Konica Minolta FS-110 User manual

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

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 tech-
nicians only.
Changes may have been made to this equipment to
improve its performance after this service manual was
printed. Accordingly, Konica Minolta Business Solu-
tions U.S.A., Inc., makes no representations or war-
ranties, either expressed or implied, that the informa-
tion 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 dam-
age 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.

Refer to the 7155/7165/7255/7272 service manual
on page.................................................................S-1
SAFETY AND IMPORTANT WARNING ITEMS
CONTENTS
2 UNIT EXPLANATION 1 OUTLINE3 DIS./ASSEMBLY
CONTENTS
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
MODEL MANUAL REVISED EDITION DATE PAGE METHOD
SERVICE MANUAL Dec. 2003
7155/7165/7255/7272 - REPLACEMENT

1 OUTLINE2 UNIT EXPLANATION3 DIS./ASSEMBLY
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 Roll-
er (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 degrad-
ing performance and safety. Such modifications are there-
fore 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 pa-
per between relay contacts, etc.).
(6) Disabling safety functions (interlocks, safety cir-
cuits, 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 hand-
book.
(8) Using parts other than specified by Konica
Minolta.
[2] Checkpoints When Performing On-
site 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 de-
signed for safety.
(2) Carry out all procedures carefully to prevent in-
jury.
(3) Be sure to disconnect the power cord of the
equipment from the AC outlet.
Simply turning off the power switch is not suffi-
cient, because paper feed units or other electri-
cal equipment may be powered also when the
power switch is turned off.
(4) Proceed with special care when performing op-
eration 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 (con-
ductor must not be exposed).
(5) Check power cord and cable ties etc. for loosen-
ing 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
3. Description of Safety Checks
CAUTION:
(1) Before performing safety check work, read all
relevant documentation (service handbook, tech-
nical 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 insu-
lation 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 electri-
cal 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, com-
ponents, wiring, connectors, etc. that were re-
moved 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 equip-
ment, make sure that the power cord has been
disconnected.
[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 precau-
tions.
(1) Disconnect the power cord from the AC outlet.
(2) 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.
(3) Perform cleaning only in an environment where
sufficient ventilation is assured. Breathing large
quantities of organic solvents can lead to dis-
comfort.
(4) Do not replace the cover or turn the unit on before
any solvent remnants on the cleaned parts have
fully evaporated.
[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 on-
site 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 appropri-
ate 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 appropri-
ate management of the equipment.

1
1 OUTLINE
OUTLINE

1 OUTLINE
Blank page

FS-110/FS-210
1-1
1 OUTLINE
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 (stitch-
and-fold), and three-folding features.
[2] Functions
Type of Paper:
Same as the main body
Paper Size:
*1 The position of the stopper must be changed
when using paper with different size.
Paper Stacking Capacity (80g/m2or 20lbs):
Sub-tray exit mode:
Maximum200sheets(same-sizesheetsonly)
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)
Maximum500sheets(A5,A5R,B6R,5.5x8.5,
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
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). Onebooklet with 6 sheets folded
is taken as two and more booklets.
• Folding
33bookletswith3orlesssheetsfoldedeach
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
FS-110/210 FS-210 only
Non-
sort Sort/ group Sta- ple Sub- tray
Book-
let
Three
-fold-
ing
A/B
stan-
dards
A3
B4
F4R
A4R *1
A4
B5R
B5
A5R
A5
B6R
By
inch
11 x
17
8.5 x
14
8.5 x
11R *1
8.5 x
11
5.5 x
8.5R
5.5 x
8.5
Wide
Other
Original pages A3, 11 x 17, A5,and5.5x
8.5
Other paper
types
2 to 9 50 stacks 100 stacks
10 to 20 50 stacks 50 stacks
21 to 30 30 stacks 30 stacks
31 to 40 25 stacks 25 stacks
41 to 50 20 stacks 20 stacks
Amount of curl Paper (5 sheets)

FS-110/FS-210
1-2
1 OUTLINE
Height of folding in the booklet mode (FS210
only):
* The height of folding may be larger after exit,
althoughthebookletmustbefoldedwithease
manually.
Width (a, b and c) and height (h) in the three-
folding mode:
Note: Measurements must be made using a
single sheet.
Amount of sort offsetting:
30mm (after sorting and grouping)
[3] Staple Mode
Number of sheets to be stapled:
50 sheets or less (the height must be 5mm or
lesswhenusing80g/m2or20lbsqualitypaper)
Positions for stapling:
A = 8.5mm ±3mm
B = 8.5mm ±3mm
C = 60mm ±3mm
D = 8.5mm ±3mm
E = 14mm ±3mm
F = 60mm ±3mm
Staple capacity:
5000 staples/cartridge
Original
pages A3, 11 x17 B4, 8.5 x 14 A4R, 8.5 x 11R
0 to 5 25mm or
less 25mm or less 25mm or less
6 to 10 50mm or
less 50mm or less Not specified*
11 to 20 Not
specified* Not specified* Not specified*
Width/
height
Mea-
sure-
ments
Nominal values Allow-
ance
A4R 8.5 x 11R
Width a 95mm 89.4mm ±2mm
b 101mm 95mm ±2mm
c 101mm 95mm ±2mm
Height h 25mm
or less 25mm or less
Height of folding
(80g/m2or 20lbs)
abch
A
B
CC
FF
D
D
E
Single staple
(rear) Two staples Single staple
(front)
Booklet mode (stitch-and-fold)
(FS-210 only)
MODEL MANUAL REVISED EDITION DATE PAGE METHOD
SERVICE MANUAL Dec. 2003
7155/7165/7255/7272 1-2 REPLACEMENT
2

FS-110/FS-210
1-3
1 OUTLINE
[4] Booklet Mode (FS-210 only)
Stitch-and-fold:
Maximum 20 sheets (when using 80g/m2or
20lbs quality paper)
Maximum 19 sheets (when using 80g/m2or
20lbs quality paper) + one sheet (200g/m2or
45lbs quality paper)
Folding:
Maximum 3 sheets (when using 80g/m2or
20lbs quality paper)
[5] Three-folding Mode (FS-210 only)
Number of three-folding:
Maximum 3 sheets (when using 80g/m2or
20lbs quality paper)
However, special paper cannot be used.
[6] Option
PI-110
(Cover sheet feeder)
PK-110
(Puncher)
[7] Machine Specifications
Power source:
24V, 5VDC (supplied from the main body)
Maximum power consumption:
100VA
Weight:
FS-110: Approx. 55kg
FS-210: Approx. 65kg
External Dimensions:
[8] Maintenance
Maintenance procedures:
Same as the main body
Service life:
Same as the main body
[9] Operating Environment
Temperature:
10 to 30 °C (50 °F to 86°F)
Humidity:
10 to 80% RH
Note: The information herein may be subject to
change for improvement without notice.
741656
656
410
990
(tray extended)
(tray closed)

FS-110/FS-210
1-4
1 OUTLINE
CROSS SECTION DIAGRAM
Sub-tray Shift unit
Paper exit
opening unit
Main tray
Booklet tray
Alignment plate/L
Components in the region enclosed by the dotted line represent those of FS-210.
Folding knife
Booklet stopper
Flat-stapling stopper
Clincher
Bypass gate
Three-folding gate
Stapler
Alignment plate/U
Gate
Three-folding
stopper

FS-110/FS-210
1-5
1 OUTLINE
DRIVE SYSTEM DIAGRAM
[1] Paper Conveyance Drive
Paper exit roller motor (M707)
Paper exit opening motor (M708)
Sub-tray paper exit motor (M721) Shift motor (M702)
Gate drive motor (M712)
By-pass gate SD (SD705)
Paper exit opening
SD (SD704)
Paper exit roller
FNS conveyance motor (M701)
Sub-tray paper exit roller
Sub-tray conveyance roller
PI conveyance roller
Entrance roller
Conveyance roller/A
Conveyance roller/B
Shift roller
Intermediate conveyance roller
By-pass gate

FS-110/FS-210
1-6
1 OUTLINE
[2] Stacker Drive
Alignment plate/U
Alignment plate/L
From paper exit roller motor (M707)
Alignment motor/U (M705)
Stacker entrance motor
(M713)
Stopper motor (M718)
Alignment motor/L (M716)
Stacker entrance roller
Paper exit arm
Flat-stapling stopper
Booklet stopper

FS-110/FS-210
1-7
1 OUTLINE
[3] Staple Drive
Stapler/F
Clincher/F
Clincher/R
Stapler/R
Clincher rotation motor
(M704)
Stapler rotation motor (M706) Stapler movement
motor (M711)
Stapler Clincher

FS-110/FS-210
1-8
1 OUTLINE
2
[4] Tray Drive
fs2101001
Up/down pulley/U
Up/down pulley/L
Main tray
Tray up/down motor
(M703)
Up/down wire
Old type
New type
2
MODEL MANUAL REVISED EDITION DATE PAGE METHOD
SERVICE MANUAL Dec. 2003
7155/7165/7255/7272 1-8 REPLACEMENT

FS-110/FS-210
1-9
1 OUTLINE
[5] Folding Drive
Folding roller
Folding knife
Folding knife motor
(M719)
Three-folding gate SD
(SD706)
Folding conveyance motor
(M720)
Three-folding roller
Three-folding gate

FS-110/FS-210
1-10
1 OUTLINE
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.
TheFNShastwopaper entranceconnections:one fromthe mainbody, andtheotherfromPI-110(optional).
Paper conveyance path Finishing mode
Non-sort, sort, and group modes
Sub-tray mode
Staple mode
Booklet mode (FS-210 only)
Three-folding mode (FS-210 only)
Sub-tray
Main tray
Booklet tray
Main body
PI-110
1
2
54
312
3
5
4
5
5
4
3
1
112
3
4
5