when no-feed, crimp of leading edge, or paper jam occurs frequently when feeding the
cover papers from the cover paper tray, or when curled cover papers need to be used.
This adjusts the vertical position of the cover paper pick-up roller. Changing the roller position changes the verti-
cal gap between the top paper surface on the tray and the bottom surface of the cover paper feed roller.
Note
• With this adjustment, cover paper pick-up ability changes accordingly. When the adjustment is
completed, make sure to perform the cover paper feed pick-up amount adjustment to check the
pick-up amount.
A. Procedure
paper tray.
Note
stopper [3].
the right and left rails and pull the cover paper tray
further out. (Refer to Theory of Operation of PB
P.203)
[2] [1] [3]

a075f3c004ca
535
7. Pull out the tray again. Remove 2 screws [1] to

/C6501P/C65hc/C5501
remove the paper feed cover [2].

bizhub PRO C6501
[1]
[2] a075f3c005ca
8. Check that the actuator [1] of the pick-up roller

[1] [2]
assy is aligned with the center [3] of the cover
paper tray upper limit sensor (PS74) [2].
9. Remove the pick-up roller section [4]. (Refer to
Theory of Operation of PB P.142)
[3]
[4]
a075f3c006ca
536
10. Mark off the position of the cover paper tray upper
/C6501P/C65hc/C5501
[2] [3] [1]
limit sensor mounting plate [1] by drawing a line
bizhub PRO C6501

[2].
11. Remove 2 screws [3] and temporarily install the
cover paper upper limit sensor mounting plate [1]
with the screws through the elongated screw
holes [4].
12. Make vertical adjustments of the cover paper
upper limit sensor mounting plate [1] and fasten it
with the screws [3].
Note
[4] [1] • Be sure to install the cover paper tray upper
limit sensor mounting plate [1] so that it
keeps in a horizontal position.
Reference
• Raising the position of the cover paper tray upper
limit sensor brings the pick-up roller [5] down
(increases the vertical gap [7] between the cover
paper feed roller [6] and the pick-up roller [5]).
• Lowering the position of the cover paper tray
upper limit sensor brings up the pick-up roller [5]
(reduces the vertical gap [7] between the cover
[3] paper feed roller [6] and the pick-up roller [5]).
[6] • When crimp of leading edge or paper jam occurs,
[5] or when curled cover papers (concave curl) need
to be used, raise the cover paper tray upper limit
sensor mounting plate.
• When feeding warped cover papers (convex curl),
lower the cover paper tray upper limit sensor
[7] mounting plate.
13. Reinstall the pick-up roller assembly.

a075f3c007ca
Note
• Be sure to install the cover paper tray upper
limit sensor mounting plate [1] so that it
keeps in a horizontal position.

close the tray.
binding as the binding method and PB cover
paper tray as the cover feeder. Check that the
errors do not occur. If the errors still occur, repeat
steps 9 to 15.
16. Check the cover paper tray pick-up adjust-
ment.(Refer to P.533)
537
10.13.15 Cover paper tray separation pressure adjustment

/C6501P/C65hc/C5501
bizhub PRO C6501
Perform this adjustment when no-feed or multi-feed from the cover paper tray occurs frequently.
Note
• A no-feed error tends to occur in low temperature environment, while a multi-feed error does in
high temperature environment.
• Excess adjustment may reverse the symptom.
A. Procedure
2. Change the position of the spring adjustment
lever [1]. The separation pressure is strengthened
when the lever moves to the direction [2] and is
weakened when the lever moves to the direction
[3].
Weak: a double feed jam is improved.
Strong: a no feed jam is improved.
Reference
• The spring force changes in increments of
about 10%.
[1]
3. Set the cover paper tray.
paper tray as the cover feeder. Check that no-
feed errors or multi-feed errors do not occur. If the
errors still occur, repeat steps 1 to 4.
5. If the errors still occur, repeat steps 1 to 4.
[2] [3]
a075f3c008ca
538
10.13.16 Cover paper tray centering adjustment
/C6501P/C65hc/C5501
bizhub PRO C6501
Perform this adjustment when the deviation between the cover paper and the inside papers is out of spec.
Standard value: 0 ± 1mm or less (aligned edges), 0 ± 1.5mm or less (trimmed edges)
A. Procedure
[1]
paper tray as the cover feeder. Check how much
the cover paper misaligns with the inside papers.
paper tray.
4. When the cover paper guides [1] are set at the
small-size position, extend them.
6. Move the cover paper guides [1] and adjust the
center position based on the misalignment
amount checked at step1, referring to the mark-
[2]
ing-off line [3].
7. Tighten 2 screws [2].
close the tray.
paper tray as the cover feeder. Check that the
misalignment amount falls into the specified
range.
Specification value: 0 ± 1mm or less
[3] (aligned edges)
a075f3c009ca
0 ± 1.5mm or less
(trimmed edges)
10. If the value falls outside the range, repeat the
steps 2 to 9.
539
10.13.17 Cover paper tray lift plate horizontal adjustment

/C6501P/C65hc/C5501
bizhub PRO C6501
A. Procedure
paper tray.
Note
stopper [3].
[2] [1] [3]

a075f3c010ca
540
6. Check if the cover paper lift plate [3] is placed hor-
/C6501P/C65hc/C5501
[2] [1]
izontally using the engraved lines on the near side
bizhub PRO C6501

[1] and the far side [2] of the tray. If the plate is not
horizontal, perform step 7 and the steps that fol-
low.
[3]
a075f3c011ca
541
7. Remove 6 screws [1] of the cover paper tray front

/C6501P/C65hc/C5501
[2]
cover [3].
bizhub PRO C6501

cover paper tray front cover [3].
[3]
[1] [1]
a075f3c012ca
542
9. Lift up the pick-up roller [1].
/C6501P/C65hc/C5501
10. Move the cover paper guides [2] to the positions
bizhub PRO C6501

for the smallest paper size.
11. Remove the screw [3] and tighten it through the
elongated screw hole [4] temporarily.
12. Loosen the screw [5] while supporting the pulley
[9] mounting plate [6] by hand, and correct the tilt of
the cover paper lift plate [8] referring to the
engraved lines [7].
13. Check that the cover paper lift plate [8] is placed
[5] [3]
horizontally, and secure the plate with the screw
[5] and [9].
Note
• When tightening the screws [5] and [9], check
that the wire [10] has not come off the pulley
or not crossed.
14. Pull down the pick-up roller [1].

close the tray.
16. Make a test and binding selecting the perfect
[4] [7]
[1] paper tray as the cover feeder. Check that cover
papers are fed normally without any jam.
[8] [2]
[10]
[6]
a075f3c013ca
543
bizhub PRO C6501
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544
Field Service Ver.3.0 Jul. 2009 11. JAM CODE
TROUBLESHOOTING
/C6501P/C65hc/C5501
bizhub PRO C6501
11. JAM CODE
11.1 Jam code list
Classification Jam code Cause Resulting Correction

operation
Bypass J-1001 After the pick-up solenoid/BP (SD5) If paper jam Remove the paper from
During operation
feed turns ON, paper supply sensor /BP occurs during the bypass feed tray,
(PS26) is not turned ON within the printing process, and remove jammed
specified time. main body stops paper, if any.
after paper exit.
J-1002 After paper empty sensor /BP (PS47) Remove paper from the
turns ON, paper lift motor /BP (M35) bypass feed tray,
is not turned ON within specified time. decrease the number
J-1003 After paper lift motor /BP (M35) turns of stacked sheets and
ON, upper limit sensor /BP (PS25) is set again.
not turned ON within specified time.
J-1051 Paper feed sensor /BP (PS26) is — Remove the paper from
When idling
turned ON in the idling condition. the bypass feed tray,

and remove jammed
paper, if any.
Paper J-1101 After the pick-up solenoid /1 (SD7) If paper jam Pull out the paper feed
During operation
feed turns ON, paper feed sensor /1 occurs during tray/1 and remove
Tray /1 (PS29) is not turned ON within the printing process, jammed paper, if any.
specified time. main body stops
after paper exit.
J-1151 Paper feed sensor /1 (PS29) is turned —

When idling
ON in the idling condition.
During operation
feed turns ON, paper feed sensor /2 occurs during tray /2 and remove
after paper exit.
J-1251 Paper feed sensor /2 (PS35) is turned —

When idling
During operation
feed turns ON, paper feed sensor /3 occurs during tray /3 and remove
after paper exit.
545
/C6501P/C65hc/C5501 11. JAM CODE Field Service Ver.3.0 Jul. 2009

operation
bizhub PRO C6501
Paper J-1351 Paper feed sensor /3 (PS41) is turned — Pull out the paper feed
When idling
feed ON in the idling condition. tray /3 and remove
Tray /3 jammed paper, if any.
LU J-1501 After the pick-up solenoid (SD100) If paper jam Open the LU upper
During operation
turns ON, pre-registration sensor occurs during door and remove
(PS106) is not turned ON within the printing process, jammed paper, if any.
J-1502 After the pre-registration clutch after paper exit.
(MC102) is turned ON, LU exit sensor
(PS107) is not turned ON within the
specified time.
J-1551 Pre-registration sensor (PS106) is —
When idling
turned ON in the idling condition.

J-1552 LU exit sensor (PS107) is turned ON
in the idling condition.
PF J-1601 After the pick-up solenoid /1 (SD1) If paper jam Pull out the paper feed
During operation
turns ON, paper feed sensor /1 (PS2) occurs during tray /4 and remove
is not turned ON within the specified printing process, jammed paper, if any.
time. main body stops
J-1602 After the pick-up solenoid /2 (SD5) after paper exit. Pull out the paper feed
turns ON, paper feed sensor /2 tray /5 and remove
(PS10) is not turned ON within the jammed paper, if any.
specified time.
J-1603 After the paper feed sensor /1 (PS2) Open the PF front door
turns ON, vertical conveyance sensor and the PF vertical con-
/1 (PS17) is not turned ON within the veyance door and
specified time. remove jammed paper,
J-1604 After the vertical conveyance sensor / if any.
1 (PS17) turns ON, vertical convey-
ance sensor /2 (PS27) is not turned
ON within the specified time.
J-1605 After the vertical conveyance sensor /
2 (PS27) turns ON, vertical convey-
ance sensor /3 (PS26) is not turned
J-1606 After the vertical conveyance sensor / Open the PF front door
3 (PS26) turns ON, horizontal convey- and the PF vertical con-
ance sensor /1 (PS18) is not turned veyance door and
ON within the specified time. remove jammed paper,
if any.
J-1607 After the paper feed sensor /2 (PS10) Pull out the paper feed
turns ON, horizontal conveyance sen- tray /5 and remove
sor /1 (PS18) is not turned ON within jammed paper, if any.
the specified time.
546
/C6501P/C65hc/C5501
operation
bizhub PRO C6501

PF J-1608 After the horizontal conveyance sen- If paper jam Open the PF front door,
During operation
sor /1 (PS18) turns ON, pre-registra- occurs during PF vertical conveyance
tion (PS20) is not turned ON within printing process, door, horizontal con-
the specified time. main body stops veyance door /Rt, hori-
after paper exit. zontal conveyance
door /Lt and remove
J-1609 After the pre-registrations sensor
jammed paper, if any.
(PS20) is turned ON, horizontal con-
veyance sensor /2 (PS19) is not
turned ON within the specified time.
J-1610 Multi feed detection board /R Stops immedi-
(MFDTB/R) detected multifeed. ately.
J-1611 Double-fed paper was separated
during being conveyed and horizontal
conveyance sensor /2 (PS19) is
turned ON by the latter conveyed
paper.
J-1651 Paper feed sensor /1 (PS2) is turned — Pull out the paper feed
When idling
ON in the idling condition. tray /4 and remove

J-1652 Paper feed sensor /2 (PS10) is turned Pull out the paper feed
ON in the idling condition. tray /5 and remove
J-1653 Vertical conveyance sensor /1 (PS17) — Open the PF front door
is turned ON in the idling condition. and the PF vertical con-
J-1654 Vertical conveyance sensor /2 (PS27) veyance door and
is turned ON in the idling condition. remove jammed paper,
J-1655 Vertical conveyance sensor /3 (PS26) if any.
is turned ON in the idling condition.
J-1656 Horizontal conveyance sensor /1 Open the PF front door,
(PS18) is turned ON in the idling con- PF vertical conveyance
dition. door, horizontal con-
J-1657 Horizontal conveyance sensor /2 veyance door /Rt, hori-
(PS19) is turned ON in the idling con- zontal conveyance
dition. door /Lt and remove
J-1658 Pre-registration sensor (PS20) is ON jammed paper, if any.
in the idling condition.
Paper J-1701 After starting print of the front side, If paper jam Pull out ADU and
During operation
feed registration sensor (PS22) is not occurs during remove jammed paper,
turned ON within specified time. printing process, if any.
main body stops
after paper exit.
J-1702 After starting print of the back side, Stops immedi-
registration sensor (PS22) is not ately.
turned ON within specified time.
547 1

operation
bizhub PRO C6501
Paper J-1703 After the pre-registration clutch /3 If paper jam Open the vertical con-
During operation
feed (MC12) is turned ON, vertical convey- occurs during veyance door and
ance sensor (PS50) is not turned ON printing process, remove jammed paper,
within specified time. main body stops if any.
J-1704 After the pre-registration clutch /2 after paper exit. Pull out the paper feed
(MC10) is turned ON, vertical convey- tray /2 and remove
ance sensor (PS50) is not turned ON jammed paper, if any.
within specified time.
J-1705 After the vertical conveyance sensor Open the vertical con-
(PS50) turns ON, intermediate conveyance door and
veyance sensor /1 (PS27) is not remove jammed paper,
turned ON within the specified time. if any.
J-1706 After the pre-registration clutch /1
(MC8) is turned ON, intermediate
conveyance sensor /1 (PS27) is not
J-1707 After the LU pre-registration clutch Open the LU front door
(MC102) is turned ON, intermediate and remove jammed
conveyance sensor /1 (PS27) is not paper, if any.
J-1708 After the intermediate conveyance Pull out ADU and
sensor /1 (PS27) is turned ON, inter- remove jammed paper,
mediate conveyance sensor /2 if any.
(PS28) is not turned ON within speci-
fied time.
J-1709 After the paper feed sensor /BP Remove the paper from
(PS26) is turned ON, intermediate the bypass feed tray,
conveyance sensor /2 (PS28) is not and remove jammed
turned ON within specified time. paper, if any.
J-1710 After the PF horizontal conveyance Open the PF front door,
sensor /2 (PS19) turns ON, intermedi- PF vertical conveyance
ate conveyance sensor /1 (PS27) is door, horizontal con-
not turned ON within the specified veyance door /Rt, hori-
time. zontal conveyance
door /Lt and remove
J-1751 Vertical conveyance sensor (PS50) is — Open the vertical con-
When idling
turned ON in the idling condition. veyance door and

remove jammed paper,
if any.
J-1752 Intermediate conveyance sensor /1 Pull out ADU and
(PS27) is turned ON in the idling con- remove jammed paper,
dition. if any.
J-1753 Intermediate conveyance sensor /2
(PS28) is turned ON in the idling con-
dition.
548
/C6501P/C65hc/C5501
operation
bizhub PRO C6501

Paper J-1754 Registration sensor (PS22) is turned — Pull out ADU and
When idling
feed in the idling condition. remove jammed paper,
if any.
OTH- J-1901 Vertical conveyance door open jam. If paper jam Close the vertical con-
During operation
ERS Vertical conveyance door sensor occurs during veyance door.
(PS51) was turned OFF when print- printing process,
ing. main body stops
after paper exit.
LU J-1902 LU upper door open jam or LU front In the case of Close the LU upper
door open jam. During printing, LU paper feed, door or the LU front
upper door sensor (PS100) or front main body stops door.
door sensor (PS115) turned OFF. after comple-
tion of paper
exit.
In the case of
paper feed other
than LCT, main
body does not
stop.
PF J-1903 Any one of the PF front door open In the case of PF Close any one of the PF
jam, PF vertical conveyance door paper feed, front door, PF vertical
open jam, horizontal conveyance main body stops conveyance door, hori-
door /Rt open jam or the horizontal after comple- zontal conveyance
conveyance door /Lt open jam. Any tion of paper door /Rt or the horizon-
one of the front door open/close sen- exit. tal conveyance door /
sor (PS23), vertical conveyance door In the case of Lt.
sensor (PS24), horizontal conveyance paper feed other
door sensor /1 (PS21) or the horizon- than PF, main
tal conveyance door sensor /2 (PS22) body does not
turned OFF during printing. stop.
Registra- J-3101 After the registration motor (M30) is Stops immedi- Pull out ADU and
tion turned ON, leading edge sensor ately. remove jammed paper,
(PS63) is not turned ON. if any.
J-3102 After the registration motor (M30) is
turned ON, Fusing paper exit sensor
(PS17) is not turned ON.
J-3151 Leading edge sensor (PS63) is ON in —
When idling
the idling condition.

J-3152 Fusing loop sensor (PS64) is turned
on in the idling condition.
Paper J-3201 After the fusing paper exit sensor Stops immedi- Pull out ADU and
During operation
exit (PS17) is turned ON, paper exit sen- ately. remove jammed paper,
sor (PS13) is not turned ON within the if any.
specified time.
549

operation
bizhub PRO C6501
Paper J-3202 After the fusing paper exit sensor Stops immedi- Pull out ADU and
During operation
exit (PS17) is turned ON, reverse/exit sen- ately. remove jammed paper,
sor (PS19) is not turned ON within the if any.
specified time.
J-3203 In the reverse paper exit mode, after
the reverse/exit sensor (PS19) is
turned ON, paper exit sensor (PS13)
is not turned ON within the specified
time.
J-3204 After the fusing paper exit sensor
(PS17) is turned ON, it is not turned
OFF within the specified time.
J-3205 After the paper exit sensor (PS13) is
turned ON, it is not turned OFF within
the specified time.
J-3206 After the fusing paper exit sensor
(PS17) is turned OFF, reverse/exit
sensor (PS19) is not turned ON within
the specified time.
J-3207 In reverse paper exit mode, after the
paper exit sensor (PS13) is turned
ON, it is not turned OFF within the
specified time.
J-3209 After the decurler sensor (PS62) is
the specified time.
J-3251 Fusing paper exit sensor (PS17) is —
When idling
turned ON in the idling condition.
J-3252 Paper exit sensor (PS13) is ON in the

idling condition.
J-3253 Reverse/exit sensor (PS19) is ON in
J-3254 Decurler sensor (PS62) is On in the
idling condition.
OTH- J-5101 Front door open jam. Front door sen- Stops immedi- Close the front door.
During operation
ERS sor (PS18) was turned OFF when ately.

printing.
550
/C6501P/C65hc/C5501
operation
bizhub PRO C6501

DF J-6101 Paper feed section cover open jam. DF stops imme- Close the paper feed
During operation
Paper feed cover sensor (PS303) was diately. section cover.
turned OFF when printing. If paper jam
J-6102 Paper feed tray open jam. Tray open/ occurs during Close the paper feed
close sensor (PS308) was turned OFF printing process, tray.
when printing. main body stops
J-6103 Paper exit section cover open jam. after paper exit. Close the paper exit
Paper exit cover sensor (PS307) was section cover.
turned OFF when printing.
J-6201 Registration sensor (PS301) is not Open the paper feed
turned OFF within specified time after section cover and
paper feed is started. remove jammed paper,
J-6203 After reversal of paper feed motor if any.
(M301) is started, timing sensor Remove jammed paper
(PS302) is not turned ON within the in the main body con-
specified time. veyance section, if any.
J-6206 After the timing sensor (PS302) is
the specified time.
J-6209 After the reverse/paper exit motor Open the paper exit
(M303) is turned ON, reverse sensor section cover and
(PS305) is not turned ON within the remove jammed paper,
specified time. if any.
J-6301 After the reverse sensor (PS305) is Remove jammed paper
turned ON, it is not turned OFF within in the main body con-
the specified time. veyance section, if any.
J-6304 In the one-sided original exit mode,
paper exit sensor (PS306) is not
turned ON within the specified time
after the start of paper exit.
In the double-sided original exit
mode, paper exit sensor (PS306) is
not turned ON within the specified
time after the reverse sensor (PS305)
is turned ON.
J-6305 After the paper exit sensor (PS306) is
the specified time.
J-6501 Registration sensor (PS301) is ON in — Open the paper feed
When idling
the idling condition. section cover and

if any.
J-6502 Reverse sensor (PS305) is ON in the Open the paper exit
idling condition. section cover and
J-6504 Paper exit sensor (PS306) is ON in remove jammed paper,
the idling condition. if any.
551

operation
bizhub PRO C6501
DF J-6508 Timing sensor (PS302) is ON in the — Open the paper feed
When idling
idling condition. section cover and
if any.
FS J-7101 (FS-521) FS/main body Remove jammed paper
During operation
FS Front door open jam. Door switch stop immedi- in the FS/main body, if
(MS1) was turned OFF when printing. ately. any.
(FS-520/607)
The front door and PI upper door are
opened while in printing.
LS J-7103 LS Front door open jam. Front door LS/main body Remove jammed paper
switch (MS1) was turned OFF when stop immedi- in the LS/main body, if
printing. ately. any.
FD J-7105 FD front door open jam. Door switch FD/main body Remove jammed paper
(MS1) was turned OFF when printing. stop immedi- in the FD/main body, if
ately. any.
RU J-7106 RU front door open jam. Interlock RU/main body Remove jammed paper
switch (MS1) was turned OFF when stop immedi- in the RU/main body, if
printing. ately. any.
SD J-7107 SD front door /Rt open jam or SD SD/main body Remove jammed paper
front door /Lt open jam. Either one of stop immedi- in the SD/main body, if
the front door switch /Rt (MS1) or the ately. any.
front door switch /Lt (MS2) of the SD
was turned OFF when printing.
PB J-7108 PB front door open jam. The front PB/main body Remove jammed paper
door switch (MS2), the upper door stop immedi- in the PB/main body, if
switch (MS3) and the stacker door ately. any.
switch (MS4) of the PB was turned
OFF when printing.
GP J-7109 The GP front door open jam. The The GP and the Remove jammed paper
door switch turns OFF while in the main body stop if any from the GP/main
print. immediately. body.
FS J-7216 (FS-520/607) FS/main body Remove jammed paper
The FNS entrance sensor (PS4) does stop immedi- in the FS/main body, if
not turn ON within a specified period ately. any.
of time after the main body paper exit
sensor (PS13) turns ON.
J-7217 (FS-521)
The main tray paper exit sensor
(PS10) does not turn OFF within a
specified period of time after the
stacker entrance sensor (PS5) turns
OFF.
(FS-520/607)
The main tray paper exit sensor (PS6)
does not turn ON within a specified
period of time after the FNS entrance
2 552
/C6501P/C65hc/C5501
operation
bizhub PRO C6501

FS J-7218 The stacker entrance sensor (PS5) FS/main body Remove jammed paper
During operation
does not turn ON within a specified stop immedi- in the FS/main body, if
period of time afer turning on the ately. any.
paper exit sensor of the front option.
J-7219 While in stapling, the stacker entranc-
esensor (PS5) does not turn OFF
within a specified period of time after
the stacker entrance motor (M13)
turns ON. While in any other opera-
tions than stapling, the PS5 does not
turn OFF within a specified period of
time after it turns ON.
J-7220 (FS-521)
While in stapling a small-size paper, the
main tray paper exit sensor (PS10) does
not turn ON or the stacker empty sen-
sor (PS20) does not turn ON within a
specified period of time after the paper
exit arm motor turns ON.
(FS-520/607)
While in stapling a small size paper, the
main tray paper exit sensor (PS6) does
not turn ON within a specified period of
time after the start of exiting paper.
J-7221 (FS-521)
While in stapling a large size paper,
the main tray exit sensor (PS10) does
not turn OFF within a specified period
of time after the paper exit arm motor
(M23) turns ON.
(FS-520/607)
While in stapling a large size paper,
the main tray paper exit sensor (PS6)
does not turn OFF within a specified
period of time after the start of exiting
paper.
J-7222 (FS-520/607)
The sub tray exit sensor (PS1) does
not turn ON within a specified period
of time after the FNS entrance sensor
(PS4) turns ON.
(FS-521)
While in exiting paper in the sub tray,
the sub tray paper exit sensor (PS1)
period of time afer turning on the
paper exit sensor of the front option.
553 2

operation
bizhub PRO C6501
FS J-7223 While in exiting paper in the sub tray, FS/main body Remove jammed paper
During operation
the sub tray paper exit sensor (PS1) stop immedi- in the FS/main body, if
does not turn OFF within a specified ately. any.
period of time after the PS1 turns ON.
J-7224 (FS-607)
The folding pass-through sensor
(PS26) does not turn ON after sta-
pling is completed.
J-7225 (FS-607)
The folding paper exit sensor (PS25)
period of time after the folding knife
motor (M19) turns ON.
J-7226 (FS-607)
period of time after it turns ON.
J-7228 (FS-521)
While in the straight/shift of the small
size paper, the main tray paper exit
sensor (PS10) does not turn OFF
the PS10 turns ON.
(FS-520/607)
While in the straight/shift of the small
size paper, the stacker entrance sen-
sor (PS5) does not turn OFF within a
specified period of time after it turns
ON.
J-7229 (FS-520/607)
The main tray paper exit sensor (PS6)
period of time after it turns ON (while
in the non-stapling mode).
The sub tray paper exit sensor (PS1)
period of time after it turns ON (while
in the stapling mode).
J-7230 (FS-521)
While in stapling a small size paper,
the main tray paper exit sensor
PS10 turns ON.
554
/C6501P/C65hc/C5501
operation
bizhub PRO C6501

FS J-7230 (FS-520/607) FS/main body Remove jammed paper
During operation
While in stapling a small size paper, stop immedi- in the FS/main body, if
the main tray paper exit sensor (PS6) ately. any.
period of time after the PS6 turns ON.
PI J-7235 The paper entrance sensor /Lw

(PS206) does not turn ON within a
conveyance clutch /Lw (MC202)
turns ON.
PK J-7243 The punch home sensor (PS301)
period of time after the punch motor
(M301) turns ON. Or, the paper size
sensor (PS305) does not turn ON
the punch shift motor (M302) turns
ON.
FS J-7248 (FS-607)
ON.
PI J-7249 The paper entrance sensor /Up Open the PI upper door
(PS201) does not turn ON within a and remove jammed
specified period of time after the paper if any.
conveyance clutch /Up (MC201) turns
ON.
J-7250 The FNS entrance sensor (PS4) does
of time after the paper entrance
sensor /Up (PS201) turns ON.
J-7251 The FNS entrance sensor (PS4) does
of time after the paper entrance
sensor /Lw (PS206) turns ON.
FS J-7281 (FS-607) Remove jammed paper
The stapler motor home sensor /Fr in the FS/main body, if
(PS31) and clincher motor home any.
sensor /Fr (PS33) do not turn ON
the stapler motor /Fr (M14) and
clincher motor /Fr (M15) turn ON.
555

operation
bizhub PRO C6501
FS J-7282 (FS-607) FS/main body Remove jammed paper
During operation
The stapler motor home sensor /Rr stop immedi- in the FS/main body, if
(PS30) and clincher motor home ately. any.
sensor /Rr (PS32) do not turn ON
the stapler motor /Rr (M9) and
clincher motor /Rr (M10) turn ON.
J-7283 (FS-607)
The stapler motor home sensor /Rr
(PS30), /Fr (PS31), clincher motor
home sensor /Rr (PS32), and /Fr
(PS33) do not turn ON within a
stapler motor /Rr (M9), /Fr (M14),
clincher motor /Rr (M10), and
/Fr (M15) turn ON.
J-7290 (FS-520/607)
The FS does not stop within a
specified period of time after the main
body sends it a stop signal.
J-7301 (FS-521) —
When idling
The main tray exit sensor (PS10) turns

ON while in idling.
(FS-520/607)
The main tray exit sensor (PS6) turns
ON while in idling.
J-7302 (FS-521)
The stacker entrance sensor (PS5)
turns ON while in idling.
J-7305 The FNS entrance sensor (PS4) turns
ON while in idling.
J-7307 The sub tray paper exit sensor (PS1)
J-7308 (FS-520/607) FS/main body
The stacker empty sensor (PS20) stop immedi-
turns ON while in an exit jam. ately.
J-7309 (FS-607)
(PS26) turns ON while in idling.
J-7310 (FS-607)
PI J-7314 The paper entrance sensor /Lw —
J-7317 The paper entrance sensor /Up
556
/C6501P/C65hc/C5501
operation
bizhub PRO C6501

RU J-7362 (RU-504) — Open the front door
When idling
Entrance sensor (PS1) is ON in the and remove jammed
idling condition. paper, if any.
(RU-506)
The entrance jam sensor (PS6) turns
ON while in idling.
J-7363 (RU-504)
Intermediate sensor (PS2) is ON in the
idling condition.
(RU-506)
The stacker jam sensor (PS5) turns
ON while in idling.
J-7364 (RU-504)
Paper exit sensor (PS3) is ON in the
idling condition.
(RU-506)
The paper exit sensor (PS2) turns ON
while in idling.
LS J-7350 Entrance sensor (PS4) is ON in the — Open the LS front door,
idling condition. then the entrance con-
veyance jam lever and
if any.
J-7351 Sub-tray paper exit sensor (PS10) is Open the LS sub-tray
ON in the idling condition. cover and remove
J-7352 Any one of the conveyance sensor /1 Open the LS jam door
(PS7), /2 (PS16), /3 (PS17) is ON in and remove jammed
the idling condition. paper, if any.
J-7353 Coupling exit sensor (PS18) is turned Open the LS front door,
ON in the idling condition. then the coupling paper
exit jam lever and
if any.
FD J-7358 Any one of the FD entrance sensor — Open the FD front door,
(PS1), punch conveyance sensor then the entrance con-
(PS5) or the punch registration sensor veyance jam lever /1, /
(PS6) is turned ON in the idling condi- 2, punch conveyance
tion. jam lever /1, /2 and
if any.
J-7359 Any one of the intermediate convey- Open the FD front door,
ance sensor (PS13), sub-tray paper then the intermediate
exit sensor (PS16) or the main tray conveyance jam lever
paper exit sensor (PS18) is ON in the and remove jammed
idling condition. paper, if any.
557 2

operation
bizhub PRO C6501
FD J-7360 Any one of the 1st folding convey- — Open the FD front door,
When idling
ance sensor (PS51), 2nd folding con- pull out the fold con-
veyance sensor (PS53), 3rd folding veyance section, then
conveyance sensor (PS54), S size open the fold convey-
conveyance sensor (PS58), folding ance jam lever /1 to /5
entrance sensor (PS52) or the folding and remove jammed
exit sensor (PS2) is ON in the idling paper, if any.
condition.
J-7361 Any one of the PI conveyance sensor Open the FD upper
/Up (PS31), PI conveyance sensor / door and remove
Lw (PS37) or the PI exit sensor (PS4) jammed paper, if any.
is ON in the idling condition. Open the entrance
conveyance jam lever /
1 and remove jammed
paper, if jammed paper
is in the PI exit.
SD J-7368 Entrance sensor (PS1) is ON in the — Open the SD front door
idling condition. /Rt and remove
J-7369 Any one of the horizontal conveyance jammed paper, if any.
sensor /1 (PS2), horizontal convey-
ance sensor /2 (PS3) or the subtray
paper exit sensor (PS11) is ON in the
idling condition.
J-7370 Horizontal conveyance exit sensor Open the SD front door
(PS4) is ON in the idling condition. /Lt and remove
J-7371 Either one of the right angle convey- Open the SD front door
ance sensor /1 (PS5) or the right /Rt and remove
angle conveyance sensor /2 (PS6) is jammed paper, if any.
J-7372 Any one of the folding sensor /1
(PS7), foling passage sensor (PS8),
tri-folding exit sensor (PS9) or the
folding sensor /2 (PS44) is ON in the
idling condition.
J-7373 Saddle stitching paper sensor (PS13) Open the SD front door
is ON in the idling condition. /Lt and remove
J-7374 Any one of the bundle sensor /1 jammed paper, if any.
(PS14), bundle sensor /2 (PS15),
bundle sensor /4(PS54) or the bundle
exit sensor /2 (PS57) is ON in the
idling condition.
558
/C6501P/C65hc/C5501
operation
bizhub PRO C6501

PB J73-80 Either of the entrance sensor (PS1), — Open the PB front door
When idling
the SC entrance sensor (PS2), the or the upper door, and
cover paper entrance sensor (PS3), or remove jammed paper,
the subtray sensor (PS4) turns ON if any.
while in idling.
J73-81 The SC paper detection sensor Open the PB upper
(PS16) turns ON while in idling. door, and remove
J73-82 The clamp paper sensor (PS28) turns Open the PB front door,
ON while in idling. pull out the clamp sec-
tion, and remove
J73-83 Either of the cover paper switchback Open the PB front door,
sensor (PS44), the cover paper sen- and remove jammed
sor /Rt (PS45), or the cover paper paper, if any
sensor /Lt (PS46) turns ON while in
idling
J73-84 The book end sensor (PS61) turns Open the PB stacker
ON while in idling. door, and remove
J73-85 The cover paper conveyance sensor / Pull out the paper feed
1 (PS75), /2 (PS76), /3 (PS77), /4 tray, and remove
(PS78), and /5 (PS79) turn ON while jammed paper, if any.
in idling.
GP J-7390 The enter sensor (S1) turns ON while — Open the GP front
in idling. door, the bypass panel
cover, and remove the
J-7391 The stepper 1 speed sensor (S2) Open the GP front
turns ON while in idling. door, the entrance
aligner panel, and
remove the jammed
paper, if any.
J-7392 The bypass sensor (S8) turns ON Open the GP front
while in idling. door, the bypass panel
J-7393 The exit sensor (S7) turns ON while in cover, and remove the
idling. jammed paper, if any.
J-7394 The punch flag sensor (S9) turns ON Open the GP front
while in idling. door, the entrance
aligner panel, the bot-
tom U-channel, and
remove the jammed
paper, if any.
559 2

operation
bizhub PRO C6501
GP J-7395 The u-channel sensor (S4) turns ON — Open the GP front
When idling
while in idling. door, the bottom U-
J-7396 The backstop sensor (S5) turns ON channel, and remove
while in idling. the jammed paper, if
any.
J-7397 The stepper 2 speed sensor (S6) Open the GP front
turns ON while in idling. door, the exit aligner
panel, and remove the
J-7590 The enter sensor (S1) does not turn The GP/main Remove jammed paper
During operation
OFF within a specified period of time body stop if any from the GP/main
after it turns ON. immediately. body.
J-7591 The stepper 1 speed sensor (S2)
J-7592 The bypass sensor (S8) does not turn
OFF within a specified period of time
after it turns ON.
J-7593 The exit sensor (S7) does not turn
OFF within a specified period of time
after it turns ON.
J-7594 The punch flag sensor (S9) does not
J-7595 The u-channel sensor (S4) does not
J-7596 The backstop sensor (S5) does not
J-7597 The stepper 2 speed sensor (S6)
LS J-7401 After the main body paper exit sensor LS/main body Remove jammed paper
During operation
(PS3) is turned ON, entrance sensor stop immedi- in the LS/main body, if
(PS4) is not turned ON within the ately. any.
specified time.
J-7402 After the entrance sensor (PS4) is
the specified time.
turned ON, sub tray paper exit sensor
specified time.
2 560
/C6501P/C65hc/C5501
operation
bizhub PRO C6501

LS J-7404 After the sub tray paper exit sensor LS/main body Remove jammed paper
During operation
(PS10) is turned ON, it is not turned stop immedi- in the LS/main body, if
OFF within the specified time. ately. any.
J-7405 After the entrance sensor /1 (PS4)
turns ON, conveyance sensor /1
specified time.
J-7406 After the conveyance sensor (PS7) is
the specified time.
J-7407 After the conveyance sensor /1 (PS7)
turns ON, conveyance sensor /2
specified time.
J-7408 After the conveyance sensor /2
(PS16) turns ON, conveyance sensor
/3 (PS17) is not turned ON within the
specified time.
(PS17) turns ON, coupling exit sensor
specified time.
J-7412 After the coupling exit sensor (PS18)
is turned ON, it is not turned OFF
within the specified time.
FD J-7501 After the main body paper exit sensor FD/main body Remove jammed paper
(PS3) is turned ON, FD entrance sen- stop immedi- in the FD/main body, if
sor (PS1) is not turned ON within the ately. any.
specified time.
J-7502 After the FD entrance sensor (PS1)
turns ON, intermediate conveyance
the specified time.
J-7503 After the intermediate conveyance
sensor (PS13) is turned ON, main tray
paper exit sensor (PS18) is not turned
J-7504 After the main tray paper exit sensor
561 2

operation
bizhub PRO C6501
FD J-7505 After the intermediate conveyance FD/main body Remove jammed paper
During operation
sensor (PS13) is turned ON, sub tray stop immedi- in the FD/main body, if
paper exit sensor (PS16) is not turned ately. any.
J-7506 After the sub tray paper exit sensor
J-7507 After the FD entrance sensor (PS1)
turns ON, punch conveyance sensor
specified time.
J-7508 After the punch conveyance sensor
(PS5) turns ON, 3rd foling convey-
ance sensor (PS54) is not turned ON
J-7509 After the punch conveyance sensor
(PS5) turns ON, punch registration
the specified time.
J-7510 After the punch registration sensor
(PS6) turns ON, 1st folding convey-
J-7511 After the first fold conveyance sensor
(PS51) turns ON, 3rd folding convey-
J-7512 After the 3rd folding conveyance sen-
sor (PS54) turns ON, intermediate
conveyance sensor (PS13) is not
J-7513 During fold operation, after the 1st
folding motor (M4) starts accelerating,
2nd folding conveyance sensor
specified time.
J-7514 During fold operation, after the 1st
3rd folding conveyance sensor (PS54)
time.
J-7515 During fold operation, after the 2nd
3rd folding conveyance sensor (PS54)
time.
562
/C6501P/C65hc/C5501
operation
bizhub PRO C6501

FD J-7516 During fold operation, after the 3rd FD/main body Remove jammed paper
During operation
folding motor (M6) starts accelerating, stop immedi- in the FD/main body, if
intermediate conveyance sensor ately. any.
specified time.
J-7517 During fold operation, after the 2nd
folding conveyance sensor (PS53)
turns ON, third fold conveyance sen-
sor (PS54) is not turned ON within the
specified time.
J-7518 During fold operation, after the 3rd
folding conveyance sensor (PS54)
turns ON, intermediate conveyance
the specified time.
J-7519 After the PI pick-up solenoid /Up
(SD13) turns ON, PI conveyance sen-
sor /Up (PS31) is not turned ON
J-7520 After PI conveyance sensor /Up
(PS31) is turned ON, PI exit sensor
specified time.
J-7521 After the PI pick-up solenoid /Lw
(SD14) turns ON, PI conveyance sen-
sor /Lw (PS37) is not turned ON
J-7522 After PI conveyance sensor /Lw
(PS37) is turned ON, PI exit sensor
specified time.
J-7523 After PI exit sensor (PS4) is turned
ON, FD entrance sensor (PS1) is not
J-7524 PI double feed was detected.
RU J-7540 (RU-504) RU/main body Remove jammed paper
After the main body paper exit sensor stop immedi- in the RU/main body, if
(PS13) is turned ON, RU entrance ately. any.
the specified time.
(RU-506)
The entrance sensor (PS1) does not
turn ON within a specified period of
time after the main body paper exit
563 2

operation
bizhub PRO C6501
RU J-7541 (RU-504) RU/main body Remove jammed paper
During operation
After the RU entrance sensor (PS1) stop immedi- in the RU/main body, if
turns ON, RU intermediate sensor ately. any.
specified time.
(RU-506)
While in the straight pass, the paper
exit sensor (PS2) does not turn ON
the entrance sensor (PS1) turns ON.
J-7542 (RU-504)
After the RU intermediate sensor
(PS2) turns ON, RU paper exit sensor
specified time.
(RU-506)
The entrance sensor (PS1) does not
J-7543 (RU-504)
After the RU paper exit sensor (PS3)
is turned ON, it is not turned OFF
(RU-506)
While in the reverse pass, the paper
exit sensor (PS2) does not turn ON
the entrance sensor (PS1) turns ON.
J-7345 (RU-506)
The paper exit sensor (PS2) does not
SD J-7561 After the main body paper exit sensor SD/main body Remove jammed paper
(PS3) is turned ON, entrance sensor stop immedi- in the SD/main body, if
(PS1) is not turned ON within the ately. any.
specified time.
J-7562 After the entrance sensor (PS1) turns
ON, horizontal conveyance sensor /1
specified time.
J-7563 After the horizontal conveyance sen-
sor/1 (PS2) turns ON, horizontal con-
veyance sensor /2 (PS3) is not turned
2 564
/C6501P/C65hc/C5501
operation
bizhub PRO C6501

SD J-7564 After the horizontal conveyance sen- SD/main body Remove jammed paper
During operation
sor/2 (PS3) turns ON, horizontal con- stop immedi- in the SD/main body, if
veyance exit sensor (PS4) is not ately. any.
J-7565 After the horizontal conveyance exit
sensor (PS4) is turned ON, it is not
turned OFF within the specified time.
J-7566 After the horizontal conveyance sen-
sor/1 (PS2) turns ON, subtray sensor
specified time.
J-7567 After the subtray paper exit sensor
(PS11) turns ON, subtray paper exit
sensor (PS11) is not turned OFF
J-7568 After the right angle conveyance
motor (M6) turns ON, right angle con-
veyance sensor/2 (PS6) is not turned
J-7569 After the folding entrance motor (M3)
turns ON, folding sensor /1 (PS7) is not
J-7570 After the folding sub scan alignment
exit motor (M8) turns ON, saddle
stitching paper sensor (PS13) is not
J-7571 After the bundle arm rotation motor
(M22) turns ON, bundle sensor /1
specified time.
J-7572 After the bundle clip motor (M11)
turns ON, bundle sensor /2 (PS15) is
time.
J-7573 After the bunch sensor /2 (PS15)
turns ON, bunch sensor /4 (PS54) is
time.
the specified time.
J-7575 After the right angle conveyance sen-
sor /2 (PS6) is turned ON, it is not
565

operation
bizhub PRO C6501
SD J-7576 After the folding sensor /2 (PS44) is SD/main body Remove jammed paper
During operation
turned ON, it is not turned OFF within stop immedi- in the SD/main body, if
the specified time. ately. any.
J-7577 After the bundle sensor /1 (PS14) is
the specified time.
J-7578 After the bundle sensor /2 (PS15) is
the specified time.
J-7579 After the folding conveyance motor
(M4) turns ON, folding passage sen-
sor (PS8) is not turned ON within the
specified time.
J-7580 After the folding conveyance motor
(M4) turns ON, tri-folding paper exit
the specified time.
J-7581 After the folding sub scan alignment
exit motor (M8) is turned ON, it is not
J-7582 After the folding passage sensor
J-7583 After the tri-folding paper exit sensor
J-7584 After the bundle press movement
motor (M17) is turned ON, trimmer
registration sensor (PS55) is not
J-7585 After the bundle registration motor
(M12) turns ON, trimmer registration
sensor (PS55) is not turned OFF
PB J-7660 The entrance sensor (PS1) does not The PB and the Remove jammed
turn ON within a specified period of main body stop paper, if any, from the
time after the main body paper exit immediately. PB/main body.
J-7661 The SC entrance sensor (PS2) does
of time after the entrance sensor
(PS1) turns ON.
J-7662 The SC entrance sensor (PS2) does
of time after it turns ON.
2 566
/C6501P/C65hc/C5501
operation
bizhub PRO C6501

PB J-7663 The cover paper entrance sensor The PB and the Remove jammed
During operation
(PS3) does not turn ON within a spec- main body stop paper, if any, from the
ified period of time after the main immediately. PB/main body.
body paper exit sensor (PS3) turns
ON.
J-7664 The sub tray exit sensor (PS4) does
of time after the entrance sensor
(PS1) turns ON.
J-7665 The sub tray exit sensor (PS4) does
of time after it turns ON.
J-7666 The SC paper detection sensor
specified period of time after the SC
entrance sensor (PS2) turns ON.
ON.
J-7668 When conveying 2 pages at a time,
the SC paper detection sensor (PS16)
period of time after the operation
starts.
J-7669 When conveying two pages at a time,
the SC paper detection sensor (PS16)
specified period of time after the SC
bundle conveynace motor (M17)
turns ON.
J-7671 The clamp paper sensor (PS28) does
of time after the Clamp motor (M22)
turns OFF.
J-7672 The glue apply position detection
sensor (PS32) does not turn ON
reversal of glue tank movement motor
(the tank moves back) turns ON.
J-7673 The glue apply position detection
sensor (PS32) does not turn OFF
it turns ON.
567 2

operation
bizhub PRO C6501
PB J-7674 The cover paper sensor/Rt (PS45) The PB and the Remove jammed
During operation
does not turn ON within a specified main body stop paper, if any, from the
period of time after the cover paper immediately. PB/main body.
pick up clutch (MC71) turns ON.
J-7676 When starting trimming of the cover
paper fed from the PB, the cover
paper switchback sensor (PS44)
time period after the cover paper con-
veyance motor (M45) turns ON.
J-7677 When trimming of the cover paper fed
from the PB is complete, the cover
paper switchback sensor (PS44)
time period after the cover paper con-
veyance motor (M45) turns ON.
J-7678 When positioning the leading edge of
the cover paper fed from the PB, the
cover paper sensor/Lt (PS46) does
not turn OFF within a specified time
period after the cover paper convey-
ance motor (M45) turns ON.
the cover paper fed from the PB, the
cover paper sensor/Lt (PS46) does
not turn ON within a specified time
period after the cover paper convey-
J-7680 When cover paper is fed from the
main body, the cover paper sensor/Rt
specified time period after the cover
paper entrance sensor (PS3) turns
ON.
J-7682 When starting trimming of the cover
paper fed from the main body, the
cover paper switchback sensor
cover paper conveyance motor (M45)
turns ON.
568
/C6501P/C65hc/C5501
operation
bizhub PRO C6501

PB J-7683 When trimming of the cover paper fed The PB and the Remove jammed
During operation
from the main body is complete, the main body stop paper, if any, from the
cover paper switchback sensor immediately. PB/main body.
cover paper conveyance motor (M45)
turns ON.
the cover paper fed from the main
body, the cover paper sensor/Lt
paper conveyance motor (M45) turns
ON.
the cover paper fed from the main
body, the cover paper sensor/Lt
paper conveyance motor (M45) turns
ON.
J-7686 The booklet end sensor (PS61) does
of time after the booklet conveyance
belt motor (M61) turns ON.
J-7687 When loading first book, the booklet
sensor /1 (PS66) does not turn ON
the booklet conveyance belt up down
J-7688 When first row of book moves, the
book sensor /2 (PS67) does not turn
ON within a specified period of time
after the book movement motor
(M64) turns ON.
J-7689 When feeding paper, the cover paper
conveyance sensor /1 (PS75) does
of time after the cover paper pick up
clutch (MC71) turns ON.
J-7690 The cover paper conveyance sensor /
2 (PS76) does not turn ON within a
cover paper conveyance sensor /1
(PS75) turns ON.
569

operation
bizhub PRO C6501
PB J-7691 When re-feeding paper, the cover The PB and the Remove jammed
During operation
paper conveyance sensor /3 (PS77) main body stop paper, if any, from the
does not turn ON within a specified immediately. PB/main body.
period of time after the cover paper
pick up clutch (MC71) turns ON.
J-7692 The cover paper conveyance sensor /
4 (PS78) does not turn ON within a
cover paper conveyance sensor /3
(PS77) turns ON.
J-7693 The multi feed detection board /2
(MFDTB72) turns OFF.
J-7696 The cover paper switchback sensor
cover paper feed motor (M74) turns
ON.
J-7697 No paper is detected (the paper has
removed) when restarting the job after
recovery.
J-7698 A cover paper has not been con-
veyed to the cover paper table sec-
tion when clamping of inside pages is
finished.
ADU J-9201 After the reverse/exit sensor (PS19) is Stops immedi- Pull out ADU and
turned ON, ADU reverse sensor ately. remove jammed paper,
(PS21) is not turned ON within the if any.
specified time.
J-9202 After the ADU stop sensor (PS20) is
the specified time.
J-9251 ADU reverse sensor (PS21) is ON in —
When idling

J-9252 ADU stop sensor (PS20) is ON in the
idling condition.
J-9301 After reversal of ADU reverse motor Stops immedi-
During operation
(M32) is turned ON, ADU conveyance ately.

the specified time.
J-9351 ADU conveyance sensor (PS61) is —

When idling
570
/C6501P/C65hc/C5501
operation
bizhub PRO C6501

ADU J-9401 After the ADU conveyance sensor Stops immedi- Pull out ADU and
During operation
(PS61) is turned ON, ADU pre-regis- ately. remove jammed paper,
tration sensor (PS23) is not turned if any.
J-9451 ADU pre-registration sensor (PS23) is —

When idling ON in the idling condition.
571
12. MALFUNCTION CODE Field Service Ver.3.0 Jul. 2009
12. MALFUNCTION CODE

/C6501P/C65hc/C5501
bizhub PRO C6501
12.1 Malfunction code list

A. Usage conditions
Error conditions are cleared by turning OFF/ON the sub power switch (SW2) of the main body.
B. Code List
DANGER
• For codes with "**" in the code column (C1540 to 1562: PB glue tank temperature abnormality,
C3501 to 3916: Fusing temperature abnormality), always repair defective parts then set the soft-
ware DipSW3-1 of service mode to 0. If DipSW3-1 is set to 0 before defective parts are fixed, it
may cause fire.
NOTE
• For codes with "*" in the code column, "Turn ON the power switch again" is displayed on the touch
panel. For other codes, "Please call service" is displayed.
Classification Code Causes Resulting opera- Estimated abnormal parts

tion
Commu- C-0001* Communication abnormality Main body Printer control board (PRCB)
Main body
nication between printer control board stops immedi- PF drive board (PFDB)
abnor- (PRCB) and PF drive board ately and main LU drive board (LUDB)
mality (PFDB) or LU drive board relay (RY1) is
(LUDB). turned OFF.
C-0002* Communication abnormality Printer control board (PRCB)
between printer control board Conveyance drive board
(PRCB) and conveyance drive (CDB)
board (CDB).
C-0003* Communication abnormality Printer control board (PRCB)
between printer control board Conveyance drive board
(PRCB) and conveyance drive (CDB)
board (CDB).
Paper C-0101 M41 abnormality detection sig- Printer control board (PRCB)
feed nal was continuously detected Paper feed motor (M41)
motor for the specified time when the
abnor- paper feed motor (M41) was
mality ON.
LU paper C-0102 M101 abnormality detection sig- LU drive board (LUDB)
LU
feed nal was continuously detected Paper feed motor (M1)

motor for the specified time when the
abnor- paper feed motor (M1) was ON.
mality
1 572
Field Service Ver.3.0 Jul. 2009 12. MALFUNCTION CODE
/C6501P/C65hc/C5501
tion
bizhub PRO C6501

PF Paper C-0103 M101 abnormality detection sig- Main body PF drive board (PFDB)
feed nal was continuously detected stops immedi- Paper feed motor (M1)
motor for the specified time when the ately and main
abnor- paper feed motor (M1) was ON. relay (RY1) is
mality turned OFF.
Paper C-0201 After paper lift motor/1 (M38) Printer control board (PRCB)
Main body
feed tray turns ON, upper limit sensor/1 Paper lift motor/1 (M38)
abnor- (PS30) is not turned ON within Upper limit sensor/1 (PS30)
mality specified time.
C-0202 After paper lift motor/2 (M39) Printer control board (PRCB)
turns ON, upper limit sensor/2 Paper lift motor/2 (M39)
(PS36) is not turned ON within Upper limit sensor/2 (PS36)
specified time.
C-0203 After paper lift motor/3 (M40) Printer control board (PRCB)
specified time.
LU paper C-0204 M100 lock signal detected when LU drive board (LUDB)
LU
lift motor the paper lift motor (M100) was Paper lift motor (M100)
abnor- ON.
mality
C-0205 When the upper limit sensor LU drive board (LUDB)
(PS109) or lower limit sensor Paper lift motor (M100)
(PS101) is ON, PS101 or PS109 Upper limit sensor (PS109)
is not turned ON within the Lower limit sensor (PS101)
specified time after the paper lift
motor (M100) is turned ON.
PF paper C-0208 After paper lift motor/1 (M2) PF drive board (PFDB)
PF
lift motor turns ON, upper limit sensor/1 Paper lift motor/1 (M2)
abnor- (PS1) is not turned ON within Upper limit sensor/1 (PS1)
mality specified time.
C-0209 Power line fuse for paper lift PF drive board (PFDB)
motor/1 (M2) out.
C-0211 After paper lift motor/2 (M3) PF drive board (PFDB)
specified time.
C-0212 Power line fuse for paper lift PF drive board (PFDB)
motor/2 (M3) out.
Paper C-0213 After the paper exit pressure AC drive board (ACDB)
Main body
exit sensor (PS10) turns OFF, it is not Printer control board (PRCB)
abnor- turned ON within the specified Paper exit motor (M54)
mality time. Paper exit pressure sensor
(PS10)
573
/C6501P/C65hc/C5501 12. MALFUNCTION CODE Field Service Ver.3.0 Jul. 2009

tion
bizhub PRO C6501
Fan C-0301 M47 abnormality detection sig- Main body Printer control board (PRCB)
Main body
abnor- nal was continuously detected stops immedi- main body fan (M47)
mality for the specified time when the ately and main
main body fan (M47) was ON. relay (RY1) is
Fan C-0302 Any one of the M26, M27, M28 turned OFF. Printer control board (PRCB)
abnor- abnormality detection signal was Tucking fan/1 (M26)
mality continuously detected for the Tucking fan/2 (M27)
specified time when the tucking Tucking fan/3 (M28)
fan/1 (M26), /2(M27) or /3 (M28)
was ON.
C-0303 Either one of the M66 abnormal- Conveyance drive board
ity detection signal was continu- (CDB)
ously detected for the specified ADU fan/1 (M66)
time when the ADU fan/1 (M66)
was ON.
C-0304 While the paper exit fans/1, /2 Printer control board (PRCB)
and /3 (M61, M62 and M63) are Paper exit fan/1 (M61)
turned ON, an error detection Paper exit fan/2 (M62)
signal of either M61, M62 or Paper exit fan/3 (M63)
M63 is detected for the specified
period of time in succession.
C-0305 M36 abnormality detection sig- Printer control board (PRCB)
nal was continuously detected Deodorization fan (M36)
for the specified time when the
deodorization fan (M36) was
ON.
LU fan C-0306 When the paper feed assist fan/ LU drive board (LUDB)
LU
abnor- Rr (M137) was ON, M137 Paper feed assist fan/Rr

mality abnormality detection signal was (M137)
continuously detected for the
specified time.
C-0307 When the paper feed assist fan/ LU drive board (LUDB)
Fr (FM1) was ON, FM1 abnor- Paper feed assist fan/Fr
mality detection signal was con- (FM1)
tinuously detected for the
specified time.
PF fan C-0308 When the paper feed assist fan/ PF drive board (PFDB)
PF
abnor- Fr11 (M136) was ON, FM1 Paper feed assist fan/Fr11
mality abnormality detection signal was (M136)
continuously detected for the
specified time.
C-0309 When the paper feed assist fan/ PF drive board (PFDB)
Fr12 (FM3) was ON, FM3 abnor- Paper feed assist fan/Fr12
specified time.
574
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PF PF fan C-0310 When the paper feed assist fan/ Main body PF drive board (PFDB)
abnor- Rr11 (FM2) was ON, FM2 abnor- stops immedi- Paper feed assist fan/Rr11
mality mality detection signal was con- ately and main (FM2)
tinuously detected for the relay (RY1) is
specified time. turned OFF.
Rr12 (FM4) was ON, FM4 abnor- Paper feed assist fan/Rr12
specified time.
specified time.
specified time.
specified time.
specified time.
C-0316 Either one of the FM11 or FM12 PF drive board (PFDB)
abnormality detection signal was Dehumidifier fan/1 (FM11)
continuously detected for the Dehumidifier fan/2 (FM12)
specified time when the dehu-
midifier fan/1 (FM11), /2 (FM12)
was ON.
C-0317 Either one of the FM13 or FM14 PF drive board (PFDB)
abnormality detection signal was Dehumidifier fan/3 (FM13)
continuously detected for the Dehumidifier fan/4 (FM14)
specified time when the dehu-
midifier fan/3 (FM13), /4 (FM14)
was ON.
575

tion
bizhub PRO C6501
PF fan C-0318 Either one of the FM10 or FM9 Main body PF drive board (PFDB)
PF
abnor- abnormality detection signal was stops immedi- Ventilation fan/1 (FM10)
mality continuously detected for the ately and main Ventilation fan/2 (FM9)
specified time when the ventila- relay (RY1) is
tion fan/1 (FM10), /2 (FM9) was turned OFF.
ON.
LU fan C-0320 FM3 abnormality detection sig- LU drive board (LUDB)
LU
abnor- nal was continuously detected Dehumidifier fan/1 (FM3)

mality for the specified time when the
dehumidifier fan/1 (FM3) was
ON.
C-0321 FM4 abnormality detection sig- LU drive board (LUDB)
nal was continuously detected Dehumidifier fan/2 (FM4)
for the specified time when the
dehumidifier fan/2 (FM4) was
ON.
Fan C-0322 M67 abnormality detection sig- Conveyance drive board
Main body
abnor- nal was continuously detected (CDB)

mality for the specified time when the ADU fan /2 (M67)
ADU fan /2 (M67) was ON.
LU C-0401 24VDC is not supplied to LU. LU drive board (LUDB)
LU
power DC power unit/1 (DCPS/1)

abnor- DC power unit/2 (DCPS/2)
mality C-0402 12VDC is not supplied to LU. LU drive board (LUDB)
DC power unit/1 (DCPS/1)
PF C-0403 24VDC is not supplied to PF. PF drive board (PFDB)
PF
power DC power unit/1 (DCPS/1)

abnor- C-0404 24VDC is not supplied to PF. PF drive board (PFDB)
mality DC power unit/2 (DCPS/2)
C-0405 12VDC is not supplied to PF. PF drive board (PFDB)
DC power unit/1 (DCPS/1)
C-0406 24VDC is not supplied to PF. PF drive board (PFDB)
AC drive board in PF (ACDB)
PF tem- C-0407 Temperature sensor/3 (TEMS/3) PF drive board (PFDB)
perature detected abnormality signal con- Temperature sensor/3
sensor tinuously for the specified time. (TEMS/3)
abnor- C-0408 Temperature sensor/4 (TEMS/4) PF drive board (PFDB)
mality detected abnormality signal con- Temperature sensor/4
tinuously for the specified time. (TEMS/4)
PF fan C-0409 Fan heater/Up (HTR3) overheat PF drive board (PFDB)
heater abnormality. AC drive board in PF (ACDB)
abnor- Temperature sensor/3 (TEMS/3) Fan heater/Up (HTR3)
mality detected temperature abnormal- Temperature sensor/3
ity signal continuously for the (TEMS/3)
specified time.
576
/C6501P/C65hc/C5501
tion
bizhub PRO C6501

PF PF fan C-0410 Fan heater/Lw (HTR4) overheat Main body PF drive board (PFDB)
heater abnormality. stops immedi- AC drive board in PF (ACDB)
abnor- Temperature sensor/4 (TEMS/4) ately and main Fan heater /Lw (HTR4)
mality detected temperature abnormal- relay (RY1) is Temperature sensor/4
ity signal continuously for the turned OFF. (TEMS/4)
specified time.
C-0411 Fan heater/Up (HTR3) low-tem- PF drive board (PFDB)
perature abnormality. AC drive board in PF (ACDB)
Temperature sensor/3 (TEMS/3) Fan heater /Up (HTR3)
detected temperature abnormal- Temperature sensor/3
specified time.
C-0412 Fan heater/Lw (HTR4) Low-tem- PF drive board (PFDB)
perature abnormality. AC drive board in PF (ACDB)
Temperature sensor/4 (TEMS/4) Fan heater/Lw (HTR4)
detected temperature abnormal- Temperature sensor /4
specified time.
C-0413 Fan heater/Up (HTR3) rising PF drive board (PFDB)
temperature abnormality. AC drive board in PF (ACDB)
Temperature sensor/3 (TEMS/3) Fan heater /Up (HTR3)
detected temperature does not Temperature sensor/3
reach the specified temperature (TEMS/3)
C-0414 Fan heater/Lw (HTR4) rising PF drive board (PFDB)
temperature abnormality. AC drive board in PF (ACDB)
Temperature sensor/4 (TEMS/4) Fan heater/Lw (HTR4)
detected temperature does not Temperature sensor/4
reach the specified temperature (TEMS/4)
LU tem- C-0415 Temperature sensor (TEMS) LU drive board (LUDB)
LU
perature detected abnormality signal con- Temperature sensor (TEMS)

sensor tinuously for the specified time.
abnor-
mality
LU dehu- C-0416 Dehumidifier heater/3 (HTR2) LU drive board (LUDB)
midifier overheat abnormality. LUAC drive board (ACDB)
heater Temperature sensor (TEMS) Dehumidifier heater /3
abnor- detected temperature abnormal- (HTR2)
mality ity signal continuously for the Temperature sensor (TEMS)
specified time.
577

tion
bizhub PRO C6501
LU dehu- C-0417 Dehumidifier heater /3 (HTR2) Main body LU drive board (LUDB)
LU
midifier low-temperature abnormality. stops immedi- LUAC drive board (ACDB)

heater Temperature sensor (TEMS) ately and main Dehumidifier heater /3
abnor- detected temperature abnormal- relay (RY1) is (HTR2)
mality ity signal continuously for the turned OFF. Temperature sensor (TEMS)
specified time.
C-0418 Dehumidifier heater /3 (HTR2)
rising temperature abnormality.
Temperature sensor (TEMS)
detected temperature does not
reach the specified temperature
FS C-1005 Communication abnormality. Main body and Printer control board (PRCB)
FS
abnor- FS stop imme- FNS control board (FNSCB)

mality diately and
main relay
(RY1) is turned
OFF.
FD C-1006 Communication abnormality. Main body and Printer control board (PRCB)
FD
abnor- FD stop imme- FD control board (FDCB)

mality diately and
main relay
(RY1) is turned
OFF.
SD C-1007 Communication abnormality. Main body and Printer control board (PRCB)
SD
abnor- SD stop imme- SD control board (SDCB)

mality diately and
main relay
(RY1) is turned
OFF.
RU C-1008 Communication abnormality. Main body and Printer control board (PRCB)
RU
abnor- RU stop imme- RU control board (RUCB)

mality diately and
main relay
(RY1) is turned
OFF.
PB C-1009 Communication abnormality Main body and PB control board (PBCB)
PB
abnor- between Main CPU in the PB PB stop imme- Control program

mality control board (PBCB) and Sub diately and
CPU1. main relay
C-1010 Communication abnormality (RY1) is turned PB control board (PBCB)
between Main CPU in the PB OFF. Control program
control board (PBCB) and Sub
CPU2.
C-1011 Paper feed abnormality between PB control board (PBCB)
the main body and the PB. Control program
578
/C6501P/C65hc/C5501
tion
bizhub PRO C6501

GP GP C-1012 Communication abnormality. Main body and Printer control board (PRCB)
abnor- GP stop imme- Punch Controller PCB
mality diately and
main relay
(RY1) is turned
OFF.
FS-520/ C-1101 Shift unit does not reach the shift Main body and FNS control board (FNSCB)
FS
607 position or the home position FS stop imme- Shift roller Motor (M2)
abnor- within the specified time. diately and Shift roller home sensor
mality main relay (PS18)
(RY1) is turned
OFF.
FS-521 C-1102 The tray up down motor (M3) FNS control board (FNSCB)
abnor- does not turn OFF after the FNS drive board (FNSDB)
mality specified time has passed. Tray up down motor (M3)
Or, the motor was rotating at a Tray upper limit sensor (PS16)
speed out of the specified range Tray lower limit sensor (PS3)
for over the permitted operating
time.
FS-520/ After the main tray up down FNS control board (FNSCB)
607 motor (M3) operation is started, Main tray up down motor
abnor- the main tray upper limit sensor (M3)
mality (PS2) is not turned ON within Main tray upper limit sensor
the specified time. (PS2)
FS-521 C-1103 After the alignment motors/Rr FNS control board (FNSCB)
abnor- (M5), /Fr (M22) home position FNS drive board (FNSDB)
mality search operation started, the Alignment motor /Rr (M5)
alignment home sensors/Rr Alignment motor /Fr (M22)
(PS8) and /Fr (PS31) are not Alignment Home Sensor /Rr
turned ON within the specified (PS8)
time. Alignment Home Sensor /Fr
(PS31)
FS-520/ After the alignment motor /Up FNS control board (FNSCB)
607 (M5) operation is started, the Alignment motor /Up (M5)
abnor- alignment home sensor /Up Alignment home Sensor /Up
mality (PS8) is not turned ON/OFF (PS8)
FS-521 C-1104 Main tray exit motor (M7) was FNS control board (FNSCB)
abnor- rotating at a speed out of the FNS drive board (FNSDB)
mality specified range for over the per- Main tray exit motor (M7)
mitted operating time.
FS-520/ After the paper exit roller motor FNS control board (FNSCB)
607 (M7) operation is started, the Paper exit roller motor (M7)
abnor- motor speed does not reach the
mality prescribed speed within the
specified time.
579 2

tion
bizhub PRO C6501
FS-521 C-1105 After the paper exit opening Main body and FNS control board (FNSCB)
FS
abnor- motor (M8) operation is started, FS stop imme- FNS drive board (FNSDB)
mality the paper exit opening unit does diately and Paper exit opening motor
not reach the specified opening main relay (M8)
position within the specified (RY1) is turned Paper exit opening sensor
time. OFF. (PS12)
FS-520/ After the paper exit opening FNS control board (FNSCB)
607 motor (M8) operation is started, Paper exit opening motor
abnor- the paper exit home sensor (M8)
mality (PS12) is not turned ON/OFF Paper exit home sensor
within the specified time. (PS12)
FS-521 C-1106 After stapler movement motor FNS control board (FNSCB)
abnor- (M11) home position search FNS drive board (FNSDB)
mality operation started, the stapler Stapler movement motor
movement home sensor (PS11) (M11)
are not turned ON within the Stapler movement home
specified time. sensor (PS11)
FS-520/ After the stapler movement FNS control board (FNSCB)
607 motor (M11) operation is started, Stapler movement motor
abnor- the Stapler movement home (M11)
mality sensor (PS11) is not turned ON/ Stapler movement home
OFF within the specified time. sensor (PS11)
FS-521 C-1107 After the stapler rotation motor FNS control board (FNSCB)
abnor- (M4) home position search oper- FNS drive board (FNSDB)
mality ation started, the stapler rotation Stapler rotation motor (M4)
home sensor (PS14) are not Stapler rotation home sensor
time.
FS-520/ After the clincher rotation motor FNS control board (FNSCB)
607 (M4) operation is started, the Clincher rotation motor (M4)
abnor- clincher rotation home sensor Clincher rotation home sen-
mality (PS14) is not turned ON/OFF sor (PS14)
FS-521 C-1108 After the stapler rotation motor FNS control board (FNSCB)
abnor- (M4) home position search oper- FNS drive board (FNSDB)
mality ation started, the stapler rotation Stapler rotation motor (M4)
home sensor (PS14) are not Stapler rotation home sensor
time.
FS-520/ After stapler rotation motor (M6) FNS control board (FNSCB)
607 operation is started, the stapler Stapler rotation motor (M6)
abnor- rotation home sensor (PS13) Stapler rotation home sensor
mality are not turned ON/OFF within (PS13)
the specified time.
580
/C6501P/C65hc/C5501
tion
bizhub PRO C6501

FS FS-521 C-1109 After the stapler motor /Fr (M31) Main body and FNS control board (FNSCB)
abnor- operation is started, the stapler FS stop imme- FNS drive board (FNSDB)
mality home sensor/Fr (PS41) is not diately and Stapler board (STB)
turned ON within the specified main relay Stapler motor/Fr (M31)
time. (RY1) is turned Stapler home sensor /Fr (PS41)
FS-520/ After the stapler motor /Fr (M14) OFF. FNS control board (FNSCB)
607 operation is started, the stapler Stapler motor /Fr (M14)
abnor- motor home sensor /Fr (PS31) Stapler motor home sensor /
mality is not turned ON within the Fr (PS31)
specified time.
FS-521 C-1110 After the stapler motor/Rr (M30) FNS control board (FNSCB)
abnor- operation is started, the opera- FNS drive board (FNSDB)
mality tion is not completed within the Stapler board (STB)
specified time and the stapler Stapler motor /Rr (M30)
home sensor/Rr (PS40) is not Stapler home sensor /Rr
turned ON . (PS40)
FS-520/ After the stapler motor /Rr (M9) FNS control board (FNSCB)
607 operation is started, the stapler Stapler motor /Rr (M9)
abnor- motor home sensor /Rr (PS30) Stapler motor home sensor /
mality is not turned ON within the Rr (PS30)
specified time.
FS-520/ C-1111 After the clincher motor /Fr FNS control board (FNSCB)
607 (M15) operation is started, the Clincher motor /Fr (M15)
abnor- clincher motor home sensor /Fr Clincher motor home sensor
mality (PS33) is not turned ON within /Fr (PS33)
the specified time.
C-1112 After the clincher motor /Rr FNS control board (FNSCB)
(M10) operation is started, the Clincher motor /Rr (M10)
clincher motor home sensor /Rr Clincher motor home sensor
(PS32) is not turned ON within /Rr (PS32)
the specified time.
FS-521 C-1113 After the rear stopper motor (M26) FNS control board (FNSCB)
abnor- home position search operation FNS drive board (FNSDB)
mality started, the rear stopper home Rear stopper motor (M26)
sensor (PS35) are not turned ON Rear stopper home sensor
within the specified time. (PS35)
FS-607 After the saddle stitching stopper FNS control board (FNSCB)
abnor- motor (M18) operation is started, Saddle stitching stopper
mality the saddle stitching stopper home motor (M18)
sensor (PS23) is not turned ON Saddle stitching stopper
within the specified time. home sensor (PS23)
C-1114 After the alignment motor /Lw FNS control board (FNSCB)
(M16) operation is started, the Alignment motor /Lw (M16)
alignment home sensor /Lw Alignment home sensor /Lw
(PS24) is not turned ON within (PS24)
the specified time.
581

tion
bizhub PRO C6501
FS-607 C-1115 After the folding knife motor Main body and FNS control board (FNSCB)
FS
abnor- (M19) operation is started, the FS stop imme- Folding knife motor (M19)
mality Folding knife home sensor diately and Folding knife home sensor
(PS22) is not turned ON within main relay (PS22)
the specified time. (RY1) is turned
FS-607 C-1116 After the folding transfer motor OFF. FNS control board (FNSCB)
abnor- (M20) operation is started, the Folding transfer motor (M20)
mality motor speed does not reach the
prescribed speed within the
specified time.
PI C-1124 After the tray lift motor /Lw FNS control board (FNSCB)
PI
abnor- (M202) operation is started, the PI drive board (PIDB)

mality tray upper limit sensor /Lw Tray lift motor /Lw (M202)
(PS209) or tray lower limit sensor Tray upper limit sensor /Lw
/Lw (PS210) is not turned ON (PS209)
within the specified time. Tray lower limit sensor /Lw
(PS210)
C-1125 After tray lift motor /Up (M201) FNS control board (FNSCB)
operation is started, the tray PI drive board (PIDB)
upper limit sensor /Up (PS204) Tray lift motor /Up (M201)
or tray lower limit sensor /Up Tray upper limit sensor /Up
the specified time. Tray lower limit sensor /Up
(PS205)
C-1126 After the PI conveyance motor FNS control board (FNSCB)
(M203) operation is started, the PI drive board (PIDB)
motor speed does not reach the PI conveyance motor (M203)
prescribed speed within the
specified time.
PK C-1127 After punch shift motor (M302) FNS control board (FNSCB)
PK
abnor- operation is started, the punch Punch drive board (PDB)

mality shift home sensor (PS303) is Punch shift motor (M302)
not turned ON within the speci- Punch shift home sensor
fied time. (PS303)
C-1132 After punch motor (M301) oper- FNS control board (FNSCB)
ation is started, the punch home Punch drive boar (PDB)
sensor (PS301) is not turned Punch motor (M301)
ON within the specified time. Punch home sensor
(PS301)
FS-520/ C-1137 After gate motor (M12) operation FNS control board (FNSCB)
FS
607 is started, the Gate home sensor Gate motor (M12)

abnor- (PS16) is not turned ON within Gate home sensor (PS16)
mality the specified time.
582
/C6501P/C65hc/C5501
tion
bizhub PRO C6501

FS FS-521 C-1140 After the Paper exit arm motor Main body and FNS control board (FNSCB)
abnor- (M23) operation is started, the FS stop imme- FNS drive board (FNSDB)
mality operation is not completed diately and Paper exit arm motor (M23)
within the specified time and the main relay Paper exit arm home sensor
paper exit arm home sensor (RY1) is turned (PS9)
(PS9) is not turned ON . OFF.
Or the motor was rotating at a
speed out of specified range for
over the permitted operating
time.
C-1141 After the stack assist guide FNS control board (FNSCB)
motor (M24) starts operations, FNS drive board (FNSDB)
the stack assist home sensor Stack assist guide motor
(PS32) does not turn ON within (M24
a specified period of time. Stack assist home sensor
(PS32)
C-1142 The intermediate roller release FNS control board (FNSCB)
solenoid (SD7) does not turn ON FNS drive board (FNSDB)
within a specified period of time Intermediate roller release
after SD7 does not turn OFF solenoid (SD7)
within a specified period of time Alignment motor /Fr (M22)
after the alignment motor /Fr Alignment motor /Rr (M5)
and Rr/ (M22 and M5) turn OFF.
Or, SD7 does not turn ON within
a specified period of time after it
turns OFF.
C-1143 The FNS conveyance motor FNS control board (FNSCB)
(M1) operation is not started FNS conveyance motor (M1)
after pressing start button. Or Main body paper exit sensor
the FNS conveyance motor (M1) (PS37)
does not shift the speed for FNS entrance sensor (PS4)
each processing.
C-1144 The paper exit alignment plate FNS control board (FNSCB)
home sensor /Fr (PS18) does FNS drive board (FNSDB)
not turn ON within a specified Paper exit alignment motor/
period of time after the paper Fr (M15)
exit alignment motor /Fr (M15) Paper exit alignment plate
starts the home position search home sensor
operation. Or, even after a speci- /Fr (PS18)
fied period of time after M15
starts the operation, it does not
stop.
583 2

tion
bizhub PRO C6501
FS-521 C-1145 The paper exit alignment plate Main body and FNS control board (FNSCB)
FS
abnor- home sensor /Rr (PS19) does FS stop imme- FNS drive board (FNSDB)
mality not turn ON within a specified diately and Paper exit alignment motor/
period of time after the paper main relay Rr (M14)
exit alignment motor /Rr (M14) (RY1) is turned Paper exit alignment plate
starts the home position search OFF. home sensor /Fr (PS19)
operation. Or, even after a speci-
fied period of time after M14
starts the operation, it does not
stop.
C-1146 The bypass roller release home FNS control board (FNSCB)
sensor (PS13) does not turn ON FNS drive board (FNSDB)
within a specified period of time Bypass roller release motor
after the bypass roller release (M12)
motor (M12) starts the home Bypass roller release home
position search operation. sensor (PS13)
Or, even after a specified period
of time after M12 starts the
operation, it does not stop.
C-1147 The paper exit alignment plate FNS control board (FNSCB)
retraction home sensor (PS24) FNS drive board (FNSDB)
does not turn ON within a speci- Paper exit alignment plate
fied period of time after the retraction motor (M18)
paper exit alignment plate Paper exit alignment plate
retraction motor (M18) starts the retraction home sensor
home position search opera- (PS24)
tion. Or, even after a specified
period of time after M18 starts
the operation, it does not stop.
C-1148 The stacker entrance roller FNS control board (FNSCB)
release home sensor (PS23) FNS drive board (FNSDB)
does not turn ON within a speci- Stacker entrance roller
fied period of time after the release motor (M16)
stacker entrance roller release Stacker entrance roller
motor (M16) starts the home release home sensor (PS23)
position search operation. Or,
even after a specified period of
time after M16 starts the opera-
tion, it does not stop.
LS C-1201 After stacker tray up down Main body and Stacker tray up down motor
LS
abnor- motor (M1) turns ON, stacker LS stop imme- (M1)

mality tray encoder sensor (PS2) is not diately and LS control board (LSCB)
turned ON within the specified main relay
time. Otherwise the initial opera- (RY1) is turned
tion or the stacker tray up/down OFF.
operation is not complete within
the specified time.
584
/C6501P/C65hc/C5501
tion
bizhub PRO C6501

LS LS C-1202 After shift unit motor (M5) turns Main body and Shift unit motor (M5)
abnor- ON, shift unit home sensor LS stop imme- LS control board (LSCB)
mality (PS11) is not turned OFF within diately and
the specified time. Otherwise main relay
PS11 is not turned ON within the (RY1) is turned
specified time. OFF.
C-1203 After alignment motor (M7) turns Alignment motor (M7)
ON, alignment plate home sen- LS control board (LSCB)
sor (PS12) is not turned OFF
within the specified time. Other-
wise PS12 is not turned ON
C-1204 After the grip conveyance motor Grip conveyance motor (M4)
(M4) turns ON, grip conveyance
sensor (PS5) is not turned ON
C-1205 When the stacker tray up down Stacker tray up down motor
motor (M1) up is ON, stacker (M1)
tray upper limit switch (MS2) is Stacker tray upper limit
ON. switch (MS2)
C-1206 When the stacker tray up down Stacker tray up down motor
motor (M1) down is ON, stacker (M1)
tray lower limit switch (MS3) is Stacker tray lower limit
ON. switch (MS3)
FD C-1221 After the 1st folding release Main body and 1st folding release motor
FD
abnor- motor (M14) turns ON, 1st fold- FD stop imme- (M14)
mality ing cam home sensor (PS55) is diately and Fold drive board (FDB)
not turned ON within the speci- main relay 1st folding cam home sensor
fied time. (RY1) is turned (PS55)
C-1222 After the 2nd folding release OFF. 2nd folding release motor
motor (M15) turns ON, 2nd fold- (M15)
ing cam home sensor (PS56) is Fold drive board (FDB)
not turned ON within the speci- 2nd folding cam home sen-
fied time. sor (PS56)
C-1223 After the 3rd folding releasie 3rd folding release motor
motor (M16) turns ON, 3rd fold- (M16)
ing cam home sensor (PS57) is Folding drive board (FDB)
not turned ON within the speci- 3rd folding cam home sen-
fied time. sor (PS57)
585

tion
bizhub PRO C6501
FD C-1224 After two holes punch home Main body and Punch motor (M10)
FD
abnor- position recovery operation FD stop imme- Punch drive board (PDB)
mality started, 2 holes punch home diately and 2 holes punch home sensor
sensor (PS8) is not turned OFF main relay (PS8)
within the specified time. Other- (RY1) is turned
wise, after punch motor (M10) OFF.
turns ON, 2 holes punch home
sensor (PS8) is not turned OFF.
C-1225 After 3 holes/4 holes punch Punch motor (M10)
home position recovery opera- Punch drive board (PDB)
tion started, 3 holes/4 holes 3 holes/4 holes punch home
punch home sensor (PS9) is not sensor (PS9)
turned OFF within the specified
time. Otherwise, after punch
motor (M10) turns ON, 3 holes/4
holes punch home sensor (PS9)
is not turned OFF.
C-1226 After the alignment home posi- Alignment motor (M12)
tion recovery operation started, Punch drive board (PDB)
alignment plate home sensor Alignment plate home sensor
the specified time. Otherwise,
after alignment motor (M12)
turns ON, alignment plate home
C-1227 After the punch registration tab Punch registration motor
home position recovery opera- (M13)
tion started, punch registration Punch drive board (PDB)
home sensor (PS11) is not Punch registration home
turned ON within the specified sensor (PS11)
time. Otherwise, after punch
registration motor (M13) turns
ON, punch registration home
C-1228 After main tray home position Tray up down motor (M11)
search started, main tray upper Main tray upper limit sensor
limit sensor (PS20) is not turned (PS20)
ON within the specified time. Punch drive board (PDB)
Otherwise, after tray up down
motor (M11) turns ON, main tray
upper limit sensor (PS20) is not
turned OFF.
C-1229 After the tray up down motor Tray up down motor (M11)
(M11) was turned ON, main tray Punch drive board (PDB)
lower limit sensor (PS22) is not Main tray lower limit sensor
time.
586
/C6501P/C65hc/C5501
tion
bizhub PRO C6501

FD FD C-1230 After lowering FD paper lift Main body and Paper lift motor/Up (M8)
abnor- motor/Up (M8) turns ON, PI lift FD stop imme- PI drive board (PIDB)
mality plate home sensor/Up (PS34) is diately and PI lift plate home sensor/Up
not turned ON within the speci- main relay (PS34)
fied time. Otherwise, after rising (RY1) is turned PI upper limit sensor/Up
paper lift motor/Up (M8) turns OFF. (PS32)
ON, PI upper limit sensor/Up
(PS32) is not turned ON within
the specified time.
C-1231 After lowering FD paper lift Paper lift motor/Lw (M9)
motor/Lw (M9) turns ON, PI lift PI drive board (PIDB)
plate home sensor/Lw (PS40) is PI lift plate home sensor/Lw
not turned ON within the speci- (PS40)
fied time. Otherwise, after rising PI upper limit sensor/Lw
paper lift motor/Lw (M9) turns (PS38)
ON, PI upper limit sensor/Lw
(PS38) is not turned ON within
the specified time.
C-1232 M1 abnormality detection signal Entrance conveyance motor
was continuously detected for (M1)
the specified time when the Punch drive board (PDB)
entrance conveyance motor
(M1) was ON.
C-1233 M3 abnormality detection signal Intermediate conveyance
was continuously detected for motor (M3)
the specified time when the Punch drive board (PDB)
intermediate conveyance motor
(M3) was ON.
C-1234 M7 abnormality detection signal PI Conveyance motor (M7)
was continuously detected for PI drive board (PIDB)
the specified time when the PI
conveyance motor (M7) was
ON.
C-1235 M17 abnormality detection sig- Main tray paper exit motor
nal was continuously detected (M17)
for the specified time when the Punch drive board (PDB)
main tray paper exit motor (M17)
was ON.
SD C-1241 After budle exit drive motor (M5) Main body and Bundle exit motor (M5)
SD
abnor- home position search operation SD stops Scraps press home sensor
mality started, scraps press home sen- immediately (PS48)
sor (PS48) is not turned ON after and main relay SD control board (SDCB)
specified time passed. (RY1) is turned SD drive board (SDDB)
OFF.
587

tion
bizhub PRO C6501
SD C-1242 After folding main scan align- Main body and Folding main scan alignment
SD
abnor- ment motor/Fr (M7) home posi- SD stops motor/Fr

mality tion search operation started, immediately (M7)
folding main scan alignment and main relay Folding main scan alignment
home sensor/Fr1 (PS18) is not (RY1) is turned home sensor
turned ON within the specified OFF. /Fr1 (PS18)
time. Otherwise, operation not SD control board (SDCB)
complete after M7 operation SD drive board (SDDB)
started and specified time has
passed.
C-1243 After folding sub scan alignment Folding sub scan alignment
motor (M8) home position exit motor (M8)
search operation started, fold- Folding exit home sensor
ing exit home sensor (PS24) is (PS24)
not turned ON after the specified SD control board (SDCB)
time has passed. Otherwise, SD drive board (SDDB)
operation not complete after M8
speed down operation started
and specified time has passed.
C-1244 After saddle stitching alignment Saddle stitching alignment
motor/Rt (M9) home position motor/Rt (M9)
search operation started, sad- Saddle stitching alignment
dle stitching alignment home home sensor/Rt (PS28)
sensor/Rt (PS28) is not turned SD control board (SDCB)
ON after specified time has SD drive board (SDDB)
passed. Otherwise, operation
not complete after M9 operation
started and specified time has
passed.
C-1245 After bundle arm motor (M10) Bundle arm motor (M10)
home position search operation Bundle arm home sensor
started, bundle arm home sen- (PS32)
sor (PS32) is not turned ON after SD control board (SDCB)
the specified time has passed. SD drive board (SDDB)
Otherwise, operation not com-
plete after M10 operation started
C-1246 After bundle clip motor (M11) Bundle clip motor (M11)
home position search operation Bundle clip upper limit sen-
started, bundle clip upper limit sor (PS33)
sensor (PS33) is not turned ON Bundle clip lower limit sensor
after the specified time has (PS30)
passed. Otherwise, operation SD control board (SDCB)
not complete after M11 opera- SD drive board (SDDB)
tion started and specified time
has passed.
588
/C6501P/C65hc/C5501
tion
bizhub PRO C6501

SD SD C-1247 After bundle registration motor Main body and Bundle registration motor
abnor- (M12) home position search SD stop imme- (M12)
mality operation started, bundle regis- diately and Bundle registration home
tration home sensor (PS34) is main relay sensor (PS34)
not turned ON after the specified (RY1) is turned SD control board (SDCB)
time has passed. Otherwise, OFF. SD drive board (SDDB)
operation not complete after
M12 operation started and
specified time has passed.
C-1248 After overlap motor (M13) home Overlap motor (M13)
position search operation Overlap home sensor (PS17)
started, overlap home sensor SD control board (SDCB)
(PS17) is not turned ON after the SD drive board (SDDB)
specified time has passed. Oth-
erwise, operation not complete
after M13 operation started and
C-1249 After folding main scan align- Folding main scan alignment
ment motor/Rr (M14) home motor/Rr (M14)
position search operation Folding main scan alignment
started, folding main scan align- home sensor/Rr (PS19)
ment home sensor/Rr (PS19) is SD control board (SDCB)
not turned ON after the specified SD drive board (SDDB)
time has passed. Otherwise,
C-1250 After the stapler movement Stapler movement motor
motor (M15) home position (M15)
search operation started, the Stapler movement home
stapler movement home sensor sensor (PS25)
(PS25) is not turned ON after the SD control board (SDCB)
specified time has passed. Oth- SD drive board (SDDB)
C-1251 After saddle stitching alignment Saddle stitching alignment
motor/Lt (M16) home position motor/Lt (M16)
search operation started, sad- Saddle stitching alignment
dle stitching alignment home home sensor/Lt (PS29)
sensor/Lt (PS29) is not turned SD control board (SDCB)
ON after specified time has SD drive board (SDDB)
not complete after M16 opera-
has passed.
589

tion
bizhub PRO C6501
SD C-1252 After the bundle press move- Main body and Bundle press movement
SD
abnor- ment motor (M17) home position SD stop imme- motor (M17)
mality search operation started, the diately and Bundle press movement
bundle press movement home main relay home sensor (PS36)
sensor (PS36) is not turned ON (RY1) is turned SD control board (SDCB)
after the specified time has OFF. SD drive board (SDDB)
not complete after M17 opera-
has passed.
C-1253 After 1st folding blade motor 1st folding blade motor
(M18) home position search (M18)
operation started, 1st folding 1st folding blade home sen-
blade home sensor/2 (PS21) is sor/1 (PS20), /2 (PS21)
PS20 is not turned ON.
C-1254 After 2nd folding blade motor 2nd folding blade motor
operation started, 2nd folding 2nd folding blade home sen-
blade home sensor/2 (PS23) is sor/2 (PS22), /2 (PS23)
PS22 is not turned ON.
C-1255 After the clincher up down motor Clincher up down motor
operation started, the clincher Clincher up down home sen-
up down home sensor (PS26) is sor (PS26)
590
/C6501P/C65hc/C5501
tion
bizhub PRO C6501

SD SD C-1256 After saddle stitching press Main body and Saddle stitching press motor
abnor- motor (M21) home position SD stop imme- (M21)
mality search operation started, sad- diately and Saddle stitching press home
dle stitching press home sensor main relay sensor (PS27)
(PS27) is not turned ON after (RY1) is turned SD control board (SDCB)
specified time has passed. Oth- OFF. SD drive board (SDDB)
C-1257 After the bundle arm rotation Bundle arm rotation motor
motor (M22) home position (M22)
search operation started, the Bundle arm rotation home
bundle arm rotation home sen- sensor (PS31)
sor (PS31) is not turned ON after SD control board (SDCB)
the specified time has passed. SD drive board (SDDB)
Otherwise, operation not com-
plete after M22 operation started
C-1258 After bundle press motor (M23) Bundle press motor (M23)
home position search operation Bundle press home sensor
started, bundle press home sen- (PS37)
sor (PS37) is not turned ON after Bundle press lower limit sen-
the specified time has passed. sor (PS47)
Otherwise, operation not com- SD control board (SDCB)
plete after M23 operation started SD drive board (SDDB)
C-1259 After the bundle press stage up Bundle press stage up down
down motor (M24) home posi- motor (M24)
tion search operation started, Bundle press stage up down
the bundle stage up down home home sensor (PS35)
sensor (PS35) is not turned ON Bundle press stage up down
after the specified time has upper limit sensor (PS45)
passed. Otherwise, after M24 SD control board (SDCB)
operation started, PS35 or bun- SD drive board (SDDB)
dle press stage up down upper
limit sensor (PS45) is not turned
ON after the specified time has
passed.
C-1260 After the guide shaft motor Guide shaft motor (M25)
(M25) home position search Guide shaft home sensor
operation started, the guide (PS46)
shaft home sensor (PS46) is not SD control board (SDCB)
turned ON after the specified SD drive board (SDDB)
time has passed. Otherwise,
591

tion
bizhub PRO C6501
SD C-1261 After stapler motor/Rt (M29) Main body and Stapler section/Rt
SD
abnor- operation started, stapler home SD stop imme- SD control board (SDCB)
mality sensor/Rt (HS1) or clincher start diately and SD drive board (SDDB)
sensor/Rt (HS2) is not turned main relay
ON after specified time has (RY1) is turned
passed. OFF.
C-1262 After stapler motor/Lt (M30) Stapler section/Lt
operation started, stapler home SD control board (SDCB)
sensor/Lt (HS3) or clincher start SD drive board (SDDB)
sensor/Lt (HS4) is not turned ON
after specified time has passed.
C-1263 Operation not complete after Trimmer blade motor (M31)
trimmer blade motor (M31) oper- Trimmer blade home sensor
ation started and specified time (PS50)
has passed. Trimmer blade upper limit
sensor (PS51)
SD drive board (SDDB)
C-1264 Operation not complete after Trimmer press motor (M32)
trimmer press motor (M32) oper- Trimmer press home sensor
ation started and specified time (PS53)
has passed. Trimmer press upper limit
sensor (PS52)
C-1265 Operation not complete after Bundle arm assist motor
bundle arm assist motor (M26) (M26)
operation started and specified Bundle arm assist home
time has passed. sensor (PS38)
Bundle arm assist upper limit
sensor (PS39)
C-1266 Rotation abnormality detected Entrance conveyance motor
continuously for the specified (M1)
time during entrance convey- SD control board (SDCB)
ance motor (M1) operation. SD drive board (SDDB)
C-1267 Rotation abnormality detected Horizontal conveyance
continuously for the specified motor (M2)
time during horizontal convey- SD control board (SDCB)
ance motor (M2) operation. SD drive board (SDDB)
592
/C6501P/C65hc/C5501
tion
bizhub PRO C6501

SD SD C-1268 Rotation abnormality detected Main body and Folding entrance motor (M3)
abnor- continuously for the specified SD stop imme- SD control board (SDCB)
mality time during folding entrance diately and SD drive board (SDDB)
motor (M3) operation. main relay
C-1269 Rotation abnormality detected (RY1) is turned Folding conveyance motor
continuously for the specified OFF. (M4)
time during folding conveyance SD control board (SDCB)
motor (M4) operation. SD drive board (SDDB)
C-1270 Rotation abnormality detected Bundle exit motor (M5)
continuously for the specified SD control board (SDCB)
time during bundle exit motor SD drive board (SDDB)
(M5) operation.
C-1271 Rotation abnormality detected Folding sub scan alignment
continuously for the specified exit motor (M8)
time during folding sub scan SD control board (SDCB)
alignment exit motor (M8) opera- SD drive board (SDDB)
tion.
C-1272 Rotation abnormality is detected Trimmer paddle motor (M33)
for a specified period of time in SD control board (SDCB)
succession while the trimmer SD drive board (SDDB)
paddle motor (M33) is driving.
C-1273 The trimmer blade upper limit Trimmer blade motor (M31)
sensor (PS62) does not turn ON Trimmer blade upper limit
even after a specified period of sensor (PS62)
time after the trimmer blade SD control board (SDCB)
motor (M31) starts the home SD drive board (SDDB)
position search operation.
C-1275 The wire slack sensor (PS62) Wire slack sensor (PS62)
detected the slack of the trim- SD control board (SDCB)
mer edge drive wire. SD drive board (SDDB)
LS C-1301 FM1 abnormality detection sig- Main body and Paper cooling fan motor/Fr
LS
abnor- nal was continuously detected LS stop imme- (FM1)

mality for the specified time when the diately and LS control board (LSCB)
paper cooling fan motor/Fr main relay
(FM1) was ON. (RY1) is turned
C-1302 FM2 abnormality detection sig- OFF. Paper cooling fan motor/1
nal was continuously detected (FM2)
for the specified time when the LS control board (LSCB)
paper cooling fan motor/1 (FM2)
was ON.
C-1303 FM3 abnormality detection sig- Paper cooling fan motor/Mi
paper cooling fan motor/Mi
(FM3) was ON.
593 2

tion
bizhub PRO C6501
LS C-1304 FM4 abnormality detection sig- Main body and Motor cooling fan motor
LS
abnor- nal was continuously detected LS stop imme- (FM4)

mality for the specified time when the diately and LS control board (LSCB)
motor cooling fan motor (FM4) main relay
was ON. (RY1) is turned
OFF.
C-1305 FM5 abnormality detection sig- Paper cooling fan motor/Rr
paper cooling fan motor/Rr
(FM5) was ON.
SD C-1311 An error detection signal is Main body and Scrap removal fan motor
SD
abnor- detected continuously for speci- SD stop imme- (FM1)

mality fied time period while the scraps diately and SD control board (SDCB)
removal fan motor (FM1) is main relay SD drive board (SDDB)
started or driving. (RY1) is turned
OFF.
RU C-1321 M2 abnormality detection signal Main body and RU control board (RUCB)
RU-504
abnor- was continuously detected for RU stop imme- Paper fan /1 (M2)
mality the specified time when the diately and
paper fan/1 (M2) was ON. main relay
C-1322 M3 abnormality detection signal (RY1) is turned RU control board (RUCB)
was continuously detected for OFF. Paper fan /2 (M3)
the specified time when the
paper fan/2 (M3) was ON.
C-1323 M4 abnormality detection signal RU control board (RUCB)
was continuously detected for Paper fan /3 (M4)
the specified time when the
paper fan/3 (M4) was ON.
was continuously detected for Ventilation assist fan /1 (M6)
the specified time when the ven-
tilation assist fan/1 (M6) was ON.
was continuously detected for Ventilation assist fan /2 (M7)
the specified time when the ven-
tilation assist fan/2 (M7) was ON.
2 594
/C6501P/C65hc/C5501
tion
bizhub PRO C6501

RU-506 RU C-1281 FD alignment motor (M3) drive Main body and RU control board (RUCB)
abnor- abnormality. RU stop imme- FD alignment motor (M3)
mality The FD alignment home sensor diately and FD alignment home sensor
(PS3) does not turn ON even main relay (PS3)
after a specified period of time (RY1) is turned
after M3 starts the home posi- OFF.
tion search operation. Or, even
after a specified period of time
after M3 starts the operation, it
does not stop.
C-1282 CD alignment motor (M4) drive RU control board (RUCB)
abnormality. CD alignment motor (M4)
The CD alignment home sensor CD alignment home sensor
(PS4) does not turn ON even (PS4)
after M4 starts the home posi-
tion search operation. Or, even
after M4 starts the operation, it
does not stop.
PB C-1330 An error detection signal is Main body and PB control board (PBCB)
PB
abnor- detected continuously for speci- PB stop imme- PB drive board (PBDB)
mality fied time period while the cover diately and Cover paper tray fan /1
paper tray fan/1 (M71) is started main relay (M71)
or driving. (RY1) is turned
C-1331 An error detection signal is OFF. PB control board (PBCB)
detected continuously for speci- PB drive board (PBDB)
fied time period while the cover Cover paper tray fan /2
paper tray fan/2 (M72) is started (M72)
or driving.
C-1332 An error detection signal is PB control board (PBCB)
detected continuously for speci- PB drive board (PBDB)
fied time period while the ventila- Exhaust fan /1 (M80)
tion fan/1 (M80) is started of
driving.
C-1333 An error detection signal is AC drive board (ACDB)
detected continuously for speci- PB control board (PBCB)
fied time period while the PB drive board (PBDB)
exhaust fan /1 (M80) is started Exhaust fan /2 (M81)
or driving.
C-1334 An error detection signal is AC drive board (ACDB)
detected continuously for speci- PB control board (PBCB)
fied time period while the PB drive board (PBDB)
exhaust fan /2 (M81) is started Pellet supply cooling fan
or driving. motor (M4)
595 2

tion
bizhub PRO C6501
RU C-1341 Stack assist fan /Fr (FM1) rota- Main body and RU control board (RUCB)
RU-506
abnor- tion abnormality. RU stop imme- Stack assist fan /Fr (FM1)
mality Rotation abnormality detected diately and
continuously for the specified main relay
time during FM1 operation. (RY1) is turned
C-1342 Stack assist fan /Rr (FM2) rota- OFF. RU control board (RUCB)
tion abnormality. Stack assist fan /Rr (FM2)
Rotation abnormality detected
continuously for the specified
time during FM2 operation.
FS C-1402 Non-volatile memory error. Main body and FNS control board (FNSCB)
FS
abnor- FS stop imme- FNS control board (FNSCB)

mality diately and
main relay
(RY1) is turned
OFF.
FD C-1403 Non-volatile memory error. Main body and FD control board (FDCB)
FD
abnor- FD stop imme-

mality diately and
main relay
(RY1) is turned
OFF.
SD C-1404 Non-volatile memory error. Main body and SD control board (SDCB)
SD
abnor- SD stop imme-

mality diately and
main relay
(RY1) is turned
OFF.
RU C-1405 Non-volatile memory error. Main body and RU control board (RUCB)
RU
abnor- RU stop imme-

mality diately and
main relay
(RY1) is turned
OFF.
PB C-1406 Non-volatile memory error in the Main body and PB control board (PBCB)
PB
abnor- PB control board (PBCB). PB stop imme- Control program

mality diately to turn
OFF the main
relay (RL1).
SD C-1411 SD drive board (SDDB) 5V error. Main body and SD drive board (SDDB)
SD
abnor- SD stop imme-

mality diately and
main relay
(RY1) is turned
OFF.
2 596
/C6501P/C65hc/C5501
tion
bizhub PRO C6501

FS-520/607 FS C-1431 FS received operation start from Main body and Software bug.
abnor- the main body when unready. FS stop imme-
mality diately and
main relay
(RY1) is turned
OFF.
FD C-1432 Communication abnormality in Main body and Software bug.
FD
abnor- the FD. FD stop imme-

mality diately and
main relay
(RY1) is turned
OFF.
SD C-1433 Communication abnormality in Main body and Software bug.
SD
abnor- the SD. SD stop imme-

mality diately and
main relay
(RY1) is turned
OFF.
RU C-1434 RU received operation start from Main body and Software bug.
RU
abnor- the main body when unready. RU stop imme-

mality diately and
main relay
(RY1) is turned
OFF.
PB C-1435 Message queue full or the con- Main body and PB control board (PBCB)
PB
abnor- trol abnormality of Sub CPU1 in PB stop imme- Control program

mality the PB control board (PBCB). diately to turn
C-1436 Message queue full or the con- OFF the main PB control board (PBCB)
trol abnormality of Sub CPU2 in relay (RL1). Control program
the PB control board (PBCB).
C-1437 Message queue of the commu- Control program
nication among tasks in the PB
is full.
FD C-1451 FD received operation start sig- Main body and Software bug.
FD
abnor- nal from the main body when the FD stop imme-
mality FD is unready. diately and
main relay
(RY1) is turned
OFF.
SD C-1452 SD received operation start sig- Main body and Software bug.
SD
abnor- nal from the main body when the SD stop imme-
mality SD is unready. diately and
main relay
(RY1) is turned
OFF.
597

tion
bizhub PRO C6501
RU C-1453 RU received operation start sig- Main body and Software bug.
RU
abnor- nal from the main body when the RU stop imme-
mality RU is unready. diately and
main relay
(RY1) is turned
OFF.
PB C-1454 PB operation prohibition abnor- Main body and Control program.
PB
abnormality. PB stop imme-

mality PB received operation start sig- diately and
nal from the main body when the main relay
PB is unready. (RY1) is turned
C-1501 The entrance conveyance has OFF. PB control board (PBCB)
not been completed within a PB drive board (PBDB)
specified period of time after the Entrance conveyance motor
entrance conveyance motor (M1)
(M1) turns ON.
detected continuously for a PB drive board (PBDB)
specified time period while the Intermediate conveyance
intermediate conveyance motor motor (M2)
(M2) is driving.
C-1504 The SC entrance conveyance PB control board (PBCB)
has not been completed within a PB drive board (PBDB)
specified period of time after the SC entrance conveyance
SC entrance conveyance motor motor (M11)
(M11) turns ON.
C-1505 The switchback conveyance has PB control board (PBCB)
specified period of time after the SC switchback conveyance
SC switchback conveyance motor (M12)
C-1506 The switchback roller release PB control board (PBCB)
operation has not completed PB drive board (PBDB)
within a specified time period SC switchback release
after the SC switchback release motor (M13)
C-1507 The SC alignment has not been PB control board (PBCB)
completed within a specified PB drive board (PBDB)
period of time after the SC align- SC alignment motor (M15)
ment motor (M15) turns ON.
C-1508 The SC paper bundle convey- PB control board (PBCB)
ance has not been completed PB drive board (PBDB)
within a specified period of time SC bundle conveynace
after the SC bundle conveyance motor (M17)
2 598
/C6501P/C65hc/C5501
tion
bizhub PRO C6501

PB PB C-1509 The SC roller release operation Main body and PB control board (PBCB)
abnor- has not completed within a PB stop imme- PB drive board (PBDB)
mality specified time period after the diately and SC roller release motor (M18)
SC roller release motor (M18) main relay
turns ON. (RY1) is turned
C-1510 The movement of the SC OFF. PB control board (PBCB)
entrance has not completed PB drive board (PBDB)
within a specified time period Clamp entranse movement
after the clamp entrance move- motor (M19)
ment motor (M19) turns ON.
C-1511 The SC entrance roller release PB control board (PBCB)
operation has not completed PB drive board (PBDB)
within a specified time period Clamp entranse roller release
after the clamp entrance roller motor (M20)
release motor (M20) turns ON
C-1512 After clamp alignment motor PB control board (PBCB)
(M21) turns on, the alignment PB drive board (PBDB)
operation is not complete within Clamp alignment motor
the specified time. (M21)
C-1513 After clamp motor (M22) turns PB control board (PBCB)
on, the open/close process of PB drive board (PBDB)
the clamp section is not com- Clamp motor (M22)
plete within the specified time.
C-1514 The rotation of the clamp section PB control board (PBCB)
has not completed within a PB drive board (PBDB)
specified time period after the Clamp rotation motor (M23)
clamp rotation motor (M23)
turns ON.
C-1515 The movement of the glue tank PB control board (PBCB)
specified time period after the Glue tank movement motor
glue tank movement motor (M31)
(M31) turns ON.
detected continuously for a PB drive board (PBDB)
specified time period while the Glue apply roller motor (M32)
glue apply roller motor (M32) is
driving.
C-1517 The count of a specified number PB control board (PBCB)
of pellets, which is counted by PB drive board (PBDB)
the pellet count sensor (PS37), Pellet supply motor (M33)
has not been reached after the
pellet supply motor (M33) turns
ON. The status was detected by
a specified number of times in
succession.
599

tion
bizhub PRO C6501
PB C-1518 The movement of the pellet sup- Main body and PB control board (PBCB)
PB
abnor- ply arm has not completed PB stop imme- PB drive board (PBDB)
mality within a specified time period diately and pellet supply arm motor
after the pellet supply arm motor main relay (M34)
(M34) turns ON. (RY1) is turned
C-1519 The alignment of the up/down OFF. PB control board (PBCB)
cover paper has not been com- PB drive board (PBDB)
pleted within a specified period Cover paper alignment
of time after the cover paper motor (M41)
alignment motor (M41) turns
ON.
C-1520 The booklet exit has not been PB control board (PBCB)
period of time after the booklet Book exit motor (M42)
exit motor (M42) turns ON.
C-1521 The driven arm /Rt shaking PB control board (PBCB)
operation start has not been PB drive board (PBDB)
completed within a specified Cover paper conveyance
period of time after the cover arm motor /Rt (M43)
paper conveyance arm motor /
Rt (M43) turns ON.
C-1522 The driven arm /Lt shaking oper- PB control board (PBCB)
ation start has not been com- PB drive board (PBDB)
pleted within a specified period Cover paper conveyance
of time after the cover paper arm motor /Lt (M44)
conveyance arm motor /Lt (M44)
turns ON.
C-1523 The cover paper conveyance PB control board (PBCB)
start has not been completed PB drive board (PBDB)
within a specified period of time Cover paper conveyance
after the cover paper convey- motor (M45)
C-1524 The cover paper table up or PB control board (PBCB)
down movement has not com- PB drive board (PBDB)
pleted within a specified time Cover paper table up down
period after the cover paper motor /Fr (M46)
table up down motor/Fr (M46)
turns ON.
C-1525 The cover paper table up or PB control board (PBCB)
down movement has not com- PB drive board (PBDB)
pleted within a specified time Cover paper table up down
period after the cover paper motor /Rr (M47)
table up down motor/Rr (M47)
turns ON.
2 600
/C6501P/C65hc/C5501
tion
bizhub PRO C6501

PB PB C-1526 The movement of the cover Main body and PB control board (PBCB)
abnor- paper folding plate/Rt has not PB stop imme- PB drive board (PBDB)
mality completed within a specified diately and Cover paper folding motor /
time period after the cover paper main relay Rt (M48)
folding motor/Rt (M48) turns (RY1) is turned
ON. OFF.
C-1527 The movement of the cover PB control board (PBCB)
paper folding plate/Lt has not PB drive board (PBDB)
completed within a specified Cover paper folding motor /
time period after the cover paper Lt (M49)
folding motor/Lt (M49) turns ON.
C-1528 The trimming of the cover paper PB control board (PBCB)
specified time period after the Cutter motor (M50)
cutter motor (M50) turns ON.
C-1530 The booklet movement of the PB control board (PBCB)
booklet conveyance section has PB drive board (PBDB)
not been completed within a Book conveyance belt motor
specified period of time after the (M61)
booklet conveyance belt motor
(M61) turns ON.
C-1531 The carriage section movement PB control board (PBCB)
according to paper size has not PB drive board (PBDB)
completed after the book con- Book conveyance belt
veyance belt movement motor movement motor (M62)
(M62) turns ON.
C-1532 The up/down process of the PB control board (PBCB)
carriage section has not com- PB drive board (PBDB)
pleted within a specified time Book conveyance belt up
period after the cover paper down motor (M63)
conveyance belt up/down motor
(M63) turns ON.
C-1534 The pressing of the back edge of PB control board (PBCB)
the book process has not com- PB drive board (PBDB)
pleted within a specified time Book stopper motor (M65)
period after the book stopper
C-1537 The tray up movement has not PB control board (PBCB)
time period after the cover paper Cover paper tray lift motor
tray lift motor (M73) turns ON. (M73)
C-1538 The paper feed operation has PB control board (PBCB)
specified period of time after the Cover paper feed motor
cover paper feed motor (M74) (M74)
turns ON.
601 2

tion
bizhub PRO C6501
PB C-1540 After the warm-up is started, Main body and AC drive board (ACDB)
PB
abnor- ** temperature detected by the PB stop imme- Glue tank heater (H1)
mality glue tank temperature sensor / diately and Glue apply roller heater (H2)
Md (TH3) has not risen to a pre- main relay PB control board (PBCB)
scribed level within a specified (RY1) is turned PB drive board (PBDB)
time period. OFF. Glue apply roller motor (M32)
Glue tank temperature sen-
sor /Md (TH3)
C-1541 After the warm-up is started, AC drive board (ACDB)
** temperature detected by the Glue tank heater (H1)
glue tank temperature sensor / Glue apply roller heater (H2)
Lw (TH4) has not risen to a pre- PB control board (PBCB)
scribed level within a specified PB drive board (PBDB)
time period. Glue apply roller motor (M32)
sor /Lw (TH4)
C-1542 After the warm-up is started, AC drive board (ACDB)
** temperature detected by the Glue tank heater (H1)
glue apply roller temperature Glue apply roller heater (H2)
sensor (TH1) has not risen to a PB control board (PBCB)
prescribed level within a speci- PB drive board (PBDB)
fied time period. Glue apply roller motor (M32)
Glue apply roller temperature
sensor (TH1)
C-1543 After the pellet supply, tempera- AC drive board (ACDB)
** ture detected by the glue tank Glue tank heater (H1)
temperature sensor/Up (TH2) Glue apply roller heater (H2)
has not risen to a prescribed PB control board (PBCB)
level within a specified time PB drive board (PBDB)
period. Glue apply roller motor (M32)
sor /Up (TH2)
C-1544 During standby, after the glue AC drive board (ACDB)
** tank heater (H1) is turned ON, Glue tank heater (H1)
temperature detected by the Glue apply roller heater (H2)
glue tank temperature sensor / PB control board (PBCB)
Md (TH3) has not risen to a pre- PB drive board (PBDB)
scribed level within a specified Glue apply roller motor (M32)
time period. Glue tank temperature sen-
sor /Md (TH3)
602
/C6501P/C65hc/C5501
tion
bizhub PRO C6501

PB PB C-1545 When control temperature is Main body and AC drive board (ACDB)
abnor- ** reached, after the glue tank PB stop imme- Glue tank heater (H1)
mality heater (H1) is turned ON, tem- diately and Glue apply roller heater (H2)
perature detected by the glue main relay PB control board (PBCB)
tank temperature sensor/Lw (RY1) is turned PB drive board (PBDB)
(TH4) has not risen to a pre- OFF. Glue apply roller motor (M32)
scribed level within a specified Glue tank temperature sen-
time period. sor /Lw (TH4)
C-1546 When control temperature is AC drive board (ACDB)
** reached, after the glue tank Glue tank heater (H1)
heater (H1) is turned ON, tem- Glue apply roller heater (H2)
perature detected by the glue PB control board (PBCB)
apply roller temperature sensor PB drive board (PBDB)
(TH1) has not risen to a pre- Glue apply roller motor (M32)
scribed level within a specified Glue apply roller temperature
time period. sensor (TH1)
C-1547 An abnormal high temperature is AC drive board (ACDB)
** detected by the glue apply roller Glue tank heater (H1)
temperature sensor (TH1). Glue apply roller heater (H2)
PB drive board (PBDB)
Glue apply roller motor (M32)
sensor (TH1)
** detected by the glue tank tem- Glue tank heater (H1)
perature sensor /Up (TH2). Glue apply roller heater (H2)
sor /Up (TH2)
perature sensor /Md (TH3). Glue apply roller heater (H2)
sor /Md (TH3)
603

tion
bizhub PRO C6501
PB C-1550 An abnormal high temperature is Main body and AC drive board (ACDB)
PB
abnor- ** detected by the glue tank tem- PB stop imme- Glue tank heater (H1)
mality perature sensor /Lw (TH4). diately and Glue apply roller heater (H2)
main relay PB control board (PBCB)
(RY1) is turned PB drive board (PBDB)
OFF. Glue apply roller motor (M32)
sor /Lw (TH4)
C-1551 The glue apply roller temperature AC drive board (ACDB)
** sensor (TH1) high temperature Glue tank heater (H1)
hardware detection. Glue apply roller heater (H2)
An abnormal high temperature is PB control board (PBCB)
detected by the glue apply roller PB drive board (PBDB)
temperature sensor (TH1). Glue apply roller motor (M32)
sensor (TH1)
C-1552 The glue tank temperature sen- AC drive board (ACDB)
** sor /Up (TH2) high temperature Glue tank heater (H1)
detected by the glue tank tem- PB drive board (PBDB)
perature sensor /Up (TH2). Glue apply roller motor (M32)
sor /Up (TH2)
** sor /Md (TH3) high temperature Glue tank heater (H1)
perature sensor /Md (TH3). Glue apply roller motor (M32)
sor /Md (TH3)
** sor /Lw (TH4) high temperature Glue tank heater (H1)
perature sensor /Lw (TH4). Glue apply roller motor (M32)
sor /Lw (TH4)
604
/C6501P/C65hc/C5501
tion
bizhub PRO C6501

PB PB C-1555 An abnormal low temperature is Main body and AC drive board (ACDB)
abnor- ** detected by the glue apply roller PB stop imme- Glue tank heater (H1)
mality temperature sensor (TH1), after diately and Glue apply roller heater (H2)
completion of warm-up. main relay PB control board (PBCB)
(RY1) is turned PB drive board (PBDB)
OFF. Glue apply roller motor (M32)
sensor (TH1)
C-1556 An abnormal low temperature is AC drive board (ACDB)
perature sensor /Up (TH2), after Glue apply roller heater (H2)
reaching glue supply control PB control board (PBCB)
temperature. PB drive board (PBDB)
sor /Up (TH2)
** detected by the glue tank Glue tank heater (H1)
temperature sensor /Md (TH3), Glue apply roller heater (H2)
after the warming-up is com- PB control board (PBCB)
pleted. PB drive board (PBDB)
sor /Md (TH3)
perature sensor /Lw (TH4), after Glue apply roller heater (H2)
the warming-up is completed. PB control board (PBCB)
sor /Lw (TH4)
C-1559 Glue apply roller temperature AC drive board (ACDB)
** sensor (TH1) low temperature Glue tank heater (H1)
abnormality hardware detection. Glue apply roller heater (H2)
TH1 detected low temperature PB control board (PBCB)
abnormality of the glue apply PB drive board (PBDB)
roller abnormality detection sig- Glue apply roller motor (M32)
nal after the warming-up is com- Glue apply roller temperature
pleted. sensor (TH1)
605

tion
bizhub PRO C6501
PB C-1560 Glue tank temperature sensor/ Main body and AC drive board (ACDB)
PB
abnor- ** Up (TH2) low temperature abnor- PB stop imme- Glue tank heater (H1)
mality mality hardware detection. diately and Glue apply roller heater (H2)
TH2 detected low temperature main relay PB control board (PBCB)
abnormality of the glue tank (RY1) is turned PB drive board (PBDB)
abnormality detection signal OFF. Glue apply roller motor (M32)
after reaching the glue supply Glue tank temperature sen-
control temperature. sor /Up (TH2)
C-1561 Glue tank temperature sensor/ AC drive board (ACDB)
** Md (TH3) low temperature Glue tank heater (H1)
abnormality of the glue tank PB drive board (PBDB)
abnormality detection signal Glue apply roller motor (M32)
after the warming-up is com- Glue tank temperature sen-
pleted. sor /Md (TH3)
C-1562 Glue tank temperature sensor / AC drive board (ACDB)
** Lw (TH4) low temperature Glue tank heater (H1)
abnormality of the glue tank PB drive board (PBDB)
abnormality detection signal Glue apply roller motor (M32)
after the warming-up is com- Glue tank temperature sen-
pleted. sor /Lw (TH4)
Commu- C-2001 Communication abnormality Printer control board (PRCB)
Main body
nication between printer control board Drum motor /Y (M14)

abnor- (PRCB) and the drum motor/Y Drum motor /M (M15)
mality (M14) or /M (M15).
C-2002 Communication abnormality Printer control board (PRCB)
between printer control board Drum motor /C (M16)
(PRCB) and the drum motor/C Drum motor /K (M17)
(M16) or /K (M17).
between printer control board Transfer belt motor (M18)
(PRCB) and transfer belt motor
(M18).
between printer control board Drum motor /Y (M14)
(PRCB) and the drum motor/Y Drum motor /M (M15)
(M14) or /M (M15).
between printer control board Drum motor /C (M16)
(PRCB) and the drum motor/C Drum motor /K (M17)
(M16) or /K (M17).
606
/C6501P/C65hc/C5501
tion
bizhub PRO C6501

Main body Commu- C-2006 Communication abnormality Main body Printer control board (PRCB)
nication between printer control board stops immedi- Transfer belt motor (M18)
abnor- (PRCB) and transfer belt motor ately and main
mality (M18). relay (RY1) is
Develop- C-2201 When the developing motor/Y turned OFF. Printer control board (PRCB)
ing (M20) was ON, M20 abnormality Developing motor /Y (M20)
motor detection signal was continu-
abnor- ously detected for the specified
mality time.
C-2202 When the developing motor/M Printer control board (PRCB)
(M21) was ON, M201 abnormal- Developing motor /M (M21)
ity detection signal was continu-
ously detected for the specified
time.
C-2203 When developing motor/C (M22) Printer control board (PRCB)
was ON, M22 abnormality Developing motor /C (M22)
detection signal was continu-
time.
C-2204 When the developing motor/K Printer control board (PRCB)
(M23) was ON, M23 abnormality Developing motor /K (M23)
time.
Drum C-2211 When the drum motor/Y (M14) Printer control board (PRCB)
motor was ON, M14 abnormality Drum motor /Y (M14)
abnor- detection signal was continu-
mality ously detected for the specified
time.
C-2212 When the drum motor/M (M15) Printer control board (PRCB)
was ON, M15 abnormality Drum motor /M (M15)
time.
C-2213 When the drum motor/C (M16) Printer control board (PRCB)
was ON, M16 abnormality Drum motor /C (M16)
time.
C-2214 When drum motor /K (M17) was Printer control board (PRCB)
ON, M17 abnormality detection Drum motor /K (M17)
signal was continuously
detected for the specified time.
607

tion
bizhub PRO C6501
Transfer C-2220 When the transfer belt motor Main body Printer control board (PRCB)
Main body
belt unit (M18) was ON, M18 abnormality stops immedi- Transfer belt motor (M18)
abnor- detection signal was continu- ately and main
mality ously detected for the specified relay (RY1) is
time. turned OFF.
C-2221 When the 1st transfer HP sensor Printer control board (PRCB)
(PS15) is ON, PS15 is not turned 1st transfer pressing/releas-
OFF within the specified time ing motor (M19)
after the 1st transfer pressing/ 1st transfer HP sensor
releasing motor (M19) is turned (PS15)
ON. When PS15 is OFF, PS15 is
not turned ON within the speci-
fied time after M19 is turned ON.
Toner C-2222 When either of the toner supply Printer control board (PRCB)
supply motor/Y, /M, /C, /K (M49, M50, Toner supply drive board
abnor- M51, or M52), toner bottle motor (TSDB)
mality (M53), or toner bottle clutch /Y, / Toner supply motor/Y (M49)
M, /C, /K (MC14, MC15, MC16, Toner supply motor/M (M50)
or MC17) was ON, either abnor- Toner supply motor/C (M51)
mality detection signal was con- Toner supply motor/K (M52)
tinuously detected for the Toner bottle motor (M53)
specified time. Toner bottle clutch/Y (MC14)
Toner bottle clutch/M (MC15)
Toner bottle clutch/C (MC16)
Toner bottle clutch/K (MC17)
Fan C-2301 When charge intake fan (M48) Printer control board (PRCB)
abnor- was ON, M48 abnormality Toner supply drive board
mality detection signal was continu- (TSDB)
ously detected for the specified Charge intake fan (M48)
time.
C-2302 Either one of the M12 or M13 Printer control board (PRCB)
abnormality detection signal was Drum fan/1 (M12)
continuously detected for the Drum fan/2 (M13)
specified time when the drum
fan/1 (M12), /2 (M13) was ON.
C-2303 When the transfer belt fan (M11) Printer control board (PRCB)
was ON, M11 abnormality Transfer belt fan (M11)
time.
C-2304 While the developing fans/1, /2 Printer control board (PRCB)
and /3 (M45, M46 and M64) are Developing fan/1 (M45)
turned ON, an error detection Developing fan/2 (M46)
signal of either M45, M46 or Developing fan/3 (M64)
M64 is detected for the specified
period of time in succession.
608
/C6501P/C65hc/C5501
tion
bizhub PRO C6501

Main body Eraser C-2401 Erase lamp/Y (EL/Y) set cannot Main body Printer control board (PRCB)
lamp be detected. stops immedi- Erase lamp/Y (EL/Y)
abnor- C-2402 Erase lamp/M (EL/M) set cannot ately and main Printer control board (PRCB)
mality be detected. relay (RY1) is Erase lamp/M (EL/M)
C-2403 Erase lamp/C (EL/C) set cannot turned OFF. Printer control board (PRCB)
be detected. Erase lamp/C (EL/C)
C-2404 Erase lamp/K (EL/K) set cannot Printer control board (PRCB)
be detected. Erase lamp/K (EL/K)
TCR C-2411 TCR sensor/Y (TCRS/Y) output Printer control board (PRCB)
sensor cannot be controlled. TCR sensor/Y (TCRS/Y)
abnor- C-2412 TCR sensor/M (TCRS/M) output Printer control board (PRCB)
mality cannot be controlled. TCR sensor/M (TCRS/M)
C-2413 TCR sensor/C (TCRS/C) output Printer control board (PRCB)
cannot be controlled. TCR sensor/C (TCRS/C)
C-2414 TCR sensor/K (TCRS/K) output Printer control board (PRCB)
cannot be controlled. TCR sensor/K (TCRS/K)
Develop- C-2421 After the developing motor/Y Printer control board (PRCB)
ing drive (M20) is ON, or TCR sensor/Y Developing motor/Y (M20)
abnor- (TCRS/Y) initial adjustment TCR sensor/Y (TCRS/Y)
mality started, TCRS/Y detected lower
than the specified value after the
specified time passed.
C-2422 After the developing motor/M Printer control board (PRCB)
(M21) is ON, or TCR sensor/M Developing motor/M (M21)
(TCRS/M) initial adjustment TCR sensor/M (TCRS/M)
started, TCRS/Y detected lower
C-2423 After the developing motor/C Printer control board (PRCB)
(M22) is ON, or TCR sensor/C Developing motor/C (M22)
(TCRS/C) initial adjustment TCR sensor/C (TCRS/C)
started, TCRS/C detected lower
C-2424 After the developing motor/K Printer control board (PRCB)
(M23) is ON, or TCR sensor/K Developing motor/K (M23)
(TCRS/K) initial adjustment TCR sensor/K (TCRS/K)
started, TCRS/K detected lower
609

tion
bizhub PRO C6501
TCR C-2431 On initial adjustment of the TCR Main body Printer control board (PRCB)
Main body
sensor sensor/Y, when the control volt- stops immedi- Developing motor/Y (M20)
initial age was minimal, TCRS/Y ately and main TCR sensor/Y (TCRS/Y)
adjust- detected over specified value. relay (RY1) is
ment C-2432 On initial adjustment of the TCR turned OFF. Printer control board (PRCB)
abnor- sensor/M, when the control volt- Developing motor/M (M21)
mality age was minimal, TCRS/M TCR sensor/M (TCRS/M)
(low den- detected over specified value.
sity) C-2433 On initial adjustment of the TCR Printer control board (PRCB)
sensor/C, when the control volt- Developing motor/C (M22)
age was minimal, TCRS/C TCR sensor/C (TCRS/C)
detected over specified value.
C-2434 On initial adjustment of the TCR Printer control board (PRCB)
sensor/K, when the control volt- Developing motor/K (M23)
age was minimal, TCRS/K TCR sensor/K (TCRS/K)
TCR C-2441 On initial adjustment of the TCR Printer control board (PRCB)
sensor sensor/Y, when the control volt- Developing motor/Y (M20)
initial age was maximum, TCRS/Y TCR sensor/Y (TCRS/Y)
adjust- detected under the specified
ment value.
abnor- C-2442 On initial adjustment of the TCR Printer control board (PRCB)
mality sensor/M, when the control volt- Developing motor/M (M21)
(high age was maximum, TCRS/M TCR sensor/M (TCRS/M)
density) detected over specified value.
sensor/C, when the control volt- Developing motor/C (M22)
age was maximum, TCRS/C TCR sensor/C (TCRS/C)
sensor/K, when the control volt- Developing motor/K (M23)
age was maximum, TCRS/K TCR sensor/K (TCRS/K)
Toner C-2451 When the developing motor/Y Printer control board (PRCB)
low den- (M20) is ON, the maximum Developing motor/Y (M20)
sity detection value of TCR sensor/Y TCR sensor/Y (TCRS/Y)
abnor- (TCRS/Y) is the specified value
mality and the difference between the
maximum detection value and
the minimum detection value is
over the specified value.
610

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Ⅰ 調整

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

bizhub PRO C6501/C6501P/C65hc/C5501

SAFETY AND IMPORTANT WARNING ITEMS

DESCRIPTION ITEMS FOR DANGER,

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

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

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

:Precaution when using the

:Prohibition when using the

:Direction when using the

• Using any fuse or thermostat not specified by KMBT.

• Disabling fuse functions or bridging fuse terminals with

• Disabling relay functions (such as wedging paper between

• Disabling safety functions (interlocks, safety circuits, etc.)

• Making any modification to the product unless instructed

• Using parts not specified by KMBT

[2] POWER PLUG SELECTION

Power Cord Set or Power Plug

• Conductors in the power cable must be connected to ter-

[3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE

Connection to Power Supply

• Connect power plug directly into wall outlet having same

• If two or more power cords can be plugged into the wall

• Make sure the power cord is plugged in the wall outlet

Connection to Power Supply

Power Plug and Cord

• Check whether the power cord is not stepped on or

• Check whether the power cord is damaged. Check

• Do not bundle or tie the power cord.

Power Plug and Cord

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

Prohibited Installation Places

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

When not Using the Product for a long time

Inspection before Servicing

• Before conducting an inspection, be sure to disconnect

• The area around the fixing unit is hot.

Work Performed with the Product Powered On

• Take every care when servicing with the external cover

• Check wiring for squeezing and any other damage.

• Carefully remove all toner remnants and dust from electri-

• Check high-voltage cables and sheaths for any damage.

• Check electrode units such as a charging corona unit for

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

• When replacing a lithium battery, replace it with a new lith-

• Check the interlock switch and actuator for loosening and

• Make sure that all screws, components, wiring, connec-

• Never throw the used cartridge and toner into fire.

Handling of Service Materials

• Do not replace the cover or turn the product ON before

• Use only a small amount of cleaner at a time and take

• When using any solvent, ventilate the room well.

5. Used Batteries Precautions

INDICATION OF WARNING ON THE MACHINE

(Large Capacity Unit LU-202)

MEASURES TO TAKE IN CASE OF

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

<Theory of Operation section>

OUTLINE: System configuration, product specifications,

<Field service section>

OUTLINE: System configuration, and product specifications

(1) bizhub PRO C6501/C6501P/C65hc/C5501: Main body