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SERVICE HANDBOOKPLAIN PAPER COPIER 65/5560

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Copyright TOSHIBA CORPORATION 1995ALL RIGHTS RESERVED

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65/5560 PRECAUTIONS 1 MAY.1997 © TOSHIBA CORP.

GENERAL PRECAUTIONS REGARDING THE INSTALLATION AND

THE SERVICE OF THE 6560

1. Transportation/Installation

• When transporting the copier, move it by the casters while lifting the stoppers.

The copier is quite heavy and weighs approximately 230 kg (507 lb); therefore, pay full attention

when handling it.

2. Installation

• Be sure to use a dedicated outlet with AC 115V/15A (220V, 230V, 240V/10A) or more for the

power source.

• The copier must be grounded for safety.

Never ground it to a gas pipe or a water pipe.

• Select a suitable place for installation.

Avoid excessive heat, high humidity, dust, vibration and direct sunlight.

Also provide proper ventilation as the copier emits a slight amount of ozone.

• To insure adequate working space for copying operations, keep a minimum clearance of 80 cm

(32") on the left, 80 cm (32") on the right and 10 cm (4") in the rear.

3. Service of Machines

• Basically, be sure to turn the main switch off and unplug the power cord during service.

• Be sure not to touch high temperature sections such as the exposure lamp, the fuser unit, the

damp heater and their periphery.• Be sure not to touch high-voltages sections such as the chargers and the high-voltage transformer.

• Be sure not to touch rotating/operating sections such as gears, belts, pulleys,etc.

• When servicing the machines with the main switch turned on, be sure not to touch live sections

such as the lamp terminal etc.

• Use suitable measuring instruments and tools.

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65/5560 PRECAUTIONSMAY.1997 © TOSHIBA CORP. 2

4. Main Service Parts for Safety

• The thermofuse,thermistor,fuse,breaker and door switches,thermostat etc. are particularly important

for safety.Be sure to handle/install them properly.

5. Notice Labels

• Be sure to check the rating plate and the notice labels such as "Unplug the power cord during

service" ,"Hot area" ,etc. to see if there is any dirt on their surface or if they are properly stuck to

the copier during servicing.

6. Disposition of Consumable Parts/Packing Materials

• Regarding the recovery and disposal of the copier, supplies, consumable parts and packing

materials, it is recommended to follow the relevant local regulations or rules.

7. When parts are disassembled, reassembly is basically the reverse of disassembly unless otherwise

noted in this manual or other related documents. Be careful not to reassemble small parts such as

screws, washers, pins, E-rings, toothed washers in the wrong places.

8. Basically, the machine should not be operated with any parts removed or disassembled.

9. Precautions Against Static Electricity

• The PC board must be stored in an anti-electrostatic bag and handled carefully using a wristband,

because the ICs on it may be damaged due to static electricity.

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65/5560 SPECIFICATIONS 1-1 MAY.1997 © TOSHIBA CORP

1. SPECIFICATIONS, ACCESSORIES AND OPTIONS

1.1 Specifications

1.2 Accessories

1.3 Options

1.4 System List

COSMOS

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Texts from 1-1 to 1-5 in the 6560 Service Handbook

are the same as texts from 1-1 to 1-5 in the 6560

Service Manual .

Do you refer to the 6560 Service Manual ?

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65/5560 ADJUSTMENT MAY.1997 © TOSHIBA CORP.2-1

2. ADJUSTMENT

2.1 TOSHIBA Supplies List

COSMOS

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65/5560 ADJUSTMENTMAY.1997 © TOSHIBA CORP. 2-2

2.2 List of Adjustment Jigs Used

COSMOS

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When either the CLEAR PAPER( )or CALL SERVICE( ) symbol appears,press the CLEAR/

STOP and "8"keys simuitaneously and the corresponding error code will be displayed.To clear the

error code,turn off the power.

Code Machine status

E1 Paper jam inside thr copier

E2 Paper jam near fuser unit

E3 Paper remaining inside the copier when the main switch is turned on

E4 The front cover is opened during copying

E5 Paper misfeed in LCF and manual feeding and paper jam in front of the aligning roller

E8 Paper misfeed (ADD)

E9 Paper misfeed (pedestal)

EC Paper misfeed (ADF)

ED Paper misfeed in ADF transport unit

EE Paper misfeed in ADF exit/reverse unit

C3 Abnormal serial transmission between main CPU and sub-CPU

C5 The optical system will not initialise;the optical system is locked

C7 Heat roller thermistor is open-circuited,

CB ADF feed motor locked

CC ADF transport motor locked

A0 Abnormal signal transmission in PFC interface

A1 Faulty charger wire cleaning operation

A2 ADD malfunction

A3 PFC (paper feed controller) malfunction

A4 Sorter malfunction

A5 Abnormal signal transmission between main CPU and IPC

A6 Abnormal signal transmission in sorter interface

A7 Abnormal signal transmission in ADF interface

A9 Blown exposure lamp or defective AES

2.3 Error Codes

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2.4 DIP Switch/Jumper/VR Functions

(1) Logic PC board

JP1

PWA-F-LGC-154/155

Jumper Name When shipped Remarks

JP1 UNT No jumper Jumper:Factory adjustment mode

(open) No jumper:Normal mode

Note: Replacement PC boards are supplied with the jumper

installed.

Be sure to cut it when replacing the PC boards.

(2) Paper feed control PC board

PWA-F-PFC-154/155

JP3(TP-SG)

VR2

VR1

R61

R60

VR FUNCTION

VR2 For adjustment ofthe paper width guide position of the

stack guide unit.

Note: Adjustoment procedure

Plus terminal of the tester Minus COM terminal of the tester Adjustment value VR

Aroow side of R60 JP3(TP-SG) 0~0.1V VR2

PWA-F-PFD-152

( T P -S G)

J P 2 5

R 3 9 V

R 2

R 1 9

V R 1

V R 3

R 4 0

(3) Paper feed drive PC board

VR Function

VR1 For adjustment of the PFP lower aligning value.

VR2 For adjustment of the PFP middle aligning value.

VR3 For adjustment of the PFP upper aligning value.

Note: Adjustment procedure

Plus teminal of the tester Minus COM terminal Adjustment value VRof the tester

Arrow side of R19 JP25(TP-SG) 0~0.1V VR1



ë ë ë

í í

ì

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(4) ADF logic PC board

1 2 3 4 5

PWA-F-LGC-758

Note: The independent operation mode is performed as in the following procedure;set the DIP switch 1

to its ON position and turn on the power.Select the menu of the independent operation mode and

then open and close the jam release cover or the ADF cover.

↑

At power on Duning independent operation mode

ON OFF ON OFF

1 Independent Normal mode Feeding mode Drive system

operation check mode

mode

2 Original set Original set Duplex Single-sided

by switchback by direct feeding mode feeding mode

stopping

3 USA/Canada Europe Aging mode Multifeeding

version version without paper mode

4 E2PROM Normal mode Not used Not used

initialigation

5 Not used Normal mode 2 in 1 mode OFF

DIP switch

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2.5 Self-Diagnosis Modes

Mode Input Definition Cleaning Display after selectionCode method

All-LEDs-lit "01" All LEDs on the control panel are lit. C/S

Aging mode "02" Aging (ADF does not operate) "09" AGING 100% 0

Test mode "03" Motor test and input/output check "09" TEST MODE C 100% C

Test mode "04" Motor test and input/output check "09" TEST MODE C 100% C

Adjustment "05" Adjustment of items "09" TEST MODE A 100% Amode

Forced ready "06" Forced entry of ready modemode

Aging mode "07" Aging (includes ADF) "09" AGING 100% 0

Setting mode "08" System switchover and setting of each "09" TEST MODE D 100% Dpriority mode,PM counter,etc.

Note: To access the desired diagnostic mode,turn on the power switch while pressing the appropriatekeys.

<Procedure>

•All-LEDs-lit mode(01):

0 1 / PWR All LEDs light C/S Exit

•Aging mode(02 or 07):

0 2 / PWR Aging C/S Exit

( 0 7 ) PRINT

•Test mode(03 or 04)

For these test modes,refer to 2.5.1 and 2.5.2.

•Adjustment mode(05):

For this mode,refer to"2.5.3 Adjustment Mode".

•Forced ready mode(06):

PWR 0 6 Forced ready

Note:This mode is for checking the paper feeding operation only.

•Setting mode(08):

For this mode,refer to"2.5.4 Setting mode".

Note: C/S : Press the CLEAR/STOP key

PWR : Turn on the power switch

INT : Press the INTERRUPT key

E/S : Press the ENERGY SAVER key

0 9

→ → →

→→→→

→ →

←

↑

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Quick reference chart for self-diagnostic mode

"P":PRINT key on."C":CLEAR/STOP key on.

*1: In case of "05"+

power on only*2: Copies cannot be made

"07"

(With ADF)"01"*2

"02"

"C"

"06"

*1

Warming up

Standby

Aging Test modeAll the displays onthe control panel llt

Adjustmentmode Setting mode

"03/04" "05" "08"

Power On

"09""C""P" "09" "09"

"05"Stops momentarily

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BVD1

Battery

living

2.5.1 Input Signal Check (03/04)

In the "03" or "04" test mode, the following input signal conditions can be checked by pressing the

appropriate keys.

Note:*:Only for machines which have an optional IC card installed

lWhen automatic exposure is selected

(1)key

(2)key

(3)key

(4)key

(5)key

(6)key

(7)key

(8)key

(9)key

ADD-PEM-SW

Paper

loaded

EMP2-SW

Paper

loaded

EMP3-SW

Paper

loaded

EMP4-SW

Paper

loaded

TUP4-SW

Top

position

GUIDE-HOME-SW

Home

position

TUP2-SW

Top

position

TUP3-SW

Top

position

ADD-STP-SW

Paper

loaded

PSTP2-SW

Paper

loaded

PSTP3-SW

Paper

loaded

PSTP4-SW

Paper

loaded

T-DWN-SW

Bottom

position

R-DOOR-SW

Opened

WP

Write

protect

TNR-HOP-SW

Opened

HOME-SW

Home

position

LNS-SW

Home

position

EXIT-SW

Paper

loaded

L-DOOR-SW

Opened

M-FEED-SW

Paper

loaded

ADD-JAM-SW

Paper

loaded

TNR-EMP-SW

Toner emptyCLN-T-SW

On

APS-C

Paper loadedAPS-F

Paper loaded

STP-HOME-SW

Home

position

FEED2-SW

Paper loaded

FEED3-SW

Paper loaded

FEED4-SW

Paper loaded

LCF-EMP-SW

Paper loaded

T-UP-SW

Top position

ADD-STR-SW

Paper loaded

P-STP-SW

Paper

loaded

LCF-FEED-SW

Paper

loaded

CNT(JPI)

Connected

CTRSIG

Connected

DF-CNT

Connected

CST2-SW

Cassette

loaded

LCFDOOR

Closed

CST3-SW

Cassette

loaded

MRR-SW

On

CLN-M-SW

ON

DEV-SW

ConnectedCD

IC card

lWhen manual exposure is selected

REG-SNS

Paper

loaded

EMP-SNS

Paper

loaded

SIZE-SNS

Paper

loaded

TURN-SNS

Paper

loaded

DF-OPN-SW

COVER-SW

Opened

(1)key

(0)key

Original-size LEDCopy-size LED

A4/LD A3/LG B4/LT A5/ST A4/LD A3/LG B4/LT A5/ST

A4/LD A3/LG B4/LT A5/ST A4/LD A3/LG B4/LT A5/ST

Original-size LEDCopy-size LEDIndicatorLEDkeyOperation

IndicatorLEDkey

OperationBVD2

Battery's

life

T-FUL-SW

Toner full

APS-STR-SW

Closed

CST4-SW

Cassette

loaded

LCFKEY

On

LCF

LCF loaded

∗ ∗ ∗ ∗

UNIVERSAL/OTHER

UNIVERSAL/OTHER

<Procedure>

0 3 PRINT EXP Digital key PWR OFF 0 9

PWR (To clear)

Note: 03 →With initialization before test mode is entered

04 →Without initialization

(

→ → → →↑

→

A4(LD)

ORIGINAL COPY

A3(LG)

B4(LT)

A5(ST)

UNIVERSAL

(OTHER)

means that when the particular key is pressed and the

condition shown exists,the LED will light.(Input signal is "H" level)

means that the LED does not light if the condition shown

exists.(Input signal is "L"level)

•

•

UNIVERSAL/ OTHER

UNIVERSAL/ OTHER

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2.5.2 Output Signal check (03/04)

In the "03"or"04"test mode,the folloeing output signal conditions can be checked by entering appropiate

codes.

Code Function Stop code

1 DRM-MOT ON 11 OFF2 FED-MOT ON 12 OFF3 RGT-MOT ON 13 OFF4 HTR-MOT ON 14 OFF5 DEV-MOT ON 15 OFF6 TNR-MOT ON 16 OFF7 OPT-FAN-MOT HIGH 17 LOW8 EXIT-FAN-MOT HIGH 18 LOW9 AUG-MOT ON 19 OFF41 ADD-FED-MOT ON 51 OFF42 ADD-RGT-MOT(Stack) ON 52 OFF43 ADD-RGT-MOT(Feed) ON 53 OFF61 PD-MOT ON 71 OFF62 FD2-CLT

FD3-CLT ON 72 OFFFD4-CLT

63 RGT2-CLTRGT3-CLT ON 73 OFFRGT4-CLT

65 DEV-FAN ON 75 OFF67 BTM-FAN HIGH 77 LOW68 CH-FAN

HTR-FANON 78 OFF

20 SCN-MOT21 LNS-MOT22 MRR-MOT23 CLN-MOT24 DCM-MOT25 CLN-TR-MOT Changes direction

26 TRAY-MOT(LCF) each time the PRINT45 STOP-MOT key is pressed.46 GUIDE-MOT64 TR2-MOT(PFP)

TR3-MOT(PFP)TR4-MOT(PFP)

*8

Group3

Code Function

30 HV-M ON/OFF(Main charger output)

31 HV-TR ON/OFF(Transfer charger output)

32 HV/AC ON/OFF(Transfer charger output)

33 EXP-LAMP ON/OFF34 GBIAS ON/OFF

(Transfer bias output)35 PRE-TR-C4 ON/OFF37 SCRP-SOL ON/OFF38 MANUAL-SOL ON/OFF48 ADD-SOL ON/OFF49 GATE-SOL ON/OFF81 ADF-FEED-MOT(CW) ON/OFF82 ADF-FEED-MOT(CCW) ON/OFF83 ADF-CLU ON/OFF

ADF-BELT-MOT(CW)84 ADF-CLU ON/OFF

ADF-BELT-MOT(CCW)85 ADF-FEED-MOT(CCW) ON/OFF

ADF-BELT-MOT(CW)ADF-CLU

86 STP-SOLFLP-SOL ON/OFFADF-CLUBRKE

*1

*2

*2

Group1

*3

*4*5*6*7

Gro

up2

*1 The feed motor will rotate in the direction appropriate for the cassette loaded at the time of the output signalcheck.

*2 For FD2~4-CLT and RGT2~4-CLT,the clutch appro priate for the cassette loaded at the time of the output signalcheck will be driven.

*3 The scanning motor will run at the correct speed for the reproduction ratio selected(and displayed)at the time ofthe output signal check.

*4 The tray motor moves the tray up when the PRINT key is pressed once,and is turned off when the tray-up switchis turned on.When the PRINT key is pressed a second time,it moves the tray down and is turned off when thetray-down switch is turned on.

*5 The length guide motor performs initalisation when the PRINT key is pressed once.When the PRINT key ispressed a second time, it moves the paper length guide to the widest setting position and then is turned off.Whenthe PRINT key is pressed a third time,it moves the paper length guide in for a narrow setting and is turned offwhen the length guide home switch is turned on.

*6 The width guide motor widens the paper width guide when the PRINT key is pressed once and is turned off whenthe width guide home switch is turned on.When the PRINT key is pressed a second time,it narrows the paperwidth guide until the A4-R size position and then is turned off.When the PRINT key is pressed a third time,it,widensthe guide until the A3 size position and is turned off.

*7 For TR2 to 4-MOT,the motor appropriate for the cassette loaded at the time of output signal check is chosen.Whenthe PRINT key is pressed once, the motor moves the tray up and is turned off when TUP2 to 4-SW is turnedon.When the PRINT key is pressed a second time,it moves the tray down and is turned off after a set time lag.

*8 The exposure lamp stays on for 5 sec.and then goes off automatically.

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<Procedure>

Group(1)

0 3 / 0 4 Operation Stop

PWR (ON) Code

Group(2)

0 3 / 0 4 Operation C/S Test mode standby

PWR (one-way) 0 9 Warm-up

Group(3)

0 3 / 0 4 Operation Operation C/S

PWR (ON) (OFF) 0 9 Warm-up

Code PRINT PRINT 0 9 Warm-UP

Code PRINT

Code PRINT PRINT

Test modestandby

↓

↓ ↓

↓ ↓

→ → → → → → →

→ → →→

→

→

→

→

→

→

→

→→→→→

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Adjustment item Code Keys to adjust with keys to store with Remarks

Auto-toner sensor 0 Zoom keys INTERRUPT See 2.6 for details.

Exposure 1~10 Digital keys/ INTERRUPT See 2.7 for details.

14~17 ZOOM keys

*Automatic adjustment 49 Not needed Not needed See 2.7 for details.

for exposure

HVT output 38~40,41,44 ZOOM keys INTERRUPT See 2.10 for details.

Registration 53~58 Digotsl keys INTERRUPT See 2.8.5 for details.

Other adjustment Except for Digital keys INTERRUPT Refer to Adjustment

above codes code list

0 5

PWRCode PRINT ADJUST INT E/S 0 9

0 5

PWR49 PRINT 0 9

Automatic adjustment

for automatic exposure

<Procedure>

ExitTest copy

Exit

↓ → → → → → →

→→ →→

↑

∗

2.5.3 Adjustment Mode (05)

In this mode,the following adjustment items can be corrected or changed(see the Adjustment Code

List for "05"Mode). To access this code,turn on the power while pressing the "0"and"5"keys.

Memory set

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Adjustment Code List ("05")

•The larger the value,the larger the sensor output,•About 3 minutes after this mode has been started,thisvalue changes automatically to make the sensor output2.45V~2.55V.

•The larger the value,the lighter the image.•The adjustment sequence must be1→2→3→4→5→6→7→8→9→10.

The larger the value,the lighter the light range.

The smaller the value,the darker the dark range.

•The larger the value,the lighter the image.•The adjustment sequence must be 14→15→16→17.

Each time the numerical value is increased by "1",thereproduction ratio in the movement direction increasesby approximately 0.15%.Range;-1.17%(reduction)to +1.05%(enlargement)

Each time the numerical value is increased by"1",thereproduction ratio in the movement direction increasesby approximately 0.10.Range:-0.77%(reduction)to +0.69%(enlargement)

Each time the numerical value is increased by"1",theheat roller motor speed increases by 0.06%.Range:-0.75%(reduction)to +0.71%(enlargement)

Each time the numerical value is increased by "1",theimage shift moves 0.5mm toward the trailing edge ofthe paper without changing the position of the imagerelative to the paper.

Motor ratings can be adjusted by the following ranges:

0:-1.19% 1:-1.03%2:-0.88% 3:-0.73%---------- -------------------- 13:+0.76%

14:+0.91% 15:+1.06%

Code Name Allowable InitialNo. Input values Value*

0 Auto-toner sensor 0~255 128

1 Manual exposure(100%) 0~255 128








9 Allowable exposure step 0~255 128range(light)

10 Allowable exposure step 0~255 128range(dark)

14 Manual photo exposure 0~255 128(100%)




20 Aligning roller speed 0~15 10adjustment

21 Drum speed adjustment 0~15 12

22 Heat roller speed adjustment 0~15 8

25 Leading edge of image shift 0~15 8(100%)



28 PFP motor speed 0~15 8

Contents

*The initial value means the one that is set by the BC-RAM initialize program, and does not mean the one set at thefactory before shipment.

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Contents

Each increase by"1"will move the editing position 0.5mmtoward the t ra i l ing edge of the paper( feedside).Adjustment should be made in the order of32→33→34.

Each time the numerical value is increased by"1",onlythe void moves 0.5mm toward the trailing edge of thepaper.

The larger the value,the higher the output.(Notnecessary to adjust)

The larger the value,the higher the output.

The larger the value,the higher the output.

The larger the value, the higher the output.

When the numerical value is increased, the outputincreases

The lager the value, the higher the separation DCwelghted output.

The larger the value, the brighter the LCD panel.

Automatically adjusts the automatic exposure based onthe manual exposure.

Each time the unmerical value is increased by "1",theimage advances approximately 0.8mm toward thelead ing edge.The ad jus tment sequence i s53→54→55→56→57→58.

Each time the numerical value is increased by "1",the

lens moves approximately 0.2mm toward theenlargement direction.

Each time the numerical value is increased by "1",thelens moves approximately 0.1mm toward theenlargement direction.

Each increase by "1" will move the edge erasing positionor the leading (trailing) edge of the paper 0.5mm towardthe trailing edge of the paper.

Code Name Allowable InitialNo. Input values Value

30 Leading edge of edge 0~15 8erasing

31 Trailing edge of edge erasing 0~15 8

32 Editing position adjustment 0~15 8(100%)



35 Leading-edge void adjust- 0~15 8ment

36 Trailing-edge void adjust- 0~15 8ment

38 Main charger output 0~255 128

39 High-voltage transformer 0~255 128(transfer)output

40 High-voltage transformer 0~255 128(separation/developer bias)output

41 Pre-transfer discharger 0~255 128transformer output

42 Main charger output 0~255 205(photo mode)

44 Separation DC output 0~255 185

45 LCD contrast adjustment 0~255 150

49 Automatic adjustment for - -automatic exposure

53 Registration(LCF/100%) 0~15 8



56 Registration(manual/100%) 0~15 8

57 Registration(PFP/100%) 0~15 8

58 Registration(ADD/100%) 0~15 8

60 Lens position(100%) 0~99 50

61 Mirror position(100%) 0~99 50

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68 Automatic adjustment of – – remaining paper quantityindication(no paper loaded)

69 Automatic adjustment of – – remaining paper quantity

indication( paper loaded)70 Remaining paper quantity 0~31 3

indication(LCF/no paperloaded)

71 Remaining paper quantity 0~31 2indication(upper cassette/no paper loaded)

72 Remaining paper quantity 0~31 2indication(middle cassette/ no paper loaded)

73 Remaining paper quantity 0~31 2indication(lower cassette/ no paper loaded)

74 Remaining paper quantity 0~31 4/3**indication(LCF/ paperloaded)

75 Remaining paper quantity 0~31 2/3**indication(upper cassette/paper loaded)

76 Remaining paper quantity 0~31 4/8**indication(middle cassette/ paper loaded)

77 Remaining paper quantity 0~31 7/3**indication(lower cassette/ paper loaded)

79 Carriage control of the 0~2 –

leading edge of the image

80 Aligning value(LCF) 0~15 8

81 Aligning value(manual) 0~15 8

82 Aligning value(PFP) 0~15 7

83 Aligning value(ADD) 0~15 7

84 ADF aligning value(1st 0~15 8page)

85 ADF aligning value(2nd 0~15 8page)

Contents


Each time the numerical value is increased by "1",the

lens moves approximately 0.1mm toward theenlargement direction.



Remove all of the paper from the LCF and PFP cassetteswhen the adjustment is performed.

Install 4,000 sheets of paper in the LCF and the 500sheets of paper in each of the PFP cassettes when the

adjustment is performed.These adjustments are made manually when theremaining paper quantity becomes down to half or less.After the adjustment of code 68 is performed,conductthese adjustments if necessary.In case the variational ratio of the remaining paperquantity indication is slower than the decrease ratio ofthe actual quantity of sheets of paper,increase thenumerical value.(Example)When" "symbol suddenly changes to" "symbol.

These adjustments are made manually when more thanhalf of the paper remains.After the adjustment of code69 is perfomed,conduct these adjustments if necessary.In case the remaining paper quantity indication isdisplayed as greater than the actual quantity of sheetsof paper,increase the numerical value.(Example)" "symbol should be actually displayed,but" "symbol is displayed.**LT series/A4 series

0:Normal control

1:To slow down the acceleration to the leading edge ofthe image.2:To increase the pre-scanning amount to the leading

edge of the image.

Each time the numerical value is increased by"1",theamount of slack increases by approximately 1.9 mm.

Each time the numerical value is increased,the originalmoves toward the paper feed side.

Each time the numerical value is increased,the originalmoves toward the exit side(original stopper side).

**Europe (A4 series) / U.S.A. and Canada (LT series)

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Each time the numerical value is increased by "1", theamount of slack increases by approximately 1.9 mm.

Each time the numerical value is increased, the gapbetween originals increases.

Each time the numerical value is increased, the originalshifts to the paper supply side on the copier (that is,moves away from the original stopper). This is carriedout after adjustment "87"(ADF aligning value).

The auto-toner adjustment value is indicated.This value can be changed.

0~31 :Negative calibration:Max.-5.35sec./month/step32~63:Positive calibration:Max.+10.7sec./month/step0,32 :Correction deactivated


86 Aligning value 0~15 7(long size paper/upper cassetle)

87 ADF aligning value 0~15 8(2in1 original gap)

88 ADF leading edge position 0~15 8(in 2in1 mode)

90 Auto-toner sensor 0~255 128adjustment value

99 Real-time clock adjustment 0~63 0

Contents

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Code Name Allowable InitialNo. Input values Value*

0 Date/time input 13digits -

1 Date indication 0~3 2

2 Time indication 0,1 0/1**

4 Auto sort mode 0~3 0

5 Automatic duplex mode 0~3 0/1**

6 Setting temperature of the 0~15 0heat-roller surface

7 Access control mode active 0~2 0

8 Version change 0~2 0/1**

9 Actual-size reproduction 0,1 0ratio

10 Timer mode 0~10 3

11 Auto power saving 0~12 0/3**

12 MAX9 0~2 0

13 Paper-feed retrial 0,1 0

14 Cassette priority selection 0~4 1

Code PRINT INT 0 9

2.5.4 Setting Mode (08)

Clear

In thismode, the various special modes listed in the Setting Code List can be set or changed.

<Procedure>

0 8

PWR

Ste/change

a value Memorize

Contents

Year/month/date/day/hour/minute/second

(Example)0:5/25 1:25/5 2:25.May 3:25.May

(Example)0:15:30 1:PM 3:30

The sort mode is selected automatically when theoriginal is placed on the ADF.0: Deactivated1: Staple sort2: Sort

3: GroupThe duplex mode is selected automatically when theoriginal is placed on the ADF.0: Deactivated1: (single-sided to dual-sided) is selected2: (dual-sided to dual-sided) is selected3: (dual-sided to single-sided) or (single-sided to dual-

sided) is selected according to the message.

0:200°C 1:197°C 2:199°C 3:200°C 4:202°C 5:204°C6:206°C 7:208°C 8:210°C 9:212°C 10:214°C 11:216°C12:218°C 13:221°C 14:223°C 1 5:2 24°C∗Never set to a value of 8 or more.

0: Access control mode deactivated1: Access control mode activated(copier)2: Access control mode activated(IC card)

0: EUR(A4/A3/FOLIO),1:UC(LT/LD)2: JPN(A4/B4)

0: 100%,1:101%

If there is no control panel operation during the readystatus for a certain length of time as shown below,thecopy-mode automatic resetting function is performed.Resetting operation start time is:1: 15 sec.,2: 30 sec.,3: 45 sec.,4: 60 sec.,-----10: 150 sec.0: Deactivates the copy-mode automatic resetting.

Auto power saving operates n minutes after ready statusis reached.The functions are:

0: Deactivated1: After 5 minutes2: After 10 minutesn: After n ×5 minutes

Copy quantity0: max.999,1:max.9,2:max.99

0: Feed-retrial mode1: No-feed-retrial mode

0: A4/LT priority1: LCF priority2: Upper cassette priority3: Middle cassette priority4: Lower cassette priority

↓ → → → → →

*The initial value means the one that is set by the BC-RAM initialize program, and does not meaus the one set at the factory

before shipment.**Europe(A4 series)/U.S.A.and Canada(LT series)***This selection is made only when the FC key is pressed or when auto-resetting works.

***

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15 Exposure priority selection 0~2 0

16 A3 double count 0,1 0

17 Manual-feed auto-start 0,1 0

18 ADF mode selection 0,1 0

19 Sort mode selection 0~3 0

20 Edge erasing priority 0~2 0selection

21 Automatic cassette 0,1 1selection

22 APS priority selection 0,1,2 1

23 Detection of manually placed 0,1 0original

24 APS start timing 0~15 5

27 ADF¥APS mode 0,1 0

31 Paper size(LCF) 0~15 3/4**

32 Paper size(upper cassette) 0~15 6/7**

33 Paper size(middle cassette) 0~15 11/14**

34 Paper size(lower cassette) 0~15 13/4**

38 Upper heater setting during 0~9 0energy saving

39 Selection of paper size

enabled by cassette key 0~2 0

43 Resettable counter display, 0~3 0original counter display

46 Toner save mode 0.1 1

Contents

0: Auto exposure priority1: Manual exposure priority2: Photo exposure priority3: Toner save priority

0: Single count1: Double count

0: PRINT key starting1: Auto-start

0: ADF mode1: SDF mode

The mode selected when power is turned ON0: Non sort1: Staple sort2: Sort3: Group

0: Deactivated1: Edge erasing priority2: Automatic edge erasing priority

0: Deactivated1: Activated

0: Deactivated1: APS priority2: AMS priority

Detects manually placed original0: Deactivated1: Activated

0: 0 sec.,1: 100 msec,2: 200 msecn: n×100 msec

0: Detection of every sheet of paper1: Detection of only the first sheet

1: A5-R 2: ST-R/B53: LT 4: A45: B5-R 6: LT-R7: A4-R 8: Sheet insertion9: Cover seet 10: COM/FOLIO11:LG 12: B413: LD 14: A3**LT series/A4 series

0: 190°C 5: 160°C1: Heater off 6: 170°C2: 130°C 7: 180°C3: 140°C 8: 190°C4: 150°C 9: 200°C

0: Enabled

1: Not allowed2: Cover sheet and sheet insertion only enabled

0: Deactivated1: Resettable counter only displayed2: Original counter only displayed3: Resettable counter and original counter displayed

0: Deactivated1: Selectable with IMAGE/PHOTO Key2: Activated

**Europe(A4 series)/U.S.A.and Canada(LT series)

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0: Activated at all times1: Activated only at automatic exposure

2: DeactivatedAuto shut-off to force when it was left for a following

contorol time (Same OFF state as weekly Timer)0:3 1:5 2:10 3:15 4:20 5:256:30 7:40 8:50 9:60 10:70

11:80 12:90 13:100 14:110 15:2016:150 17:180 18:210 19:240(min)20:∞

Other than 0: PM call when set value ≤ Copy count(code"79")

Current copy quantity

Telephone numbers of up to 14 digits can beentered.Use the HELP key to enter hyphens(min.).

0: Normal1: LCF forced paper OFF state (LCF tray does not move)

Heat-roller thermistor breakdown counter0~2:Normal operation3:Copier does not operate

0:800V 1:830V 2:840V 3:850V4:860V 5:870V 6:880V 7:890V8:900V 9:910V 10:920V 11:930V12:940V 13:950V 14:960V 15:970V

∗Never set to a value of 5 or more.

Changing the number of alarm sounds when an erroroccurs0: No sound1: 5 times2: ∞

1 A5-R 6 FOL10 11 LT-R2 B5 7 B4 12 LG3 B5-R 8 A3 13 COMP4 A4 9 ST-R 14 LD5 A4-R 10 LT

Turning on the power supply Rogo is displayed on theMessage display.0: Display1: No Display

After the end of copying the stacked copy paper ispushed out into each bin.(When the MG-2011 is connected and a mode otherthan the multi-stacking mode is selected)0: Function

1: No Function

ContentsCode Name Allowable InitialNo. Input values Value

50 Paper retry counter 0~999,999 000000

53 Exposure burnout detection 0~2 0

56 Auto shut-off 16/12**0~16/0~15**

69 PM counter setting value 0~999,999 0(Total)

79 Current PM counter value 0~999,999 0(Total)

80 Telephone number 14 digits 0

86 LCF tray lock counter 0.1 0

89 C7 counter 0~3 0

91 Copy counter of unit 0~999,999 000000~97

Code Unit nameNO.

91 ADD

92 ADF

93 SBF

94 LCF95 Upper cassetle(PFP)

96 Middle cassetle(PFP)

97 Lower cassetle(PFP)

98 The setting value of the drum ∗1 0~15

surface potential

108 Error alarm 0~2 0

109 Universal paper 0~14 1/9**

134 TOSHIBA Rogo Display. 0~1 0

135 Front access sorter 0~1 0unloading mode(MG-2011)

**Europe(A4 series)/U.S.A.and Canada(LT series)

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2.5.5 How to Register/Change ID Codes (access control mode)

COSMOS

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Text 2-19 in the65/5560 Service Handbook

is sameas text 2-19 in the 76/7550 Service Handbook .

Do you refer to the 76/7550 Service Handbook ?

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At the initial machine setup or when the developer material is replaced,the auto-toner sensor needs

to be adjusted.

<Key Operation>

0 5

POWER

PRINT

0: Enter code

(operation state ofdeveloper, drum, etc.)

<Display, Supplementary Explanation>

INT

0 9

(developer, drum,

etc. stop)

ZOOM Adjust so that "XXX" on the display panel is within thepermissible range only when outside of range 245 to 255.

XXX ZZZ

ZOOM UP key Increases Increases

ZOOM DOWN key Decreases Decreases

* Auto-toner sensor output range: 2.45 to 2.55V

After about two minutes, "XXX" and "ZZZ" automaticallystart to change. Then the following is displayed:

:Cancel adjustmentmode.

2.6 Auto-Toner Sensor Adjustment

↓

↓

↓

↓

↓

ò

XXX Z Z ZWAIT 100%

ò

Auto-toner sensor output voltage: X.XXV↓

←

XXX Z Z ZADJUST MODE 100%

Stops changing

↓ ↓

TEST MODE A 100% A

TEST MODE A 100% A

Numerical value correspondingto auto-toner adjusting value

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At the initial machine set-up or when the light distribution is adjusted, the exposure needs to be

adjusted. Adjustment must be also performed in accordance with any special request of the user.

2.7 Exposure Adjustment

Adjustment order

<Key Operation>

POWER

PRINT

ZOOM : Adjustment

[numerical keys]

: Cancel adjustmentmode.

: Output test chart

To readjust, go to

Newly entered adjustment values (default: YYY)

·To darken: value smaller than YYY

·To lighten: value larger than YYY

code # XXX1,5,11 1002,6,12 1543,7,13 504,8,14 2009,10 Any value

Adjustment of variable step exposure (codes #9 and 10) are

not related with the copy reproduction ratio.

ENERGY SAVER

0 9

→

→

DEGITAL KEYS

<Display,Supplemntary Explanation>

Values "ZZZ" are stored in BC-RAM in place of "YYY"

Manual exposure

(49) (5) (6) (7) (8)

→ → →100%

Manual exposure

154%→50%→200%

(2) (3) (4)(1)

Automatic exposure

50∼200% 100% →154% →50% →200%

Automatic adjustmentof automatic exposure

C1

C1 → →→

→

→Light gradataion

100%

(9)

Dark gradation

100%

(10)

100%

(14)

Manual photoexposure Manual photo exposure

Adjust the above items by following the procedures below using the operation keys while comparing

adjustment values stored to memory for each item and copies made under those conditions.

1) Setting of the exposure electric potential output value

Note: In the dotted-line squares are the adjustment to be performed according to any special request of the user.

0 5

154%→50%→200%

(15) (16) (17)

∗

∗

INT

↓

↓

↓

↓

↓

↓

*1: You can make only single-sided copies. (You cannot make dual-

sided copies.)

*2: Test copies can be made immediately after starting the test mode.

When outputing this test chart, match to the desired reproduction

ratio and exposure conditions for adjustment.

Currently stored adjustment value

Y Y Y Z Z ZADJUST MODE XXX%

TEST MODE A 100% A

·Code becomes "ZZZ"according to the entire

code.

·The order of above adjustment is fixed.

↑

TEST MODE A 100% A

COPYING 100% A

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2) Automatic exposure adjustment

• Adjust manual exposure (100%), and then carry out automatic exposure adjustment.

• Place a blank sheet of A3 paper on the original glass, and close the ADF with the original aligned

against the original scale.

• After completing the above preparations, follow the procedure below to automatically adjust.

<Key Operation>

0 5

POWER

PRINT

0 9

TEST MODE A 100% A

: Start of automaticadjustment

Display returns to testmode, and automaticadjustment ends


49 : Enter code


↓

↓

↓

↓

Adjustment values for thereproduction ratio displayedat XXX are displayed.

During automatic adjustment,display changes as follows:100->154->50->200

TEST MODE A 100% A

Y Y Y

ADJUST MODE XXX%

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Adjustment Code Adjustment Item20~22,30~34 Edge erasing, Aligning value,80~84 etc53~58 Registration(100%)25~27 Leading edge of image shift35 Leading edge void36 Trailing edge void

To readjust, go to

LCF Manual PFP ADD

2.8 Adjustment of Drum/Aligning Roller/Heat Roller Speed,Aligning Value,Registration,Leading

Edge of Edge Erasing,Trailing Edge of Edge Erasing,Leading Edge of Image Shift, Editing

Position,Leading-Edge Void and Trailing-Edge Void.

<Adjustment procedure>

Drum speedAligning roller

speed Heat roller speed Aligning value

(21) (20) (22) (80) (81) (82) (83)

Registration

(53) ~ (58)

Leading edge of edge erasingTrailing edge of edge erasing

(25) (26) (27)

Leading edge ofimage shift

(32) (33) (34)

100% 200% 50%

Editing position

(35)→(36)

(Note) In the dotted-line squares are the items which normally do not require adjustment.

Leading edge voidTrailing edge void

<Key Operation>

0 5

POWER

: Output test chart

INTERRUPT

ENERGY SAVER

0 9

Follow the procedure below to adjust each of the adjustment value so that the measured values

obtained from the test chart satisfy the specifications. Immediately after starting test mode "05",

only single-sided test charts (normal copies) can be output with the ENERGY SAVER key.

Copy mode key : Set the copy mode using thepaper size, original size andcassette keys.

PRINT

*1: You can make only single-sided copies. (You cannot make dual-

sided copies.)

*2: Test copies can be made immediately after starting the test mode.

When outputing this test chart, match to the desired reproduction

ratio and exposure conditions for adjustment.

→ → → →

→→→

<Display,Supplemntary Explanation>

DEGITAL KEYS

DEGITAL KEYS: Enter adjustmentvalue


→

→

(30) ~ (31)

→ → →

→→

100% 200% 50%→ → →

↓

↓

↓

↓

↓

↓

: Value ZZZ is stored inplace of value YYY.

∗

∗

TEST MODE A 100% A

TEST MODE A 100% A

COPYING 100% A

Y Y Y Z Z ZADJUST MODE XXX%

New adjustment value displayed

Y Y Y Z ZADJUST MODE XXX%

Preset copy reproduction ratio

Adjustment value storedto BC-RAM

Selected code #

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2-24MAY.1997 © TOSHIBA CORP. 65/5560 ADJUSTMENT

COSMOS

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Texts from 2-24 to 2-33 in the 65/5560 Service

Handbook are the same as texts from 2-24 to 2-33 inthe 76/7550 Service Handbook .


2.8.1 Drum Speed Adjustment AJ:Codes 21

2.8.2 Aligning Roller Speed Adjustment AJ:Code 20

2.8.3 Heat Roller Speed Adjustment AJ:Code 22

2.8.4 Aligning Value Adjustment AJ:Code 80~83

2.8.5 Registration Adjustment AJ:Codes 53 to 58

2.8.6 Leading Edge of Edge Erasing, Trailing Edge of Edge Erasing AJ: Code 30, 31

2.8.7 Leading Edge of Image Shift AJ: Code 25 to 27

2.8.8 Editing Position (adjusting trimming and masking) AJ: Code 32 to 34

2.8.9 Leading-Edge Void and Trailing-Edge Void AJ: Code 35, 36

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2-34MAY.1997 © TOSHIBA CORP. 65/5560 ADJUSTMENT

2.9 Automatic Adjustment of Remaining Paper Quantity

(1) Before automatic adjustment, prepare following the instructions in the following table.

(2) Set the PFP cassettes in the copier, and mount the LCF. Then, close the LCF door.

(3) Follow the procedure below to carry out automatic adjustment.

Code 68 (no paper) 69 (paper)

PFP Remove all paper

LCF in the LCF and PFP.

Place 500 sheets of paper in all PFP cassettes, and 4,000 sheets

of paper in the LCF. (The LCF elevator must be lowered as far as

possible.)

DEGIAL KEYS : Enter code.

<Operation Keys>

0 5

POWER


↓

↓

PRINT : Automatic adjustment starts. The paper selection LED flashes during automatic

adjustment.

* Automatic adjustment does not start if a cassette or LCF is not properly in place, or the

LCF door is open.

TEST MODE A 100% A

Successful : Paper selection display lights.

Error : Paper selection display flashes, and automatic adjustment must

be carried out again.

End of Automatic Adjustment

C/S : Ended.

Note: Before carrying out automatic adjustment by code 69, the user must set the paper (type and size)

in actual use in the PFP and LCF.

↓

TEST MODE A 100% A

Paper selectiondisplay

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65/5560 ADJUSTMENT 2-35 MAY.1997 © TOSHIBA CORP.

2.10 Check/Adjustment of High-voltage Transformer

When replacing the high-voltage transformer,check and adjust the main charger,transfer

charger,separation charger,and developer bias voltage.

2.10.1 Check/Adjustment of Transfer Charger/Separation Charger/Pre-transfer Discharge Charger

(1) Separation

Items to Check before Adjustment

� Check that the charger wire is positioned correctly and is clean. Also check that the separation

charger guide is correctly positioned.

� Check that the developer unit is installed, and that the magnetic brush is in contact with the drum.

Check that the developer unit turns when a copy is being made. Check also that the toner density

is set sufficiently high.

� Check that the copy paper is flat and dry.

� Check that the aligning rollers rotate correctly.

� Check the output of the grid (for the main charger).

� Check that the transfer output is at the set value.

� Check that the developer bias is appropriate.

� Check that the transfer/separation charger case is earthed. Check also that the high-voltage

transformer is earthed.

CAUTIONS

(1) When pockmarks occurs:

When irregularities (pockmarks) are generated on the halftone areas, reduce the separation output.

Note:

Do not reduce the output excessively. Otherwise, the separation ability will decrease.(2) Defective separation:

When defective paper separation occurs despite the charger wires being clean, or when the user is

likely to use a large quantity of thin paper, raise the output.

Note:

Do not increase the output excessively, otherwise pockmarks will be generated and the separation

ability will decrease.

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2-3765/5560 ADJUSTMENT MAY.1997 © TOSHIBA CORP.

� Follow the adjustment procedure below.

<Key Operation>

0 5

POWER

PRINT

0 : Enter code

ZOOM

: Cancel adjustmentmode.0 9

INT Value YYY is stored in place of value XXX.

To readjust, go to

→

→

↓

↓

: Adjust so that display voltage of the digitaltester satisfies the values in the following table.

↓

↓

↓

∗

∗


TEST MODE A 100% A

Adjustment code ItemDigital tester(adjustment standard voltage value)

39 Transfer DC -78~ -88mV

40 SeparationRMS AC 133~ 151mV

AVG AC 127~ 144mV

41 Pre-transfer DC 40~ 56mV

X X X Y Y Y Z ZADJUST MODE 100% Selected code #

↓


→↓

Newly entered adjustment value(default:XXX)

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MAY.1997 © TOSHIBA CORP. 2-38 65/5560 ADJUSTMENT

2.10.2 Check/Adjustment of Main charger/Separation DC

� Remove the developer unit.

� In the case of main charger: the digital tester must

be connected as follows:

• Setting Range 1,000 VDC

• (+)terminal Connect to main charger rail.

• (-)terminal Fix earth to the copier frame.

� Follow the procedure below to adjust.

<Key Operation>

0 5

POWER

PRINT

ZOOM

→

↓

∗


TEST MODE A 100% A

Main Charger Adjust by the ZOOM key so that the digital tester displayvoltage is within the range -780 to -800V.

Separation DC Check that XXX is 185.If XXX is not 185, adjust the ZOOM key so that YYY is185.

DEGITAL KEYS

↓

↓

X X Y Y Y Z ZADJUST MODE 100%

↓

Main Charger 38

Separation DC 44

0 9

INT Value YYY is stored in place of value XXX.

→

↓

To read just, go to ∗.

: Cancel adjustment mode.

↓

(+) terminal

: Enter code.

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2.10.3 Check/Adjustment of Developer Bias

If fogging occurs all over the copy despite the fact that there is no underexposure or overtoning,

rotate VR1(white) clockwise to increase the bias output.

Note:

If the bias output is raised excessively:,

• The image contrast will deteriorate,

• Bias leaking is liable to occur,

• Carrier is liable to adhere to the drum, resulting in its becoming damaged.

• Don't touch the VR (Vdc).

�Remove the developer unit and cleaner unit.

�Connect the + terminal of a digital tester to the connector J73 and the - COM terminal to the frame

ground. (The selected range of the degital tester must be "DC 100V" .)

(3) Follow the adjustment procedure below.

<Key Operation>

0 5

POWER

INT

PRINT

(adjustment) Make sure that the voltage is 200 VDC+2V using the digital tester.Turn VR1 if adjustment is required.


40

(-) COM terminal

Frame ground

J73Door switch bracket

Digital tester

: Enter code

VR(Vdc)(Blue)

VR1 for developer biasadjstment(White)

LargeSmall

TEST MODE A 100% A

X X X Y Y Y 40ADJUST MODE 100%


↓: Selected code #

↓↓

↓

↓

(+)terminal

: End

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2.11 Setting the Surface Potential Output Value

2.12 Automatic Drum Surface Potential and Manual Exposure Adjustment

2.13 Setting of the Exposure Electric Potential Output Value

The above mentioned functions 2.11 through 2.13 are not included with the 6560.

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2.14 Adjustment of Carriage Drive Belt

2.15 Image Inclination and Distortion

2.15.1 Image Inclination

2.15.2 Image Distortion

2.16 Light Distribution

2.17 Lens Position (focus) Adjustment

2.18 Adjustment of Focus and Lateral Reproduction Ratlo

2.19 Adjustment of Side Deviation in Feeding

2.20 Checking and Adjustment of the Magnetic Brush Thickness(leveler)

2.21 Drum/Sleeve Gap Adjustment

2.22 Developer-Pole Position Adjustment

2.23 Heat Roller Pressure Adjustment

2.24 Stack Guide Unit Adjustment

2.25 Adjustment of ADD Pick-Up Roller Position

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2.27 Change of the Paper Size

2.27.1 LCF paper size

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Electrical Changes

•The electrical settings must be changed according to the procedure below when mechanical changes

have been made.

•After changing the electrical settings, select the cassette that has been changed using the

CASSETTE key, and make sure that the LED for the set paper size lights.

(2) When setting by touch panel

<Key Operation>

Cassette select key

(1) When setting by entering a code

<Key Operation>

0 8

POWER

0 9

PRINT

:Cancel adjustment

mode.

DEGITAL KEYS : Enter the code (select the cassette)

DEGITAL KEYS


: Enter the setting of the new paper size.

↓

↓

↓

↓

TEST MODE D 100% D

XX XX YYSYSTEM MODE 100%

Cassette Code

LCF 31

Upper 32

Middle 33

Lower 34

Paper Size Setting Value Paper Size Setting Value

A5-R 1 Insert sheet 8

B5,ST-R 2 Cover 9

LT 3 FOLIO,COMP 10

A4 4 LG 11

B5-R 5 B4 12

LT-R 6 LD 13

A4-R 7 A3 14

Setting value of selected cassette

TEST MODE D 100% D

XX ZZ YYSYSTEM MODE 100%

INT

↓

Program

↓

↓

Cassette select icon

↓Paper size key

: Select cassette.

: Press key of new paper size.

: Change to cassette size specification screen.

: Change to program mode selection screen.

↓

↓New setting value is displayed

↑

: Store the new paper size setting value (ZZ) in the memory.

↓END

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2.34 The Setting Temperature of the Heat-Roller Surface and the Setting Pressure of the

Heat Roller

2.35 The Adjustment of Fuser Entrance Guide

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65/5560 GENERAL 3-1 MAY.1997 © TOSHIBA CORP.

3 GENERAL DESCRIPTION

3.1 Front/Rear Vlew

3.1.1 Front Sectional View except Drive System

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MAY.1997 © TOSHIBA CORP. 3-2 65/5560 GENERAL

3.1.2 Front Drive System

3.1.3 Rear Drive System

3.1.4 Automatic Document Feeder (ADF) Front Sectional View

COSMOS

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Texts from 3-2 to 3-4 in the 65/5560 Service Handbook

are the same as texts from 2-4 to 2-6 in the 76/7550

Service Manual .


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3.2 Electrical Parts Layout

3.2.1 DC Electrical Parts (Copier)

(1) DC Electrical Parts Except Motors (Upper Unit)

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(2) DC Electrical Parts except Motors (Lower Unit)

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(3) Motors

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3.2.2 AC Electrical Parts (Copier)

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3.2.3 Electrical Parts of Automatic Document Feeder (ADF)

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3.3 Symbols and Functions of Electrical Parts

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Handbook are the same as texts from 2-10 to 2-18 inthe 65/5560 Service Manual .


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3.4 Wire-Harness Location Diagrams

3.4.1 Location Diagram for Upper Unit

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3.4.2 Location Diagram for Lower Unit

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3.5 AC Wire-Harness Connection Diagram

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3.6 DC Wire-Harness Connection Diagram3.6.1 Copier DC Wire-Harness Connection Diagram

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3.6.2 ADF DC Wire-Harness Connection Diagram

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3.7 Control Block Diagram

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4-165/5560 PERIODIC MAY.1997 © TOSHIBA CORP.

•Inspection and Overhaul every 800,000 Coples

(1) Replace all the consumables.

(2) Check to see if there is any damage to parts of the driving section (gears, pulleys, timing belts, etc.).

Replace parts on principle if damaged.

(3) Check to see if there is any damage or peeling of adhered parts (tape, Mylar sheet, etc.).

Replace any affected parts.

(4) Check to see if all the switches and sensors operate properly. Replace them if they are not

operating properly.

(5) Clean the inside of the machine thoroughly.

4. PERIODIC MAINTENANCE

•Inspection every 200,000 Copies

(1) Preparation

1) Ask the key operator about the present machine conditions and note them down.

2) Before starting the maintenance work, make and retain a few sample copies for later

comparison.

3) Turn off the power switch and disconnect the power cord plug.

(2) The periodic inspection should be conducted in accordance with the Periodic Inspection Check

List shown below. Perform the inspection by referring to the figures, as well as to the

explanations in the Service Manual when necessary.

(3) After the inspection has been completed, plug in the machine and turn the power switch on, and

confirm the general operation of the machine by making a few copies and comparing them to

those made previously.

Note: For inspection and maintenance of the PFP, remove the PFP upper aligning unit and the

PFP feed units from the copier

4.1 Perlodic Inspection Check List

Symbols used in the periodic inspection check list

(A) Cleaning with alcohol

(P) Cleaning with heat roller

cleaner(RC60)

Cleaning with soft pad,

cloth, or cleaner

(vacuum cleaner)

(D) Cleaning with a slightly

damp cloth

Customer's

name

Machine

No.

Inspector

Remarks

(100)Every 100,000 copies

(200) Every 200,000 copies

(400) Every

Same thereafter

( ) Replace in event of

deformation or other

damage

(V) Vacuoline

(L) Launa 40

Application

(SI) Silicone Oil

(W) White grease(Molycoat)

(M) Molytherm

Cleaning Lubrication Replacement Date

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4-2MAY.1997 © TOSHIBA CORP. 65/5560 PERIODIC

copies200,000Clean at

copies copiesItem to checkArea

Lubricate at

Periodic Inspection Check List

200,000Checkwhileon

Remarks×1,000

Replace

Cleaner 1. Overall unit ¡

2. Main blade (200) *1

3. Toner bag Conducted

(100) by key

operator

4. Recovery blade ¡ ( ) *2

5. Drum bushing ¡

6. Separation claw ¡ (400) ¡ * 3

7. Fur Brush (200)

7-1. Used toner-transport auger (W) *13

drive sections(front,rear)

Drum 8. Drum shaft ¡ or(A)

9. Drum (400) *4

10. Ozone filter (for the exit fan) (400)

10-1. Ozone filter (for the developer fan) (400)

Original 11. Glass ¡ or(A)

holder

Optical 12. Mirror 1 ¡

system 13. Mirror 2 ¡

14. Mirror 3 ¡

15. Mirror 4 ¡

16. Mirror 5 ¡

17. Mirror 6 ¡

18. Slit glass ¡ Both sides

19. Reflector ¡

20. Lens ¡

21. Exposure lamp ( ) ¡

22. Copy area indicator ¡

22-1. Harf tone patch ¡

23. Automatic exposure sensor ¡ ¡

24. Automatic paper-size detector ¡ ¡

25. Reproduction mechanism¡

(mirror)

26. Reproduction mechanism ¡

(lens)

27. Slider sheet(front, rear) ¡ or (L) ( )

28. Air filter ¡ (200) *5

Charger 29. Case (D) *6

31. Charger wire (Main/transfer/ (200)( ) ¡ *6

separation)

32. Terminal contact ¡

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Charger 33. Charger wire cleaner (200)

(main/pre-transfeer/transfer/separation)

35. Pre-transfer guide ¡35-1. Grid (for main charger) (200)

Devel- 36. Overall unit ¡

oper 37. Developer material (200) *7

unit 38. Front shield ¡ ( )

38-1. Oil seal (mixer shaft) *15

39. Guide roller ¡ or(A) ( )

40. Duct bottom ¡

40-1. Duct filter clean at

800,000

copies

41. Toner hopper drive worm gear (W)

Paper 42. Pick-up roller (A) (100)( ) *LCF:(200)

feed 43. Feed roller (A) (100)( ) *LCF:(200)

system 44. Separation roller (A) (100)( ) *LCF:(200)

45. Aligning roller (A) ( )

46. Paper guide ¡

47. Brush ¡ ( )

48.Transport belt ¡ ( )

49. Paper-feed system drive gears (W)

(tooth faces)

50. GCB bushings and plastic (L)bushings

Fuser 52. Upper heat roller(Teflon roller) ¡ or(P) (400) *8

unit 53. Lower heat roller(rubber roller) ¡ or(P) (400) *8

54. Upper separation claw ¡ or(P) (400)( ) *9

55. Lower separation claw ¡ or(P) ( ) *9

56. Heat roller cleaning roller (200) *10

57. Cleaning felt roller (200) *10

58. Press roller cleaning roller (200) *10

59. Upper and lower thermistors ¡ or(P) ( )

60. Heat roller guide ¡or(P)

61. Heat roller exit guide ¡or(P)

62. Paper dust recovery bracket ¡

63. Exit roller (A)

64. Heat roller and cleaning rollers (SI)

drive gears

65. Cleaning roller bushings (SI)

Item to checkAreacopies

200,000copies on

WhileCheck Remaks

200,000Lubricate atClean at

copies×1,000

Replace

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ReplaceItem to checkArea

ADD 66. ADD pick-up roller (A) (100)( )

and 67. ADD feed roller (A) (100)( )

decurler 68. ADD separation roller (A) (100)( )69. Transport rollers 1 to 4 (A) ( )

70. ADD aligning roller (A) ( )

71. GCB bushings and plastic (L)

bushings

72. Drive gears(tooth faces) (W)

73. ADD exit gate and ADD exit (A)

roller

73-1. Decurler belt ¡

73-2. Decurler bushings (L)

73-3. Decurler gear (W)

PFP 74. PFP pick-up roller (A) (100)( )

75. PFP feed roller (A) (100)( )

76. PFP separation roller (A) (100)( )

77. PFP aligning roller (A) ( )

78. Paper guide ¡

79. Tray drive worm wheels and (W) *11

gears(tooth faces)

80. PFP drive gears(tooth faces) (W)

81. GCB bushings and plastic (L)

bushings

ADF 82. ADF pick-up roller (A) (400)

83. ADF feed roller (A) (400)

84. ADF separation belt (A) (400)

85. Transport belt (A) (400)

86. ADF aligning roller (A)

87. ADF reverse rollers (A)

88. ADF empty sensor ¡

89. ADF aligning sensor ¡

90. ADF size sensor ¡

91. Turn guide sensor ¡

92. ADF Timing sensor¡

LCF 93. Gears (W) *14

94. Worm and worm wheel (W) *14

95. Worm shaft (L) *14

96. Wire pulley (L) *14

97. Slit for the elevator tray (w)

Others 98. Clamshell lock section (w) *12

Clean at200,000copies on

WhileCheck RemarksLubricate at

200,000copies copies

×1,000

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4 -

5

6 5 / 5 5 6 0 P E R I OD

I C

MA Y .1 9 9 7 © T OS H I B A C OR P . Front section view (upper unit)

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4 -

6

MA Y .1 9 9 7 © T OS H I B A C OR P .

6 5 / 5 5 6 0 P E R I OD I C

Front section view (lower unit)

74 75 74 76 75 74 76 75 76 77 77

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4 -

7

6 5 / 5 5 6 0 P E R I OD

I C

MA Y .1 9 9 7 © T OS H I B A C OR P . Rear side view (upper unit)

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4 -

8

MA Y .1 9 9 7 © T OS H I B A C OR P .

6 5 / 5 5 6 0 P E R I OD I C

Rear side view (lower unit)

80 :W

80 :W

3

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Explanation of items in the "REMARKS" column of the Periodic Inspection Check List

*1 Main blade

If poor cleaning occurs due to the adhesion of paper dust, etc. before the specified number of copies

for replacement have been reached, the edge of the blade has been damaged.

Replace the blade if necessary,while change fur brush siwuitaneously.

*2 Recovery blade

If the edge of the blade is damaged, replace the blade regardiess of the number of copies made so

far.

*3 Separation claw

If any abnormal condition (e.g. coating wear) is observed on the tip of separation claw and ifthe mark

of the separation claw is observed on the copy image, replace the claw regardless of the number of

copies made so far.

Clean the tip of the claw by lightly wiping with a dry cloth. In addition, be sure to apply patting powder

(lubricant) to the separation claw after cleaning the claw and when replacing the claw or drum.

*4 Drum

Refer to section 5.2 "Inspection and Cleaning of the OPC Drum".

*5 Air filter

If the air filter is dirty, replace it.

*6 Charger wire and case

Clearn the charger case and the charger wire with a cloth which should be soaked in water and then

squeezed tightly.

*7 Developer material

After replacing the developer material, be sure to adjust the auto-toner sensor.

*8 Upper and lower heat rollers

Refer to section 5.4 "Checking and Cleaning of the Upper and Lower Heat Rollers".

ADF front section view

84 83 88 82

89 90

86 92 85 87 91

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*9 Separation claws

If the tip of any of the separation claws is chipped, replace it regardless of the number of copies

made so far. If toner adhering to a separation claw is forcibly scraped off, it may be damaged.

Therefore,if the tip of the claw is heavily coated with toner, replace the claw.

*10 Cleaning felt roller, heat roller cleaning roller and cleaning felt roller

Refer to section 5.5 "Checking and Replacing of the Cleaning Felt Roller, Heat Roller Cleaning

Roller and Cleaning Felt Roller".

*11 Tray drive worm wheels and gears.

Apply white grease to the tray drive worm wheels and gears.

79 :W

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*12 Clamshell lock section

Apply white grease to the clamshell lock section.

*13 Used toner-transport auger drive sections

Apply white grease to the used toner-transport auger drive sections(front and rear).

–Rear side– –Front side–

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*14 LCF drive sections

*15 Oil Seal (mixer shaft)

When 800k has been reached, replace the oil seals

(four) of the developer mixer shaft. When replacing,

apply grease (Alvania No.2) shown as below.

Oil seal

1. Push the new oil seal in parallel to the mounting

holes of the developer frame (or the nozzlemixer).

* Pay attention to the direction that the oil seal is

assembled. (See figure on right.)

2. Apply a uniform coating of grease to the inside

surface of the oil seal.

• Amount: Two large drops

• Grease: Alvania No.2

3. Wipe off any surplus grease that oozes out from

inside.

Mixer shaft

Coat the entire periphery of the mixer shaft with

grease (Alvania No.2) and assemble the bearing.

Oil seal

Outside

Developer frame

(Nozzle mixer)

GreaseInside

BearingMixer shaft

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4.2 Oiling Cycle Table

7-1 Used toner-transport auger drive section (front, White grease 200

rear)

41 Toner hopper drive worm gear White grease 200

49 Paper-feed system drive gears (tooth faces) White grease 200

50 GCB bushings and plastic bushings Launa 40 200

64 Heat roller and cleaning rollers drive gears Silicone oil 200

65 Cleaning roller bushings Siliconeoil 200

71 GCB bushings and plastic bushings Launa 40 200

72 ADD drive gears (tooth faces) White grease 200

73-2 Decurler bushings Laua 40 200

73-3 Decurler gear White grease 200

79 Tray drive worm wheels and gears (tooth faces) White grease 200

80 PFP drive gears (tooth faces) White grease 200

81 GCB bushing and plastic bushings Launa 40 200

93 Gears White grease 200

94 Worm and worm wheel White grease 200

95 Worm shaft Launa 40 200

96 Wire pulley shaft Launa 40 200

97 Slit for the elevator tray White grease 200

98 Clamshell lock section White grease 200

Tyre of oilNumber of coples ×1000

Oiling CycleItem to LubricateNumber

* The number is the same as that in the Periodic Inspection Check List.

Notes:

1) Do not apply oil to the rollers,belt and belt pulley.

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2 Main blade ASM-S-BL7550 200 P.56 - #.46

3 Toner bag PS-TB6550 100 P.59 - #.19

PS-TB6550E (For Europe)6 Separation claw (drum) K-CLAW-DRUM(4 pcs.) 400 P.57 - #.29

7 Fur brush B-6560 200 P.56 - #.32

9 Drum PS-OD6560 400 P.48 - #.1

10 Ozone filter (for the exit fan) K-FILTER-TNR 400 P.60 - #.8

10-1 Ozone filter (for the developer fan) K-FILTER-DEV-2 400 P.50 - #.26

28 Air filter(developer unit) FILTER-DEV 200 P.50 - #.25

Charger wire WIRE-CH-PT-060*398(main) P.47 - #.13

31 (main/pre-transfer/transfer/separation) WIRE-CH-PT-060*409(transfer and 200 P.30 - #.25

separation:3pcs.)

WIRE-CH-PT-354(pre-transfer) P.57 - #.11

Charger wire cleaner K-BASE-PAD-CH-M(main) P.47 - #.9

33 (main/transfer/separation) K-BASE-PAD-TR(transfer) 200 P.30 - #.18

K-BASE-PAD-SEP(separation) P.30 - #.19

35-1 Grid(for main charger) GRID-154 200 P.47 - #.22

37 Developer material PS-ZD6560 200 P.202 - #.2

42 Pick-up roller(manual/LCF) K-ROL-P/U-CW-H(manual) 100 P.27 - #.25

K-ROL-PICK-2(LCF) 200*1 P.26 - #.7

43 Feed roller(manual/LCF) K-ROL-FED-CW-H(manual) 100 P.27 - #.22

K-ROL-FEED-2(LCF) 200 P.26 - #.7

44 Separation roller(LCF) K-ROL-SPT-CW-H 200 P.26 - #.37

44-1 Separation roller (manual) K-ROL-SPT-URT 100 P.29 - #.59

52 Upper heat roller ASM-HR7550U 400 P.33 - #.1

53 Lower heat roller ASM-HR6550L 400 P.33 - #.2

54 Upper separation claw(fuser unit) K-SCRAPER-HR 400 P.34 - #.33

56 Heat roller cleaning roller PS-SR6550H 200 P.34 - #.42

57 Cleaning felt roller PS-ZB6550H 200 P.34 - #.41

58 Press roller cleaning roller PS-SR7550L 200 P.34 - #.9

66 ADD pick-up roller ROL-PICK-ADD 100*2 P.22 - #.39

67 ADD feed roller K-ROL-FEED-1 100*

2

P.22 - #.968 ADD separation roller K-ROL-SPT-CCW-H 100*2 P.22 - #.17

74 PFP pick-up roller K-ROL-P/U-CCW-H(3 pcs.) 100*3 P.11 - #.43

75 PFP feed roller K-ROL-FEED-1(3 pcs.) 100*3 P.11 - #.21

76 PFP separation roller K-ROL-SPT-CCW-H(3 pcs.) 100*3 P.12 - #.21

82 ADF pick-up roller ROL-ORG-IN-714 400 P.88 - #.4

83 ADF feed roller K-ROL-FEED-714 400 P.88 - #.5

84 ADF separation belt BLT/R-SEPARATE(4 pcs.) 400 P.89 - #.9

85 Transport belt(ADF) BELT-DF-714 400 P.83 - #.1

4.3 Repracement Schedule of Disposable Parts and Supplies

Replacement CycleParts Name Code

*4P.#.

*1

*1

*1

Number of copies ×1000Number

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Notes:

* The number is the same as that in the Periodic Inspection Check List.

*1 Indicates a manual feed or LCF feed count.

*2 Indicates an ADD feedcount.

*3 Indicates a feed count for each PFP stage.

*4 Refer to PARTS LIST.

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4.4 PM Kit (200K Kit)

1 Developer material (660-84996) ZD6550 1 202-2 9-12

2 Main blade 4409 847260 BL-7550D 1 56-46 10-5

3 Cleaning felt roller (upper) 4409 830570 SR-6550H 1 34-41 11-7

4 Cleaning felt roller (lower) 4409 847280 SR-7550L 1 34-9 11-17

5 Cleaning roller 4409 832310 B-6550H 1 34-42 11-17

6 Fur brush 4409 890710 B-6560 1 56-32 10-7

7 Separation roller (LCF) 4401 773010 K-ROL-SPT-CW-H 1 26-37 7-11

8 Pick-up roller (LCF) 4402 038420 K-ROL-PICK-2 1 26-20 7-11

9 Paper-feed roller (LCF) 4402 038540 K-ROL-FEED-2 1 26-7 7-11

10 Charger wire cleaner(main) 4401 905050 K-BASE-PAD-CH-M 1 47-9 8-17

11 Charger wire cleaner (transfer) 4401 905180 K-BASE-PAD-TR 1 30-18 8-19

12 Charger wire cleaner (separation) 4401 905160 K-BASE-PAD-SEP 1 30-19 8-19

13 Charger wire (main) 4402 308040 WIRE-CH-060∗398 1 47-13 8-17

14 Charger wire (transfer/separation ) 4402 308690 WIRE-CH-060∗409 3 30-25 8-17

15 Air filter (developer unit) 4401 906250 FILTER-DEV 1 50-25 9-23

16 Grid (for main charger) 4402 868430 GRID-155 1 47-22 8-17

17 Charger wire (pre-transfer) 4408 607930 WIRE-CH-PT-354 1 57-11 8-17

PARTS NAME

[Items of a Kit]

PAGE &ITEM OFTHE P/L

Q'TYTOSHIBAPARTS NAME

PARTS NO.ITEMNO.

REFERENCEPAGE OFTHE S/M

[Copier interior arrangement]

t e w !0!3!6

q

!5

!7

o

i

u

r y !2!4x2 !1!4

5 2

8

17

15

9

1

3

7

1412

10 13 16

14114 6

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5-165/5560 PRECAUTIONS MAY.1997 © TOSHIBA CORP.

5. PRECAUTIONS REGARDING THE STORAGE AND HANDLING OF SUPPLIES

5.1 Precautions Regarding the Storage of TOSHIBA Supplies

5.2 Inspection and Cleaning of the OPC Drum

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5.6 Grease/Oil/Powder List

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