SERVICE MANUAL
Models
7145/7222/7228/7235
APRIL 2004
CSM-7145/7222/7228/7235
KONICA MINOLTA BUSINESS SOLUTIONS U.S.A., INC.
Return to Main Form
CONTENTS i I OUTLINE II UNIT EXPLANA TION III DIS./ASSEMBL Y 2
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 . . . C. Copy paper . . . D. Machine data . . . E. Maintenance . . . F. Consumables. . . G. Operating environment . . .3. CENTER CROSS SECTION . . . 4. DRIVE SYSTEM DIAGRAM . . . 4.1 Drum drive . . . 4.2 Cleaning/Developer agitation drive . . .
4.3 Fixing/Paper exit section/IT-101/RU-101 drive . . .
4.4 Developing drive . . .
4.5 Paper feed drive . . .
4.5.1 Drive from paper feed motor to loop clutch . . .
4.5.2 Tray 1 drive . . .
4.5.3 Tray 2 drive . . .
4.5.4 Bypass feed drive . . .
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
CONTENTS ii I OUTLINE II UNIT EXPLANA TION DIS./ASSEMBL Y 2
II
UNIT EXPLANATION
1. SCANNER SECTION . . . 2-1.1 Composition . . . 2-1.2 Operation . . .2-1.2.1 Initial operation when power is turned on and shading correction reading. . .
2-1.2.2 Original reading mode . . .
2-1.2.3 Original read control . . .
2-1.2.4 APS control. . . 2-1.2.5 AE control . . . 2-1.2.6 Image processing . . . 2. WRITE UNIT . . . 2-2.1 Composition . . . 2-2.2 Operation . . . 2-1 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
CONT I OUTLINE II UNIT EXPLANA TION III DIS./ASSEMBL Y 2 9. INTERFACE SECTION . . . 9.1 Composition. . . 10. NETWORK SECTION . . . 10.1 Composition. . . 11. OTHER CONTROLS . . . 11.1 Parts energized when the main power switch is off. . . 11.2 Components operated when the power switch is on . . .
11.2.1 Components operated when the SW1 (Main power switch) is on . . .
11.2.2 Components operated when the SW2 (Sub power switch) is on . . .
11.3 Fan control. . .
11.3.1 Composition of the cooling fan . . .
11.3.2 Fan operation . . .
11.4 Operation unit control . . .
11.4.1 Composition of operation unit . . .
11.5 Counter control . . .
11.5.1 Counter composition . . .
11.5.2 Counter operation . . . 2-43
III DISASSEMBLY/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
CONTENTS I OUTLINE II UNIT EXPLANA TION III DIS./ASSEMBL Y 2
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
SAFETY AND IMPORTANT WARNING ITEMS
S-17 3
3. Rear/Left side (7235/7228/7222 only)
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.
7322sf005e
SERVICE MANUAL
Models
7145/7222/7228/7235
Service Section
APRIL 2004
CONTENTS i I ADJUSTMENT IV DIAGRA 3
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
I
ADJUSTMENT
1. HOW TO USE THE ADJUSTMENT SECTION . . . 1-1
1.1 Composition. . . 1-1
2. ADJUSTMENTS WHEN REPLACING PARTS . . . 1-1 3. LIST OF ADJUSTMENT ITEMS . . . 1-2 4. CE PASSWORD SETTING . . . 1-4 5. MODE CHANGE MENU . . . 1-4
5.1 Setting method . . . 1-4
6. CHECKING BY THE COUNTER KEY FUNCTION . . . 1-5
6.1 Checking method of the counter key function . . . 1-5
7. 25 MODE . . . 1-6
7.1 Setting method . . . 1-8
7.2 Setting software DIPSW . . . 1-8
7.3 PM count setting . . . 1-30
7.3.1 PM count reset . . . 1-30
7.3.2 Entering PM count start date . . . 1-30
7.3.3 Setting of PM cycle . . . 1-30
7.3.4 Counter clear . . . 1-30
7.4 Data collection . . . 1-31
7.5 Copy count for each part to be replaced . . . 1-37
7.5.1 Copy count by parts to be replaced (fixed). . . 1-37
7.5.2 Copy count by parts to be replaced (Named; arbitrarily) . . . 1-39
7.6 Password setting . . . 1-41
7.7 Setting phone number of the service center . . . 1-42
7.8 Setting the serial number/the destination . . . 1-42
7.8.1 Setting the serial number . . . 1-42
7.8.2 Setting the destination . . . 1-43
7.9 Displaying the ROM version . . . 1-43
7.10 KRDS setting . . . 1-43 7.11 ISW setting . . . 1-43 7.12 Root counter display . . . 1-43 7.13 Setting date . . . 1-44 7.14 Tray size setting . . . 1-44
CONTENTS ii II ISW III SER VICE IV DIAGRAMS 3 8. 36 MODE . . . 1-45 8.1 Setting method. . . 1-45 8.2 Process adjustment . . . 1-45 8.3 L detection adjustment. . . 1-46
8.4 Toner density adjustment. . . 1-46
8.5 Dot diameter adjustment . . . 1-47
8.6 LD1 offset adjustment . . . 1-47
8.7 LD2 offset adjustment (7145 only) . . . 1-48
8.8 Timing adjustment . . . 1-49
8.8.1 Vertical/Horizontal magnification adjustment . . . 1-49
8.8.2 Restart timing adjustment . . . 1-52
8.8.3 Paper feed loop amount adjustment. . . 1-54
8.8.4 Leading edge original erasure adjustment . . . 1-55
8.8.5 Centering adjustment . . . 1-56
8.8.6 Image read point adjustment . . . 1-58
8.8.7 Recall standard data. . . 1-59
8.9 Running test mode. . . 1-59
8.9.1 Setting method . . . 1-60
8.10 Test pattern output. . . 1-60 8.11 Test pattern density adjustment. . . 1-65 8.12 Image quality adjustment . . . 1-65
8.12.1 RADF scanning density adjustment . . . 1-65
8.12.2 Non-image area erase check . . . 1-66
8.13 List print . . . 1-67 8.14 Counter clear . . . 1-68 8.15 Adjustment of RADF . . . 1-68
8.15.1 Vertical magnification adjustment in RADF system . . . 1-68
8.15.2 Adjustment of restart timing . . . 1-69
8.15.3 Paper feed loop adjustment . . . 1-70
8.15.4 Centering adjustment . . . 1-70
8.15.5 RADF scanning density adjustment . . . 1-71
8.15.6 RADF image read point adjustment . . . 1-71
8.16 FNS adjustment (FS-112 only) . . . 1-71 8.17 FNS adjustment (FS-114 only) . . . 1-72
8.17.1 Fold & Stitch position adjustment (SK-114) . . . 1-72
8.17.2 Fold position adjustment (SK-114) . . . 1-73
8.17.3 Punch position adjustment (PK-114) . . . 1-73
8.17.4 Punch loop adjustment (PK-114) . . . 1-74
9. 47 MODE . . . 1-76
9.1 47 mode setting method . . . 1-76
9.2 RADF original size detection . . . 1-77
9.3 Bypass size detection adjustment . . . 1-77
9.4 Action for mounting when reinstalling the HDD . . . 1-77
9.5 Input check list . . . 1-78
9.6 Output check list . . . 1-84
10. OTHER ADJUSTMENTS . . . 1-89 10.1 RADF height adjustment . . . 1-89
CONTENTS iii I ADJUSTMENT II ISW III SER VICE IV DIAGRAMS
10.2 RADF distortion adjustment. . . 1-90 10.3 RADF original skew adjustment (front side) . . . 1-91 10.4 RADF original skew adjustment (back side) . . . 1-92 10.5 DB-411 paper-centering adjustment . . . 1-94 10.6 DB-411 tray tilt adjustment . . . 1-95 10.7 LT tray tilt adjustment . . . 1-96 10.8 FS-113 Output Check Mode . . . 1-98 10.9 Lengthwise position adjustment of punch hole of FS-113 . . . 1-103 10.10Adjustment of FS-113 Solenoids . . . 1-104 10.11FS-113 Timing Belt Tension Adjustment . . . 1-105 10.12FS-113 Adjustment of the Elevator Tray Upper Limit Sensor . . . 1-106 10.13Adjustment of FS-113 Elevator Tray Overload Detection Level . . . 1-107 10.14Staple Position Adjustment of FS-114. . . 1-108 10.15Adjustment of the Installation Position of the Shutter Drive Gear of FS-114. . . 1-109 10.16Punch Hole Deviance Adjustment of FS-114 (PK-114). . . 1-110 10.17Fold Angle Adjustment of SK-114 . . . 1-111 10.18Staple Angle Adjustment of SK-114 . . . 1-112
II
ISW
1. DESCRIPTION OF THE ISW . . . 2-1 2. SETUP . . . 2-1 3. USB ISW. . . 2-5
III SERVICE
1. SERVICE SCHEDULE . . . 3-1 1.1 Service schedule . . . 3-1 1.1.1 7145 . . . 3-1 1.1.2 7235 . . . 3-2 1.1.3 7228/7222 . . . 3-3 1.2 Maintenance items . . . 3-5 1.2.1 7145 . . . 3-5 1.2.2 7235/7228/7222 . . . 3-6 1.2.3 DF-318/320 . . . 3-7 1.2.4 DB-211/411 . . . 3-8 1.2.5 LT-203 . . . 3-8 1.2.6 FS-112 . . . 3-8 1.2.7 FS-113/RU-101 . . . 3-9 1.2.8 FS-114 . . . 3-9 1.2.9 PK-114 . . . 3-9 1.2.10 SK-114 . . . 3-10 1.2.11 BK-114 . . . 3-101.3 Periodic check items . . . 3-11
1.3.1 7145 . . . 3-11
1.3.2 7235/7228/7222 . . . 3-13
1.3.3 DF-318 . . . 3-15
1.3.4 DF-320 . . . 3-15
CONTENTS iv I ADJUSTMENT II ISW III SER VICE IV DIAGRAMS 3 1.3.5 DB-211 . . . 3-16 1.3.6 DB-411 . . . 3-16 1.3.7 LT-203 . . . 3-16 1.3.8 FS-112 . . . 3-17
1.4 Replacement parts list . . . 3-18
1.5 Important maintenance parts . . . 3-20
2. 1 PM PARTS KIT . . . 3-21 3. SERVICE MATERIALS LIST . . . 3-22 4. CE TOOLS LIST . . . 3-23
IV DIAGRAMS
1. PARTS LAYOUT DRAWING . . . 4-1
1.1 Main body parts layout drawing . . . 4-1
1.2 DF-318/320 parts layout drawing. . . 4-14
1.3 DB-211 parts layout drawing . . . 4-15
1.4 DB-411 parts layout drawing . . . 4-16
1.5 LT-203 parts layout drawing . . . 4-17
1.6 FS-112 parts layout drawing . . . 4-18
1.7 RU-101 parts layout drawing . . . 4-21
1.8 IT-101 parts layout drawing . . . 4-21
2. CONNECTOR LAYOUT DRAWING . . . 4-22
2.1 Main body connector layout drawing . . . 4-22
2.2 DF-318/320 connector layout drawing . . . 4-28
2.3 DB-211 connector layout drawing . . . 4-28
2.4 DB-411 connector layout drawing . . . 4-29
2.5 LT-203 connector layout drawing. . . 4-29
2.6 FS-112 connector layout drawing . . . 4-30
2.7 RU-101 connector layout drawing . . . 4-30
3. JAM CODE LIST . . . 4-31 4. ERROR CODE LIST . . . 4-39
4.1 Error code list. . . 4-39
4.2 About abnormal units isolation. . . 4-73
4.3 L detection error code list. . . 4-74
4.4 Network section status indication. . . 4-74
5. TIMING CHART . . . 4-75
5.1 7145 timing chart . . . 4-75
5.2 7235/7228/7222 timing chart . . . 4-76
5.3 7145 ADU timing chart. . . 4-77
5.4 7235/7228/7222 ADU timing chart. . . 4-78
5.5 DF-318/DF-320 timing chart . . . 4-79 5.6 DB-211/DB-411 timing chart . . . 4-81 5.7 LT-203 timing chart . . . 4-82 5.8 FS-112 timing chart . . . 4-83 5.9 FS-113 timing chart . . . 4-85 5.10 FS-114 timing chart . . . 4-89 5.11 SK-114 timing chart . . . 4-91 6. OVERALL WIRING DIAGRAM . . . 4-93
CONTENTS v ADJUSTMENT IV DIAGRAMS 3
6.1 DF-318/320 Overall Wiring Diagram . . . 4-93
6.2 DB-211/411 Overall Wiring Diagram . . . 4-94
6.3 LT-203 Overall Wiring Diagram . . . 4-95
6.4 FS-112 Overall Wiring Diagram. . . 4-97
6.5 RU-101 Overall Wiring Diagram . . . 4-99
6.6 FS-113 Overall Wiring Diagram. . . 4-101
6.7 SK-114 Overall Wiring Diagram . . . 4-103
7. APPENDIX
7.1 7145 Overall Wiring Diagram (1/4) . . . Appendix-1
7.2 7145 Overall Wiring Diagram (2/4) . . . Appendix-2
7.3 7145 Overall Wiring Diagram (3/4) . . . Appendix-3
7.4 7145 Overall Wiring Diagram (4/4) . . . Appendix-4
7.5 7235/7228/7222 Overall Wiring Diagram (1/4) . . . Appendix-6
7.6 7235/7228/7222 Overall Wiring Diagram (2/4) . . . Appendix-7
7.7 7235/7228/7222 Overall Wiring Diagram (3/4) . . . Appendix-8
7.8 7235/7228/7222 Overall Wiring Diagram (4/4) . . . Appendix-9
7.9 FS-114 Overall Wiring Diagram. . . Appendix-11
