MINOLTA 7145, 7235, 7228, 7222 Service Manual

SERVICE MANUAL

Models

7145/7222/7228/7235

APRIL 2004

CSM-7145/7222/7228/7235

KONICA MINOLTA BUSINESS SOLUTIONS U.S.A., INC.

7145/7222/7228/7235

SERVICE MANUAL

APRIL 2004

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 Minolta-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 Publications Department

© 2004, KONICA MINOLTA BUSINESS SOLUTIONS U.S.A. , INC.

All rights reserved.

Printed in U.S.A.

CONTENTS

CONTENTS

SAFETY AND IMPORTANT WARNING ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1

IMPORTANT NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1

DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1

SAFETY WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2

SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-10

IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-10

SAFETY CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-11

INDICATION OF WARNING ON THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-13

List of major differences between the 7145, 7235, 7228 and 7222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

List of options corresponding to the 7145/7235/7228/7222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

I OUTLINE

1. OUTLINE OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. PRODUCT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

A. Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

B. Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

C. Copy paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

D. Machine data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

E. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

F. Consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

G. Operating environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

3. CENTER CROSS SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

4. DRIVE SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

4.1 Drum drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

4.2 Cleaning/Developer agitation drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

4.3 Fixing/Paper exit section/IT-101/RU-101 drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

4.4 Developing drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

4.5 Paper feed drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

4.5.1 Drive from paper feed motor to loop clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

4.5.2 Tray 1 drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

4.5.3 Tray 2 drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

4.5.4 Bypass feed drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

4.5.5 Registration clutch drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

4.6 ADU drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

4.7 Scanner drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

4.8 Toner supply drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

I OUTLINEII UNIT EXPLANATIONIII DIS./ASSEMBLY

i

2

CONTENTS

I OUTLINEII UNIT EXPLANATIONIII DIS./ASSEMBLY

II UNIT EXPLANATION

1. SCANNER SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

1.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

1.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

1.2.1 Initial operation when power is turned on and shading correction reading. . . . . . . . . . . . . . 2-2

1.2.2 Original reading mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

1.2.3 Original read control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

1.2.4 APS control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

1.2.5 AE control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

1.2.6 Image processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2. WRITE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2.2.1 Image writing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2.2.2 Write control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

3. DRUM UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

3.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

3.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

3.2.1 Image formation timing (when copying two sheets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

4. DEVELOPING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

4.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

4.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

4.2.1 Developing control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

4.2.2 Control of toner density in the developing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

5. TONER SUPPLY/CLEANING/RECYCLE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

5.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

5.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

5.2.1 Toner supply control when the toner level in the toner supply section gets reduced . . . . . 2-18

5.2.2 Toner supply control when toner density in the developing unit gets reduced . . . . . . . . . . 2-19

6. PAPER FEED UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

6.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

6.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

6.2.1 Tray up drive control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

6.2.2 Paper feed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

6.2.3 Remaining paper detection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

6.2.4 Paper size detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

7. FIXING UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

7.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

7.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

7.2.1 Fixing temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

7.2.2 Cleaning web control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

8. ADU/PAPER EXIT SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

8.1 Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

8.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

8.2.1 Switching control of the paper exit/ADU conveyance path . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

8.2.2 ADU conveyance control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

8.2.3 Paper reverse control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

2

ii

CONTENTS

9. INTERFACE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

9.1 Composition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

10.NETWORK SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

10.1 Composition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

11.OTHER CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37

11.1 Parts energized when the main power switch is off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37

11.2 Components operated when the power switch is on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

11.2.1 Components operated when the SW1 (Main power switch) is on . . . . . . . . . . . . . . . . . . . 2-38

11.2.2 Components operated when the SW2 (Sub power switch) is on . . . . . . . . . . . . . . . . . . . . 2-39

11.3 Fan control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

11.3.1 Composition of the cooling fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

11.3.2 Fan operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

11.4 Operation unit control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

11.4.1 Composition of operation unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

11.5 Counter control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

11.5.1 Counter composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

11.5.2 Counter operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

III DISASSEMBLY/ASSEMBLY

I OUTLINEII UNIT EXPLANATIONIII DIS./ASSEMBLY

1. EXTERNAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

1.1 Replacing the ozone filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

1.2 Replacing the filter cover assembly and suction filter/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

2. DRIVE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

2.1 Removing and reinstalling the motor units (main, fixing, feed, developing) . . . . . . . . . . . . . . . . . 3-3

2.2 Replacing the registration clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

2.3 Replacing the loop clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

2.4 Removing the ribbon cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

2.5 Reinstalling the ribbon cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3. SCANNER SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3.1 Screws that must not be removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3.2 Adjusting the angle of the operation unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.3 Removing the operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.4 Removing the platen glass/slit glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3.5 Removing and reinstalling the CCD unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3.6 Replacing the exposure lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3.7 Removing and reinstalling the exposure unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

3.8 Removing the optics wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3.9 Installing the optics wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

4. WRITE UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

4.1 Removing and reinstalling the write unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

5. DRUM UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

5.1 Removing and reinstalling the drum unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

5.2 Removing and reinstalling the charging corona unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

5.3 Removing and reinstalling the charge control plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

5.4 Replacing the charging wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

5.5 Removing and reinstalling the drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

5.6 Removing and reinstalling the separation claw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

iii

2

CONTENTS

I OUTLINEII UNIT EXPLANATIONIII DIS./ASSEMBLY

5.7 Removing and reinstalling the transfer and separation corona unit. . . . . . . . . . . . . . . . . . . . . . . 3-34

5.8 Replacing the transfer and separation wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

6. DEVELOPING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

6.1 Screws that must not be removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

6.2 Removing and reinstalling the developing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

6.3 Replacing the developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

7. TONER SUPPLY/CLEANING/RECYCLE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

7.1 Removing and reinstalling the toner bottle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

7.2 Removing and reinstalling the toner supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

7.3 Removing and reinstalling the cleaning blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

8. PAPER FEED UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

8.1 Replacing the paper feed roller and the feed roller (by-pass) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

8.2 Replacing the double feed prevention roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

8.3 Replacing the paper feed rubber and the feed rubber (tray 1). . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

8.4 Replacing the double feed prevention rubber (tray 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

8.5 Replacing the paper feed rubber and the feed rubber (tray 2). . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

8.6 Replacing the double feed prevention rubber (tray 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

8.7 Cleaning the paper dust removing brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

9. FIXING UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

9.1 Removing and reinstalling the fixing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

9.2 Replacing the fixing heater lamps/1, /2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

9.3 Removing and reinstalling the fixing claw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

9.4 Replacing the fixing web . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

9.5 Removing and reinstalling the fixing heat roller, fixing pressure roller,
heat insulating sleeve/A, /B, fixing idling gear/B, fixing bearing/U, /L,

fixing heater lamp/1, /2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

9.6 Removing and reinstalling the fixing temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64

9.7 Removing and reinstalling the Fuse mounting plate assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66

2

iv

SAFETY AND IMPORTANT WARNING ITEMS

SAFETY AND IMPORTANT WARNING ITEMS

Read carefully the Safety and Important Warning Items described below to understand them before doing ser-

vice work.

IMPORTANT NOTICE

Because of possible hazards to an inexperienced person servicing this copier as well as the risk of damage to

the copier, Konica Minolta Business Technologies, INC. (hereafter called the KMBT) strongly recommends that

all servicing be performed only by KMBT-trained service technicians.

Changes may have been made to this copier to improve its performance after this Service Manual was printed.

Accordingly, KMBT does not warrant, either explicitly or implicitly, that the information contained in this Service

Manual is complete and accurate.

The user of this Service Manual must assume all risks of personal injury and/or damage to the copier while ser-

vicing the copier for which this Service Manual is intended.

Therefore, this Service Manual must be carefully read before doing service work both in the course of technical

training and even after that, for performing maintenance and control of the copier properly.

Keep this Service Manual also for future service.

DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION

In this Service Manual, each of three expressions “ DANGER”, “ WARNING”, and “ CAUTION” is defined

as follows together with a symbol mark to be used in a limited meaning.

When servicing the copier, the relevant works (disassembling, reassembling, adjustment, repair, maintenance,

etc.) need to be conducted with utmost care.

DANGER

WARNING

CAUTION

Symbols used for safety and important warning items are defined as follows:

:Precaution when using the copier.

:Prohibition when using the copier.

:Action having a high possibility of suffering death or serious injury

:Action having a possibility of suffering death or serious injury

:Action having a possibility of suffering a slight wound, medium trouble, and

property damage

General precaution Electric hazard High temperature

General prohibition Do not touch with wet hand Do not disassemble

:Direction when using the copier.

General instruction

S-1

Unplug

Ground/Earth

1

SAFETY AND IMPORTANT WARNING ITEMS

SAFETY WARNINGS

[1] MODIFICATIONS NOT AUTHORIZED BY

KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.

Konica Minolta brand copiers are renowned for their high reliability. This reliability is achieved through high-qual-

ity design and a solid service network.

Copier design is a highly complicated and delicate process where numerous mechanical, physical, and electrical

aspects have to be taken into consideration, with the aim of arriving at proper tolerances and safety factors. For

this reason, unauthorized modifications involve a high risk of degradation in performance and safety. Such mod-

ifications are therefore strictly prohibited. the points listed below are not exhaustive, but they illustrate the rea-

soning behind this policy.

DANGER : PROHIBITED ACTIONS

• Using any cables or power cord not specified by KMBT.

• Using any fuse or thermostat not specified by KMBT. Safety will not be

assured, leading to a risk of fire and injury.

• Disabling fuse functions or bridging fuse terminals with wire, metal clips, sol-

der or similar object.

• Disabling relay functions (such as wedging paper between relay contacts)

• Disabling safety functions (interlocks, safety circuits, etc.) Safety will not be

assured, leading to a risk of fire and injury.

• Making any modification to the copier unless instructed by KMBT

• Using parts not specified by KMBT

1

S-2

SAFETY AND IMPORTANT WARNING ITEMS

[2] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE

Konica Minolta brand copiers are extensively tested before shipping, to ensure that all applicable safety stan-

dards are met, in order to protect the customer and customer engineer (hereafter called the CE) from the risk of

injury. However, in daily use, any electrical equipment may be subject to parts wear and eventual failure. In order

to maintain safety and reliability, the CE must perform regular safety checks.

1.Power Supply

WARNING: Wall Outlet

• Check that mains voltage is as specified. Plug the power cord into the dedi-

cated wall outlet with a capacity greater than the maximum power consump-

tion.

If excessive current flows in the wall outlet, fire may result.

• If two or more power cords can be plugged into the wall outlet, the total load

must not exceed the rating of the wall outlet.

If excessive current flows in the wall outlet, fire may result.

kw

WARNING: Power Plug and Cord

• Make sure the power cord is plugged in the wall outlet securely.

Contact problems may lead to increased resistance, overheating, and the

risk of fire.

• Check whether the power cord is damaged. Check whether the sheath is

damaged.

If the power plug, cord, or sheath is damaged, replace with a new power

cord (with plugs on both ends) specified by KMBT. Using the damaged

power cord may result in fire or electric shock.

• When using the power cord (inlet type) that came with this copier, be sure to

observe the following precautions:

a. Make sure the copier-side power plug is securely inserted in the socket

on the rear panel of the copier.

Secure the cord with a fixture properly.

b. If the power cord or sheath is damaged, replace with a new power cord

(with plugs on both ends) specified by KMBT.

If the power cord (inlet type) is not connected to the copier securely, a

contact problem may lead to increased resistance, overheating, and risk

of fire.

• Check whether the power cord is not stepped on or pinched by a table and

so on.

Overheating may occur there, leading to a risk of fire.

S-3

1

SAFETY AND IMPORTANT WARNING ITEMS

WARNING: Power Plug and Cord

• Do not bundle or tie the power cord.

Overheating may occur there, leading to a risk of fire.

• Check whether dust is collected around the power plug and wall outlet.

Using the power plug and wall outlet without removing dust may result in

fire.

• Do not insert the power plug into the wall outlet with a wet hand.

The risk of electric shock exists.

• When unplugging the power cord, grasp the plug, not the cable.

The cable may be broken, leading to a risk of fire and electric shock.

WARNING: Wiring

• Never use multi-plug adapters to plug multiple power cords in the same out-

let.

If used, the risk of fire exists.

• When an extension cord is required, use a specified one.

Current that can flow in the extension cord is limited, so using a too long

extension cord may result in fire.

Do not use an extension cable reel with the cable taken up. Fire may

result.

WARNING: Ground Lead

• Check whether the copier is grounded properly.

If current leakage occurs in an ungrounded copier, you may suffer electric

shock while operating the copier. Connect the ground lead to one of the

following points:

a. Ground terminal of wall outlet

b. Ground terminal for which Class D work has been done

S-4

SAFETY AND IMPORTANT WARNING ITEMS

WARNING: Ground Lead

• Pay attention to the point to which the ground lead is connected.

Connecting the ground lead to an improper point such as the points listed

below results in a risk of explosion and electric shock:

a. Gas pipe (A risk of explosion or fire exists.)

b. Lightning rod (A risk of electric shock or fire exists.)

c. Telephone line ground (A risk of electric shock or fire exists in the case

of lightning.)

d. Water pipe or faucet (It may include a plastic portion.)

2.Installation Requirements

WARNING: Prohibited Installation Place

• Do not place the copier near flammable materials such as curtains or volatile

materials that may catch fire.

A risk of fire exists.

• Do not place the copier in a place exposed to water such as rain water.

A risk of fire and electric shock exists.

WARNING: Nonoperational Handling

• When the copier is not used over an extended period of time (holidays, etc.),

switch it off and unplug the power cord.

Dust collected around the power plug and outlet may cause fire.

CAUTION: Temperature and Humidity

• Do not place the copier in a place exposed to direct sunlight or near a heat

source such as a heater.

A risk of degradation in copier performance or deformation exists.

Do not place the copier in a place exposed to cool wind.

Recommended temperature and humidity are as follows:

Temperature: 10

Humidity: 10% to 80% (no dew condensation)

Avoid other environments as much as possible.

°

C

to 30

C

°

CAUTION: Ventilation

• Do not place the copier in a place where there is much dust, cigarette

smoke, or ammonia gas.

Place the copier in a well ventilated place to prevent machine problems

and image faults.

S-5

SAFETY AND IMPORTANT WARNING ITEMS

CAUTION: Ventilation

• The copier generates ozone gas during operation, but it is not sufficient to be

harmful to the human body.

If a bad smell of ozone is present in the following cases, ventilate the

room.

a. When the copier is used in a poorly ventilated room

b. When taking a lot of copies

c. When using multiple copiers at the same time

CAUTION: Vibration

• When installing the copier, read the Installation Guide thoroughly. Be sure to

install the copier in a level and sturdy place.

Constant vibration will cause problems.

• Be sure to lock the caster stoppers.

In the case of an earthquake and so on, the copier may slide, leading to a

injury.

CAUTION: Inspection before Servicing

• Before conducting an inspection, read all relevant documentation (service

manual, technical notices, etc.) and proceed with the inspection following the

prescribed procedure in safety clothes, using only the prescribed tools. Do

not make any adjustment not described in the documentation.

If the prescribed procedure or tool is not used, the copier may break and a

risk of injury or fire exists.

• Before conducting an inspection, be sure to disconnect the power plugs from

the copier and options.

When the power plug is inserted in the wall outlet, some units are still pow-

ered even if the POWER switch is turned OFF. A risk of electric shock

exists.

• The area around the fixing unit is hot.

You may get burnt.

DANGER: Work Performed with the Copier Powered

• Take every care when making adjustments or performing an operation check

with the copier powered.

If you make adjustments or perform an operation check with the external

cover detached, you may touch live or high-voltage parts or you may be

caught in moving gears or the timing belt, leading to a risk of injury.

2

S-6

SAFETY AND IMPORTANT WARNING ITEMS

DANGER: Work Performed with the Copier Powered

• Take every care when servicing with the external cover detached.

High-voltage exists around the drum unit. A risk of electric shock exists.

WARNING: Safety Checkpoints

• Check the exterior and frame for edges, burrs, and other damages.

The user or CE may be injured.

• Do not allow any metal parts such as clips, staples, and screws to fall into the

copier.

They can short internal circuits and cause electric shock or fire.

• Check wiring for squeezing and any other damage.

Current can leak, leading to a risk of electric shock or fire.

• When disconnecting connectors, grasp the connector, not the cable.

(Specifically, connectors of the AC line and high-voltage parts)

Current can leak, leading to a risk of electric shock or fire.

• Carefully remove all toner remnants and dust from electrical parts and elec-

trode units such as a charging corona unit.

Current can leak, leading to a risk of copier trouble or fire.

• Check high-voltage cables and sheaths for any damage.

Current can leak, leading to a risk of electric shock or fire.

• Check electrode units such as a charging corona unit for deterioration and

sign of leakage.

Current can leak, leading to a risk of trouble or fire.

• Before disassembling or adjusting the write unit incorporating a laser, make

sure that the power cord has been disconnected.

The laser light can enter your eye, leading to a risk of loss of eyesight.

• Do not remove the cover of the write unit. Do not supply power with the write

unit shifted from the specified mounting position.

The laser light can enter your eye, leading to a risk of loss of eyesight.

• When replacing a lithium battery, replace it with a new lithium battery speci-

fied in the Parts Guide Manual. Dispose of the used lithium battery using the

method specified by local authority.

Improper replacement can cause explosion.

S-7

SAFETY AND IMPORTANT WARNING ITEMS

WARNING: Safety Checkpoints

• After replacing a part to which AC voltage is applied (e.g., optical lamp and

fixing lamp), be sure to check the installation state.

A risk of fire exists.

• Check the interlock switch and actuator for loosening and check whether the

interlock functions properly.

If the interlock does not function, you may receive an electric shock or be

injured when you insert your hand in the copier (e.g., for clearing paper

jam).

• Make sure the wiring cannot come into contact with sharp edges, burrs, or

other pointed parts.

Current can leak, leading to a risk of electric shock or fire.

• Make sure that all screws, components, wiring, connectors, etc. that were

removed for safety check and maintenance have been reinstalled in the orig-

inal location. (Pay special attention to forgotten connectors, pinched cables,

forgotten screws, etc.)

A risk of copier trouble, electric shock, and fire exists.

DANGER: HANDLING OF SERVICE MATERIALS

• Toner and developer are not harmful substances, but care must be taken not

to breathe excessive amounts or let the substances come into contact with

eyes, etc. It may be stimulative.

If the substances get in the eye, rinse with plenty of water immediately.

When symptoms are noticeable, consult a physician.

• Never throw the used cartridge and toner into fire.

You may be burned due to dust explosion.

S-8

SAFETY AND IMPORTANT WARNING ITEMS

DANGER : HANDLING OF SERVICE MATERIALS

• Unplug the power cord from the wall outlet.

Drum cleaner (isopropyl alcohol) and roller cleaner (acetone-based) are

highly flammable and must be handled with care. A risk of fire exists.

• Do not replace the cover or turn the copier ON before any solvent remnants

on the cleaned parts have fully evaporated.

A risk of fire exists.

• 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.

A risk of fire exists.

• When using any solvent, ventilate the room well.

Breathing large quantities of organic solvents can lead to discomfort.

[3] MEASURES TO TAKE IN CASE OF AN ACCIDENT

1. If an accident has occurred, the distributor who has been notified first must immediately take emergency

measures to provide relief to affected persons and to prevent further damage.

2. If a report of a serious accident has been received from a customer, an on-site evaluation must be carried

out quickly and KMBT must be notified.

3. To determine the cause of the accident, conditions and materials must be recorded through direct on-site

checks, in accordance with instructions issued by KMBT.

4. For reports and measures concerning serious accidents, follow the regulations given in “Serious Accident

Report/Follow-up Procedures”.

[4] CONCLUSION

1. Safety of users and customer engineers depends highly on accurate maintenance and administration.

Therefore, safety can be maintained by the appropriate daily service work conducted by the customer

engineer.

2. When performing service, each copier on the site must be tested for safety. The customer engineer must

verify the safety of parts and ensure appropriate management of the equipment.

S-9

1

SAFETY AND IMPORTANT WARNING ITEMS

SAFETY INFORMATION

IMPORTANT INFORMATION

The Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration implemented

regulations for laser products manufactured since August 1, 1976. Compliance is mandatory for products mar-

keted in the United States.

This copier is certified as a “Class 1” laser product under the U.S.

Department of Health and Human Services (DHHS) Radiation Performance Standard according to the Radiation

Control for Health and Safety Act of 1968. Since radiation emitted inside this copier is completely confined within

protective housings and external covers, the laser beam cannot escape during any phase of normal user opera-

tion.

S-10

SAFETY CIRCUITS

SAFETY AND IMPORTANT WARNING ITEMS

This machine is provided with the following safety circuits

to prevent machine faults from resulting in serious acci-

dents.

[1] Overall protection circuit

[2] L2 and L3 (fixing heater lamp/1, /2) overheat-

ing prevention circuit

These safety circuits are described below to provide

the service engineer with a renewed awareness of

them in order to prevent servicing errors that may

impair their functions.

[1] Overall protection circuit

CBR1

DCPS

CBR2

1. Protection by CBR1 and CBR2 (circuit

breaker/1, /2)

CBR1 and CBR2 interrupt the AC line instanta-

neously when an excessive current flows due

to a short in the AC line.

CAUTION:

The CBR1 and CBR2 functions must not

be deactivated under any circumstances.

[2] L2 and L3 (fixing heater lamp/1, /2)

overheating prevention circuit

DCPS

RL1

CB

RL1

TH1 TH2

Control
section

AC driver

section

1. Protection by software

The output voltage from TH1, TH2 (fixing tem-

perature sensor/1, /2) is read by the CPU. If

this voltage is abnormal, L2 (fixing heater

lamp/1), L3 (fixing heater lamp/2) and RL1

(main relay) are turned OFF.

CAUTION:

The RL1 function must not be deactivated

under any circumstances.

TS

L2

FCB

L3

S-11

SAFETY AND IMPORTANT WARNING ITEMS

2. Protection by the hardware circuit

The output voltages from TH1, TH2 (fixing tem-

perature sensor/1, /2) are compared with the

abnormality judgment reference value in the

comparator circuit. If the output voltage from

TH1 or TH2 exceeds the reference value, L2

(fixing heater lamp/1), L3 (fixing heater lamp/2)

and RL1 (main relay) are turned OFF in hard-

ware means.

CAUTION:

Periodically check the TH1, TH2 face

contacting the roller, and replace TH2 if

any abnormality is detected.

The RL1 function must not be deactivated

under any circumstances.

3. Protection by TS (thermostat)

When the fixing heat roller exceeds the speci-

fied value, TSs (thermostats) are turned OFF,

thus interrupting the power to L2 (fixing heater

lamp/1), and L3 (fixing heater lamp/2) directly.

CAUTION:

Do not use any other electrical conductor

in place of TS1 and TS2.

2

S-12

SAFETY AND IMPORTANT WARNING ITEMS

INDICATION OF WARNING ON THE MACHINE

Caution labels shown below are attached in some areas on/in the machine.

When accessing these areas for maintenance, repair, or adjustment, special care should be taken to avoid burns

and electric shock.

[1] Main body

1. Right side

<7145>

CAUTION

The fixing unit is very hot.

To avoid getting burned

DO NOT TOUCH.

CAUTION

This area generates
high voltage.
If touched, electrical
shock may occur.
DO NOT TOUCH!

(Inside of the main
body front door)

CAUTION

The roller shaft on the inside

(Inside of the main
body right side door)

of the cover is very hot.
To avoid getting burned DO
NOT TOUCH.
If the cover comes off, return
it to its original position.

7322sf001e

CAUTION

You may be burned or injured if you touch any area that you are advised by any caution label to keep your-

self away from.

Do not remove caution labels. If any caution label has come off or soiled and therefore the caution cannot

be read, contact our Service Office.

S-13

2

SAFETY AND IMPORTANT WARNING ITEMS

<7235/7228/7222>

7322sf002e

CAUTION

You may be burned or injured if you touch any area that you are advised by any caution label to keep your-

self away from.

Do not remove caution labels. If any caution label has come off or soiled and therefore the caution cannot

be read, contact our Service Office.

2

S-14

2. Front side

<7145>

SAFETY AND IMPORTANT WARNING ITEMS

7322sf003e

CAUTION

You may be burned or injured if you touch any area that you are advised by any caution label to keep your-

self away from.

Do not remove caution labels. If any caution label has come off or soiled and therefore the caution cannot

be read, contact our Service Office.

S-15

2

SAFETY AND IMPORTANT WARNING ITEMS

<7235/7228/7222>

7322sf004e

CAUTION

You may be burned or injured if you touch any area that you are advised by any caution label to keep your-

self away from.

Do not remove caution labels. If any caution label has come off or soiled and therefore the caution cannot

be read, contact our Service Office.

2

S-16

3. Rear/Left side (7235/7228/7222 only)

SAFETY AND IMPORTANT WARNING ITEMS

7322sf005e

CAUTION

You may be burned or injured if you touch any area that you are advised by any caution label to keep your-

self away from.

Do not remove caution labels. If any caution label has come off or soiled and therefore the caution cannot

be read, contact our Service Office.

S-17

2

SAFETY AND IMPORTANT WARNING ITEMS

4. Scanner section

<7145>

7322sf006

CAUTION

You may be burned or injured if you touch any area that you are advised by any caution label to keep your-

self away from.

Do not remove caution labels. If any caution label has come off or soiled and therefore the caution cannot

be read, contact our Service Office.

2

S-18

<7235/7228/7222>

SAFETY AND IMPORTANT WARNING ITEMS

7322sf007e

CAUTION

You may be burned or injured if you touch any area that you are advised by any caution label to keep your-

self away from.

Do not remove caution labels. If any caution label has come off or soiled and therefore the caution cannot

be read, contact our Service Office.

S-19

2

SAFETY AND IMPORTANT WARNING ITEMS

[2] FS-113

CAUTION

This area is very hot.
To avoid getting
burned DO NOT
TOUCH.

CAUTION

To avoid injury, DO NOT put your hand on the top
of the printed sheets. Be sure to hold both sides
of the printed sheets when removing them, and
DO NOT leave your hand on the printed sheets
while the primary (main) tray goes up.

(Inside of the Finisher)

FS-113 Finisher

7322sf009

[3] FS-114

FS-114 Finisher

7322sf010

CAUTION

You may be burned or injured if you touch any area that you are advised by any caution label to keep your-

self away from.

Do not remove caution labels. If any caution label has come off or soiled and therefore the caution cannot

be read, contact our Service Office.

2

S-20

List of major differences between the 7145, 7235, 7228 and 7222

List of major differences between the 7145, 7235, 7228 and 7222

Classification 7145 7235 7228 7222 Reason

Warmup time

First copy out time

(8.5x11)

Continuous copy

speed (8.5x11)

Maximum E-RDH

memory

Less than

30 sec.

Less than

3.8 sec.

Less than

4.3 sec.

Less than 19 sec.

45 sheets/min. 35 sheets/min. 28 sheets/min.

320MB

DF Standard Optional

ADU Standard

Paper exit tray

Optional

Standard

23.2in (W)

Machine dimensions

(with DF and DB)

Specifications

Maintenance

Developer

Toner

Materials

Drum

x

23.4in (D)

x

42.6in (H)

Once every

120,000 copies

Exclusively

for 7145

Exclusively

for 7145

Exclusively

for 7145

23.4in (W) x 25.8in (D) x 44.6in (H)

Once every 100,000 copies

Exclusively for 7235/7228/7222

Exclusively for

7235 (Common

to 7135)

Exclusively for 7228/7222

(Common to 7022/7120/7135)

Exclusively for 7235/7228/7222

Flywheel f 103mm f 132mm

Developing sleeve

drive

Developing

motor

Main motor

Less than 4.9 sec.

22 sheets/min.

Change of

specifications

Vibration insulator Not provided Provided Not provided

Drive section

Scanner drive board Provided Not provided

section

Scanner

Laser 2 beams 1 beam

Number of rotations

of polygon motor

Polygon cooling Not provided Provided Not provided

Write section

27,165rpm 38,976rpm 33,070rpm

1

Change of

CPM

Change of

specifications

2

List of major differences between the 7145, 7235, 7228 and 7222

Classification 7145 7235 7228 7222 Reason

Exclusively

for 7145

Exclusively for 7235/7228/7222

Fixing

section

Fixing unit

Decurler roller Provided Not provided

ADU drive board Not provided Provided

ADU/Paper

exit section

Developing motor Provided Not provided

ADU motor Provided

Fixing cooling fan Provided Not provided

Internal cooling fan/2 Provided Not provided

Polygon cooling fan Not provided Provided Not provided

ADU gate solenoid Provided

Electrical parts

ADU sensor Provided

Timing sensor/U Provided Not provided

Timing sensor/L Provided Not provided

Overall control

Image control

Control

Exclusively

for 7145

Exclusively

for 7235

Exclusively

for 7228

Exclusively

Change of

specifications

for 7222

2

2

List of options corresponding to the 7145/7235/7228/7222

List of options corresponding to the 7145/7235/7228/7222

Optional 7145 7235 7228 7222

RADF DF-318 Standard Not corresponding

DF-320

Finisher FS-112

FT-107

Not corresponding

Corresponding

Corresponding Not corresponding

FS-113

RU-101

FS-114

BK-114

Corresponding

PK-114

SK-114

Paper exit tray ET-101 Corresponding Corresponding*1

Inner tray IT-101 Corresponding

Desk DK-110

Not corresponding

Corresponding

DB DB-211

CorrespondingDB-411

LCT LT-203

ADU AD-307 Standard

Post script PS-344 Corresponding Not corresponding

PS-346

Printer

controller

FAX controll

board

2 lines

expansion kit

IP-432 Corresponding Not corresponding

IP-424

FK-102 Type-A

FK-103

FL-102 Corresponding Not corresponding

FL-103

Hard disk HD-103 Type-A

Not corresponding

Not corresponding

Corresponding

Corresponding

Corresponding Not corresponding

Not corresponding

Not corresponding

Corresponding

Corresponding

Corresponding

Total counter Standard Corresponding

Key counter Corresponding

*1 A paper exit tray is provided as standard equipment that is different from ET-101. When ET-101 is pro-

vided, it is integrated into the main body as seen from the point of design.

3

2

List of options corresponding to the 7145/7235/7228/7222

Blank Page

4

IOUTLINE

1. OUTLINE OF SYSTEM

[16]

OUTLINE OF SYSTEM

I OUTLINE

[14] [19][15]

[10]

[13]

[8]

[6]

[12]

[11]

[9]

[7]

[5]

[3]

[4]

[17]

[18][1]

[2]

1-1

7322ma1001

2

OUTLINE OF SYSTEM

I OUTLINE

*1 As a standard equipment, the 7235/7228/7222 are provided with a paper exit tray that is different from

[1] Main body [10]

RADF (DF-318: 7145 provided as a standard equipment)

(DF-320: 7235/7228/7222)[2] LCT (LT-203)

[3] LCT DB (DB-411) [11] Paper exit tray (ET-101)*1

[4] 2-Tray DB (DB-211) [12] Finisher (FS-114)

[5] Conveyance unit (RU-101) [13] Additional tray (BK-114)

[6] Finisher (FS-113) [14] Punch kit (PK-114)

[7] Inner tray (IT-101) [15] Crease unit (included in SK-114)

[8] Finisher tray (FT-107: FS-112) [16] Saddle unit (SK-114)

[9] Finisher (FS-112: 7145 only) [17] Desk (DK-110: 7235/7228/7222 only)

[18] ADU (provided as a standard equipment)

[19] Platen cover (CV-109: 7235/7228/7222 only)

the one with which the ET-101 is equipped.

[7]

[5][6]

[1]

[8]

[1] Postscript (PS-344: 7145)

(PS-346: 7235/7228/7222)

Printer controller (IP-432: 7145)

[2]

(IP-424: 7235/7228/7222)

[3]

2 line expansion kit (shipments only to the

United States and

Oceania)

(FL-102:FK-102 Type-A)

(FL-103:FK-103)

[4] Fax control board(FK-102 Type-A: 7145)

(FK-103: 7235/7228/7222)

E-RDH expansion memory (MU-404: 64MB/MU-405: 128MB)

[5]

[2]

[4]

[3]

[6]

Hard disk (HD-103 Type-A)

[7]

Total counter

(7145 provided as standard equipment)

(In the case of the 7235/7228/7222, ship-

ments only to the United States are pro-

vided with the total counter.)

Key counter

[8]

Expansion memory for the printer controller

[9]

(Not displayed here. For details, see the

Service Manual of the controller.)

7145ma1020

2

1-2

2. PRODUCT SPECIFICATIONS

A. Type

Type: Semi-console type (7145)

Desk-top type (7235/7228/7222)

Copying method: Indirect electrostatic method

Original table: Fixed

Original alignment: Left rear standard

Photosensitive material: OPC

Sensitizing method: Laser writing

Paper feed trays: Two trays (500 sheets x 2, 80g/m

Multisheet bypass tray (50 sheets, 80g/m

DB-211 (500 sheets x 2, 80g/m2 or 20lbs) *1

DB-411 (1500 sheets, 80g/m

LT-203 (2000 sheets, 80g/m

*1 Optional

B. Functions

2

or 20lbs)

2

or 20lbs) *1

2

or 20lbs) *1

PRODUCT SPECIFICATIONS

2

)

I OUTLINE

Original: Sheet, book, solid object (Thickness: up to 1.2in. Weight: up to 15lbs)

Maximum original size: A3, or 11 x 17

Copy size (for metric area):

Tray 1: B4, A4, A4R, B5, B5R, A5R, 8.5 x 14, 8.5 x 11, 8.5 x 11R, 5.5 x 8.5R, F4

Tray 2: A3, B4, A4, A4R, B5, B5R, A5R, 11 x 17, 8.5 x 11, 8.5 x 11R, F4

Bypass tray: A3, B4, A4, A4R, B5, B5R, A5R, B6R, 8.5 x 11R (7145 only),

8.5 x 11 (except the 7145), F4 (except the 7145)

ADU: A3, B4, A4, A4R, B5, B5R, A5R, 11 x 17, 8.5 x 11, 8.5 x 11R, 8.5 x 14, 5.5

x 8.5R, F4

Copy size (for inch area):

Tray 1: 8.5 x 14, 8.5 x 11, 8.5 x 11R, 5.5 x 8.5R, F4, B4R (7145 only), A4, A4R,

B5, A5R

Tray 2: 11 x 17, 8.5 x 14, 8.5 x 11, 8.5 x 11R, 5.5 x 8.5R, F4, A3, A4, A4R, A5R

Bypass tray: 11 x 17, 8.5 x 14, 8.5 x 11, 8.5 x 11R, 5.5 x 8.5R, A4

ADU: 11 x 17, 8.5 x 14, 8.5 x 11, 8.5 x 11R, 5.5 x 8.5R, A3, B4 (7145 only), A4,

A4R, B5, A5R, F4

Magnification:

Fixed magnification (for metric area):

x 1.00, x 1.41, x 1.22, x 1.15, x 0.86, x 0.82, x 0.71

Fixed magnification (for inch area):

x 1.00, x 2.00, x 1.55, x 1.29, x 0.77, x 0.65, x 0.50

Special ratio: Three kinds

Zoom magnification: x 0.25 to x 4.00 (at 1% step)

Vertical magnification: x 0.25 to x 4.00 (at 1% step)

Horizontal magnification: x 0.25 to x 4.00 (at 1% step)

1-3

2

PRODUCT SPECIFICATIONS

Warm-up time: Less than 30 sec. (7145)

(at temperature of 68°F, Less than 19 sec. (7235/7228/7222)

at rated voltage)

First copy out time: Less than 3.8 sec. (7145)

I OUTLINE

Continuous copy speed: 45 copies/min. (7145)

(A4 or 8.5 x 11, 35 copies/min. (7235)

in memory copy) 28 copies/min. (7228)

Continuous copy count: Up to 999

No. of sheets loadable

on the paper exit tray: Up to 100 (8.5x11)

Copy density selection: AE, manual (9 steps), arbitrary density (2 modes)

Resolution:

Scan: 600 dpi x 600 dpi

Write: 600 dpi x 600 dpi

ERDH memory *1: Standard 64MB, Maximum 320MB

Interface section: Serial port (USB TypeB), Serial port (RS-232C), RJ45 Ethernet connector,

Network section: Ethernet frame type: IEEE 802.3/802.3/Ethernet II/

*1 Since the standard 64MB memory is packaged on the board, it is not possible to replace it with a new

one.

Only one slot is provided for expansion. It can be installed with MU-404 (64MB), MU-405 (128MB), or

256MB (commercially available).

For 256MB (commercially available), be sure to use those of make and model No. specified separately.

Less than 4.3 sec. (7235)

Less than 4.9 sec. (7228/7222)

* platen mode, manual density, life size, tray 1, paper exit with face down,

A4 or 8.5 x 11

22 copies/min. (7222)

Parallel port (IEEE1284 (Compatible, Nible, ECP))

IEEE 802.3 SNAP

Connecting type: 10 Base-T/100 Base-TX

Corresponding protocol: TCP/IP (BOOTP, ARP, ICMP, DHCP,

SNMP, HTTP, SMTP, POP3, FTP, IPP),

IPX/SPX, AppleTalk (EtherTalk),

Corresponding OS: Novell NetWare (3.x, 4.x, 5.x), Microsoft

Windows 95/98/Me, Microsoft Windows

NT4.0/2000/XP, Mac OS8.x and later,

Mac OS10.2.5

Multi-protocol: Automatic discrimination

Corresponding printing method: Peer-to-Peer (TCP/IP), LPD/LPR (TCP/

IP), PServer (IPX/SPX), RPrinter (IPX,

SPX), AppleTalk (EtherTalk)

General purpose utility: Web browser (Internet Explorer,

Netscape Navigator)

Status indicator LED: Green LED and orange LED, one for

each

2

1-4

PRODUCT SPECIFICATIONS

Number of originals to be stored:More than 140 sheets under the following conditions:

Original: Konica standard chart

Density: Manual 5

Mode: Character/photograph

Memory capacity: 64MB (provided only as standard)

Job: Job in mode with page memory not used

C. Copy Paper

Plain paper: 60g/m2 or 17lbs to 105g/m2 or 28lbs, high-quality paper

Special paper *1 Label paper, OHP film, blueprint-master paper, 50g/m

or 16lbs high-quality paper (thin), 106g/m2 or 28lbs to 130g/m2 or 35lbs

high-quality paper (thick1), 131g/m

quality paper (thick2 *2)

*1 With bypass feed method, paper should be fed one sheet at a time. Double sided copy not allowed.

*2 Only bypass feed.

2

or 35lbs to 160g/m2 or 43lbs high-

2

or 13lbs to 59g/m

D. Machine Data

I OUTLINE

2

Power source: 230VAC –14% to 10.6% 50Hz/60Hz

120VAC –14% to 6% 60Hz

Power consumption: Maximum 1500W or less (fully optional)

Weight: Approximately 183lbs (with DF provided)

Dimensions: 7145: 23.2in (W) x 23.4in (D) x 42.6in (H) (with DF + DB)

7235/7228/7222: 23.4in (W) x 25.8in (D) x 44.6in (H) (with DF + DB)

E. Maintenance

Maintenance: Once every 120,000 copies (7145)

Once every 100,000 copies (7235/7228/7222)

F. Consumables

Developer: Exclusively for 7145

Exclusively for 7235/7228/7222

Toner: Exclusively for 7145

Exclusively for 7235 (Common to 7135)

Exclusively for 7228/7222 (Common to 7022/7120/7130)

Drum: Exclusively for 7145 (φ 60)

Exclusively for 7235/7228/7222 (φ 60)

1-5

2

PRODUCT SPECIFICATIONS

G. Operating Environment

Temperature: 10°C to 30°C (50°F to 86°F)

Humidity: 10% RH to 80% RH

I OUTLINE

Note:

• The information herein may be subject to change for improvement without notice.

1-6

3. CENTER CROSS SECTION

[18] [19] [20]

CENTER CROSS SECTION

[17]

[16]

[15]

[14]

[13]

[12]

I OUTLINE

[1]

[2]

[3]

[4]

[5]

[6]

[11]

[10]

[1] Fixing unit [10] DB

[2] Drum unit [11] Developing unit

[3] Separation corona unit [12] Tray 2

[4] Transfer corona unit [13] Tray 1

[5] ADU unit [14] Charging corona unit

[6] Bypass tray [15] Cleaning/toner recycling unit

[7] Paper feed path for making a double-sided

copy (DB unprovided)

[8] Paper feed path for making a double-sided

copy (DB provided)

[9] DB paper feed path [20] CCD unit

[16]

[17]

[18]

[19]

Toner bottle

Scanner unit

V-mirror unit

Exposure unit

[7]

[8]

[9]

7322ma1002

1-7

2

DRIVE SYSTEM DIAGRAM

4. DRIVE SYSTEM DIAGRAM

4.1 Drum Drive

I OUTLINE

4.2 Cleaning/Developer Agitation Drive

[1]

[2]

[1] M1 (Main motor) [2] Drum drive shaft

[1]

[2]

[3]

[1] M1 (Main motor) [3] Developer agitation drive

[2] Cleaning/toner recycling unit drive

1-8

4.3 Fixing/Paper Exit Section/IT-101/RU-101 Drive

DRIVE SYSTEM DIAGRAM

[4]

[3]

[1] IT-101 [4] Paper exit drive

[2] M11 (Fixing motor) [5] Drive coupling for IT-101 and RU-101

[3] Fixing unit drive

[5]

[1]

[2]

I OUTLINE

4.4 Developing Drive

In the case of the 7145

[4]

[1] Developing sleeve [3] M3 (Developing motor)

[2] Developing unit [4] Drum drive shaft

[1]

[2]

[3]

1-9

2

DRIVE SYSTEM DIAGRAM

In the case of the 7235/7228/7222

I OUTLINE

[1]

[2]

[3]

[4]

7322ma1003

[1] M1 (Main motor) [3] Developing unit

[2] Developing sleeve [4] Drum drive shaft

4.5 Paper Feed Drive

4.5.1 Drive from paper feed motor to loop clutch

[2]

[1]

[1] MC2 (Loop clutch) [2] M9 (Paper feed motor)

2

1-10

4.5.2 Tray 1 drive

DRIVE SYSTEM DIAGRAM

[5][4]

[1]

SD1 (1st paper feed solenoid/U)

[1]

Conveyance roller

[2]

[3] MC2 (Loop clutch) [5] Feed roller

[4] Driven when SD1

(1st paper feed solenoid/U) is on.

I OUTLINE

[2]

[3]

4.5.3 Tray 2 drive

[2]

[5]

[4]

MC2 (Loop clutch)

[1]

Feed roller

[2]

[3] SD2 (1st paper feed solenoid/L) [5] Conveyance roller

[4] Driven when SD2

(1st paper feed solenoid/L) is on.

[1]

[3]

1-11

DRIVE SYSTEM DIAGRAM

4.5.4 Bypass feed drive

I OUTLINE

[1] MC2 (Loop clutch) [3] SD3 (Bypass solenoid)

[2] Conveyance roller [4] Driven when SD3 (Bypass solenoid) is on.

[4] [5]

[1]

[3]

[2]

[5] Paper feed roller

4.5.5 Registration clutch drive

[2]

[1]

[1] M9 (Paper feed motor) [2] MC1 (Registration clutch)

1-12

4.6 ADU Drive

DRIVE SYSTEM DIAGRAM

[9]

I OUTLINE

[8]

[1]

[7]

[6]

[2]

[5]

[3]

[4]

[1] M1 (Main motor) [5] ADU roller

[2] Timing belt [6] ADU conveyance roller/2

[3] M9 (Paper feed motor) [7] Decurler roller

[4] M6 (ADU motor) [8] ADU conveyance roller/1

[9] M11 (Fixing motor)

1-13

DRIVE SYSTEM DIAGRAM

4.7 Scanner Drive

I OUTLINE

[3]

[2]

[1] Optical wire/R [4] Exposure unit

[2] Optical wire/F [5] M2 (Scanner motor)

[3] V-mirror unit

[4]

[5]

[1]

1-14

4.8 Toner Supply Drive

[5]

[4]

DRIVE SYSTEM DIAGRAM

I OUTLINE

[2]

[3]

[1] Toner agitation plate [4] M4 (Toner supply motor 1)

[2] Toner conveyance screw [5] M10 (Toner supply motor 2)

[3] SD9 (Toner solenoid)

[1]

1-15

DRIVE SYSTEM DIAGRAM

I OUTLINE

Blank page

1-16

II UNIT EXPLANATION

1. SCANNER SECTION

1.1 Composition

SCANNER SECTION

7235/7228/7222

[12][11][10][9][8][7]

CB

7145

SCDB

II UNIT EXPLANATION

CB

SCB

[2][3][4][5][6] [1]

Symbol Name Function or method

[1] INV1 (Exposure lamp inverter) L1 (Exposure lamp) turn on

[2] PS17 (APS sensor) Detection of original size in the direction of sub-scanning

[3] ADB (A/D converter board) Digital conversion of analog signal

[4] CCD unit Photoelectric conversion of read image (600dpi)

[5] Exposure unit Image reading

Light source slit exposure

Scan speed

• Forward: 230mm/sec. (in 1:1 magnification)

• Backward: 383mm/sec.

[6] Optical wire Transmission of driving force from M2 to the exposure unit and

the V-mirror unit (front and rear)

[7] V-mirror unit Reflection of reading light (2nd and 3rd mirrors)

[8] PS14 (Scanner HP sensor) Exposure unit HP detection

[9] L1 (Exposure lamp) Light source for reading image,

Xenon lamp

[10] L1INVB (Power supply board

for exposure lamp)

[11] M2 (Scanner motor) Driving of the optical wire used to move the exposure unit and

[12] PS15 (APS timing sensor) RADF open/close detection

Relay board for INV1 (Exposure lamp inverter) and L1 (Expo-

sure lamp)

the V-mirror unit

Three-phase step motor

7322ma2001e

2-1

2

SCANNER SECTION

1.2 Operation

1.2.1 Initial operation when power is turned on and shading correction reading

When the SW2 (Sub power switch) comes on, the exposure unit starts a home position search. At this

time, the exposure unit uses the white reference plate attached on the back side of the original pressing

board for shading correction. However, two places on the white reference plate are read for correction.

The search procedure differs depending on whether the PS14 (Scanner HP sensor) is on or off while the

SW2 is on.

A. Home position search when the PS14 is turned on

II UNIT EXPLANATION

[1] Exposure unit standby position [3] Shading correction position 1

[2] PS14 [4] Shading correction position 2

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

7322ma2015

B. Home position search when PS14 is turned off

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

7322ma2016

[1] Exposure unit standby position [3] Shading correction position 1

[2] PS14 [4] Shading correction position 2

1.2.2 Original reading mode

The following two modes are available for original reading; platen mode and DF mode. In platen mode, the

exposure unit moves as necessary to scan the original for reading. In DF mode, the RADF side moves the

original while the exposure unit stays fixed in a specified position (DF reading position).

2

2-2

SCANNER SECTION

A. Exposure unit movement in platen mode

In platen mode, the scan sequence depends on the copy density selection (either AE or manual).

(1) In manual density copy:

[1][6][2][3][4][5]

7322ma2017

Exposure unit standby position

[1]

PS14

[2]

Shading correction position 1

[3]

Shading correction position 2

[4]

[5] Position at which the approach run of the

exposure unit is started

[6] Position at which the reading of an image

is started

Note:

• When the tray 1 is selected manually, but not in APS, the shading operation is not executed.

(2) In AE copy:

[3][4][5][6]

[1][7]

[2]

Exposure unit standby position

[1]

AE scanning range

[2]

PS14

[3]

Shading correction position 1

[4]

[5] Shading correction position 2

[6] Position at which the approach run of the

exposure unit is started

[7] Position at which the reading of an image

is started

II UNIT EXPLANATION

7322ma2018

B. Exposure unit movement in DF mode

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

[1] Exposure unit standby position [4] Shading correction position 2

[2] PS14 [5] DF reading position

[3] Shading correction position 1

2-3

7322ma2019

2

SCANNER SECTION

1.2.3 Original read control

The light from the exposure lamp reflects back from the original, passes through a lens, and hits the CCD

sensor. The CCD sensor generates an electric signal (analog signal) corresponding to the light intensity.

Then, according to the instruction from the SCB (System control board), the ADB (A/D conversion board)

converts this signal into a digital signal.

A. Original read timing

(1) Platen mode, when the manual density is being set

[2] [5]

II UNIT EXPLANATION

M2 (Scanner motor)

PS14 (Scanner HP sensor)

F

R

[1] [3] [4]

[1] START button (ON) [4]

[2] Exposure lamp (forward) [5] Exposure scanning (backward)

[3] Position to which the exposure unit starts

(2) Platen mode, when the AE density is being set

Position at which reading of the original starts

[6] [8][2] [5]

M2 (Scanner motor)

PS14 (Scanner HP sensor)

F

R

[4] [7][1]

[3][3]

START button (ON)

[1]

AE scanning (forward)

[2]

Position to which the exposure unit starts

[3]

Position at which reading of the AE density

[4]

started

2-4

AE scanning (backward)

[5]

Exposure lamp (forward)

[6]

Position at which reading of the original

[7]

starts

Exposure scanning (backward)

[8]

B. Original read timing (DF mode) *1

SCANNER SECTION

[4][2]

M2 (Scanner motor)

F

R

PS14 (Scanner HP sensor)

M301

(Original feed motor)

R

250mm/s

230mm/s

F

460mm/s

M302

(Original conveyance motor)

F

230mm/s

460mm/s

[3]

PS308 (Original registration sensor)

[1]

[5] [6]

[1] START button (ON) [4] Exposure conveyance

[2] DF reading position [5]

[3] Position to which the original has been

conveyed in the specified distance.

Position at which reading of the original starts.

[6] Starting point from the DF reading position

to the home position (exposure unit).

*1 In the DF mode, the operation when the manual density setting and the AE density setting is the same.

II UNIT EXPLANATION

1.2.4 APS control

The APS control is carried out at close detection of the RADF, and controlled by the CB (Main body control

board), based on signals from the PS17 (APS sensor) and the CCD sensor. (For APS control by the

RADF, see DF service manual.)

A. APS operation

The PS17 (APS sensor) detects the original size in the sub scanning direction, while the CCD sensor

detects the original size in the main scanning direction.

B. Relationship between each of the sensors and the original size

Original size CCD sensor

(Length of detection: mm)

PS17

(ON/OFF)

A3 297 ON

11 x 17 279.4 ON

B4 257 ON

2-5

2

SCANNER SECTION

II UNIT EXPLANATION

Original size CCD sensor

(Length of detection: mm)

8.5 x 14 *1 215.9 ON

8.5 x 11R 215.9 Metric system: ON Inch system: OFF

A4R 210 Metric system: ON Inch system: OFF

A4 297 OFF

8.5 x 11 279.4 OFF

B5R 257 OFF

A5R 210 OFF

B5 182 OFF

A5 148 OFF

5.5 x 8.5 139.7 OFF

B6 128 OFF

Postcard 102 OFF

*1 8.5 x 14 cannot be distinguished from 8.5 x 11R, and is detected as 8.5 x 11R.

(ON/OFF)

PS17

C. APS detection timing

(1) Platen mode (when the RADF is closed)

[1] [2]

PS17 (APS sensor)

PS15 (APS timing sensor)

PS303 (DF open/close sensor)

[1] 1st original size detection [2] 2nd original size detection

(2) Platen mode (when the RADF is open)

[1]

PS17 (APS sensor)

PS15 (APS timing sensor)

PS303 (DF open/close sensor)

[2]

[1] Original size detection [2] START button (ON)

2-6

SCANNER SECTION

1.2.5 AE control

During AE scan, the CCD sensor provided on the ADB (A/D conversion board) reads the density level of

the original. The CPU on the SCB (System control board) process the data and, based on the results,

selects the γ correction curve that will best reproduce the original.

A. AE sampling range

(1) While in platen copying

Main scanning direction

• Based on the original size recognized in the APS or out-of-original erasure mode, the range excepting

10mm in front and in rear.

Sub-scanning direction

• The range of 30mm from the leading edge of the original. However, the range excepting L/100mm in

left and right when the length of the original is L mm.

[3]

10 mm

[1]

[2]

10 mm

L

100

30 mm

mm

L

100

L mm

mm

[1] Original [3] AE sampling range

[2] Leading edge of original

II UNIT EXPLANATION

2-7

SCANNER SECTION

(2) While in DF copying

Main scanning direction

• Based on the original size recognized in the APS, the range excepting 20mm in front and in rear.

Sub-scanning direction

• The range between 1.5mm and 2.9mm from the leading edge of the original.

[3]

20 mm

[1]

[2]

20 mm

1.5 mm

1.4 mm

II UNIT EXPLANATION

2.9 mm

[1] Original [3] AE sampling range

[2] Leading edge of original

1.2.6 Image processing

A. AOC (Automatic offset control)

The analog offset voltage for the CCD sensor output is automatically adjusted by IC on the ADB (A/D

conversion board) so that this level becomes the lower limit for the A/D converter.

B. AGC (Automatic gain control)

The analog amplification for the CCD sensor output is automatically adjusted so that the CCD sensor

output level in the shading white correction becomes the upper limit for the A/D converter.

C. Shading correction

(1) Types of the shading correction

• White correction

• Black correction

(2) Execution timing

• At SW2 (Sub power switch) ON

• At the start of scan job

D. Other image processing

(1) Brightness/density conversion

(2) Text/dot pattern judgement

(3) Filtering

(4) Magnification change processing

(5) Error diffusion processing

(6) Data compression/elongation processing

2-8

2. WRITE UNIT

2.1 Composition

WRITE UNIT

[11][10][9][8][7][6][5]

SCB

CB

7235 only

FM7

[3][4]

Symbol Name Function or method

[1] Index lens Converging of laser beams reflected from the index mirror

[2] INDEX (Index sensor board)

[3] Polygon mirror Laser beam scanning

[4] M5 (Polygon motor) Polygon mirror drive

[5] LDB (LD drive board) Laser emission drive

[6] Collimator lens Making diffused laser beam parallel

[7] Cylindrical lens 1

[8] Index mirror Reflection of laser beam upon the INDEX (Index senror board)

[9] fθ lens

[10] Cylindrical lens 2

[11] Dust-proof glass

FM7*1 Polygon cooling fan

Control of the laser write position in the main scanning direction

Hexahedron, 27,165rpm (7145) /38,976rpm (7235) /

33,071rpm (7228/7222)

DC brushless motor, PLL control

1-chip/2-beam system, 15mW 780mm (7145)

1-chip/1-beam system, 5mW 780mm (Except the 7145)

Correction of the laser path against error in the angle of the polygon mirror

Unified laser scanning speed against the laser irradiation surface on the drum

Correction of the laser path against error in the angle of the polygon mirror

Preventive measure for keeping the interior of the write unit clean

Cooling of the M5 (

Polygon motor

)

[1]

[2]

7322ma2002

II UNIT EXPLANATION

*1 7235 only

2-9

2

WRITE UNIT

2.2 Operation

2.2.1 Image writing

The image data from the CCD sensor is converted into digital form by the ADB (A/D conversion board),

and its image processing is then carried out on the SCB (System control board). Based on the processed

image data, the image is written onto the drum by the laser beam output from the LDB (LD drive board).

2.2.2 Write control

A. Dot diameter adjustment

The sensor on the toner control sensor board detects the patch image density on the drum, and the

LDB (LD drive board) controls the quantity of laser beam so that its output value becomes the speci-

fied value.

II UNIT EXPLANATION

(1) Timing for execution

a. While in copying

• Executed once for every 20 copies added up. However, when 20 copies are added up in the middle of

the job, the execution is made at the time of completion of the job.

b. Anytime other than while in copying

• While in the L inspection

• When the drum counter is reset

• When the sub power is turned on. However, this is subject to the settings 6 and 7 of the DIPSW16 in

the 25 mode.

B. APC (Automatic power control)

The LDB (LD drive board) monitors the laser output value for every one scan, and maintains the laser

beam quantity at the fixed level by driving the laser so that it becomes the output value set for the dot

diameter adjustment.

C. Write timing

The SCB (System control board) uses a laser detection signal from the INDEX (Index sensor board) to

determine the starting point for laser writing for every one scan in the drum shaft direction.

2

2-10

3. DRUM UNIT

3.1 Composition

[6]

DRUM UNIT

[10][9][8][7]

SD7

M1

CB

II UNIT EXPLANATION

HV

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

Symbol Name Function or method

[1] TSL

(Transfer synchronization lamp)

[2] Transfer corona unit Transfer of toner from the drum to paper

[3] Paper entrance guide plate Conveyance guide for paper supplied

[4] Drum Image formation base

[5] Developing unit Formation of a toner image on the drum

[6] Charging corona unit Application of electric charge on the drum surface

Separation support

LED

DC positive corona discharge *1

Wire discharge: Tungsten wire with oxide film (φ 0.06mm)

With manual wire cleaning mechanism provided

Constant current DC output range: 0 to 350 µA

High voltage applied to prevent toner adhesion: -500VDC

(constant voltage)

OPC drum (φ 60mm)

(See “4. Developing unit”.)

DC corona discharge (Scotron)

Wire discharge: Gold-plated skin-pass tungsten wire

(φ 0.06mm)

With manual wire cleaning mechanism provided

Constant current DC output range: -320 to -1000 µA

Grid bias: Charging control plate

Constant current DC output range: -450 to -1090V

[1]

TCSB

2-11

2

DRUM UNIT

II UNIT EXPLANATION

Symbol Name Function or method

[7] PCL

(Pre-charging exposure lamp)

Erasure of potential on the drum surface

LED

[8] Cleaning/recycle section Cleaning and collection of toner on the drum

(See “5. Toner supply/cleaning/recycle section”.)

[9] Separation claw Support for the separation of paper from the drum

Pressure/release method by SD7 (Separation claw solenoid)

[10] Separation corona unit Separation of transferred paper from the drum

AC/DC corona discharge *1

Wire discharge: Tungsten wire with oxide film (φ 0.06mm)

With manual wire cleaning mechanism provided

Constant current AC output range: 1.5 to 5.0kV

Constant current DC output range: 0 to -300µA

SD7 Separation claw solenoid Separation claw pressure/release

24VDC drive

M1 Main motor Driving of the drum, cleaning/recycling section

DC brushless motor, PLL control

HV High voltage power High voltage power supply to the charging corona, transfer

corona, separation corona, paper entrance guide plate and

developing bias

Method to increase voltage by inverter from 24VDC

TCSB Toner control sensor board Detection of the patch image density on the drum

Detection of temperature around the drum

*1 Control is made so that an output value becomes a little higher for a thick paper and a little lower for a

thin paper as compared with a plain paper.

Note for the transfer/separation corona

Caution:

• A copy should not be made when the ADU door is open with the interlock forcibly turned on. Oth-

erwise, the contact (spring) of the ADU door develops high voltage and you may get an electric

shock.

2

2-12

[4]

DRUM UNIT

[3]

[2]

[1]

[1] ADU door [3] Transfer/separation corona unit

[2] Contact [4] HV (High voltage unit)

3.2 Operation

3.2.1 Image formation timing (when copying two sheets)

A. In the case of the 7145

M1 (Main motor)

M3 (Developing motor)

PS1 (Registration sensor)

MC1 (Registration clutch)

PCL (Pre-charging exposure lamp)

HV (Charging corona)

HV (Developing bias)

HV (Transfer corona)

II UNIT EXPLANATION

HV (Separation corona)

HV (Paper entrance guide plate)

TSL (Transfer synchronization lamp)

DS7 (Separation claw solenoid)

PS2 (Fixing exit sensor)

[2]

[3][1]

7322ma2020

[1] START button (ON) [3] Driving of the separation claw to prevent

[2] Varies depending on the type of paper.

the trailing edge of paper from getting

stained.

2-13

2

DRUM UNIT

B. In the case of the 7235/7228/7222

M1 (Main motor)

PS1 (Registration sensor)

MC1 (Registration clutch)

PCL (Pre-charging exposure lamp)

HV (Charging corona)

HV (Developing bias)

HV (Transfer corona)

HV (Separation corona)

HV (Paper entrance guide plate)

II UNIT EXPLANATION

TSL (Transfer synchronization lamp)

DS7 (Separation claw solenoid)

PS2 (Fixing exit sensor)

[1]

[2]

[3]

7322ma2012

[1] START button (ON) [3] Varies depending on the environment in

which it is installed.[2] Varies depending on the type of paper.

2

2-14

4. DEVELOPING UNIT

4.1 Composition

DEVELOPING UNIT

7235/7228/7222

M1

[5][4]

CB

7145

M1

M3

HV

[2][3]

Symbol Name Function or method

[1] TDS (Toner density sensor) Detection of toner density in the developing unit

L detection method

[2] Developing sleeve Coveyance of developing materials by magnetic force to the

drum surface

Two-component developing method (developing materials:

Toner + Carrier)

Developing bias voltage applied

Constant voltage DC output range: -350 to -830V

[3] Developing regulation plate Regulation of the spiking amount of developing materials on

the developing sleeve

Regulation plate method

[4] Agitator screw Agitation of developer and conveyance of developing materials

to the agitator wheel

Agitator wheel method

[5] Agitator wheel Agitation of developer and conveyance of developing materials

to the developing sleeve

4-vane wheel method

M1 Main motor Driving of the agitating turbine, the agitating screw and the

developing sleeve (except the 7145)

DC brushless motor, PLL control

M3*1 Developing motor Driving of the developing sleeve

[1]

CB

7322ma2003e

II UNIT EXPLANATION

*1 7145 only

2-15

2

DEVELOPING UNIT

4.2 Operation

4.2.1 Developing control

For details of each operation timing of developing, see “3. Drum section”.

4.2.2 Control of toner density in the developing unit

The TDS (Toner density sensor) uses the L detection method (detection of permeability in developing

materials) to detect the toner density of developing materials. The value thus obtained is compared with

the standard value of the toner density for the L detection adjustment that is recorded in the PCU con-

tained in the CB (Main body control board) to see if toner should be supplied or not. (For details of toner

supply, see “5. Toner supply/cleaning/recycling section”.)

II UNIT EXPLANATION

2-16

TONER SUPPLY/CLEANING/RECYCLE UNIT

5. TONER SUPPLY/CLEANING/RECYCLE UNIT

5.1 Composition

[7][6] [8][5] [9][4]

M1

M10

CB

SD9

M4

Symbol Name Function or method

[1] Toner collection sheet Collection of toner separated by the cleaning blade from the drum

surface

Rotating collection method

[2] Cleaning blade Drun cleaning

Drum contact/separation method

[3] Toner conveyance screw Agitation of toner and conveyance of toner to the developing unit

Screw method

[4] TLD (Toner level sensor) Detection of the toner level in the toner supply unit (Detected

when the residual quantity of toner gets to about 30g.)

Piezo element method

[5] Toner bottle Toner supply (bottle capacity: 676g)

Toner bottle rotation method

[6] Toner supply paddle Conveyance of toner from the toner bottle to the toner supply unit

Fixed method (Since the toner bottle rotates, this serves as the

toner introduction section.)

[7] Toner agitation plate Agitation of toner supplied from the toner bottle and the cleaning/

recycle section, and conveyance of the toner to the toner convey-

ance screw

Screw method

[8] Collected toner conveyance

screw

Conveyance of toner from the cleaning section to the toner supply

unit

Screw method

[3]

[1]

[2]

II UNIT EXPLANATION

2-17

TONER SUPPLY/CLEANING/RECYCLE UNIT

Symbol Name Function or method

[9] PS5 (Toner bottle sensor) Detection of the setting of the toner bottle

M1 Main motor Driving of the toner collection sheet and the collected toner con-

M4 Toner supply motor 1 Driving of the toner conveyance screw and the toner agitator plate

M10 Toner supply motor 2 Toner bottle

SD9 Toner solenoid Transmission of driving force from the M4 (Toner supply motor) to

5.2 Operation

II UNIT EXPLANATION

5.2.1 Toner supply control when the toner level in the toner supply section gets reduced

A. Toner supply operation:

When toner in the toner supply unit is running short, the TLD (Toner level sensor) turns on. This

causes the M10 (Toner supply motor 2) to turn on to rotate the toner bottle and replenish toner to the

toner supply unit. When toner has been supplied, the TLD turns off to monitor the toner level.

Photosensor

veyance screw

DC brushless motor, PLL control

Stepping motor

Stepping motor

the toner conveyance screw

24VDC drive

B. Operation when toner is not supplied:

When the TLD (Toner level sensor) has been kept turned on for the specified period of time, it is con-

sidered that no toner remains in the toner bottle and a message is displayed on the operation LCD.

C. Toner level detection timing:

The TLD (Toner level sensor) detects at all times the toner level during copy operation.

2-18

TONER SUPPLY/CLEANING/RECYCLE UNIT

5.2.2 Toner supply control when toner density in the developing unit gets reduced

A. When power is on:

The TDS (Toner density sensor) detects the toner density in the developing unit the specified period of

time after the SW2 (Sub power switch) is turned on. When the value thus detected at this time is

below the initial density recorded in the CPU contained in the CB (Main body control board), the M4

(Toner supply motor 1) and the SD9 (Toner solenoid) are turned on to start to replenish toner up to the

specified level of density.

B. While in copy operation:

While in copy operation, the TDS (Toner density sensor) monitors the toner density. Using the output

voltage of the TDS to turn on the SD9 (Toner solenoid), the M4 (Toner supply motor 1) determines the

time required for toner supply.

TDS output voltage Time required for toner supply

2.01V or less 0 sec.

2.02 to 2.08V 0.10 sec.

2.09 to 2.16V 0.20 sec.

2.17 to 2.23V 0.30 sec.

2.24 to 2.31V 0.40 sec.

2.32 to 2.39V 0.50 sec.

2.40V or more 0.70 sec.

II UNIT EXPLANATION

2-19

PAPER FEED UNIT

6. PAPER FEED UNIT

6.1 Composition

[18] [19] [20] [21] [22] [23] [24] [25] [26] [27]

SD1

II UNIT EXPLANATION

[17]

[16]

[15]

[14]

[13]

SD3

SD2

[3][4][5][6][7][8][9][10][11][12]

MC2

M9

PFDB/U

PFDB/L

[1]

[2]

CB

Symbol Name Function or method

[1] VRI (Bypass tray paper size

sensor VR)

[2] PS20

(Bypass tray paper size sensor)

[3] PS13

Detection of paper size in the direction of the width of the by-

pass tray

Detection of paper size in the direction of the length of the by-

pass tray

Detection of the presence of bypass feed paper

(Bypass tray no paper sensor)

[4] Double feed prevention roller Double feed prevention of paper, Torque limiter

[5] Conveyance roller Paper conveyance

[6]*1 PS22 (Timing sensor/L) Detection of tray 2 paper conveyance condition

[7] Double feed prevention roller Double feed prevention of paper, Torque limiter

[8] M8 (Tray motor/L) Tray 2 paper liftup plate drive, DC motor

[9] Feed roller 1st paper feed power transmission

[10] PS12 (Tray set sensor/L) Tray 2 detection and remaining paper detection

[11] PS10 (Upper limit sensor/L) Tray 2 paper upper limit detection

[12] PS11 (No paper sensor/L) Detection of the presence of tray 2 paper

[13] Paper feed roller Tray 2 paper feed

[14] M7 (Tray motor/U) Tray 1 paper liftup plate drive, DC motor

*1 7145/7235/7228 only

2

2-20

PAPER FEED UNIT

Symbol Name Function or method

[15] PS9 (Tray set sensor/U) Tray 1 detection and remaining paper detection

[16] PS8 (No paper sensor/U) Detection of the presence of tray 1 paper

[17] PS7 (Upper limit sensor/U) Tray 1 paper upper limit detection

[18] Paper feed roller Tray 1 paper feed

[19] Double feed prevention roller Double feed prevention of paper, Torque limiter

[20] Feed roller 1st paper feed power transmission

[21]*1 PS21 (Timing sensor/U) Detection of tray 1 paper conveyance condition

[22] Conveyance roller Paper conveyance

[23] PS1 (Registration sensor) Detection of the paper passage for the Registration roller rota-

tion ON/OFF

[24] Registration roller Paper conveyance

[25] Conveyance roller Paper conveyance

[26] Feed roller Bypass tray paper feed

[27] Paper feed roller Paper feed

M9 Paper feed motor Paper feed system drive, DC brushless PLL control

MC2 Loop clutch 1st paper feed power transmission

SD1 1st paper feed solenoid/U Tray 1 paper feed power transmission

SD2 1st paper feed solenoid/L Tray 2 paper feed power transmission

SD3 Bypass solenoid Bypass tray paper feed power transmission

PFDB/U

PFDB/L

*1 7145/7235/7228 only

Paper feed detection board/U Tray 1 paper size detection

Paper feed detection board/L Tray 2 paper size detection

CB Main body control board Overall control

II UNIT EXPLANATION

6.2 Operation

6.2.1 Tray up drive control

Since the operation is the same for both the tray 1 and the tray 2, the explanation is given of the tray 1.

When the paper feed tray is set, the PS9 (Tray set sensor/U) detects the tray with the M7 (Tray motor/U)

turned on. This causes the paper up/down plate in the tray to go up. When the PS7 (Upper limit sensor/U)

detects the paper upper limit, the M7 is turned off. When the sheets of paper get reduced as they are being

fed through, the PS7 detects no remaining paper. At this time, the M7 is kept turned on until it detects the

paper upper limit again, and paper is raised up to the specified level at all times.

When the tray is removed, its coupling with the drive section is disconnected to let the paper up/down plate

go down by its own weight.

When papar is supplied by the bypass feed method and the SD3 (Bypass solenoid) turns on after the M9

(Paper feed motor) turns on, the bypass plate goes up to raise paper.

2-21

2

PAPER FEED UNIT

6.2.2 Paper feed control

The following shows the timing of paper feed by the tray 1. The timing of paper feed is basically the same

for both the tray 2 and the bypass tray, and the actual paper feed in each case starts when the SD2 (1st

paper feed solenoid/L) or the SD3 (Bypass solenoid) turns on respectively.

[1]

M9 (Paper feed motor)

SD1 (1st paper feed solenoid/U)

PS21 (Timing sensor/U)

MC2 (Loop clutch)

PS1 (Registration sensor)

II UNIT EXPLANATION

[1] START button (ON)

6.2.3 Remaining paper detection control

Since the operation is the same for both the tray 1 and the tray 2, the explanation is given of the tray 1

only.

The remaining paper quantity is detected by the PS9 (Tray set sensor/U). As the remaining paper is get-

ting reduced, the actuator provided on the rear side of the tray starts to ratate gradually as shown in the

drawing. The PS9 turns on and off each time it passes through a slit. The remaining paper quantity is

detected by counting the number of ON/OFF's after the installation of the tray.

0 count: Full 1 count: Medium 2 counts: Low

[1]

[2]

[3]

[4]

[1] Rotating direction when the paper up/down

plate is going up.

[2] PS9 (Tray set sensor/U) [5] Actuator

2-22

[3]

[4]

Slit 1

Slit 2

[5]

PAPER FEED UNIT

6.2.4 Paper size detection

The paper size in the tray is detected by the CB (Main body control board), using signals sent from the

PFDB/U (Paper feed detection board/U) and the PFDB/L (Paper feed detection board/L).

The paper size in the tray is set by the SW1 of the PFDB/U and the PFDB/L, and the CB detects a switch

signal according to the position of the SW1. The table below shows the relationship between the switch

signal and the paper size.

For metric area

Paper size Switch signal

Tray 1 Tray 2 SIZE A SIZE B SIZE C SIZE D

8.5 x 14 11 x 17

B5 B5 {

B4 B4 {

A5R A5R {{

A4 A4 {

A4R A4R {{

II UNIT EXPLANATION

F4 A3 {{

5.5 x 8.5R F4 {{{

8.5 x 11 8.5 x 11 {

8.5 x 11R 8.5 x 11R {{

For inch area

Paper size Switch signal

Tray 1 Tray 2 SIZE A SIZE B SIZE C SIZE D

8.5 x 14 11 x 17

B5R A5R {

B4 A4 {

A5R A4R {{

A4 A3 {

A4R F4 {{

F4 5.5 x 8.5R {{

5.5 x 8.5R 8.5 x 11 {{{

8.5 x 11 8.5 x 11R {

8.5 x 11R 8.5 x 14 {{

2-23

FIXING UNIT

7. FIXING UNIT

7.1 Composition

[9]

[10]

[13]

[12]

[11]

[1]

[2]

II UNIT EXPLANATION

DCPS

FCB

CB

Symbol Name Function or method

[1] Fixing pressure roller Fixing of toner by pressure

[2] Fixing heat roller Toner fixing by means of heat

M11

SD4

[8] [7] [6]

Silicon rubber + PFA tube

Aluminum + PFA coating

Temperature setting:

Idling: 376 to 369°F

While in copy operation - Other than when feeding paper by the

by-pass tray in the single sided copy mode: 381°F

While in copy operation - When feeding paper by the bypass tray

in the single sided copy mode (by selecting the type of paper)

• Thick paper mode 1: 381 + 50°F

• Thick paper mode 2: 381 + 50°F

• Thin paper: 381 - 50°F (Except the 7145)

• Other than the above: 381°F

Copying - 381 - 41°F, when a double sided copy is being made.

Low power mode: 185°F (can be changed in the 25 mode)

[3]

[4]

[5]

2

2-24

FIXING UNIT

Symbol Name Function or method

[3] TH2 (Fixing temperature

sensor/2)

[4] TH1 (Fixing temperature

sensor/1)

[5] Cleaning web Cleaning of the fixing heat roller

[6] Fixing cleaning roller Tension pressure on the cleaning web

[7] TS (Thermostat) Protection of the fixing heat roller against high temperature abnor-

[8] L3 (Fixing heater lamp/2) Heating of the fixing heat roller (Sub)

[9] L2 (Fixing heater lamp/1) Heating of the fixing heat roller (Main)

[10] Fixing guide Paper conveyance guide, pressure/release of the fixing pressure

[11] PS2 (Fixing exit sensor) Detection of paper at the fixing unit exit

[12] Neutralizing brush Neutralizing of paper that is exited

[13] Fixing claw Separation of paper from the fixing heat roller

M11 Fixing motor Driving of the fixing heat roller and the ADU conveyance roller/1

SD4 Cleaning web solenoid Driving of the cleaning web

FCB Fixing control board Prevention of noise leak in the drive power for L3 (Fixing heater lamp

Detection of temperature at the edge (front side) of the fixing heating

roller

Contact type

Detection of temperature at the center of the fixing heating roller

Contact type

Web wind-up method

Spring pressure

mality (about 428°F)

Contact type

AC drive

AC drive

roller

Photosensor + actuator

Neutralizing by means of a brush

Spring pressure type (6 pcs.)

DC brushless motor, PLL control

24V drive

/2)

220V system only

II UNIT EXPLANATION

2-25

FIXING UNIT

II UNIT EXPLANATION

7.2 Operation

7.2.1 Fixing temperature control

The CB (Main body control board) uses the TH1 (Fixing temperature sensor/1) and the TH2 (Fixing tem-

perature sensor/2) to detect the temperature of the fixing heating roller, and turns on and off the L2 (Fixing

heater lamp/1) and the L3 (Fixing heater lamp/2) separately through the DCPS (DC power source) to

maintain both the TH1 and the TH2 at the specified temperature.

A. Warm-up

The CB (Main body control board) turns on the fixing heater lamp circuit within the DCPS (DC power

source) immediately after the SW2 turns on, and keeps the L2 (Fixing heater lamp/1) and L3 the (Fix-

ing heater lamp/2) turned on until the fixing heat roller reaches the specified temperature.

Once warm-up has completed, the CB switches the L2 and the L3 on and off so that the fixing heat

roller can be maintained to the set temperature for idling.

• Warm-up time: 30 seconds or less (at the room temperature of 68°F) (7145)

• Warm-up time: 19 seconds or less (at the room temperature of 68°F) (7235/7228/7222)

7.2.2 Cleaning web control

For each output of paper, the cleaning web is let off to be wound up.

The SD4 (Cleaning web solenoid) turns on based on the output of the PS2, causing the cleaning web to be

driven to start a wind-up operation.

PS2 (Fixing exit sensor)

SD4 (Cleaning web solenoid)

[1] [2]

[1] START button (ON) [2] 100 msec

2

2-26

8. ADU/PAPER EXIT SECTION

8.1 Composition

ADU/PAPER EXIT SECTION

[9]

[10]

CB

7145

7235/7228/7222

M11

SD5

M9

M6

[1]

[2]

[3]

[4]

II UNIT EXPLANATION

[5]

[6]

CB

Symbol Name Function or method

[1] PS2 (Fixing exit sensor) Detection of paper at the fixing unit exit

[2] ADU unit (ADU door) Paper conveyance while in double sided copy

[3] ADU conveyance roller/1 Paper conveyance through the ADU entrance

[4] Decurler roller (7145)

Conveyance roller (7235/

7228/7222)

[5] ADU conveyance roller/2 Paper conveyance through the ADU intermediate section

[6] Switching sheet Switching of conveyance path at the paper reverse section

ADUDB

M6

[8]

Photosensor + actuator

Jam removal while in double sided copy

Motor drive

Paper conveyance through the ADU intermediate section and the cor-

rection of paper curling (7145)

Paper conveyance through the ADU intermediate section (7235/7228/

7222)

Motor drive

Motor drive

Switching by means of the elasticity of the PET sheet

[7]

7322ma2004e

2-27

2

ADU/PAPER EXIT SECTION

Symbol Name Function or method

[7] ADU roller

[8] PS4 (ADU sensor) Detection of paper at the ADU exit

[9] Paper exit roller Paper exit

[10] Switching guide Switching of the paper exit path at the fixing unit exit

ADUDB*1ADU drive board Driving of the M6 (ADU motor)

M6 ADU motor Driving of the ADU motor

M9 Paper feed motor Driving of the decurler roller (7145 only) and the ADU conveyance

II UNIT EXPLANATION

SD5 ADU gate solenoid Pressure and release of the switching guide

M11 Fixing motor Driving of the paper exit roller

*1 Except the 7145

Paper conveyance through the ADU exit and switching of the conveyance direction

Motor drive

Photosensor + actuator

Motor drive

Solenoid drive

Stepping motor

rollers/2

DC brushless motor, PLL control

24VDC drive

DC brushless motor, PLL control

2

2-28

ADU/PAPER EXIT SECTION

8.2 Operation

8.2.1 Switching control of the paper exit/ADU conveyance path

A. Straight paper exit path

The straight paper exit path is applicable when a single side is copied as well as after the back side

copy of paper is completed in the double sided copy mode.

[8]

[1]

[7]

[2]

II UNIT EXPLANATION

[3]

[4][5][6]

[1] Switching guide (SD5 OFF) [5] Fixing pressure roller

[2] PS2 (Fixing exit sensor) [6] Fixing heat roller

[3] ADU conveyance driven roller/1 [7] Paper exit driven roller

[4] ADU conveyance roller/1 [8] Paper exit drive roller

2-29

ADU/PAPER EXIT SECTION

B. ADU conveyance path

The ADU conveyance path is applicable after the front side copy is completed in the double sided

copy mode.

II UNIT EXPLANATION

[8]

[7]

[1]

[6]

[2]

[3][4][5]

[1] PS2 (Fixing exit sensor) [5] Fixing heat roller

[2] ADU conveyance driven roller/1 [6] Switching guide (SD5 ON)

[3] ADU conveyance roller/1 [7] Paper exit driven roller

[4] Fixing pressure roller [8] Paper exit drive roller

C. Straight paper exit operation (single sided 3 copies)

PS2 (Fixing exit sensor)

SD5 (ADU gate solenoid)

M1 (Main motor)

M11 (Fixing motor)

[1]

[1] 1st paper exit

2-30

D. ADU conveyance operation (double sided 3 copies)

MC2 (Loop clutch)

PS2 (Fixing exit sensor)

SD5 (ADU gate solenoid)

M1 (Main motor)

M11 (Fixing motor)

ADU/PAPER EXIT SECTION

[2][1]

7322ma2005

[1] 1st paper exit for the front side [2] 1st paper exit for the back side

8.2.2 ADU conveyance control

When a sheet of paper, the front of which has been printed in the double sided mode is conveyed to the

ADU unit, it is further conveyed to the ADU roller by the decurler roller (7145) or conveyance roller (except

the 7145) and the ADU conveyance rollers/2 which are in turn driven by the M9 (Paper feed motor).

II UNIT EXPLANATION

2-31

2

ADU/PAPER EXIT SECTION

8.2.3 Paper reverse control

A. Paper reverse path

(1) When conveying paper

When a sheet of paper is conveyed from the ADU conveyance roller/2, it is further conveyed to the

ADU roller by pushing the switching sheet open.

[9]

[1]

[8]

[7]

II UNIT EXPLANATION

[6]

[2]

[3]

[5]

[4]

[1] ADU conveyance driven roller/2 [6] ADU roller

[2] ADU driven roller [7] Switching sheet

[3] Conveyance path when DB is provided [8] PS4 (ADU sensor)

[4] DB [9] ADU conveyance roller/2

[5] Conveyance path when DB is not provided

7322ma2006

2

2-32

ADU/PAPER EXIT SECTION

(2) When paper reverse

Paper that has been conveyed is sent back by means of the reverse rotation of the ADU roller. At this

time, the switching sheet uses its own elastic power to block the conveyance path to the ADU convey-

ance roller/2, and the paper is conveyed to the loop roller of the tray 2. As a result, the paper is turned

inside out to be copied on the back side after passing through the same route as that for the paper

sent from the tray 2.

[7]

[1]

[2]

[3]

[4]

[6]

[5]

II UNIT EXPLANATION

7322ma2007

[1] Loop roller [5] DB

[2] PS4 (ADU sensor) [6] ADU roller

[3] Switching sheet [7] ADU conveyance roller/2

[4] ADU driven roller

B. Paper reverse operation (7145)

PS4 (ADU sensor)

M6 (ADU motor) F

600mm/s

230mm/s

R

230mm/s

M9 (Paper feed motor)

[1] [2] [3] [4] [5] [6]

[1] Start of 1st paper conveyance [4] Start of reverse operation of 2nd paper

[2] Start of revere operation of 1st paper [5] Start of 3rd paper conveyance

[3] Start of 2nd paper conveyance [6] Start of reverse operation of 3rd paper

2-33

2

ADU/PAPER EXIT SECTION

C. Paper reverse operation (7235/7228/7222)

PS4 (ADU sensor)

II UNIT EXPLANATION

M6 (ADU motor) F

600mm/s

*1

*1

R

M9 (Paper feed motor)

[1] [2] [3] [4] [5] [6]

7322ma2013

*1 165mm/s (7235) 140mm/s (7228/7222)

[1] Start of 1st paper conveyance [4] Start of reverse operation of 2nd paper

[2] Start of revere operation of 1st paper [5] Start of 3rd paper conveyance

[3] Start of 2nd paper conveyance [6] Start of reverse operation of 3rd paper

2

2-34

9. INTERFACE SECTION

9.1 Composition

In the case of the 7145

INTERFACE SECTION

[1]

[2]

[3]

[4]

In the case of the 7235/7228/7222

[2]

[4]

[3]
[1]

Symbol Name Function or method

[1] Serial port (USB TypeB) For ISW of copier/FAX, For serial output of the printer

Ver. 1.1

[2] Serial port (RS-232C) For KRDS communication

D-SUB 9-pin connector

[3] RJ45 Ethernet port Port for network

[4] Parallel port

(IEEE1284 (Compatible,

Nible, ECP))

For ISW of copier/FAX/printer

For parallel output of the printer

36-pin parallel interface

II UNIT EXPLANATION

7322ma2008

2-35

2

NETWORK SECTION

10.NETWORK SECTION

10.1 Composition

Item Function name Function Purpose Remarks

TCP/IP service Arp { Obtain IP address

II UNIT EXPLANATION

Netware service Bindery { Print

AppleTalk service

MS Network service

BootP { Obtain IP address

DHCP { Obtain IP address

DNS { Settle IP address

FTP Client { Scan to FTP

FTP Serve r { Scan to Box

IPP { Print Support Ver. 1.0

LPD/LPR { Print

Raw Socket { Print

SMTP { Scan to Email

POP { For POP before SMTP

POP before SMTP { Authorization of SMTP

server access

HTTP 1.1 { WebUtility

SNMP v1

(SNMP over TCP)

SNMP v1

(

SNMP over IPX

Telnet X

SLP X

NDS (including simul-

taneous support of

Bindery)

• PServer mode {

RPrinter/NPrinter mode

•

NDPS

PCONSOLE /NWAD-

MIN, interchangeable

Frame Type (802.3, 8-

02.3, 802.3 SNAP,

Ethernet II)

EtherTalk PAP { Print

SMB over NetBEUI X Print

(

Gateway

)

)

{ MIB access

{ MIB access

{ Print

{

{ Print Corresponding in general

{

{ MAC frame corre-

sponding

Default port number = 9100

purpose Gateway

2-36

11. OTHER CONTROLS

11.1 Parts Energized When the Main Power Switch is OFF

SW1

CBR1

AC(H)

OTHER CONTROLS

NF

CBR2

AC(N)

DCPS

The follwing components are powered regardless of whether the SW1 (Main power switch) is on or off,

provided that the power cord remains plugged in.

A. CBR 1 and CBR 2 (Circuit breakers/1 and /2)

The circuit breakers serve to protect internal components against damage from short circuit. If current

exceeds the specified value, the circuit breaker(s) will go off, cutting the power to the system.

B. NF (Noise filter)

This filter reduces noises that enter through the power line.

C. DCPS (DC power source)

This supplies power to each unit, and also controls the ON/OFF state of the fixing heater lamp.

II UNIT EXPLANATION

2-37

OTHER CONTROLS

11.2 Components Operated When the Power Switch is ON

11.2.1 Components operated when the SW1 (Main power switch) is on

In the case of the 7145

II UNIT EXPLANATION

SW2

PSW2B

7322ma2009

SW1

DCPS

+12VDC

-12VDC

+5VDC

+24VDC

SCB

PTC

(OPTION)

+12VDC

-12VDC

+5VDC

+12VDC

-12VDC

+5VDC

+12VDC

-12VDC

+5VDC

SGND

+5VDC

SUB_SW

OB

FK-102/FL-102

(OPTION)

IP-432

(OPTION)

Setting the SW1 (Main power switch) to the ON position supplies AC power to the DCPS (DC power

source) which in turn supplies +12DVC, -12VDC, and +5DVC to the SCB (System control board). The

DCPS also supplies +5DVC to the OB (Operation board) through the SCB.

When the PTC (Internal heater) is provided as an option for service parts, according to the setting of the

25 mode DIP SW16-2, +24VDC is supplied to the PTC (Heater) from the DCPS (DC power source).

If options such as a printer controller (IP-432) and/or fax control board (FK-102 Type A/FL-102) are

installed, +12VDC, -12VDC and +5VDC are also supplied to these options through the SCB (System con-

trol board).

In the automatic start-up mode, the same operation is made consecutively as when the SW2 (Sub power

switch) is turned on according to the discretion of the SCB (System control board).

2

2-38

In the case of the 7235/7228/7222

OTHER CONTROLS

SW2

PSW2B

7322ma2021

SW1

DCPS

+12VDC

+5VDC

+24VDC

SCB

PTC

(OPTION)

+12VDC

+5VDC

+12VDC

+5VDC

+12VDC

+5VDC

SGND

+5VDC

SUB_SW

OB

FK-103/FL-103

(OPTION)

IP-424

(OPTION)

Setting the SW1 (Main power switch) to the ON position supplies AC power to the DCPS (DC power

source) which in turn supplies +12DVC and +5DVC to the SCB (System control board). The DCPS also

supplies +5DVC to the OB (Operation board) through the SCB.

When the PTC (Internal heater) is provided as an option for service parts, according to the setting of the

25 mode DIP SW16-2, +24VDC is supplied to the PTC (Heater) from the DCPS (DC power source).

If options such as a printer controller (IP-424) and/or fax control board (FK-103/FL-103) are installed,

+12VDC and +5VDC are also supplied to these options through the SCB (System control board). How-

ever, when the LAN cables are not connected with none of these options provided, a part of the section

within the SCB (System control board) is not supplied with +5 VDC.

In the automatic start-up mode, the same operation is made consecutively as when the SW2 (Sub power

switch) is turned on according to the discretion of the SCB (System control board).

II UNIT EXPLANATION

11.2.2 Components operated when the SW2 (Sub power switch) is on

The SW2 (Sub power switch) is located on the PSW2B (Power SW2 board). Upon the SW2 on, an ON sig-

nal is sent from the SW2 to the SCB (System control board) through the OB (Operation board). As a result,

the SCB sends a control signal to the DCPS (DC power source), thus causing the DCPS to supply

+12VDC, -12VDC (7145 only) and +5VDC to all of the boards and options, including the CB (Main body

control board).

The SCB (System control board) then sends to the DCPS (DC power source) a control signal that causes

the DCPS to generate +24VDC. This 24VDC power is supplied to all of the drive boards and options.

2-39

2

OTHER CONTROLS

11.3 Fan Control

11.3.1 Composition of the cooling fan

II UNIT EXPLANATION

DCPS

FM2FM1

FM3 FM4 FM5 FM6 FM7

CB

Symbol Name Function or method

FM1 DC power supply cooling fan Cooling of the DCPS (DC power source)

FM2*1 Fixing cooling fan Preventing the ends of the fixing roller from getting overheated

FM3 Internal dehumidifying fan/1 Prevention of internal dew condensation, removal of internal

ozone, and prevention against internal temperature getting too

high

FM4 Internal cooling fan/1 Cooling of the drum unit, the write unit and their surroundings

FM5 Developing suction fan Prevention against scattering of toner around the developing unit

FM6 Internal dehumidifying fan/2 Prevention of internal dew condensation, removal of internal

ozone, and prevention against internal temperature getting too

high

FM7*2 Internal cooling fan/2 Cooling of the interior of the developing unit

FM7*3 Polygon cooling fan Cooling of the M5 (Polygon motor)

*1 7145/7235 only

*2 7145 only

*3 7235 only

2

2-40

11.3.2 Fan operation

A. Operation of fans other than FM4 (Internal cooling fan/1)

[1]

M1 (Main motor)

M3 (Developing motor)*2

FM1 (DC power source fan)

FM2 (Fixing cooling fan)*1

FM3 (Internal dehumidifying fan/1)

FM5 (Developing suction fan)

FM6 (Internal dehumidifying fan/2)

OTHER CONTROLS

FM7 (Internal cooling fan/2)*3

FM7 (Polygon cooling fan)*4

7322ma2014

[1] START button (ON)

*1 Operation for a small sized paper (such as B5R, A5R, B6R, postcard, 5.5 x 8.5R, 16KR). For paper

sizes other than these small ones, the fan turns on when the TH2 (Fixing temperature sensor/2)

detects a temperature above 417°F, and turns off when it gets below 408°F

*2 7145 only

In the case of the 7235/7228/7222, the operation of the fan, that is based on whether the M3 (Develop-

ing motor) turns ON or OFF while in the 7145, is based on whether the M1 (Main motor) turns ON or

OFF.

*3 7145 only

*4 7235 only

B. Operation of FM4 (Internal cooling fan/1)

(1) ON/OFF timing

The FM4 (Internal cooling fan/1) is turned on when the machine-inside temperature sensor provided

on the TCSB (Toner control sensor board) detects a temperature of 109°F, and turned off when the

temperature gets below 105°F.

II UNIT EXPLANATION

(2) Abnormality detection

The internal temperature sensor installed on the TCSB (Toner control sensor board) detects a temper-

ature of 136°F, error code F22-1 is displayed on the operation unit and the machine is stopped.

2-41

2

OTHER CONTROLS

11.4 Operation Unit Control

11.4.1 Composition of operation unit

II UNIT EXPLANATION

SW2

PSW2B

LCD

LCDB

INV2

PAKB

SP

(OPTION)

SCB

SGND

SUB_SW

OB

Symbol Name Function or method

SW2 Sub power switch Power switch for the operating section

Does not function when the SW1 (Main power switch) is off.

PSW2B Power SW2 board LED packaging to display the on/off status of the SW1 (Main

power switch)

LCD LCD Use to display various information

LCDB Display board Backlight for the LCD

INV2 Display inverter Inverter used to drive the LCD (Display board)

PAKB Panel key board Touch switch board used to directly select items displayed on the

LCD

SP Speaker When an optional fax control board is installed, a monitor sound

on the line while a call is being made.

OB Operation board Used to control the PSW2B (Power SW2 board), the LCD (Dis-

play board), the INV2 (Display inverter) and the PAKB (Panel key

board), and also used to control the LED inside the OB and the

ten-key

2

2-42

11.5 Counter Control

11.5.1 Counter composition

OTHER CONTROLS

SCB

OB

7145 7235/7228/7222

TC

CB

KC

(OPTION)

PS2

TC

(OPTION)

7322ma2011e

Symbol Name Function or method

OB Operation board Displays the number of copies by means of the LED.

TC Total counter

(7145 provided as a standard equipment)

Displays the total number of copies.

This is a mechanical counter driven by an electric signal.

(7235/7228/7222 optional)

KC Key counter (optional) A counter used to make copying unavailable after the

specified number of copies is counted

This is a mechanical counter driven by an electric signal.

PS2 Fixing exit sensor Detects paper at the fixing exit. This information

becomes a control signal source for each counter.

Photosensor + actuator

II UNIT EXPLANATION

11.5.2 Counter operation

This machine uses the following two software counters to count the number of copies. However, the con-

tent of the number display counter on the OB (Operation board) may differ depending on the operating

condition of the machine.

A. Paper feed counter

This counter increments when the 1st paper feed for the next copy comes ON.

B. Paper exit counter

This counter increments when the PS2 (Fixing exit sensor) goes ON → OFF.

C. Number display counter on the OB (Operation board)

Normal operation Jam

Indicator shows a count from the paper feed counter. Indicator shows a count from the paper exit counter.

2-43

2

OTHER CONTROLS

II UNIT EXPLANATION

Blank page

2-44

III DISASSEMBLY/ASSEMBLY

Caution:

• Make sure the power cord of the copier is

unplugged from the power outlet before dis-

assembly or assembly.

1. EXTERNAL SECTION

1.1 Replacing the Ozone Filter

A. Periodically replaced parts/cycle

• Ozone filter: Every 240,000 copies (7145)

• Ozone filter: Every 200,000 copies (7235/7228/

7222)

B. Procedure

1. Remove the 4 screws [1], and remove the scan-

ner exterior/R [2].

EXTERNAL SECTION

[1]

Note:

• If an unusual noise is emitted when you open or

close the bypass tray, clean the ADU door rib [3]

with alcohol.

2. Remove the ozone filter [1].

3. Reinstall the above parts following the removal

steps in reverse.

Note:

• When installing the ozone filter, take care not to

break it.

III DIS./ASSEMBLY

[1]

[2]

[3]

3-1

[1]

2

EXTERNAL SECTION

1.2 Replacing the Filter Cover Assembly & Suction Filter/A

A. Periodically replaced parts/cycle

• Suction filter/A: Every 120,000 copies (7145)

• Suction filter/A: Every 100,000 copies (7235/

7228/7222)

• Filter cover assembly: Every 120,000 copies

(7145)

• Filter cover assembly: Every 100,000 copies

(7235/7228/7222)

B. Procedure

1. Remove the screw [1], then remove the filter

cover assembly [2].

2. Remove the suction filter /A [3].

3. Reinstall the above parts following the removal

steps in reverse.

[1]

Note:

• When installing the suction filter/A, be sure to

install it so that the white filter face is turned to the

inside of the main body.

III DIS./ASSEMBLY

Note:

• When an elevator tray unit is fitted, perform the

following to access the filter section.

• While pressing [1], lift up [2], and pull out the ele-

vator tray unit and the horizontal conveyance unit.

Do not remove the finisher.

To remove the finisher, see [III. DISASSEMBLY/

ASSEMBLY] of the finisher section.

[3]

[2]

[1]

[2]

2

3-2

7145ma3130

2. DRIVE SECTION

2.1 Removing and Reinstalling
the Motor Units (Main, Fix­ing, Feed, Developing)

Caution:

• Be sure to remove the drum unit from the

main body before removing or reinstalling

the main motor unit. If the drum unit is in

place at this time, the drum will rotate when

you install or remove the drum rotating plate,

resulting in possible damage to the cleaning

blade.

A. Procedure

1. Remove the developing unit and drum unit from

the main body.

2. Remove the screw [1], and remove the cord

cover/B [2].

3. Remove the 2 screws [3], and remove the cord

cover/A [4].

4. Remove the 9 screws [5], and remove the rear

cover [6].

DRIVE SECTION

2

[6]

[5]

III DIS./ASSEMBLY

5. Remove the 2 screws [1], and remove the rear

cover/R [2], the rear cover/L [3].

6. Remove the 3 screws [4], and remove the wire-

bundle guide plate [5].

[1]

[5]

[2]

[3]

[2][4]

[4]

[1]

7322ma3001

[3]

[1]

3-3

2

DRIVE SECTION

7. Remove the 15 screws [1], and remove the

board cover/D [2] (7145 only).

8. Remove the 13 screws [3], and remove the

board cover/A [4].

9. Remove the various wiring connectors from the

SCB (System control board) [1].

Note:

• Be very careful when handling the ribbon cable

connector from the SCB (System control board).

See “2.4 Removing the ribbon cable” and “2.5

Installing the ribbon cable”.

[4]

[1]

[1]

[3]

2

[2]

[1]

[2] [3]

III DIS./ASSEMBLY

10. Remove the 12 screws [2] (7145) or the 11

[2]

screws [3] (7235/7228/7222), and remove the

system control board unit [4].

[2] [3]

[4]

[2] [3]

7322ma3002

11. Disconnect the connectors from each motor unit

[1].

12. Remove the 4 screws [2], then remove each

motor unit [3], [4] (7145 only), [5].

[1]

2

[3]

[2]

[1]

[2]

[3]

13. Reinstall the above parts following the removal

steps in reverse.

[4]

[2]

[1] [5]

7322ma3003

2

3-4

2.2 Replacing the Registration
Clutch

Caution:

• Be sure to remove the drum unit from the

main body before carry out the following pro-

cedure. If the drum unit is in place at this

time, the drum will rotate when you install or

remove the drum rotating plate, resulting in

possible damage to the cleaning blade.

A. Procedure

1. Remove the system control board unit.

• For removal procedure, see “2.1 Removing and

reinstalling the motor units (main, fixing, feed,

developing)”.

2. Remove the set screw [1], and remove the drum

rotating plate [2].

DRIVE SECTION

[2]

3. Remove the clutch connector [1].

4. Remove the E-ring [2]. Pull the registration

clutch [3] toward you and rotate it to remove.

[1]

III DIS./ASSEMBLY

[3]

[1]

[2]

3-5

DRIVE SECTION

5. Reinstall the above parts following the removal

Note:

• When installing the registration clutch [1], be sure

to set the groove of the clutch detent in the stop-

per [3].

2.3 Replacing the Loop Clutch

A. Procedure

1. Remove the system control board unit.

• For removal procedure, see “2.1 Removing and

2. Remove the wire bundle from the clamp on the

III DIS./ASSEMBLY

3. Remove the 2 E-rings [2], 3 screws [3] and 2

steps in reverse.

reinstalling the motor units (main, fixing, feed,

developing)”.

conveyance drive panel [1].

bearing [4] , and remove the conveyance drive

panel [1]. (Do not remove the rotation preven-

tion screws on the clutch.)

[2][3]

[1]

[1]

[3]

[4]

[2]

4. Remove the E-ring [1], then remove the gear [2]

and the connector [3], remove the gear [4] at the

front, and then remove the clutch [5].

5. Reinstall the above parts following the removal

steps in reverse.

3-6

[4]

[3]

[1]

[5]

[2]

2.4 Removing the Ribbon Cable

A. Procedure

1. Move the lock lever [1] forward to release the

lock, then pull out the ribbon cable [2].

DRIVE SECTION

[2]

[1]

III DIS./ASSEMBLY

3-7

DRIVE SECTION

2.5 Reinstalling the Ribbon Cable

A. Procedure

1. Move the lock lever [1] forward, then insert the

ribbon cable [2] firmly into the connector while

ensuring that the conductive face of the ribbon

cable [3] is positioned on the opposite side of

the lock lever.

[2]

[1]

2. Push back the lock lever [1] to lock the ribbon

III DIS./ASSEMBLY

cable [2].

[2]

[1]

[3]

3-8