SERVICE MANUAL

Models

LT-402/LT-412

JANUARY 2004 CSM-LT402
KONICA MINOLTA BUSINESS SOLUTIONS U.S.A., INC.
LT-402/LT-412 SERVICE MANUAL

JANUARY 2004

Used on Konica Models 7155/7165/7255/7272

IMPORTANT NOTICE

Because of the possible hazards to an inexperienced person servicing this equipment, as well as the risk of damage to the equipment, Konica Minolta Business Solutions U.S.A., Inc. strongly recommends that all servicing be performed by Konica-trained service technicians only. Changes may have been made to this equipment to improve its performance after this service manual was printed. Accordingly, Konica Minolta Business Solutions U.S.A., Inc., makes no representations or warranties, either expressed or implied, that the information contained in this service manual is complete or accurate. It is understood that the user of this manual must assume all risks or personal injury and/or damage to the equipment while servicing the equipment for which this service manual is intended.
Corporate Publishing Department
2004, KONICA MINOLTA BUSINESS SOLUTIONS U.S.A., INC. All rights reserved. Printed in U.S.A.

CONTENTS

SAFETY AND IMPORTANT WARNING ITEMS Refer to the 7155/7165/7255/7272 Service Manual

1. OUTLINE

LT-402/LT-412 PRODUCT SPECIFICATIONS.1-1 CENTER CROSS-SECTIONAL DRAWING.1-2 DRIVE SYSTEM DRAWING..1-3 [1] Paper feed drive section..1-3 [2] Stacked paper up/down wire drive section.1-4

2. UNIT EXPLANATION

PAPER FEED SECTION..2-1 [1] Composition..2-1 [2] Mechanisms..2-1 [3] First paper feed control..2-2 [4] Up/down plate drive control.2-4 [5] Remaining paper detection/No paper detection control...2-5

3. DISASSEMBLY/ASSEMBLY

PAPER FEED SECTION..3-1 [1] Cleaning the Paper Dust Removing Brush.3-1 [2] Cleaning the LT feed PS (PS106)/ LT first paper feed PS(PS107).3-1 [3] Removing and Reinstalling the Paper Feed Roller Unit.3-2 [4] Replacing the Paper Feed Roller Rubber/ Feed Roller Rubber.3-2 [5] Replacing the Double Feed Prevention Roller Rubber..3-3 [6] Replacing the LT feed MC (MC101)/ LT first paper feed MC (MC102)..3-5 [7] Replacing the LT-402 Up/Down Wires.3-6 [8] Replacing the LT-412 Up/Down Wires..3-10

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SAFETY WARNINGS
[1] Modifications Not Authorized by Konica Minolta
Konica Minolta equipment is renowned for their high reliability. This reliability is achieved through high-quality design and a solid service network. Unauthorized modifications involve a high risk of degrading performance and safety. Such modifications are therefore strictly prohibited. The points listed below are not exhaustive, but they illustrate the reasoning behind this policy. PROHIBITED ACTIONS : (1) Using extension cables or a different power cord than specified by Konica Minolta. (2) Using other fuses than specified by Konica Minolta. Safety will not be assured, leading to a risk of fire and injury. (3) Disabling fuses or bridging fuse terminals with wire, metal clips, solder or similar. (This applies also to thermal fuses.) (4) Removing air filters (except for replacement). (5) Disabling relay functions (such as wedging paper between relay contacts, etc.). (6) Disabling safety functions (interlocks, safety circuits, etc.). Safety will not be assured, leading to a risk of fire and injury. (7) Performing actions to equipment not described in the instruction manual or the service handbook. (8) Using parts other than specified by Konica Minolta. (3) Be sure to disconnect the power cord of the equipment from the AC outlet. Simply turning off the power switch is not sufficient, because paper feed units or other electrical equipment may be powered also when the power switch is turned off. (4) Proceed with special care when performing operation checks or adjustment while the unit is powered. When carrying out operation checks or adjustment while external covers are removed, the risk of electrical shock exists when touching parts which carry high voltage or electrical charge. The risk of injury exists when touching moving parts such as gears or chains.

[4] Measures to Take in Case of an Accident
(1) If an accident has occurred, the distributor who has been notified first must immediately take emergency measures to provide relief to affected persons and to prevent further damage. (2) If a report of a serious accident has been received from a customer, an on-site evaluation must be carried out quickly and Konica Minolta must be notified. (3) To determine the cause of the accident, conditions and materials must be recorded through direct onsite checks, in accordance with instructions issued by Konica Minolta. (4) For reports and measures concerning accidents, consult your superior, and follow the regulations set in "Standards for the Control Program for Measures Against Electrical Equipment Accidents".

[5] Conclusion

(1) Safety of users and customer engineers depends highly on accurate maintenance and administration. Therefore, safety can be maintained by the appropriate by the proper daily service work conducted by the customer engineer. (2) When performing service, equipment on the site must be tested for safety. The customer engineer must verify the safety of parts and ensure appropriate management of the equipment.
[3] Handling of Materials for Servicing
CAUTION: Alcohol-based and acetone- based cleaners are highly flammable and must be handled with care. When using these materials for cleaning parts, observe the following precautions. Disconnect the power cord from the AC outlet. 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. Perform cleaning only in an environment where sufficient ventilation is assured. Breathing large quantities of organic solvents can lead to discomfort. Do not replace the cover or turn the unit on before any solvent remnants on the cleaned parts have fully evaporated.

(1) (2)

OUTLINE
LT-402/LT-412 PRODUCT SPECIFICATIONS

[1] Type

Type: Side mount type large volume paper feed tray

[4] Maintenance

Maintenance: Same as the main body Machine life: Same as the main body

[2] Functions

Standard size paper : LT-402 Metric area A4 / B5 / 8.5 x 11 Wide paper (314mm x 223mm max.) Inch area 8.5 x 11 / A4 Wide paper (314mm x 223mm max.) LT-412 Metric area A3 / B4 / A4 / A4R / Fx 17 / 8.5 x 14 / 8.5 x 11 / 8.5 x 11R Wide paper (314mm x 459mm max.) Inch area 11 x 17 / 8.5 x 14 / 8.5 x 11 / 8.5 x 11R A3 / B4 / A4 / A4R / F4 Wide paper (314mm x 459mm max.) Maximum quantity: 4000 sheets (80 g/m2 or 20lbs)

[5] Operating Environment
Temperature: 10C to 30C (50F to 86F) Humidity: 10% to 80%RH Note: The information herein may be subject to change for improvement without notice.

[3] Machine Data

Power source 24V DC/5V (supplied from the main body), AC27.3V Max. power consumption LT-402 Max. 82W LT-412 Max. 100 W Weight LT-402 Approx. 30 kg LT-412 Approx. 42 kg Machine dimensions LT-402 430(W) x 639(D) x 690(H) mm LT-412 670(W) x 639(D) x 695(H) mm
CENTER CROSS-SECTIONAL DRAWING
Feed roller Conveyance roller Paper feed roller Top cover
Up/down wire (the other side wire as well)
Double feed prevention roller Up/down plate

DRIVE SYSTEM DRAWING

[1] Paper feed drive section

Feed roller

LT First paper feed SD (SD100)

Paper feed roller

LT paper feed motor (M101) LT First paper feed MC (MC 102)

Conveyance roller

LT feed drive MC (MC101)
Double feed prevention roller Feed roller
[2] Stacked paper up/down wire drive section

a. LT-402

Up/down plate

LT up/down motor (M100)

Up/down shaft

LT-412

UNIT EXPLANATION

PAPER FEED SECTION

[1] Composition
LT first paper feed SD (SD100) LT feed MC (MC101) LT paper feed motor (M101) LT first paper feed MC (MC102) Paper dust removing brush Conveyance roller LT feed PS (PS106)
LT first paper feed PS (PS107)
Up/down wire (the other side wire as well) LT up/down motor (M100) Remaining paper detection gear
Up/down plate LT tray down drive switch (SW 100)

[2] Mechanisms

Mechanism Paper lifting *1 Paper feed Method Wire drive Paper feed roller
No paper detection Photo sensor (PS108) +actuator Remaining paper detection *2 Remaining paper detection gear+ photo sensor (PS102, PS103, PS104, PS105)
Remaining paper detection The LCT is equipped with a remaining paper detection gear which rotates together with LT up/ down motor (M100) driving the up/down plate. The remaining paper detection gear has an actuator to turn ON/OFF LT remaining paper detection PS1 (PS102), LT remaining paper detection PS2 (PS103), LT remaining paper detection PS3 (PS104), and LT remaining paper detection PS4 (PS105).
Paper conveyance Roller conveyance *1 Paper lifting a.Up/down plate lifting drive operation The up/down plate is lifted with the up/down wires. When the top cover closes, LT up/down motor (M100) rotates and the up/down plate connected to the up/down wires rises. b.Up/down plate down drive operation The up/down plate automatically lowers by 120 mm when the top cover is opened. Subsequently, it is lowered by 120 mm each time LT tray down drive switch (SW100) is pressed.

Each sensor is turned ON/OFF according to the rotating position of the remaining paper detection gear and since this is linked with the up/down position of the up/down plate, the remaining paper quantity in the LCT can be determined by monitoring the ON/OFF of each sensor. The remaining paper quantity detected with the four sensors is displayed on the main body display. a. LT-402
[3] First paper feed control

5V UPOP_PS S_GND

5V CONV_PS S_GND

SIDOP_PS

HTR101
LT up/down motor (M100) Actuator
LT remaining paper detection PS1 (PS102) LT remaining paper detection PS2 (PS103)

24V CONT

MAIN BODY
24V PGND 5V SGND IO_DTXD IO_UCLK LCT_LATCH IO_DCLK ERR_OUT4 IO_URXD ACK4 REQ4
Gear for M100 Remaining paper detection gear
LT remaining paper detection PS3 (PS104) LT remaining paper detection PS4 (PS105)
LT remaining paper detection PS2 (PS103) LT remaining paper LT remaining paper detection PS3 (PS104) detection PS1 (PS102)
The first paper is fed by the paper feed roller and the feed roller driven by M101(LT paper feed) via MC101(LT feed MC). The paper feed roller and feed roller touche the paper when SD100 (LT first feed) is ON, feeding the paper to the conveyance roller. Then, SD100 (LT first paper feed) turns OFF to release the paper feed roller and feed roller from the paper. The conveyance roller is also driven by M101, by turning ON MC102 (LT first feed MC), paper is fed to the main body. The related signals are: PS100 (LT top cover open/close detection), PS106 (LT feed), PS107 (LT first feed), and PS110 (LT jam access door open/close detection).
Actuator Remaining paper detection gear
Gear for M100 LT remaining paper detection PS4 (PS105)

1. Operation

a. First paper feed timing (1) Start of first paper feed At predefined interval after the START button is pressed. (2) Start of second and subsequent papers When PS106 (LT feed) is turned OFF by the preceding paper. (3) OFF timing When the main body M7 (paper exit) turns OFF. b. Interlock The power supply line of M101 (LT paper feed) is equipped with MS101 (LT interlock/1) and MS102 (LT interlock/2). When the top cover is opened, MS101 turns OFF, and when the jam access door is opened MS102 turns OFF, thereby cutting off the power supply to M101. Furthermore, the top cover is equipped with PS100 (LT top cover open/close detection) and the jam access door is equipped with PS110 (LT jam access door open/close detection) and when either of these doors is opened during paper feed, the M101 drive signal is turned OFF to stop the paper feed operation. c. Internal heater The LCT is equipped with HTR101 (LT internal heater) to protect the paper from humidity. HTR101 is directly controlled by the main body PRCB (printer control board) rather than by the LTDB (LT drive board).

2. Signals

a. Input signals (1) UPOP_PS (PS100 to LTDB) Top cover open/close detection signal [L]: Cover opened [H]: Cover closed (2) CONV_PS (PS106 to LTDB) Conveyance roller exit paper detection signal [L]: Paper detected [H]: Paper not detected (3) PR_PS (PS107 to LTDB) Conveyance roller entrance (pre-registration position) paper detection signal [L]: Paper detected [H]: Paper not detected (4) SIDOP_PS (PS110 to LTDB) Jam access door open/close detection signal [L]: Door opened [H]: Door closed (5) LCTM_EM (M101 to LTDB) M101 rotation error detection signal [L]: M101 rotating [H]: M101 not rotating (6) IO_DTXD (MAIN BODY to LTDB) Serial data to transmit main body PRCB (printer control board) operating status to LTDB (7) LCT_LATCH (MAIN BODY to LTDB) IO_DTXD signal latch signal (8) IO_DCLK (MAIN BODY to LTDB) IO_DTXD signal clock signal (9) ERR_OUT4 (MAIN BODY to LTDB) Signal to notify LTDB (LT drive board) when there is error in the main body (10) ACK4 (MAIN BODY to LTDB) Serial data transmission enable signal from LCT to main body PRCB (printer control board)
b. Output signals (1) CONT (LTDB to MC101) MC101 (LT feed MC) ON/OFF drive signal [L]: MC101 ON [H]: MC101 OFF (2) CONT (LTDB to MC102) MC102 (LT first paper feed MC) ON/OFF drive signal [L]: MC102 ON [H]: MC102 OFF (3) CONT (LTDB to SD100) SD100 ( LT first paper feed) ON/OFF drive signal [L]: SD100 ON [H]: SD100 OFF (4) LCTM_CONT (LTDB to M101) M101 (LT paper feed) ON/OFF control signal [L]: M101 ON [H]: M101 OFF (5) IO_URXD (LTDB to MAIN BODY) Serial data to transmit the LTDB (LT drive board) operating status to main body PRCB (6) IO_UCLK (LTDB to MAIN BODY) IO_URXD signal clock signal (7) REQ4 (LTDB to MAIN BODY) Serial data send request signal from LCT to main body PRCB (8) LCTM_CLK (M101 to LTDB) M101 (LT paper feed) rotational speed control clock signal (9) LCTM_F/R (M101 to LTDB) M101 (LT paper feed) rotational direction indication signal This machine always indicates [H]: normal rotation.
[4] Up/down plate drive control

5V SIG S_GND

PS101 SW100
24V PGND 5V SGND 5V UP_PS S_GND
IO_DTXD IO_UCLK LCT_LATCH IO_DCLK ERR_OUT4 IO_URXD ACK4 REQ4
When the top cover opens or closes, M100 (LT up/down motor) rotates forward or backward to move the up/down plate up or down. The up/ down plate descends by 120 mm each time SW100 (LT tray down drive) is pressed while the top cover is opened. The related signals are PS100 (LT top cover open/close detection), PS101 (LT lower limit detection), and PS109 (LT upper limit detection).
a. Up/down plate descend timing (1) ON timing When the top cover is opened and PS100 (LT top cover open/close detection) is turned OFF, M100 rotates backward to lower the up/down plate. When SW100 (LT tray down drive) turns ON by pressing, M100 rotates backward to move the up/down plate down. (2) OFF timing M100 turns OFF at predefined interval after PS100 turns OFF or SW100 turns ON. This in turn lowers the up/down plate by 120 mm. (3) Others The up/down plate descends by 120 mm each time SW100 is pressed until PS101 turns ON to indicate the bottom limit of the up/down plate.

b. Up/down plate ascend timing (1) ON timing When the top cover is closed and PS100 (LT top cover open/close detection) is turned ON, M100 (LT UP/DOWN) rotates forward to raise the up/ down plate. (2) OFF timing When the up/down plate rises and PS109 (LT upper limit detection) turns ON to indicate the detection of the topmost paper, M100 (LT UP/ DOWN) turns OFF and stops the up/down plate. The up/down plate also stops when the top cover is opened and PS100 (LT top cover open/ close detection) turns OFF.
[5] Remaining paper detection/No paper detection control

24V PGND 5V SGND

a. Input signals (1) SIG (PS101 to LTDB) Up/down plate lower limit detection signal [L]: Up/down plate not at lower limit [H]: Up/down plate at lower limit (2) UP_PS (PS109 to LTDB) Up/down plate upper limit detection signal [L]: Up/down plate not at upper limit [H]: Up/down plate at upper limit (3) DW_SW (SW100 to LTDB) SW100 (LT tray down switch) ON/OFF detection signal [L]: SW100 ON [H]: SW100 OFF b. Output signal (1) D1, 2 (LTDB to M100) M100 (LT UP/DOWN) drive signal These signals switches the direction of the drive current to control the rotation direction of M100.

5V 0_PS S_GND

The remaining paper quantity is detected by PS102 (LT remaining paper detection 1), PS103 (LT remaining paper detection 2), PS104 (LT remaining paper detection 3), and PS105 (LT remaining paper detection 4) and no paper detection is made by PS108 (LT no paper detection). The signals detected by these sensors are controlled by LTDB (LT drive board) and displayed on the main body display.
a. Remaining paper detection control The remaining paper quantity is determined from the ON/OFF combination of sensors PS102 (LT remaining paper detection 1), PS103 (LT remaining paper detection 2), PS104 (LT remaining paper detection 3), and PS105 (LT remaining paper detection 4) which detect the rotational position of M100 (LT UP/DOWN) that is driving the up/down plate. Each sensor turns ON or OFF according to the position of the remaining paper detection gear which is linked with the rotation of M100. The remaining paper quantity is detectable at eight levels, but it is displayed on the main body display as five levels.
<Remaining paper quantity and display> Stacked paper quantity 0 to to 1200 Remaining PS102 PS103 PS104 PS105 paper quantity display OFF OFF OFF OFF 1 flashing ON OFF OFF OFF 1 on ON ON ON OFF OFF 2 on ON ON ON OFF 2 on ON ON ON 3 on 3 on 4 on 4 on

1201 to 1700 ON 1701 to 2200 ON 2201 to 2700 ON

2701 to 3200 OFF ON

3201 to 3700 OFF OFF ON
3701 or more OFF OFF OFF ON
Caution:The remaining paper quantity is indicated on the control panel with four horizontal bars. Stacked paper quantity differs depending on the thickness of the paper. b. No paper detection control When there is no more paper inside the LCT, PS108 (LT no paper detection) turns ON and a message is displayed on the main body display.
a. Input signals (1) SIG (PS102 to LTDB) Remaining paper detection gear rotational position detection signal [L]: PS102 OFF [H]: PS102 ON (2) SIG (PS103 to LTDB) Remaining paper detection gear rotational position detection signal [L]: PS103 OFF [H]: PS103 ON (3) SIG (PS104 to LTDB) Remaining paper detection gear rotational position detection signal [L]: PS104 OFF [H]: PS104 ON (4) SIG (PS105 to LTDB) Remaining paper detection gear rotational position detection signal [L]: PS105 OFF [H]: PS105 ON (5) 0_PS (PS108 to LTDB) LCT no paper detection signal [L]: No paper [H]: Paper present

DISASSEMBLY/ASSEMBLY

This section explains how to disassemble and reassemble the machine. When disassembling and reassembling the machine, follow the precautions given below. 1. Be sure the power cord has been unplugged from the wall outlet. 2. The disassembled parts must be reassembled following the disassembly procedure in reverse unless otherwise specified. 3. Care should be taken not to lose small parts. Care should also be taken not to install small parts in wrong places. 4. Do not operate the machine before installing all the disassembled parts completely. 5. Removal of some screws is prohibited in this section. Never loosen them.
[1] Cleaning the Paper Dust Removing Brush
Caution:If LT is connected to the main body, make sure that main body power plug is disconnected from the power outlet. a. Procedure (1) Open the top cover. (2) Remove six screws to detach the paper feed cover B.
[2] Cleaning the LT feed PS (PS106)/LT first paper feed PS (PS107)
Caution:If LT is connected to the main body, make sure that main body power plug is disconnected from the power outlet. a. Procedure (1) Looking into the paper exit side of the LCT from below, and clean sensors through the cavity for LT feed PS (PS106) and the cavity for LT first paper feed (PS107) using a blower brush.

Top cover Screws Screws

Cavity for PS106 Cavity for PS107

Paper exit side

Paper feed cover B

Double feed prevention roller unit cover Double feed prevention roller
Stop ring Bearing Feed roller rubber

Paint mark

(8) Reinstall the above parts following the removal steps in reverse. Caution1: Make sure rollers and rubber portions are oriented properly when reinstalling them. Caution2: Make sure the one-way clutch direction is correct. Caution3: Check whether grease or the like is present on each roller.

Screws

(3) Remove two screws to detach the double feed prevention roller unit. Caution: When reinstalling the double feed prevention roller unit, tighten the screws on the rear side first.
Double feed prevention roller unit
(5) Remove the double feed prevention roller rubber from the double feed prevention roller.
Paint mark Double feed prevention roller
Double feed prevention roller rubber Screws
(4) Remove two stop rings, fit the shaft into the D-cut in the fitting, and remove the double feed prevention roller together with the shaft.
Double feed prevention roller
(6) Reinstall the double feed prevention roller in the reverse order of the removal procedure. Caution1: Make sure the double feed prevention roller rubber is oriented properly when reinstalling it. Caution2: Check whether scratch or the like is visible on the pet cover for the drive gear. Caution3: Check whether grease or the like is present on double feed prevention roller.

Stop ring

[6] Replacing the LT feed MC (MC101)/LT first paper feed MC (MC102)
a. Procedure (1) Open the top cover. (2) Remove the spring from the paper feed roller unit. (3) Remove two screws to detach the top cover.

Top cover Screws

(5) Disconnect two relay connectors (CN765, CN766) of the clutches. (6) Remove the stop ring to detach each clutch.
LT first paper feed MC (MC102) LT feed MC (MC101)

Stop ring Stop ring

Relay connector (CN766) Relay connector (CN765)
(7) Reinstall the above parts following the removal steps in reverse. Caution: When installing each MC, make sure that the stopper of each clutch is on the predefined position.
(4) Remove three screws to detach the clutch replacement cover.
Screws Clutch replacement cover
[7] Replacing the LT-402 Up/Down Wires
Caution: With the power held on, press the LT tray down switch (SW100) to move the up/down plate down to the bottom in advance. a. Procedure (1) Open the top cover. (2) Remove the clutch replacement cover. (3) Remove five screws to detach the right side cover.
(5) Remove twelve screws to detach the rear cover.
Screws Screws Screws Screws Rear cover

Right side cover

(6) Remove the five relay connectors (CN749, CN780, CN781, CN782, CN783) to disconnect the wiring harness from the up/down motor mounting assembly. (7) Remove the E-ring to detach the up/down gear. (8) Pull the pin from the shaft. (9) Remove the E-ring to detach the bearing. (10) Remove three screws to detach the up/down motor assembly.

Relay connector (CN749) Up/down motor mounting assembly Screw Relay connector (CN780) Relay connector (CN781) Relay connector (CN782) Relay connector (CN783) Screw Bearing E-ring Up/down gear E-ring
(4) After opening the jam access door, remove six screws to detach the front cover. Caution: When removing the front cover, close the jam access door after removing the screws.

Jam access door

Shaft Screw Pin Screws Right side cover Screws
(11) Replace the up/down wire following the instructions in Removing Up/Down Wires and Installing Up/Down Wires. Caution: Two sets of four up/down wires with different length, one set at the front and the other at the back, are used. Wires with the same length can be used either at the front or back if they are used in the same location.

1323.6mm Wire A

1250.3mm Wire B

769.3mm Wire C

661mm Wire D
<Removing the Up/Down Wires>
Up/down plate Wire B Wire A Wire A Wire B 4. Release the metal ball to remove wire D. 14. Release the metal ball to remove wire A. 7. Release the metal ball to remove wire C. 9. Release the metal ball to remove wire D. 12. Release the metal ball to remove wire B. Wire C Wire D 6. Remove the E-ring. 8. Remove the pulley. FRONT Up/down shaft Wire D Wire C 1. Remove the E-ring. 3. Remove the pulley. 5. Remove the pulley. 15. Remove the Ering, then remove the pulley to release wire B. 16. Release the metal ball to remove wire B. 18. Release the metal ball to remove wire A. 2. Release the metal ball to remove wire C.

10. Remove the pulley.

11. Remove the E-ring, then remove the pulley to release wire B.
13. Remove the pulley to release wire A.
17. Remove the pulley to release wire A.
<Installing the Up/Down Wires>
Up/down plate Wire B Wire A Wire A Wire B 7. Insert wire A in the pulleys, then attach a metal ball. 15. Insert wire C in the pulleys, then attach a metal ball. 12. Insert wire D in the pulleys, then attach a metal ball. 10. Insert wire B in the pulleys, then attach a metal ball. Wire C Wire D 13. Insert wire C in the up/ down shaft, attach a pulley, and secure the pulley with an E-ring. 14. Wind wire C around the pulley by 6 turns in such a manner that the wire can be pulled from over the pulley. FRONT Up/down shaft 1. Insert wire A in 6. the up/down shaft, attach pulleys, then pull the wire from under the pulleys.

20. Insert wire B in the pulleys, then attach a metal ball.
2. Insert wire A in the pulleys, then attach a metal ball.
17. Insert wire D in the pulleys, then attach a metal ball.
5. Insert wire B in the pulleys, then attach a metal ball.

Wire D Wire C

18. Insert wire C in the up/ down shaft, attach a pulley, and secure the pulley with an E-ring. 19. Wind wire C around the pulley by 6 turns in such a manner that the wire can be pulled from over the pulley.

6 turns

6 turns 11. Insert wire D in the up/ down shaft, attach a pulley, and wind wire D around the pulley by six turns in such a manner that the wire can be pulled from over the pulley. 3. Insert wire B in the up/ 8. down shaft, attach a pulley, and secure the pulley with E-rings. 4. Pull wire B from under the 9. pulleys. 16. Insert wire D in the up/ down shaft, attach a pulley, and wind wire D around the pulley by six turns in such a manner that the wire can be pulled from over the pulley.
(12) After installing the up/down wires, make sure the up/down wires are passed in the grooves in the pulleys properly and wires do not run on the sides of the pulleys. Also make sure the up/down plate can be moved up and down smoothly by hand. Caution: If the up/down plate does not move up and down smoothly, reinstall the up/ down wires. (13) Install the up/down wire drive motor assembly, up/down gear, and relay connectors, following the removal steps in reverse. (14) Remove the E-ring to detach the idle gear. (15) Rotate the remaining paper detection gear until the round hole in this gear is aligned with the oblong hole in the up/down motor mounting assembly. Caution: Align when the up/down plate is in lowest position.
Up/down motor mounting assembly Remaining paper detection gear
[8] Replacing the LT-412 Up/Down Wires
a. Procedure Caution: With the power held on, press the LT tray down switch (SW100) to move the up/down plate down to the bottom in advance. Remove the clutch replacement cover, side cover (right), front cover, and rear cover following the steps (1) to (5) in [7] Replacing the LT-402 Up/Down Wires. Remove the E-ring. Remove the five screws to detach the gear cover. Remove the two bearings.

(2) (3) (4)

Screw Gear cover E-ring Bearing Screws Bearing

Idle gear

E-ring

Oblong hole

Round hole
(5) Remove the gear A. (6) Remove the E-ring to remove gear B. (7) Remove the detent pin for gear B from the up/ down pulley shaft. (8) Remove the E-ring and bearing to remove gear C.

Bearing Gear C

(16) Install the idle gear. (17) Attach the covers following the removal steps in reverse. Caution1: After replacing the up/down wires, make horizontal and centering adjustment of the up/down plate. (Refer to ADJUSTMENT SECTION.)

Gear A Pin Gear B

E-ring E-ring Up/down pulley shaft
(9) Remove the bearing behind gear C. (10) Remove the E-ring to remove the up/down gear. (11) Remove the detent pin for up/down gear from the up/down pulley shaft. (12) Remove the E-ring to remove gear D. (13) Remove the E-ring to remove the remaining paper detection gear. (14) Remove four relay connectors (CN780, CN781, CN782, and CN783) to disconnect the wiring harness from the up/down motor mounting assembly.
Relay connector Relay Relay connector connector (CN782) (CN780) (CN781) Up/down Remaining paper motor mounting detection gear assembly Gear D
(17) Replace the up/down wires following the instructions in Removing the Up/Down Wires and Installing Up/Down Wires. Caution: Two sets of four up/down wires with different length, one set at the front and the other at the back, are used. Wires with the same length can be used either at the front or back if they are used in the same location.

1057.3mm Wire A

692.1mm Wire B

1321.7mm Wire C

1303.1mm E-ring Wire D
Pin Up/down gear E-ring Up/down pulley shaft Bearing Relay connector (CN783) E-ring
(15) Remove the E-ring to remove the bearing. (16) Remove the six screws to remove the up/down motor mounting assembly.
Up/down motor mounting assembly Screws
Up/down plate 2. Release the metal ball to remove wire A.
Wire C Wire D Wire C Wire D 14. Release the metal ball to remove wire D. 7. Release the metal ball to remove wire A. 9. Release the metal ball to remove wire B. 12. Release the metal ball to remove wire C. Wire A Wire B 6. Remove the E-ring. 8. Remove the pulley. 10. Remove the pulley. 11. Remove the E-ring, then remove the pulley to release wire C. 18. Release the metal ball to remove wire D. 4. Release the metal ball to remove wire B. 16. Release the metal ball to remove wire C. Wire B Wire A
1. Remove the E-ring. 3. Remove the pulley. 5. Remove the pulley. FRONT Up/down shaft 15. Remove the E-ring, then remove the pulley to release wire C.
13. Remove the pulley to release wire D.

17. Remove the pulley to release wire D.
Up/down plate 20. Insert wire A in the pulleys, then attach a metal ball.
Wire C Wire D Wire C Wire D 7. Insert wire D in the pulleys, then attach a metal ball. 15. Insert wire A in the pulleys, then attach a metal ball. 12. Insert wire B in the pulleys, then attach a metal ball. 10. Insert wire C in the pulleys, then attach a metal ball. Wire A Wire B 13. Insert wire A in the up/down shaft, attach a pulley, and secure the pulley with an E-ring. 14. Wind wire A around the pulley by 6 turns in such a manner that the wire can be pulled from over the pulley. 2. Insert wire D in the pulleys, then attach a metal ball. 17. Insert wire B in the pulleys, then attach a metal ball. 5. Insert wire C in the pulleys, then attach a metal ball. Wire B Wire A
18. Insert wire A in the up/ down shaft, attach a pulley, and secure the pulley with an E-ring. FRONT Up/down shaft 19. Wind wire A around the pulley by 6 turns in such a manner that the wire can be pulled from over the pulley. 6 turns
1. Insert wire D in the 6. up/down shaft, attach pulleys, then pull wire D from under the pulleys.
6 turns 11. Insert wire B in the up/down shaft, attach a pulley, and wind wire B around the pulley by six turns in such a manner that the wire can be pulled from over the pulley. 3. Insert wire C in the up/down 8. shaft, attach a pulley, and secure the pulley with E-rings. 4. Pull wire C from under the 9. pulleys.
16. Insert wire B in the up/ down shaft, attach a pulley, and wind wire B around the pulley by six turns in such a manner that the wire can be pulled from over the pulley.

6 turns 6 turns

(18) After installing the up/down wires, check whether they are engaged with the pulleys properly and whether they do not ride over the pulleys. Next, move the up/down plate manually to check whether it moves up and down smoothly. Caution: If the up/down plate does not move smoothly, remove the up/down wires and install them again. (19) Install the up/down motor mounting assembly, relay connectors, remaining paper detection gear, gear D, and up/down gear following the removal steps in reverse. (20) Rotate the remaining paper detection gear until the round hole in this gear is aligned with the oblong hole in the up/down motor mounting assembly.

Oblong hole Round hole

Caution: Align them when the up/down plate is at the bottom. (21) Install gear C. (22) Attach the other gears, gear cover, and external covers following the removal steps in reverse. Caution: After replacing the up/down wires, make horizontal and centering adjustment of the up/down plate. (Refer to ADJUSTMENT SECTION.)

SERVICE MANUAL

Models

FS-110/FS-210

JANUARY 2004 CSM-FS110
KONICA MINOLTA BUSINESS SOLUTIONS U.S.A., INC.
FS-110/FS-210 SERVICE MANUAL

JANUARY 2004

Used on Konica Models 7155/7165/FORCE 65/7255/7272

IMPORTANT NOTICE

Because of the possible hazards to an inexperienced person servicing this equipment, as well as the risk of damage to the equipment, Konica Minolta Business Solutions U.S.A., Inc. strongly recommends that all servicing be performed by Konica-trained service technicians only. Changes may have been made to this equipment to improve its performance after this service manual was printed. Accordingly, Konica Minolta Business Solutions U.S.A., Inc., makes no representations or warranties, either expressed or implied, that the information contained in this service manual is complete or accurate. It is understood that the user of this manual must assume all risks or personal injury and/or damage to the equipment while servicing the equipment for which this service manual is intended.
Corporate Publishing Department
2004, KONICA MINOLTA BUSINESS SOLUTIONS U.S.A., INC. All rights reserved. Printed in U.S.A.

CONTENTS

SAFETY AND IMPORTANT WARNING ITEMS Refer to the 7155/7165/7255/7272 service manual on page... S-1

1. OUTLINE

FS-110/FS-210 PRODUCT SPECIFICATIONS.1-1 CROSS SECTION DIAGRAM..1-4 DRIVE SYSTEM DIAGRAM..1-5 [1] Paper Conveyance Drive..1-5 [2] Stacker Drive...1-6 [3] Staple Drive..1-7 [4] Tray Drive...1-8 [5] Folding Drive...1-9 PAPER CONVEYANCE PATH..1-10 [1] Paper Conveyance Path.1-10 [2] Non-Sort Mode...1-11 [3] Sort, and Group Modes..1-12 [4] Sub-tray Mode..1-13 [5] Staple Mode..1-14 [6] Booklet Mode..1-16 [7] Three-folding Mode..1-17

2. UNIT EXPLANATION

EXTERNAL SECTION..2-1 [1] Composition..2-1 [2] Mechanism..2-1 CONVEYANCE SECTION...2-2 [1] Composition..2-2 [2] Mechanism..2-3 [3] M701 (FNS Conveyance) Control.2-6 [4] M712 (gate drive) Control..2-7 [5] SD705 (by-pass gate) Control..2-7 [6] M702 (shift) Control.2-8 [7] M707 (paper exit roller) Control.2-9 [8] SD704 (paper exit opening solenoid) Control..2-11 [9] M708 (paper exit opening) Control.2-12 [10] M721 (sub-tray paper exit) Control.2-13 MAIN TRAY SECTION..2-14 [1] Composition..2-14 [2] Mechanism..2-14 [3] M703 (tray up/down) Control..2-15 STACKER SECTION..2-17 [1] Composition..2-17 [2] Mechanism..2-18 [3] M705 (alignment/U) Control.2-21 [4] M716 (alignment/L) Control (FS-210 only)..2-22 [5] M718 (folding stopper) Control (FS-210 only)..2-23 [6] M713 (stacker entrance) Control.2-25

7155/7165/7255/7272

MANUAL SERVICE MANUAL

REVISED EDITION

DATE Dec. 2003

PAGE -

METHOD REPLACEMENT

3 DIS./ASSEMBLY

2 UNIT EXPLANATION

1 OUTLINE

STAPLER SECTION... 2-27 [1] Composition.. 2-27 [2] Mechanism... 2-28 [3] Stapler Movement Control.. 2-30 [4] Staple Control.. 2-32 FOLDING/THREE-FOLDING SECTION (FS-210 ONLY).. 2-35 [1] Composition.. 2-35 [2] Mechanism... 2-36 [3] M719 (folding knife) Control.. 2-37 [4] M720 (folding conveyance) Control. 2-38 [5] SD706 (three-folding gate) Control.. 2-39

3. DISASSEMBLY/ASSEMBLY

EXTERNAL SECTION... 3-1 [1] Removing and Reinstalling the Booklet Tray (FS-210 only).. 3-1 [2] Removing and Reinstalling the Top Cover/1.. 3-1 [3] Removing and Reinstalling the Top Cover/2.. 3-2 [4] Removing and Reinstalling the Side Cover.. 3-2 [5] Removing and Reinstalling the Front Door... 3-3 [6] Removing and Reinstalling the Rear Cover.. 3-3 [7] Removing and Reinstalling the Main Tray... 3-4 [8] Removing and Reinstalling the Main Paper Exit Opening Cover.. 3-5 [9] Removing and Reinstalling the Booklet Paper Exit Opening Cover.. 3-5 CONVEYANCE SECTION.. 3-6 [1] Replacing the Paper Exit Roller (Sponge Roller)... 3-6 [2] Replacing the Intermediate Conveyance Roller (Sponge Roller).. 3-7 [3] Removing and Reinstalling the Paper Exit Opening Unit... 3-8 MAIN TRAY SECTION.. 3-9 [1] Replacing the Tray Up/down Motor (M703).. 3-9 [2] Replacing the Up/Down Wire.. 3-9 STACKER SECTION... 3-13 [1] Removing and Reinstalling the Stacker Unit Cover.. 3-13 [2] Removing and Reinstalling the Stacker Unit... 3-13 STAPLER SECTION... 3-15 [1] Removing and Reinstalling the Stapler Unit Cover.. 3-15 [2] Removing and Reinstalling the Clincher. 3-16 [3] Removing and Reinstalling the Stapler. 3-17

SAFETY WARNINGS

[1] Modifications Not Authorized by Konica Minolta
Konica Minolta equipment is renowned for their high reliability. This reliability is achieved through high-quality design and a solid service network. Unauthorized modifications involve a high risk of degrading performance and safety. Such modifications are therefore strictly prohibited. The points listed below are not exhaustive, but they illustrate the reasoning behind this policy. PROHIBITED ACTIONS : (1) Using extension cables or a different power cord than specified by Konica Minolta. (2) Using other fuses than specified by Konica Minolta. Safety will not be assured, leading to a risk of fire and injury. (3) Disabling fuses or bridging fuse terminals with wire, metal clips, solder or similar. (This applies also to thermal fuses.) (4) Removing air filters (except for replacement). (5) Disabling relay functions (such as wedging paper between relay contacts, etc.). (6) Disabling safety functions (interlocks, safety circuits, etc.). Safety will not be assured, leading to a risk of fire and injury. (7) Performing actions to equipment not described in the instruction manual or the service handbook. (8) Using parts other than specified by Konica Minolta. (3) Be sure to disconnect the power cord of the equipment from the AC outlet. Simply turning off the power switch is not sufficient, because paper feed units or other electrical equipment may be powered also when the power switch is turned off. (4) Proceed with special care when performing operation checks or adjustment while the unit is powered. When carrying out operation checks or adjustment while external covers are removed, the risk of electrical shock exists when touching parts which carry high voltage or electrical charge. The risk of injury exists when touching moving parts such as gears or chains.

2. Safety Checkpoints

The following list is not exhaustive, but it includes actions which must be carried out at every on-site service. CAUTION: (1) Check external covers and the frame for sharp edges, burrs, or nicks. (2) Check external covers and hinges for loosening or damage. (3) Check wiring for squeezing or damage. (4) Check power cord for insulation problems (conductor must not be exposed). (5) Check power cord and cable ties etc. for loosening from frame. WARNING: (1) Verify that the equipment is properly grounded. If a problem is detected, establish a proper ground connection. (2) Connecting the ground lead to an improper point such as listed below results in a risk of explosion and electric shock. Unsuitable ground points: - Gas pipe - Lightning rod - Telephone line ground - Plastic water pipe or water pipe or faucet that has not been approved by authorities for grounding use

[2] Checkpoints When Performing Onsite Service
Konica Minolta equipment is extensively tested before shipping, to ensure that all applicable safety standards are met, in order to protect the customer and customer engineer 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 customer engineer must perform regular safety checks.
1. Advance Preparation for Safety Checks
CAUTION: (1) Wear clothing that facilitates work and is designed for safety. (2) Carry out all procedures carefully to prevent injury.
3. Description of Safety Checks
CAUTION: (1) Before performing safety check work, read all relevant documentation (service handbook, technical notices, etc.) and proceed according to the prescribed procedure, using only the prescribed tools. Do not carry out any adjustments not described in the documentation.
(2) If the power cord is damaged, replace it only with the specified power cord. If the power cord insulation has been damaged and there are exposed sections, short- circuits and overheating may occur, leading to a serious fire risk. (3) Do not route the power cord so that it can be stepped on or pinched. Otherwise overheating may occur, leading to a serious fire risk. (4) When disconnecting any cables, always grasp the connector and not the cable (especially in the case of AC and high-voltage leads). (5) Carefully remove all toner remnants from electrical parts, electrodes, etc. (6) Make sure that wiring cannot come into contact with sharp edges, burrs, or other pointed parts. (7) Double-check to make sure that all screws, components, wiring, connectors, etc. that were removed for safety check maintenance have been reinstalled in the original location. (Pay special attention to forgotten connectors, pinched cables, forgotten screws, etc.) (8) When installation and preventive maintenance, verify that the power cord has been securely plugged into the AC outlet. Contact problems may lead to increased resistance, overheating, and the risk of fire. WARNING: Before disassembling or adjusting the equipment, make sure that the power cord has been disconnected.
[4] Measures to Take in Case of an Accident
(1) If an accident has occurred, the distributor who has been notified first must immediately take emergency measures to provide relief to affected persons and to prevent further damage. (2) If a report of a serious accident has been received from a customer, an on-site evaluation must be carried out quickly and Konica Minolta must be notified. (3) To determine the cause of the accident, conditions and materials must be recorded through direct onsite checks, in accordance with instructions issued by Konica Minolta. (4) For reports and measures concerning accidents, consult your superior, and follow the regulations set in "Standards for the Control Program for Measures Against Electrical Equipment Accidents".

[5] Conclusion

(1) Safety of users and customer engineers depends highly on accurate maintenance and administration. Therefore, safety can be maintained by the appropriate by the proper daily service work conducted by the customer engineer. (2) When performing service, equipment on the site must be tested for safety. The customer engineer must verify the safety of parts and ensure appropriate management of the equipment.
[3] Handling of Materials for Servicing
CAUTION: Alcohol-based and acetone- based cleaners are highly flammable and must be handled with care. When using these materials for cleaning parts, observe the following precautions. Disconnect the power cord from the AC outlet. 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. Perform cleaning only in an environment where sufficient ventilation is assured. Breathing large quantities of organic solvents can lead to discomfort. Do not replace the cover or turn the unit on before any solvent remnants on the cleaned parts have fully evaporated.

(1) (2)

OUTLINE

Blank page

FS-110/FS-210 PRODUCT SPECIFICATIONS

[1] Type

FS-110: Finishing device with offset collation (sort and group), stapling, and sub-tray eject features. FS-210: Finishing device with offset collation (sort and group), stapling, sub-tray eject, booklet (stitchand-fold), and three-folding features. Paper Stacking Capacity (80g/m2 or 20lbs): Sub-tray exit mode: Maximum 200 sheets (same-size sheets only) Non-Staple, Group, and Offset modes: Maximum 1500 sheets (A3, B4, F4R, 11 x 17, and 8.5 x 14) Maximum 3000 sheets (A4, A4R, B5, B5R, 8.5 x 11, and 8.5 x 11R) Maximum 500 sheets (A5, A5R, B6R, 5.5 x 8.5, and 5.5 x 8.5R) Note: For FS-210, the maximum stacking capacity is 2500 sheets for A4, A4R, B5, B5R, 8.5 x 11, and 8.5 x 11R paper. Staple Mode: Maximum 1000 sheets (paper must be the same size) Main-Tray Capacity Original pages 2 to to to to to 50 A3, 11 x 17, Other paper A5, and 5.5 x types 8.stacks 100 stacks 50 stacks 50 stacks 30 stacks 30 stacks 25 stacks 25 stacks 20 stacks 20 stacks

[2] Functions

Type of Paper: Same as the main body Paper Size:
FS-110/210 FS-210 only Non- Sort/ Sta- Sub- Book- Three sort group ple tray let -folding A3 B4 F4R A4R A/B A4 standards B5R B5 A5R A5 B6R 11 x 17 8.5 x 14 8.5 x 11R 8.5 x 11 5.5 x 8.5R 5.5 x 8.5 Wide Other

By inch

Booklet Mode (FS-210 only): Stitch-and-fold 20 booklets with 5 sheets folded each. 15 booklets in case of small size paper (A4R/ 8.5 x 11R). One booklet with 6 sheets folded is taken as two and more booklets. Folding 33 booklets with 3 or less sheets folded each 25 booklets in case of small size paper (A4R/8.5 x 11R). Three-folding Tray capacity is a maximum of 50 individual folded sheets. Paper curling: 10mm or less

Power source: 24V, 5VDC (supplied from the main body) Maximum power consumption: 100VA Weight: FS-110: Approx. 55kg FS-210: Approx. 65kg External Dimensions:
(tray extended) 656 (tray closed) 410

CROSS SECTION DIAGRAM

Sub-tray Paper exit opening unit Main tray Shift unit
Bypass gate Clincher Alignment plate/U Flat-stapling stopper
Stapler Three-folding stopper Three-folding gate Booklet tray

Booklet stopper

Folding knife Alignment plate/L
Components in the region enclosed by the dotted line represent those of FS-210.

DRIVE SYSTEM DIAGRAM

[1] Paper Conveyance Drive
Sub-tray paper exit roller Sub-tray paper exit motor (M721) Paper exit opening motor (M708) Shift motor (M702) Sub-tray conveyance roller Gate drive motor (M712)
Paper exit roller motor (M707)
FNS conveyance motor (M701) Paper exit opening SD (SD704) PI conveyance roller

Paper exit roller

Shift roller Entrance roller Conveyance roller/A Conveyance roller/B
By-pass gate SD (SD705) By-pass gate
Intermediate conveyance roller

[2] Stacker Drive

Alignment plate/U Paper exit arm From paper exit roller motor (M707)

Alignment motor/U (M705)

Stacker entrance motor (M713) Stacker entrance roller

Flat-stapling stopper

Alignment motor/L (M716)
Booklet stopper Alignment plate/L Stopper motor (M718)

[3] Staple Drive

Stapler

Clincher

Stapler/R Stapler/F
Stapler rotation motor (M706) Clincher/F
Stapler movement motor (M711)
Clincher rotation motor (M704)

Clincher/R

[4] Tray Drive

Up/down pulley/U

Main tray

Up/down wire

Up/down pulley/L

Old type

Tray up/down motor (M703)

New type

fs2101001

REVISED EDITION 1-8

PAGE 1-8

[5] Folding Drive

Folding roller Three-folding gate

Folding knife

Three-folding gate SD (SD706)
Folding knife motor (M719)

Three-folding roller

Folding conveyance motor (M720)

PAPER CONVEYANCE PATH

[1] Paper Conveyance Path
The finisher (FNS) consists of five paper paths, as shown in the diagram below. Sheets are turned over by the main body's exit page inverter, and then passed to the FNS. The FNS has two paper entrance connections: one from the main body, and the other from PI-110 (optional).

a. Straight, sort, and group modes When PS704 (FNS entrance) detects the leading edge of the paper, M707 starts to rotate at a high speed. When PS704 has detected the trailing edge of the paper and a predefined time period has elapsed, the rotation of M707 changes to low. Then the paper delivery action is performed. When PS706 (main tray paper exit) has detected the trailing edge of the paper (preparation for the next paper conveyance) and a predefined time period has elapsed, the rotation speed of M707 returns to high. When PS704 has detected the last paper and a predefined time period has elapsed, M707 ceases to rotate.
Staple mode (for papers whose length in the feeding direction is smaller than B5R) The FNS operation signal from the main body lets M707 (paper exit roller) rotate. When PS709 (paper exit belt HP) signal has changed from OFF to ON and a predefined time period has elapsed, M707 stops. The paper exit arm moves to the staple mode HP. When the stapling operation has been completed, M707 rotates to drive the paper exit belt of the stacker section. This action allows the paper exit arm to lift the paper to the level of the paper exit roller, which delivers it to the main tray. When PS709 detects the change in signal, from OFF to ON, M707 stops. Staple mode (other than those above) The FNS operation signal from the main body lets M707 (paper exit roller) rotate. When PS709 (paper exit belt HP) signal has changed from OFF to ON and a predefined time period has elapsed, M707 stops. The paper exit arm moves to the staple mode HP. When paper other than those described above is used, the paper exit opening is open. The paper exit opening is closed by M708 upon the completion of stapling. When PS712 (paper exit opening HP) detects that the paper exit opening has been closed, M707 starts rotating to drive the paper exit arm. This allows the paper exit arm to lift the paper to the level of the paper exit roller, which delivers it to the main tray. When PS709 detects the change in signal, from OFF to ON, M707 stops.
Folding and stitch-and-fold modes The FNS operation signal from the main body lets M707 (paper exit roller) counter-rotate. When PS709 (paper exit belt HP) signal has changed from OFF to ON, M707 stops. The paper exit arm moves to the booklet mode HP. When the stapling operation has completed, the paper is moved to the folding position. At this stage, the paper exit arm will not operate. This is because the paper exit arm may come into contact with the paper, which is waiting for a process at the folding position Three-folding mode The FNS operation signal from the main body lets M707 (paper exit roller) counter-rotate. When PS709 (paper exit belt HP) signal has changed from OFF to ON, M707 stops. The paper exit arm moves to the booklet mode HP. When the paper alignment has been completed, M707 (paper exit roller) counter-rotates helping the paper to be carried to the three-folding position. When PS709 signal has changed from OFF to ON, M707 stops.

[10] M721 (sub-tray paper exit) Control
24V 24V M721 DRV A M721 DRV A M721 DRV B M721 DRV B 5V PS701 IN GND 5V PS704 IN GND 5V PS719 IN GND MAIN BODY FNS CB
a. FNS CB input signals (1) PS701 IN (PS701 to FNS CB) Signal indicating the existence of the paper at the location of the sub-tray paper exit sensor. [L]: Paper does not exist. [H]: Paper exists. (2) PS719 IN (PS719 to FNS CB) Signal indicating the sub-tray full [L]: Sub-tray full [H]: Sub-tray not full b. FNS CB output signals (1) M721 DRV A, A(FNS CB to M721) Pulse signal to drive/control the Phase A of M721 (2) M721 DRV B, B(FNS CB to M721) Pulse signal to drive/control the Phase B of M721
M721 (sub-tray paper exit), controlled by the FNS CB (FNS control board), drives the sub-tray paper exit roller. The related signals are PS701 (sub-tary paper exit), PS704 (FNS entrance), and PS719 (subtray full).
a. M721 (sub-tray paper exit) Control M721 (sub-tray paper exit) starts its high-speed rotation when PS701 (sub-tray paper exit) detects the leading edge of the paper. When PS704 (FNS entrance) has detected the trailing edge of the paper and a predefined time period has elapsed since then, the rotation of M721 changes to low. When PS701 detects the trailing edge of the paper and a predefined time period has elapsed, M721 stops. Sub-tray full detection When the papers ejected to sub-tray reach to specified height, PS719 (sub-tray full) turns ON, and FNS transmits "sub-tray full" information to the main body. When the main body receives it, the message is displayed on the operation panel.

MAIN TRAY SECTION

Stapler paper exit upper limit PS (PS707) Tray upper limit PS (PS702)
Counter reset PS (PS715) Upper up/down pulley Tray lower limit PS (PS703) Tray up/down motor (M703) Timing belt
New type Tray up/down motor (M703)

fs2102001

Mechanism Main tray up/down*1 Paper detection*2 Method Wire drive Photo sensor
*1 Main Tray Up/Down The tray up/down motor (M703) and the worm gear installed on the motor shaft perform the winding operation of the up/down wire. The rotation direction of the motor shaft determines the moving direction of the main tray, i.e. rise or fall. If the up/down pulley/L rotates clockwise seen from the front, the main tray rises. Otherwise, the main tray falls. 2 In old type, a brush motor is used for M703 but in new type brushless motor and timing belt are used to enhance the silence effectiveness. *2 Paper Detection The distance between the top surface of the piled sheets on the main tray (the top surface of the main tray if there's no sheet on the tray) and the paper exit opening is monitored using the tray upper limit PS (PS702) and the stapler paper exit MODEL

a. FNS CB input signals (1) PS723 IN (PS723 to RB to FNS CB) Signal relating to the detection of the booklet stopper's home position [L]: Not in the home position [H]: In the home position (2) PS725 IN (PS725 to RB to FNS CB) Signal relating to the detection of the paper at the folding paper exit position [L]: Paper not detected [H]: Paper detected b. FNS CB output signals (1) M718 CLK (FNS CB to RB) Signal relating to the clock for controlling the rotation speed of the M718 (2) M718 RESET (FNS CB to RB) Reset signal for the M718 (3) M718 F/R (FNS CB to RB) Signal to control the rotation direction of the M718 [L]: CCW [H]: CW (4) M718 CONT (FNS CB to RB) Signal to activate or deactivate the M718 [L]: M718 ON [H]: M718 OFF c. RB output signals (1) M718 DRV A, A (RB to M718) Pulse signal to drive/control the Phase A of M718 (2) M718 DRV B, B (RB to M718) Pulse signal to drive/control the Phase B of M718
[6] M713 (stacker entrance) Control
24V M713 CLK M713 RESET M713 CONT 24V 24V M713 DRV A M713 DRV A M713 DRV B M713 DRV B
5V PS705 IN GND 5V PS725 IN GND RB
5V PS704 IN GND MAIN BODY FNS CB
M713 (stacker entrance) drives the stacker entrance roller and the swing belt. These components are responsible for conveying the paper to the stacker, aligning the paper rear end, and controlling the timing for stapling. The FNS CB (FNS control board) controls the operation of M713 through the RB (relay board). The related signals are PS704 (FNS entrance), PS705 (stacker entrance), and PS725 (folding paper exit).
a. Staple mode (for sheets of all paper sizes except A4, B5, and 8.5 x 11 = without by-pass feature) The FNS operation signal from the main body lets M713 (stacker entrance) start to rotate at a high-speed. When PS705 (stacker entrance) has detected the rear end of the paper, the rotation speed of M713 changes to low, conveying the paper slowly to the stacker. Then, after a predefined time has elapsed, the rotation returns to the highspeed mode to prepare for the next conveyance of paper. When the last sheet of the set has passed through and the stapling operation has started, M713 stops. 2-25
When M708 (paper exit) has closed the opening, the rotation of M713 changes to a high speed to prepare for the conveyance of the paper to be stapled. b. Staple mode (for sheets of paper sizes A4, B5, and 8.5 x 11 = with by-pass feature) (1) Sheets of the first set The sheets of the first set are processed in the same way as in the staple mode described above (for sheets of all paper sizes except A4, B5, and 8.5 x 11 = without by-pass feature). (2) First sheets of the second and subsequent sets When PS705 (stacker entrance) has detected the rear end of the last sheet of the first set, and a predefined time period has elapsed, M713 (stacker entrance) stops. This action ensures that the stapling of the first set completes before the sheets of the second set are fed to the stacker section (the first sheet waits on the bypass channel).

(3) Second sheets of the second and subsequent sets When PS704 (FNS entrance) has detected the trailing edge of the second sheet of the second (and subsequent sets), and a predefined time period has elapsed, M713 (stacker entrance) rotates as a high speed. This action allows the first and second sheets to be conveyed to the stacker section at the same time. (4) Third and subsequent sheets of the second and subsequent sets The third and subsequent sheets of the second (and subsequent sets) are conveyed to the stacker in the same manner as the sheets of the first set. c. Folding and stitch-and- folding modes The FNS operation signal from the main body lets M713 (stacker entrance) start to rotate at a high-speed. When PS705 (stacker entrance) has detected the rear end of the paper, the rotation speed of M713 changes to low, conveying the paper slowly to the stacker. Then, after a predefined time has elapsed, the rotation returns to the highspeed mode to prepare for the next conveyance of paper. When the last sheet of the set has been aligned, M713 stops. When PS725 (folding paper exit) has detected the rear end of the set, M713 (stacker entrance) returns to its high-speed rotation mode to prepare for the next paper conveyance. d. Three-folding mode The FNS operation signal from the main body lets M713 (stacker entrance) start to rotate at a high-speed. When PS705 (stacker entrance) has detected the trailing edge of the paper, the rotation speed of M713 changes to low, conveying the paper slowly to the stacker. Then, after a predefined time has elapsed, the rotation returns to the highspeed mode to prepare for the next conveyance of paper. When the last sheet of the set has been aligned and the booklet stopper has moved to the threefolding position, M713 stops. When PS729 (folding full) has detected the trailing edge of the set, M713 (stacker entrance) returns to its high-speed rotation mode to prepare for the next paper conveyance. 2-26
a. FNS CB output signals (1) M713 CLK (FNS CB to RB) Signal relating to the clock for controlling the rotation speed of M713 (2) M713 RESET (FNS CB to RB) Reset signal for M713 (3) M713 CONT (FNS CB to RB) Signal to activate or deactivate M713 [L]: M713 ON [H]: M713 OFF b. RB output signals (1) M713 DRV A, A (RB to M713) Pulse signal to drive/control the Phase A of M713 (2) M713 DRV B, B (RB to M713) Pulse signal to drive/control the Phase B of M713

a. Single staple (front) The FNS operation signal from the main body activates M711 (stapler movement) to carry the staplers to extend the distance between the staplers and the clinchers, and then M711 stops at the appropriate positions. When PS706 (main tray paper exit) has detected the last sheet and a predefined time period has elapsed, M711 is activated again to move the staplers to the home position, and M711 stops when PS711 (stapler movement HP) turns ON.
Single staple (rear, oblique) The FNS operation signal from the main body activates M711 (stapler movement) to extend the distances between the two staples as well as the two clinchers. After a predefined time period has elapsed, M706 (stapler rotation) and M704 (clincher rotation) start to rotate the stapler/R and the clincher/R respectively. When the staplers and clinchers are set in place, M704, M706, and M711 stop. PS706 (main tray paper exit) turns ON by detecting the last paper, and after a predefined time has elapsed, M704 and M706 start to rotate the stapler/R and the clincher/R back to their home positions. The rotating actions of the stapler/R and the clincher/R stop when PS713 (stapler rotation HP) and PS714 (clincher rotation HP) detect them respectively. At the same time, M711 starts moving the staplers to the home position. The operation of M711 stops when PS711 (stapler movement HP) turns ON. Two staples When two staples are used, the staplers and the clinchers stay in their home positions for the stapling operation.
a. FNS CB input signals (1) PS711 IN (PS711 to RB to FNS CB) Signal indicating whether the staplers (/F and /R) are in the home position [L]: Not in the home position [H]: In the home position (2) PS713 IN (PS713 to RB to FNS CB) Signal indicating whether the stapler/R is in the home position [L]: Not in the home position [H]: In the home position (3) PS714 IN (PS714 to RB to FNS CB) Signal indicating whether the clincher/R is in the home position [L]: Not in the home position [H]: In the home position b. FNS CB output signals (1) M704 DRV A, A (FNSCB to RB to M704) Pulse signal to drive/control the Phase A of M704 (2) M704 DRV B, B (FNSCB to RB to M704) Pulse signal to drive/control the Phase B of M704 (3) M706 DRV A, A (FNSCB to RB to M706) Pulse signal to drive/control the Phase A of M706 (4) M706 DRV B, B (FNSCB to RB to M706) Pulse signal to drive/control the Phase B of M706 (5) M711 DRV A, A (FNSCB to RB to M711) Pulse signal to drive/control the Phase A of M711 (6) M711 DRV B, B (FNSCB to RB to M711) Pulse signal to drive/control the Phase B of M711

Three-folding gate SD (SD706) Paper Three-folding gate Folding rollers
*3 Booklet full detection The folding full LED (LES729) and the folding full PS (PS729), which consist of a pair of translucent sensors, detect the booklet tray full condition. If a predefined time period has elapsed since the paper shielded the sensor light, a booklet full condition is reported. 2-36
[3] M719 (folding knife) Control
24V M719 DRV 1 M719 DRV 2 24V M719 DRV M719

PS722 IN

5V PS722 IN GND

5V PS725 IN GND

PS726 IN

5V PS726 IN GND

M719 (folding knife) drives the folding knife. This knife is used when the mode is folding, stitchand-fold, or three-folding. The FNS CB (FNS control board) controls the operation of M719. The related signals are PS722 (folding knife HP), PS725 (folding paper exit), and PS726 (folding passage).
b. FNS CB output signals (1) M719 DRV 1 and 2 (FNS CB to RB) Signal to activate or deactivate M719 DRV1 Normal rotation Reverse rotation Halt H L L DRV2 L H L
PS726 (folding passage) detects the paper and the booklet stopper stops at the folding position. After a predefined time period has elapsed since then, M719 (folding knife) is activated, letting the folding knife protrude toward the paper. The operation of PS726 ends when the folding knife returns and the signal from PS722 (folding knife HP) changes from H to L. a. FNS CB input signals (1) PS722 IN (PS722 to RB to FNS CB) Signal indicating whether the folding knife is in the home position [L]: In the home position [H]: Not in the home position (2) PS726 IN (PS726 to RB to FNS CB) Signal indicating whether the paper has passed through the folding passage sensor. [L]: Paper exists. [H]: Paper does not exist.
c. RB output signals (1) M719 DRV (RB to M719) Signal to drive/control M709
[4] M720 (folding conveyance) Control
M720 BLK M720 CONT M720 CLK M720 PLL M720 F/R 24V M720 BLK M720 CONT M720 CLK M720 PLL M720 F/R 24V 24V PGND PGND SGND
5V PS722 IN GND 5V PS725 IN GND 5V PS726 IN GND RB
M720 (folding conveyance) operates the folding roller(s), which rotates the three-folding roller. The FNS CB (FNS control board) controls the operation of M720. The related signals are PS722 (folding knife HP), PS725 (folding paper exit), and PS726 (folding passage).
a. FNS CB input signals (1) M720 PLL (M720 to RB to FNS CB) Signal for monitoring the rotation of M720 [L]: M720 is rotating as a specified speed [H]: M720 is not rotating as a specified speed b. FNS CB output signals (1) M720 BLK (FNS CB to RB to M720) Signal to apply braking to the M720 [L]: Braking ON [H]: Braking OFF (2) M720 CONT (FNS CB to RB to M720) Signal to drive/control M720 [L]: M720 ON [H]: M720 OFF (3) M720 CLK (FNS CB to RB to M720) Signal relating to the clock for controlling the rotation speed of M720 (4) M720 F/R (FNS CB to RB to M720) Signal to control the rotation direction of M720 [L]: CW [H]: CCW

[3] Removing and Reinstalling the Top Cover/2
Caution: Make sure that the power cord of the main body is unplugged from the power outlet. CAUTION: Uninstall the PI (optional) if installed. a. Procedure (1) Remove the top cover/1. (2) Open the front door. (3) Remove four screws, and pull out the sub-tray. Then remove the top cover/2.
[4] Removing and Reinstalling the Side Cover
Caution: Make sure that the power cord of the main body is unplugged from the power outlet. a. Procedure (1) Open the front door. (2) Remove three screws, and remove the side cover.

Screws Side cover

Sub-tray

Screws

Top cover/2
(4) Reinstall the above parts following the removal steps in reverse.
[5] Removing and Reinstalling the Front Door
Caution: Make sure that the power cord of the main body is unplugged from the power outlet. a. Procedure (1) Open the front door. (2) Remove the two mounting screws holding the hinge plate at the bottom, and remove the front door.
[6] Removing and Reinstalling the Rear Cover
Caution: Make sure that the power cord of the main body is unplugged from the power outlet. a. Procedure (1) Remove the six mounting screws, and detach the rear cover.

Screws Front door Screw

Hinge plate

Tab Rear cover

(2) Reinstall the above parts following the removal steps in reverse. (3) Reinstall the above parts following the removal steps in reverse.
[7] Removing and Reinstalling the Main Tray
Caution: After you have lowered 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 of the main tray exit with your finger to lower the main tray.
(3) Remove the two mounting screws. (4) Lift the main tray and detach it from the hooks of the up/down stay.

Screws Actuator

Up/down stay Paper exit roller
(5) Reinstall the above parts following the removal steps in reverse.
(2) Turn the main body's main power switch (SW1) OFF, and unplug the power cord from the power outlet.
[8] Removing and Reinstalling the Main Paper Exit Opening Cover
Caution: Make sure that the power cord of the main body is unplugged from the power outlet. a. Procedure (1) Remove the following parts: Top cover/1 or optional PI (if installed) Top cover/2 Side cover Rear cover Main tray (2) Remove four screws and detach the main paper exit opening cover.

Screw Stapler/F

(5) Remove two screws holding the sensor cover of the stapler/R. Remove one screw securing the wire binding band and the screw securing the ground cable. Detach the connector (CN182) of the stapler rotation HP PS (PS713).
Screw Wire binding band Sensor cover Stapler/R
Ground Screw Screw securing the ground terminal
Connector (CN182) Stapler rotation HP PS (PS713)

fs2103007

(6) Remove four screws. Detach the stapler/R and the connector (CN180). CAUTION: Take care not to damage the stapler rotation HP PS (PS713) when removing the stapler/R.

Stapler/R

Ground Connector Screw securing the ground cable (CN181)
Connector (CN180) Stapler rotation HP PS (PS713)
(7) Reinstall the above parts following the removal steps in reverse. CAUTION: When installing the sensor cover of the stapler/R, take care that the bundled cable does not disturb the stapler rotation HPPS (PS713) and is not nip by the gears. MODEL

REVISED EDITION 3-19

PAGE 3-17