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.
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 precautionElectric hazardHigh temperature
General prohibitionDo 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
TH1TH2
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