7661-4396-11

SERVICE MANUAL

GENERAL SERVICE

Di551/Di650 Di5510/Di7210
Di5510: Europe and North America only.

2004.01 Ver. 1.0

There are using both Official Options name and Popular Options name in the Di551/Di650/Di5510/Di7210 Service Manual and Option Service Manual. EDH-4, EDH-7 FN-112, FN-6, FN-121, FN-10, FN-113, FN-122 OT-104 C-403, C-404 Cover Inserter B, Cover Inserter E PK-2, PK-5 ZK-2, ZK-3 In-System Writer : RADF : FNS : SF : LT & LCT : PI : PK : PZ : ISW
KONICA BUSINESS TECHNOLOGIES CORPORATION COPYRIGHT 2003

N56AF1200

CONTENTS
SAFETY AND IMPORTANT WARNING ITEMS IMPORTANT NOTICE.S-1
LIST OF DIFFERENCE for Di551/Di650 and Di5510/Di7210..1

. S-1.S-1

1. OUTLINE
OUTLINE OF SYSTEM..1-1 Di551/Di650/Di5510/Di7210 PRODUCT SPECIFICATIONS...1-3 CENTRAL CROSS-SECTIONAL VIEW..1-5 DRIVE SYSTEM DIAGRAM..1-7 [1] Fixing/Web Drive Section..1-7 [2] Drum Drive Section.1-8 [3] Developing Drive Section..1-8 [4] Paper Feed/Vertical Conveyance/Tray Up Drive Section...1-9 [5] By-pass Paper Feed/ADU Pre-registration Drive Section..1-11 [6] Charging and Transfer/Separation Wire Cleaning Drive Section..1-12 [7] ADU Conveyance Drive Section.1-13 [8] Paper Exit Drive Section.1-14 [9] Toner Supply Drive Section..1-14 [10] Optics Drive Section..1-15
SAFETY WARNINGS SAFETY INFORMATION

.S-2.S-10. S-10

IMPORTANT INFORMATION SAFETY CIRCUITS

. S-11.S-13

INDICATION OF WARNING ON THE MACHINE

2. UNIT EXPLANATION

EXTERNAL SECTION.. 2-A-1 [1] Composition.. 2-A-1 DRIVE SECTION... 2-B-1 [1] Composition.. 2-B-1 [2] Mechanisms.. 2-B-1 [3] M2 (Drum) Control.. 2-B-2 [4] M4 (Fixing) Control.. 2-B-3 SCANNER SECTION..2-C-1 [1] Composition..2-C-1 [2] Mechanisms..2-C-1 [3] M11 (Scanner) Control..2-C-2 [4] Exposure control.2-C-5 [5] Original Read Control..2-C-5 [6] APS Control..2-C-7 [7] AE Control...2-C-8 WRITE UNIT...2-D-1 [1] Composition..2-D-1 [2] Mechanisms..2-D-1 [3] M15 (Polygon) Control..2-D-2 [4] Image Write Control.2-D-3 DRUM UNIT... 2-E-1 [1] Composition.. 2-E-1 [2] Mechanisms.. 2-E-1 [3] Separation Claw Control. 2-E-2 [4] Paper Guide Plate Control. 2-E-2 CORONA UNIT SECTION.. 2-F-1 [1] Composition.. 2-F-1 [2] Mechanisms.. 2-F-1 [3] Charging Control. 2-F-2 [4] Transfer/Separation Control. 2-F-3 [5] M14 (Charger Cleaning) Control. 2-F-4

3 DIS./ASSEMBLY

2 UNIT EXPLANATION 3 DIS./ASSEMBLY
DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION
3 DIS./ASSEMBLY 1 OUTLINE
M10 (Transfer/Separation Cleaning) Control.. 2-F-5 [7] PCL/TSL Control. 2-F-6 DEVELOPING UNIT.. 2-G-1 [1] Composition.. 2-G-1 [2] Mechanisms.. 2-G-1 [3] M3 (Developing) Control. 2-G-2 [4] Developing Bias Control. 2-G-3 [5] Dmax Control... 2-G-4 [6] Gradation Correction Control.. 2-G-6 [7] Dot Diameter Correction Control. 2-G-7 [8] Toner Density Control.. 2-G-7 [9] FM4 (Developing Suction) Control. 2-G-8 TONER SUPPLY UNIT..2-H-1 [1] Composition..2-H-1 [2] Mechanisms..2-H-1 [3] Toner Level Detection Control.2-H-2 [4] M12 (Toner Supply) Control.2-H-3 CLEANING/TONER RECYCLE UNIT.. 2-I-1 [1] Composition.. 2-I-1 [2] Mechanisms.. 2-I-1 [3] TGR (Toner Guide Roller) Control. 2-I-2 [4] Other Control.. 2-I-2 TRAY 1/2 (Di551/Di650), TRAY 3/4 (Di5510/Di7210) PAPER FEED UNIT.. 2-J-1 [1] Composition.. 2-J-1 [2] Mechanisms.. 2-J-1 [3] First Paper Feed Control. 2-J-3 [4] Paper Up Drive Control. 2-J-5 [5] Paper Size Detection Control.. 2-J-6 [6] No paper detection control. 2-J-7 TRAY 1/2 PAPER FEED UNIT (Di5510/Di7210). 2-J-8 [1] Composition.. 2-J-8 [2] Mechanisms.. 2-J-8 [3] First Paper Feed Control.. 2-J-10 [4] Horizontal Conveyance Control (Tray 1). 2-J-12 [5] Paper Up Drive Control. 2-J-14 [6] No paper detection control. 2-J-15 TRAY 3 PAPER FEED UNIT (Di551/Di650).. 2-K-1 [1] Composition.. 2-K-1 [2] Mechanisms.. 2-K-1 [3] First Paper Feed Control. 2-K-3 [4] Paper Up Drive Control. 2-K-5 [5] Paper Size Detection Control.. 2-K-6 [6] No paper detection control. 2-K-7 BY-PASS TRAY... 2-L-1 [1] Composition.. 2-L-1 [2] Mechanisms.. 2-L-1 [3] First Paper Feed Control. 2-L-2 [4] Paper Up/Down Control. 2-L-3 [5] Paper Size Detection Control.. 2-L-4 [6] No paper detection control. 2-L-5 VERTICAL CONVEYANCE SECTION.. 2-M-1 [1] Composition.. 2-M-1 [2] Mechanisms.. 2-M-1 [3] Vertical Conveyance Control.. 2-M-2

[Transfer and separation corona unit] FRONT
Transfer/separation cleaning motor (M10)
[7] ADU Conveyance Drive Section

Di5510/Di7210

Conveyance support roller
Pre-transfer roller Registration roller
Registration MC (MC1) Conveyance belt ADU conveyance roller/4 ADU conveyance roller/3 Registration roller knob
ADU conveyance roller/2 ADU conveyance roller/1 Conveyance motor (M5)
ADU deceleration MC (MC2) ADU reverse roller ADU reverse motor (M9) ADU conveyance MC (MC13)

Reverse/exit gate

Reverse/exit motor (M8) Reverse/exit roller ADU gate Reverse/exit roller knob

7272ma1004

[8] Paper Exit Drive Section

Paper exit motor (M7)

Paper exit roller

Exit conveyance roller

[9] Toner Supply Drive Section

Toner cartridge

Toner bottle motor (M13) Toner supply motor (M12) Toner supply screws Toner supply screw [Rear view]
Toner conveyance screw [Front view]
[10] Optics Drive Section
Scanner drive wire (rear) Scanner motor (M11) Exposure unit
FRONT Scanner drive wire (front) V-mirror unit

2 UNIT EXPLANATION

UNIT EXPLANATION

EXTERNAL SECTION

[1] Composition

Operation panel

Toner supply cover Front right cover Front left cover
Right side cover (upper) Developing suction filter cover

Tray 1 Tray 2 Tray 3

Bypass tray
Right side cover (lower rear) Vertical conveyance door Right side cover (lower middle) Right side cover (lower front) Main power switch (SW1)

Ozone filter cover

Paper exit tray Optional cover

Rear cover

Left side cover

Sub power switch (SW2)

Operation panel Sub power switch (SW2) RADF Right side cover (upper) Developing suction filter cover
Tray 1 Bypass tray Tray 3 Tray 4 Tray 2 Horizontal conveyance section Main power switch (SW1) Right side cover (lower rear) Vertical conveyance door Right side cover (lower middle) Right side cover (lower front)

2. Flow of developer

The developer inside the developing unit is supplied to the developing sleeve by the agitator wheel, and maintained at a constant thickness by the developer regulation plate (bristle height regulation plate). The developer remaining on the developing sleeve is returned to the agitator screws.
[3] M3 (Developing) Control
5V P.GND DEVM CONT DEVM CLK DEVM CW/CCW DEVM GAIN DEVM EM
a. Input signals (1) DEVM_EM (M3 to PRCB) M3 (developing) abnormality detection signal [H] Abnormal rotation (when motor speed changes by 6.5% more or less than the motor speed specified value) [L] Normal rotation b. Output signals (1) DEVM_CONT (PRCB to M3) M3 (developing) drive control signal [L] M3 ON [H] M3 OFF (2) DEVM_CLK (PRCB to M3) M3 (developing) rotational speed control clock signal (3) DEVM_CW/CCW (PRCB to M3) M3 (developing) rotational direction indication signal [H]: CW direction rotation [L]: CCW direction rotation (4) EDVM_GAIN (PRCB to M3) M3 (developing) rotational speed range indication signal [H]: High speed range [L]: Low speed range

M3 MS2

M3 (developing) is controlled by PRCB (printer control board) and the motor drive power is supplied from DCPS (DC power supply unit).
M3 (developing) is a DC motor driven by 24 V. It drives the developing sleeve, agitator wheel, and agitator screws. M3 turns ON when the PRINT button is pressed, and turns OFF after lapse of the specified time from turning OFF of the charging.
[4] Developing Bias Control
B.CONT TXD CLK LATCH BIAS

24V1 P.GND

The developing bias voltage is supplied from HV (high voltage unit) and is controlled by PRCB (printer control board). The output level of the developing bias voltage is transmitted using 8-bit serial data. This serial data includes the level information for all outputs driven by HV, excluding the ON/OFF control signal. Accordingly, a separate signal line is provided to turn ON/OFF only the developing bias.
Application of the developing bias voltage starts after a lapse of the specified time from turning ON of the START button, and stops after a lapse of the specified time from turning OFF of PS43 (leading edge) by the last copy paper. Developing bias output range: -300 V to -700 V
a. Output signal (1) B.CONT (PRCB to HV) Developing bias output ON/OFF control signal. [L]: Developing bias ON [H]:Develpoing bias OFF

[5] Dmax Control

5V 12V P.GND A.GND DMLED CONT DRUM CONT DRUM CLK DM MONI EX CW/CCW DJLED CONT DRUM EM DM SIG EX DRUM JSIG EX TNLED REF TEMP 3.3V2

a. Input signals (1) G_SIG_EX (TCSB to PRCB) This signal monitors the output voltage from the sensor (PD2) on the TCSB (toner control sensor board) as well as the light reflected by the drum surface (without toner). The voltage applied to the gradation detection LED is corrected by TNLED_REF so that the output voltage becomes 3.0 V (calibration). Reference voltage: 3.0 V <Timing> Before gradation correction. b. Output signal (1) LED CONT (PRCB to TCSB) Gradation detection LED ON/OFF control signal [L]: LED ON [H]: LED OFF
[7] Dot Diameter Correction Control
[8] Toner Density Control
12V A.GND DMLED CONT DM MONI EX DJLED CONT DM SIG EX DRUM JSIG EX TNLED REF TEMP 3.3V2 TNSM24V TNSM24V TNSM A TNSM AB TNSM B TNSM BB
12V A.GND G SIG EX LED CONT TNLED REF

12V2 S.GND

PRCB DCPS
Dot diameter is detected by TCSB (toner control sensor board) and is controlled by PRCB (printer control board).
Dot diameter correction is performed to prevent the 1-dot laser beam diameter from fluctuating due to the change in developing characteristics (caused by deteriorated developer) and soil in the write unit. (1) Method Multiple dot pattern patches with the same condensation are created to be read by the sensor (PD2). The laser power where the sensor output reaches the reference voltage is used as the MPC value. (2) Timing a) Every 10,000 prints, upon completion of the last job. a.
The density of toner is controlled by controlling M12 (toner supply) from PRCB (printer control board).
Toner density detection The reference patch density is detected using the patch detection method of TCSB (toner control sensor board) and the corresponding analog voltage signal is output to PRCB (printer control board), thus detecting the toner density. The PRCB compares the detected voltage with the reference value to determine whether toner must be added. Toner supply operation Upon read of the patch, M12 (toner supply) is turned ON to supply toner. The time needed to add toner depends on the paper size.
a. Output signals (1) TNSM_A, AB (PRCB to M12) A-phase drive signal of M12 (toner supply) (2) TNSM_B, BB (PRCB to M12) B-phase drive signal of M12 (toner supply)
[9] FM4 (Developing Suction) Control

SUCTFAN D SFAN EM

FM4 (developing suction) is controlled by PRCB (printer control board).
a. ON timing FM4 (developing suction) is turned ON when M2 (drum) is turned ON. OFF timing FM4 (developing suction) is turned OFF after a lapse of the specified time from turning OFF of M2 (drum).
a. Input signal (1) FM2 EM (FM4 to PRCB) FM4 (developing suction) abnormality detection signal [L]: FM4 is normal. [H]: FM4 is abnormal. b. Output signal (1) SUCTFAN_D (ACDB to FM4) FM4 (developing suction) drive signal [L]: FM4 OFF [H]: FM4 ON

Paper size VR gear Rack gear Side guide (front)
[3] First Paper Feed Control

MC24V_1 T1PREMC_DRV

MC4 PS1

Tray 1

FEEDM_CONT FEEDM_CLK FEEDM_F/E FEEDM_EM 5V P.GND
5V3 T1PRE_PS SGND MC24V_1 C MC24_1 T2PREMC_DRV 5V3 T2PRE_PS SGND

MC5 MC6 PS7 Tray 2

The 1st paper feed from tray 1/2 takes place as the result of the transmission of the drive force from M1 (paper feed) to each paper feed roller by MC3/5 (paper feed MC/1/2) and MC4/6(pre-registration MC/1/2). The feed roller picks up paper using its own weight. The above operations are controlled by the PRCB (printer control board). Related signals are PS1/7 (paper feed/1/2) and PS25/26 (vertical conveyance/1/2) issued from the vertical conveyance section.
a. Operation of the MC3/5 (paper feed MC/1/2) (1) Start timing of printing of the first copy MC3/5 (paper feed MC/1/2) turns ON at the timing that is determined by the P counter from when copying starts, and turns OFF after a lapse of the specified time from PS1/7 (paper feed/1/7) turning OFF. Thus, paper skew is corrected by forming the loop before pre-registration roller. (2) Start timing of printing of the second copy When the preceding paper turns OFF PS1/7. (3) OFF timing When PS1/7 is turned ON. b. Operation of the MC4/6 (pre-registration MC1/2) (1) ON timing After a specified time from MC3/5 (paper feed MC/1/2) turning ON. (2) OFF timing When PS1/7 (paper feed/1/2) is turned OFF.

24V1 P.GND 5V2 S.GND

MC24V_1 T1FEED_DRV
a. PRCB input signals (1) T1PRE_PS (PS1 to PRCB) Paper passage detection signal (tray 1) [L]: Detected. [H]: Not detected. (2) T2PRE_PS (PS7 to PRCB) Paper passage detection signal (tray 2) [L]: Detected. [H]: Not detected. b. PRCB output signals (1) T1FEED_DRV (PRCB to MC3) MC3 drive control signal (tray 1) [L]: MC3 ON [H]: MC3 OFF (2) T1PREMC_DRV (PRCB to MC4) MC4 drive control signal (tray 1) [L]: MC4 ON [H]: MC4 OFF (3) T2FEED_DRV (PRCB to MC5) MC5 drive control signal (tray 2) [L]: MC5 ON [H]: MC5 OFF (4) T2PREMC_DRV (PRCB to MC6) MC6 drive control signal (tray 2) [L]: MC6 ON [H]: MC6 OFF
[4] Paper Up Drive Control

5V3 TIRM_PS SGND

Tray 1 PS4

T1RISEM_24V T1RISEM_D

5V3 T2UP_PS SGND 5V3 T2RM_PS SGND

PS8 Tray 2 PS10

T2RISEM_24 T2RISEM_D
Paper stacked in the tray is pushed up by transmitting the drive force of M16/17 (tray up drive/ 1/2) to the up/down plate in the tray via drive wires. M16/17 are controlled by the PRCB (printer control board). Related signals are PS2/ 8 (tray upper limit/1/2) and PS4/10 (remaining paper/1/2).
a. Paper up drive control When tray 1/2 is loaded, M16/17 (tray up drive/1/ 2) turns ON to lift the up/down plate in the tray. When PS2/8 (tray upper limit/1/2) detects the upper limit of paper as the paper up/down plate in the tray goes up, it turns ON and consequently M16/17 goes OFF, causing the tray to stop going up. When PS2/8 turns OFF after paper is fed, M16/17 goes ON again to move the paper up/ down plate upward. The up/down plate in the tray is lowered mechanically by its own weight.

Right side cover (lower rear)
Right side cover (lower front)
Right side cover (lower middle)
(8) Open the RADF. (9) Remove the two shoulder screws to remove the original stopper plate (left). (10) Remove the three shoulder screws to remove the original stopper plate (rear). (11) Remove the platen glass. (12) Remove two screws to detach the top cover (left). (13) Remove two screws to detach the top cover (right).
(15) Open the front right door and front left door. (16) Remove one screw to remove the front open/ close stopper. (17) Remove two screws to remove the front right door open/close hinge (lower) and front right door. (18) Remove two screws and remove the front left door hinge (lower) and the front left door.

Front open/close stopper

[4] Changing the Operation Panel Attachment Angle and Removing/ Reinstalling
Caution: Be sure the power cord has been unplugged from the wall outlet. a. Procedure (1) Open the front left door and front right door. (2) Remove two screws to remove the operation panel cover (middle).
Operation panel cover (middle)
Front right door hinge (lower) Front right door
Front left door hinge (lower)
(3) Remove two screws to unlock the operation panel.
Screw Operation panel Screw

Front left door

(19) Reinstall the above parts following the removal steps in reverse.
Attachment holes when changing the operation panel angle
(4) When changing the operation panel attachment angle, align the operation panel stopper with the stopper hole at the front side on the bottom of the operation panel and fasten using two screws in the operation cover attachment holes. Caution1: To remove the operation panel, skip this step and proceed to step (5). Caution2: When the attachment angle of the operation panel is changed, the operation panel cover and two screws will become unnecessary.
(5) Remove the relay connectors (CN163, 164). Caution: Each relay connector consist of two male sides and one female side. Be sure to remove only the male side (shown below). (6) Remove the operation panel.
Relay connector (CN164) Relay connector (CN163)

a. (1) (2)

Four turns

Metal bead

3Four turns

Front Five turns

Five turns Metal bead Wire stopper
Pulley 1 Exposure unit mounting piece V-mirror pulley Wire stopper V-mirror unit Exposure unit mounting piece Drive pulley Wire stopper Spring Pulley 2 Pulley 1

Pulley 3

5 Spring fixing plate 7

Drive pulley

6 Spring fixing plate

Pulley 3 Pulley 2

V-mirror pulley

Wire stopper

Caution: There are two grooves in the wire stopper. Ensure that the outer groove is at the rear and the inner groove is at the front. (5) Reverse the inner wire at pulley 2, pass it along the inside of the V-mirror pulley and pulley 3, then attach the wire terminal to the spring fixing plate. At this time, secure the spring fixing plate temporarily with one screw.
(6) Install the other wire following the same procedure. (7) Loosen each screw that was tightened temporarily, install the spring on the spring fixing plate, and tighten each screw.
[6] Cleaning the Slit Glass and Platen Glass
Caution: Be sure the power cord has been unplugged from the wall outlet. (1) Remove the original stopper plates (left and rear), platen glass, and top cover (right, left, front center, and rear center). (See "EXTERNAL SECTION.") (2) Remove two screws to detach the slit glass. (3) Place the removed slit glass and platen glass on a rag and clean with isopropyl alcohol and waste.
[7] Replacing the Scanner Motor (M11)
Caution: Be sure the power cord has been unplugged from the wall outlet. a. Procedure (1) Remove the RADF unit, original stopper plates (left and rear), platen glass, and top cover (right, left, front center, and rear center). (See "EXTERNAL SECTION.") (2) Remove one connector (CN639) from the APS timing PS (PS51).

Connector(CN639)

Slit glass

Slit glass Screw

(3) Remove the hinge mounting plate (rear side) from the scanner unit. (12 screws) (4) Remove four screws from the scanner motor (M11), then remove the scanner belt and the scanner motor.
(5) Install the scanner motor (M11) and the scanner belt. Tighten the scanner motor loosely with four screws. Caution1: Make sure to install the belt in the middle of two pulleys. Also make sure that the belt is not placed on the edges of pulleys, or that it is running off from the pulleys. Caution2: Tighten the motor by first tightening the screw and then give it one turn to loosen slightly.

Scanner Belt

(7) Pull the spring scale upward, and tighten the scanner motor (M11) tightly with the tension pressure of 2 0.2kgf. (Use four screws) Caution: Make sure that the scanner motor moves up and down when confirming the tension pressure.

Spring scale Scanner motor (M11)

Pulley

(8) Make sure that the belt is not slacked off after marking an adjustment. (9) Insert the connector to the scanner motor (M11). (10) Follow the disassembly procedures in reverse order to install.
(6) Hook the spring scale on the upper hole of the scanner motor (M11).

Spring scale

Upper hole

WRITE SECTION

[1] Removing and Reinstalling the Write Unit
In the case of the Di551/Di650 Warning: (1) Do not energize the write unit when it is not in the correct position. (2) Never remove the write unit cover and the polygon unit cover. (3) Never look directly into the laser beam. It can cause blindness. (4) Never remove the write unit for at least two minutes after turning OFF the main switch. Caution: Be sure the power cord has been unplugged from the wall outlet. a. Procedure (1) Remove the left side cover. (See "EXTERNAL SECTION.") (2) Remove nine screws to detach the fan holder assembly. (3) Remove the relay connector (CN338). Caution: Each relay connector consists of two male sides and one female side. Be sure to remove only the male side (shown below) of the CN338 connector.
Fan holder assembly Relay connector (CN338)
(4) Remove the three connectors (CN185, 187, 188). (5) Loosen the screw to draw out and remove the write unit.
Connector (CN187) Connector (CN185) Connector (CN188)

Screw Write unit

(6) Reinstall the above parts following the removal steps in reverse.
In the case of the Di5510/Di7210 Warning: (1) Do not energize the write unit when it is not in the correct position. (2) Never remove the write unit cover and the polygon unit cover. (3) Never look directly into the laser beam. It can cause blindness. (4) Never remove the write unit for at least two minutes after turning OFF the main switch. Caution: Be sure the power cord has been unplugged from the wall outlet. b. Procedure (1) Remove the left side cover. (See "EXTERNAL SECTION.") (2) Remove the relay connector (CN338). (3) Remove eleven screws to detach the fan holder assembly.
Screws Fan folder assembly
Relay connector(CN187) Relay connector(CN185)

Relay connector (CN187)

Developing sleeve Developing unit stopper roller
[4] Cleaning the Developing Unit Bias shaft
Caution: Be sure the power cord has been unplugged from the wall outlet. a. Procedure (1) Draw out the drum unit from the main body. (See "DRUM UNIT.") (2) Remove the developing unit from the drum unit. (3) Wipe the dirt on the developing unit bias shaft with waste.
(9) Install the developing unit cover, then install the developing unit in the drum unit. Caution: After installing the developing unit in the drum unit, make sure the developing unit stopper roller is in contact with the developing unit stopper plate (allocation of DSD).
Developing sleeve Developing unit bias shaft
[1] Replacing and Cleaning the Toner Cartridge
a. Procedure (1) Open the toner supply door and pull the toner supply unit forward.

Toner supply door

Toner supply unit
(2) Remove the toner cartridge. (3) After removing the toner cartridge, clean the area around the toner cartridge insertion hole with a waste.

Cartridge insertion hole

[1] Removing and Reinstalling the Cleaning Blade
Caution: Be sure the power cord has been unplugged from the wall outlet. Caution1: Be sure to replace the following parts at the same time: Cleaning blade Toner guide roller (TGR) Caution2: Do not touch the edges of the cleaning blade with bare hands. Caution3: When reinstalling the cleaning blade, apply setting powder to the entire surface of the drum and cleaning blade regardless of whether the drum and cleaning blade are new or old. Caution4: When you have applied setting powder to the drum, perform the following before installing the drum unit on the main body: 1) To ensure accurate toner concentration, wipe scattered setting powder off the sensor and Dmax/JAM sensor on the toner control sensor board with a rag moistened with alcohol. 2) With the charging corona unit and developing unit removed, turn the drum once (to prevent setting powder from scattering onto the charging corona unit, and to prevent image defects). Procedure Remove the drum unit. (See "DRUM UNIT.") Remove the charging corona unit. (See "CHARGING CORONA UNIT.") Remove the developing unit. (See "DEVELOPING UNIT.") Remove two screws to remove the cleaner cover.
(5) Check that the blade fixing component is released. If it is not, release it referring to"DRUM UNIT."

Released position

Blade support bearing
(7) Reinstall the above parts following the removal steps in reverse. Caution: After replacing the cleaning blade, be sure to perform Blade Setting Mode Adjustment in the 36 mode. (To prevent the blade from peeling.)

Cleaner cover

(6) Remove the blade support bearing to remove the cleaning blade.

Wire B (White)

Wire B (White) Wire A (Black) E-ring Drive pulley Drive shaft
8. Pull out and remove the wire B (white) toward the bottom side of the up/down plate. 10. Pull out and remove the wire B (white) toward the bottom side of the up/down plate. Drive pulley E-ring Wire A (Black) Drive shaft
3. Remove the E-ring, slide the drive pulley in ward, and remove the wire B (white) from the drive shaft.
Bearing Gear assembly Bearing E-ring
2. Remove the bearing. 9. Remove the E-ring, slide the drive pulley outward, and remove the wire A (black) from the drive shaft.
1. Remove the E-ring and bearing to detach the gear assembly.

7272ma3017

3-J-13
6. Remove the E-ring. 7. Remove the pulley and wire restraining cover to release the wire B (white).
4. Remove the E-ring. 5. Remove the pulley and wire restraining cover to release the wire A (black) and B(white).
(4) Remove the wires C and D according to steps 1 to 8 of the figure below.
Wire restraining cover Wire C (Black) Pulley E-ring Wire D (White) 4. Pull out and remove the wire C (black) toward the bottom side of the up/down plate. 8. Pull out and remove the wire D (white) toward the bottom side of the up/down plate.
2. Remove the E-ring. 3. Remove the pulley and wire restraining cover to release the wire C (black) and Dire restraining cover to release the wire C (black) and D (white). Wire D (White) Wire restraining cover Pulley E-ring
6. Remove the E-ring. 7. Remove the pulley and wire restraining cover to release the wire D (white). Wire C (Black) Wire D (White) Drive shaft Wire D (White) Wire C (Black) Drive pulley E-ring Drive shaft
1. Remove the E-ring, slide the drive pulley inward, and remove the wire C (black) from the drive shaft.
5. Remove the E-ring, slide the drive pulley outward, and remove the wire D (white) from the drive shaft.

7272ma3018

3-J-14
294.8 232.4 Wire A, C 391.7 329.2 Wire B, D 1mm(Tray 1) 1mm(Tray 2)

7272ma3019

1mm(Tray 1) 1mm(Tray 2)
<Installing Wires> Reinstall the wires following the removal steps in reverse.

3-J-15

PAPER FEED UNIT OF TRAY 3 (Di551/Di650)
Caution: Be sure the power cord has been unplugged from the wall outlet. a. Procedure (1) Draw out paper feed tray 3. (2) Loosen the securing shaft screw, and remove one screw. (3) Disconnect the relay connector (CN854) and remove the paper feed unit by lifting.

Relay connector (CN814, 834) Securing shaft screw Paper feed unit Screws Screw
[2] Removing and Reinstalling Paper Feed Tray 3
Warning: When removing the tray, stand in a proper position so that you do not hurt your back and waist. If the tray contains paper, remove all paper before removing the tray. Caution: Be sure the power cord has been unplugged from the wall outlet. a. Procedure (1) Draw out paper feed tray 3. (2) Remove the paper feed unit. (3) Remove four screws and remove tray 3 by lifting. 3 DIS./ASSEMBLY
a. Procedure (1) Remove the paper feed unit. (2) Remove two stop rings and slide the two bearings outward. (3) Release the feed roller axis from the holder slit to detach the paper feed roller unit.
(4) Remove two stop rings from the paper feed roller unit to detach the paper feed roller and feed roller. (5) Remove the rubber from each roller.
(6) Reinstall the above parts following the removal steps in reverse. Caution1: When reinstalling the rollers, pay attention to their orientation. Caution2: Check that no grease or the like remains on each roller. 3-K-2
a. (1) (2) (3) Procedure Remove the paper feed unit. Remove two connectors (CN850, 851). Remove two stop rings to detach the pre-registration MC/3 (MC8) and feed MC/3 (MC7).
Caution1: After replacing or reinstalling the wires, manually rotate the up/down drive shaft to check that the tray moves up and down smoothly. Caution2: Be sure to install the wires so that they do not cross or ride over each other. <Removing Wires> (1) Remove the paper feed unit. (2) Remove two claws to remove the tray front cover. (3) Remove two screws to remover shaft supporting plate. (4) Remove three screws to remove the wire cover(front) and wire cover (rear).
Screws Wire cover (rear) Screws Wire cover (front) Shaft supporting plate

Tray cover (front)

(5) Remove the front and rear wires according to steps 1 to 7 below.
Remove the E-ring to detach the wire restraining cover and pulley.
Remove two E-rings to slide out the drive pulley. Wire D (white) E-ring E-ring Wire D (white) Wire C (black) Wire C (black)

Wire restraining cover

Pulley E-ring Drive pulley
and three E-rings and pull out the drive pulley. Wire B (white) Wire A (black) E-ring Wire A (black) E-ring
298.91 mm (Tray 3) Wire A, C 589.21 mm (Tray 3) Wire B, D
inside the drive shaft hole, push in the drive pulley, and secure with E-rings. Wire D (white) Wire C (black) E-ring E-ring

3. Pass wire C through

the up/down plate.
inside the drive shaft hole, push in the drive pulley, and secure with E-rings. Next, install the drive pulley holder. Wire C (black) Wire B (white) Wire D (white) Wire A (black)

Connector (CN881) Spacer axis

a. (1) (2) (3)

Vertical conveyance door
Vertical conveyance section Gear
Vertical conveyance MC/1(MC11)
Connector (CN882) Spacer axis Connector (CN880) Vertical conveyance MC/2(MC12)
(4) Reinstall the above parts following the removal steps in reverse. Caution: When installing the vertical conveyance section, be sure to secure the screws with the vertical conveyance door closed.

Vertical conveyance MC

(5) Reinstall the above parts following the removal steps in reverse. Caution: When installing, be sure the detent of the clutch is at the position shown above.

ADU UNIT

[1] Drawing out and Reinstalling the ADU Stand
Warning: The interlock which is turned OFF when the front right or left door opens or closes should never be turned ON forcibly with the ADU stand drawn out. Caution: Be sure the power cord has been unplugged from the wall outlet. a. Procedure (1) Open the front right and left doors. (2) With the solenoid release lever on the ADU stand pushed to the left, turn down the ADU drawing lever to the left. (3) Grip the ADU stand drawing lever and draw out the ADU stand.
ADU stand Lock lever Second paper feed unit Paper dust removing brush
[2] Cleaning the Paper Dust Removing Brush
In the case of the Di551/Di650 Caution: Be sure the power cord has been unplugged from the wall outlet. a. Procedure (1) Draw out the ADU stand from the main body. (2) Release the left and right lock levers, lift the brush handles by the handles to remove the paper dust removing brush.

Brush handles Lock lever

Projections

Left door

Right door Positioning holes

Solenoid release lever

(3) Using a blower brush, clean the paper dust removing brush.
Paper dust removing brush ADU stand drawing lever
(4) To reinstall the ADU stand, push in the ADU stand and then turn the ADU stand drawing lever upright.

Cleaning area

(4) Reinstall the above parts following the removal steps in reverse. Caution: When installing, align the projection on the paper dust removing brush with the positioning hole on the second paper feed unit.
In the case of the Di5510/Di7210 Caution: Be sure the power cord has been unplugged from the wall outlet. b. Procedure (1) Draw out the ADU stand from the main body. (2) Push two projections for each to release the lock and remove the paper dust removing brush.

(8) Slide the registration roller to the front, then remove it by lifting the rear end. (9) Remove the bearing from the registration roller.

b. (1) (2) (3) (4) (5)

7272ma3029

(6) (7)

(10) Reinstall the above parts following the removal steps in reverse.
Bearing Registration roller E-ring

Bearing E-ring

7272ma3028
[8] Removing and Reinstalling the Pretransfer Roller
Warning: The interlock which is turned OFF when the front right or left door opens or closes should never be turned ON forcibly with the ADU stand drawn out. Caution: Be sure the power cord has been unplugged from the wall outlet. a. Procedure (1) Draw out the ADU stand from the main body. (2) Remove the two springs. (3) Open the pre-transfer jam handler to remove the pre-transfer roller assembly.
(4) Remove the E-ring to remove the pre-transfer roller from the shaft. Caution: When reinstalling, pay attention to the position of the E-ring.

Pre-transfer roller

Pre-transfer jam handler Pre-transfer roller assembly
[9] Cleaning the ADU Paper Reverse PS (PS45)/Reverse/Exit PS (PS46)
Warning: The interlock which is turned OFF when the front right or left door opens or closes should never be turned ON forcibly with the ADU stand drawn out. Caution: Be sure the power cord has been unplugged from the wall outlet. Procedure Draw out the ADU stand from the main body. Remove the fixing unit. (See "FIXING UNIT.") Remove the ADU cover. Remove one screw to remove the ground plate. Remove the open/close spring from the paper exit side open/close wire.
(7) Remove two screws to remove the ADU reverse guide assembly. Caution: When reinstalling, align the projection on the rear of the ADU reverse guide assembly with the hole on the ADU bottom plate assembly.
Open/close wire ADU bottom plate assembly Screws
Screws ADU reverse guide assembly

Open/close wire assembly

Holes ADU bottom plate assembly

Open/close wire

Projections ADU reverse guide assembly Open/close spring Ground plate Screw
(6) Remove two screws to remove the open/close wire assembly.
ADU reverse guide assembly

3-N-10

(8) Remove the nine screws illustrated from the bottom of the ADU stand.
(10) Lower the ADU bottom plate assembly straight down and remove the ADU guide cover.
ADU bottom plate assembly ADU bottom plate assembly
(9) Remove one screw while holding the ADU bottom plate assembly to remove the paper feed side open/close wire. Caution: Be sure to hold ADU bottom plate assembly when removing the screws because the ADU bottom plate assembly becomes free when the paper feed side open/close wire is removed.

RZ_Di7210/7272 11.06.2004 14:32 Uhr Seite 1
www.konicaminoltaeurope.com Black & White Office System Di7210/7272

Di7210/7272

The production pro
RZ_Di7210/7272 11.06.2004 14:32 Uhr Seite 2
Black & White Office System Di7210/7272
Document production is your business. And you know full well how time-critical it is. Downtime is dead time and you cant just switch to a different system or put back a deadline. We know that a fast and, above all, reliable printing, copying and scanning system is crucial to your business. Thats how weve designed the Di7210/7272.

The secret

of success
As an internal or external print service provider, you have to deliver documents fast to meet very tight deadlines. The Di7210 / 7272 monochrome output station from Konica Minolta not only gives you 72 prints, copies or scans per minute, twice that number in a tandem configuration and, even more significantly, a monthly output volume of up to 300,000 pages. But the Di7210 / 7272 not only prepares jobs for printing and produces them at great speed, it also offers you a variety of useful online finishing functions. As a result, the documents it produces are ready for delivery to the customer punched, stapled, folded or even finished with a coloured cover or separating sheets and no manual intervention is required. That saves a lot of time. The secret of success in a production environment? We believe its a fast and reliable system like the Di7210 / 7272 the production pro.

How you benefit

" Time-critical production " High monthly output capacity " Versatile finishing
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What a user-friendly GUI means in practice
The Di7210 / 7272 brings the benefits of a sensibly designed GUI to the production environment. The user-friendly concept with clear symbols, e.g. on the touch-screen panel or for the printer driver, makes the Di7210 / 7272 much easier to operate than many production systems were in the past.
" Effective job preparation " Time savings " Ease of operation

Easy-as-pie

preparation
In your time-critical production environment you dont want to spend too much time getting jobs ready for printing. The Di7210/7272 is designed to make the job preparation process as efficient as possible.
How the document server enhances your workflow
By linking all electronically created and paperbased originals from various applications, the Di7210 / 7272s document server enables you to manage your documents and perform many other workflow-enhancing functions such as file merge printing, on-demand printing or proof printing. File merge printing allows two print jobs to be linked on the document server and then printed as a single document. Since jobs can also be stored on the document server and are ready for printing as and when required, the Di7210 / 7272s document server also makes traditional on-demand printing possible.
How DocBuilder makes imposition more efficient

DocBuilder Pro, a feature of the Di7210 / 7272s Fiery controller, enables you to edit and assemble entire documents before RIPping. The latest version of this PDF-based imposition tool includes a number of improvements that brings performance gains of up to 70% and support for mixed page sites. Other new features include negative gutter sizes, customisable trim and fold marks, right edge binding, addition, deletion and duplication of sheets, gang-up unique collation, late editing and enhanced templates. All in all, DocBuilder Pro is a powerful imposition tool that eliminates the need for third-party software and saves time, paper and toner.
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Why ppm isnt everything

72 pages per minute isnt bad. 144 pages per minute is even better. For jobs with an extremely short deadline, the Di7210 / 7272s tandem capability is a big advantage. In a tandem configuration any print or copy job can be executed on two machines at once, doubling the capacity to 144 ppm. In a production environment, however, the monthly output volume is probably the most significant figure. After all, you need a machine to keep working day in, day out. The robust construction of the Di7210 / 7272 means it is equipped for up to 300,000 pages per month and has the reliability to ensure this isnt just some theoretical figure.
When on-the-fly refills are useful
Other useful features ensure your Di7210 / 7272 stays up-and-running. If the huge paper reserve of up to 7,600 sheets should prove too small for some massive job, you can even refill the tandem cassette on the fly. The same applies to the toner. An empty bottle can be replaced while the system carries on working at full speed and in the usual high quality.
How polymerized achieves the impossible
Noticeably improved output quality and reduced toner consumption? Polymerized toner makes this unlikely equation possible. With particles only half the size of conventional toner and uniform in shape, polymerized toner improves the reproduction of thin lines and dots as well as producing sharper text and smoother halftone gradations. Your customers will notice the difference.

Output

Speed and quality are crucial to successful production printing. The Di7210/7272 has been designed to meet the needs of a production environment and do so extremely reliably.
" Faster document production " Better-quality output " Improved workflow efficiency
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Finishing finesse is essential in a production environment. The Di7210/7272 offers you a range of options for online

Finishing

finishing with no manual intervention required on your part.

finesse

How stapling capacity is significant
The Di7210 / 7272 staples in eight different positions and hole-punches them as required. But the crucial advantage is the systems 100-sheet capacity just what a production environment needs to deal with multi-page documents.

Where folding counts

The Di7210 / 7272 offers three different folding functions: half-folding, three-folding and Z-folding. The combination of half-folding and stapling means booklets can be created online with no need for additional finishing equipment. Z-folding reduces A3 documents to A4 format, e.g. so an architects A3 floor plans can be archived in A4 files, and three-folding is particularly important for mailings because letters are folded ready for insertion into envelopes.
" Versatility in finishing " Online booklet creation " Colour covers
Where colour makes a difference
Didnt we say the Di7210 / 7272 was a monochrome machine? It is. But the page insertion capability also means you can add pre-printed colour pages to document sets in a single online operation and the Di7210 / 7272 does the whole job automatically. In this way, coloured covers can be added to brochures that have already been printed and stapled or coloured sheets introduced to separate chapters in document sets.
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The professional choice!

FN-10/FS-210 finisher
The production pro has a lot to offer. You can make your choice from the options detailed below.
Cover inserter CI-E/PI-110

HDD-2/HD-105

64/186/256/512 system memory Punch-kit PK-2/PK-110/PK-5/PK-120 Z-fold unit ZK-3/PZ-109
Large capacity cassette CN-403N/LT-042
FN-121/FS-110 finisher Large capacity cassette CN-404N/LT-412

Base system

FN-115/FS-111 finisher
Printer controller Pi7200e/IP-511A

DocBuilder Pro

Token Ring card
Offset tray OT-104/SF-101 Tandem kit PS-3/Scan kit PS-351A (IP-511A only)
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Copier specifications

Copy speed A4 Up to 72 copies/min. Copy speed A3 Up to 41 copies/min. Copy resolution Max. 600 x 600 dpi 1st copy Less than 3 sec. (A4 crosswise) Gradations 256 gradations Magnification 25% 400% in 0.1% steps Multiple copy 1 9,999, countdown, interruption mode Copy memory Standard: 64 MB Max.: 576 MB Copier HDD 20 GB (optional) Copy features Tandem copying Booklet creation Cover / chapter insertion Image rotation Watermark Multi-up

Print memory 128 MB Printer HDD 10 GB Operating systems Windows 95/98/2000/ME/XP/NT4.0 Mac OS 8.5.1 or higher Linux (e.g. Red Hat, Caldera, SuSE) Unix (e.g. Solaris, HP-UX, IBM-AIX) Other environments SAP, AS400 / OS400 Print features Secure printing Automatic eMail attachment printing Full-bleed printing Variable data printing (Fiery FreeForm) Page impositioning (Fiery DocBuilder/Pro)
Scan features Electronic document handling (PageScope Cabinet) Automatic attachment division

System specifications

Automatic document feeder Max. 100 sheets Output paper size A6 to A3+ Paper weight g/m2 Paper input capacity Standard: 3,600 sheets Max.: 7,600 sheets Sheet bypass Multi-bypass tray (max. 100 sheets) Output capacity Max. 3,250 sheets Finishing modes (optional) Sorting Stapling Punching Folding (Z-fold, 3-fold, half fold) Pre-printed cover insertion Warm-up time Less than 360 sec. Cost accounting (optional) Printer driver Accounting software Coin&Card system Device management (optional) Bi-directional drivers PageScope/Light Plug-ins for Unicenter TNG / Tivoli NetView / Microsoft Management Console / HP OpenView System dimensions (W x D x H, mm) 650 x 766 x 1,140 System weight Approx. 216 kg
Scanner specifications (optional)
Scan speed Up to 70 scans/min. Scan resolution Max. 600 x 600 dpi Scan modes TWAIN scan Scan-to-HDD Scan-to-eMail Scan-to-FTP Scan-to-URL Scan features Scan speed Up to 70 scans/min. Scan resolution Max. 600 x 600 dpi Scan modes TWAIN scan Scan-to-HDD Scan-to-eMail Scan-to-FTP Scan-to-URL

Printer specifications

Print speed A4 Up to 72 prints/min. Print speed A3 Up to 41 prints/min. Print resolution Max. 600 x 600 dpi Page description language PCL 6, PS 3 Interface Parallel (IEEE1284), Ethernet (10/100Base-T) Wireless Ethernet (IEEE 802.11b) Token Ring
All specifications relating to paper capacity refer to A4-sized paper of 80 g / m2 quality. All specifications relating to scanning, copying or printing speeds refer to A4-sized paper that is scanned, copied or printed crosswise in multipage, simplex mode. The memory capacities listed refer to A4-sized paper with the toner coverage detailed in the respective foot note. Some of the product illustrations contain optional accessories. Konica Minolta does not warrant that any prices or specifications mentioned will be error-free. Specifications are subject to change without notice. Microsoft, Windows and the Windows logo are trademarks or registered trademarks of Microsoft Corporation in the United States and / or other countries. All other brand and product names may be registered trademarks or trademarks of their respective holders and are hereby acknowledged. Printed in Germany on chlorine-free bleached paper. 51011721000/05-04/Kuthal