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Level one
User Manual
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Toshiba Level one User Manual

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LEVEL ONE
BASIC MULTI-FUNCTION PRODUCT TECHNOLOGY
July 26, 2022
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TABLE OF CONTENTS

INTRODUCTION ............................................................................................................................................................. 5
Minimum Technician Requirements .............................................................................................................................. 5
Baseline Exam ................................................................ ................................................................ ............................. 5
GOALS ........................................................................................................................................................................ 6
Copy Process ............................................................................................................................................................... 6
Mechanical ................................................................................................................................................................... 6
Use of Digital Multimeter (DMM) ................................................................................................................................... 6
Electronics ................................................................................................................................................................... 6
Terminology ................................................................................................................................................................. 6
COPIER TECHNOLOGY: AS OLD AS HISTORY ......................................................................................................... 7
SECTION ONE ................................................................................................................................................................ 9
The Copy Process ........................................................................................................................................................ 9
Introduction .................................................................................................................................................................. 9
Goals ........................................................................................................................................................................... 9
Example ......................................................................................................................................................................10
THE TEN PHASES OF THE COPY PROCESS ................................................................................................ ...........11
1. Main Charge ........................................................................................................................................................11
2. Exposing ................................................................................................................................ .............................11
3. Data Reading ................................................................................................................................ ......................11
4. Data Writing ........................................................................................................................................................11
5. Development .......................................................................................................................................................11
6. First Transfer .......................................................................................................................................................12
7. Second Transfer ..................................................................................................................................................12
8. Fusing .................................................................................................................................................................12
9. Cleaning ..............................................................................................................................................................12
10. Discharge Process ..............................................................................................................................................12
Copy Process ..............................................................................................................................................................13
SECTION TWO...............................................................................................................................................................17
The Copy Process .......................................................................................................................................................17
Goals ..........................................................................................................................................................................17
Main Charge ................................................................ ................................................................ ...............................23
Exposure.....................................................................................................................................................................27
Data Reading ..............................................................................................................................................................29
Data Writing ................................................................................................................................................................33
Development ...............................................................................................................................................................39
Transfer ................................................................ ................................................................ ......................................43
Fuser Unit ...................................................................................................................................................................49
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Cleaning......................................................................................................................................................................53
Discharge....................................................................................................................................................................55
SECTION THREE ...........................................................................................................................................................59
Mechanical Components .............................................................................................................................................59
Goals ..........................................................................................................................................................................59
Clutch Mechanisms .....................................................................................................................................................59
Electromagnetic Clutch................................................................................................................................................60
Spring Clutch ..............................................................................................................................................................61
Spring Clutch as a Torque Limiter ...............................................................................................................................62
One Way Clutch (Needle Bearings) ............................................................................................................................. 64
Solonoid ......................................................................................................................................................................67
Bushings .....................................................................................................................................................................68
Bearings......................................................................................................................................................................69
Gears ..........................................................................................................................................................................70
Worm Gears................................................................................................................................................................70
Pulley and Toothed Belt (Timing Belt) ..........................................................................................................................71
SECTION FOUR .............................................................................................................................................................73
Electricity and the use of a Multimeter ......................................................................................................................... 73
Introduction .................................................................................................................................................................73
Principles of Electricity ................................................................................................................................................74
Voltage and Current ................................................................ ................................................................ ....................75
Resistance ..................................................................................................................................................................75
Ohm’s Law ..................................................................................................................................................................76
TYPES OF CIRCUITS.....................................................................................................................................................77
Direct Current (DC) and Alternating Current (AC) ........................................................................................................77
Digital Multimeters (DMM) ...........................................................................................................................................81
Measuring Voltage (Volts) ...........................................................................................................................................87
Measuring Resistance ................................................................ ................................................................ .................91
SECTION FIVE ...............................................................................................................................................................99
MFP Electronics ..........................................................................................................................................................99
The Driver Circuit ......................................................................................................................................................100
Solid State Relays (SSR) ..........................................................................................................................................101
Thermistors and Thermostats ....................................................................................................................................105
Photo Interrupters and Photo Reflectors ....................................................................................................................107
Main Switch and Power Supply .................................................................................................................................109
GLOSSERY ..................................................................................................................................................................115
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INTRODUCTION

Expert service is essential to the success of your company and ours. To help us achieve the goal of expert service, Toshiba America Business Solutions offers a wide range of general and product specific training programs (Toshiba Technical Training Schools). To succeed in product specific classroom or computer-based training programs, a minimal knowledge of basic copier technology and electronics is required. And that’s the purpose of this course: to make sure every candidate that enters a Toshiba Technical Training School
possesses the minimum prerequisites necessary to succeed.
Different technicians possess different levels of knowledge and training. Some are thoroughly informed and have lots of experience. Others are still acquiring basic skills. Since time in the classroom is limited, the more time we spend on basic technical skills, the less time we can devote to important product specific issues. It is important, therefore, that each technician possess the minimum prerequisites listed below BEFORE beginning
this course:

Minimum Technician Requirements

• One-year high school or college electronics
• Six months experience in a field which requires use of hand tools and mechanical aptitude.
• 60 days’ work experience in the dealer’s shop or in the field.
This preparation course will prove to be an invaluable aid in preparing technicians for Toshiba schools, but we
want to emphasize it is not intended as a substitute for instruction gained through formal education or training.

Baseline Exam

A closed book baseline exam will be administered upon arrival at the Toshiba Digital University. This exam is
derived from the prerequisite WebStep CBT for which the technician completed prior to attending class.
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GOALS

Copy Process

• Understand the copy process used in most Toshiba MFP devices.
• Understand PM issues and common troubleshooting techniques associated with each
phase of the copy process.

Mechanical

• Understand the theory of operation of different standard mechanical components used in Toshiba MFD devices.
• Understand PM issues and troubleshooting techniques associated with pertinent mechanical components.
• Know how to repair and maintain basic mechanical components.

Use of Digital Multimeter (DMM)

• Use a DMM to make simple voltage, resistance and current measurements which are commonly associated with the maintenance of MFP systems.
• Check continuity in components, wire harnesses, and switches.

Electronics

• Understand the theory of copier electronics and know how to check the following devices: Circuit Boards (Inputs and outputs), Power Supply, Switches, and Sensors.

Terminology

• Understand the specialized terms used in service manuals for Toshiba Multi- Functional Products.
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COPIER TECHNOLOGY: AS OLD AS HISTORY

Think about it. People have been making copies since the beginning of recorded history. In fact, the advent of primitive copier technologies was the beginning of recorded history. Early societies engraved symbols on clay
tablets. It was slow and costly. Then came the stylus, papyrus and different types of dyes
which were used in a very labor-intensive way to create scrolls. Scribes spent their entire
lives hand-copying scrolls for kings, dukes, and other department heads. This was way before “White-Out” when a mistake could cost a good scribe a couple of years to correct. In
the fifteenth century, the idea of moveable type put Gutenberg’s Printing Press into the
history books and a lot of those scribes were out of work. That one technological advancement cut copy time from a few years for a standard Bible to a couple of months. And after that, it was only another five hundred more years before mimeograph machines began appearing in public schools across the U.S. To this day, retired classroom
teachers still haven’t gotten that blue ink residue off their hands. But it was a lot better
than scrolls.
The pace picked up rather quickly after that. In 1954 Eastman Kodak™ introduced Verifax™ which was a dye transfer process that combined photography and printing to duplicate an original document. Thermography was introduced by 3M™ in 1956. By skipping the need for a master negative, this heat transfer process streamlined the copying process. A copy could be made within four to six seconds, and copies were less expensive. But it still required special paper and there were other limitations. In 1960, the world of copier technology took a giant step with the introduction of the indirect electrostatic copier process. The process was owned by Xerox™ and earned itself the name “Xerography” which is Greek for “dry writing”. The electrostatic process enabled businesses to copy on plain bond paper instead of chemically treated paper. It was fast and automatic. It copied large originals up to nine inches by fourteen inches. Clearly, the modern age of copier technology had begun. Toshiba copiers still use a version of the
electrostatic copy process in its Multi-Functional Products.
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SECTION ONE The Copy Process
(An Overview)

Introduction

In section one and two, we examine the ten phases of the electrostatic copy process. First, we will look at an overview of the entire process and then study each phase in detail. At the end of the detailed study of each phase we will identify Print Quality and other troubleshooting issues that are frequently associated with that phase. The more a technician knows about each phase of the process, of course, the easier it will be to track down and diagnose problems in the field.

Goals

Upon completion of this section, you will:
• Understand the ten major phases of the electrostatic copy process.
• Know the basic construction of the photosensitive drum and how it reacts to light.
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TEN PHASES OF THE ELECTROSTATIC COPY PROCESS

1. Main Charge
2. Exposure
3. Data Reading
4. Data Writing
5. Development
6. First Transfer
7. Second Transfer (If used)
8. Fusing
9. Cleaning
10. Discharging

The Drum

All phases of the copy process, except Exposure, Data Reading, Second Transfer, and Fusing, act upon the Photoconductive Drum. It receives the image to its light sensitive surface and then transfers the image from the surface to either the paper or a transfer belt.
Various materials are used to make different types of drums. Organic Photoconductors (OPC) are the type of drums used in Toshiba MFPs.

Structure of the OPC Drum

The photoconductive drum consists of two layers. The outer layer is a photoconductive layer made of an organic photoconductive carrier (OPC), and the inner layer is an aluminum conductive base in a cylindrical form.
The photoconductor carrier has a special property: when it is exposed to light, the electrical resistance it possesses increases or decreases with the strength of the light. These two properties are crucial to the execution of the copy process.

Example

Strong incident light - Decreases resistance (works as a conductor.) Weak incident light – Increases resistance (works as an insulator.)
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THE TEN PHASES OF THE COPY PROCESS

1. Main Charge

To prepare for the latent image, the main charger generates a high negative voltage which places a uniform negative charge across the surface of the Drum. The charge remains on the drum because the surface has a high electrical resistance in the dark.

2. Exposing

Exposure is a process of illuminating the original with light and reflecting the light through a series of mirrors and a lens unit onto a Charged Couple Device

3. Data Reading

The light reflected from the original is directed to the Charge Coupled Device (CCD) and this optical image information is converted to electrical signals (image signals), which are then transmitted to the image processing section. The CCD for color processing has RGB filters provided over its surface, which allow the CCD to read the light amount in the respective ranges of wavelength. The image data corresponding to the respective RGB colors is then transmitted to the image processing section.

4. Data Writing

Data writing is the process of converting the image signals transmitted from the image processing section into light signals and exposing the drum surface with the light signal.

5. Development

Development is a process of making the electrostatic latent (invisible image) images visible to the eye (visible image). Developer material is supplied to the photoconductive drum surface by means of a magnetic roller, allowing the toner in the developer material to adhere to the areas on the drum surface where the potential is lower than the developer bias which is applied to the magnetic roller.
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THE TEN PHASES OF THE COPY PROCESS continued…

6. First Transfer

First transfer is a process of transcribing the toner image (visible form) formed on the photoconductive drum to a transfer belt. A positive bias is applied to the 1st transfer roller, causing the transfer belt to be positively charged. This in turn helps to form an electric field between the transfer belt (positive) and the photoconductive layer of the photoconductive drum (grounded), this making the toner image transferred to the transfer belt.

7. Second Transfer

An electric field is formed between the 2nd transfer roller and the 2nd transfer facing roller, which generates a paper polarization and thus the toner is transferred from the belt to the paper. When the negative bias is applied to the 2nd transfer facing roller, the 2nd transfer roller is charged (positive), and thus the toner is transferred from the belt to the paper.

8. Fusing

Fusing is a process of melting the toner on the paper and fixing it firmly onto the paper.

9. Cleaning

When toner is transferred from the transfer belt (or the OPC) to paper, a small amount remains on the transfer belt (or the OPC). As remaining toner lowers the image quality, it must be scraped off. The edge of the cleaning blade is pressed against the photoconductive drum surface to scrape off the residual toner.

10. Discharge Process

Discharging is the process of eliminating the (-) charge remaining on the photoconductive drum before the next charging process.
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Copy Process

1 Charging: Places a negative charge on the surface of the photoconductive drum. 2 Exposure: Converts images on the original into optical signals. 3 Data Reading: The optical image signals are read into the CCD and converted into electrical signals. 4 Data Writing: The electrical image signals are changed to light signals (by laser emission) which
exposes the surface of the photoconductive drum.
5 Development: Negatively charged toner is made to adhere to the photoconductive drum, producing a
visual image. 6 1st Transfer: Transfers the visible image (toner) on the photoconductive drum to the transfer belt. 7 2nd Transfer: Transfers the visible image (toner) on the transfer belt to paper. 8 Fusing: Fuses the toner image to the paper by applying heat and pressure. 9 Cleaning: Scrapes off the residual toner from the drum by the blade. 10 Discharging: Eliminates the residual charge from the surface of the photoconductive drum.
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Review
The following questions will help you review the material you’ve just studied and enable you to assess your own understanding of the program.
1. Which part of the drum is most sensitive to light?
A. Upper Layer
B. Lower Layer
2. According to the passage in the workbook, in what year did the process known as “Xerography”
appear?
A. 1940
B. 1960
C. 1980
D. 1990
3. What is the charge of the latent image?
A. Positive
B. Negative
C. Neutral
D. AC
Memory
Put the following important items into “memory”
• During the electrostatic copy process, light reflected off the original image is directed to a Charge Coupled Device (CCD). The CCD converts the reflected light into electrical signals. These signals are then sent to the Data Writing section where the signals are turned back into light (using either an LED array or a LASER). This light strikes the drum surface which eliminates or reduces the charge. The eliminated or reduced charge causes toner to be attracted to the drum surface. The toner is then transferred to a belt and then to paper or directly to paper and fused to form an identical copy.
• The important characteristic of photoconductors is their ability to change resistance in proportion to the intensity of light.
• In the dark, the photosensitive layer of the drum has a high resistance (insulator).
• When exposed to light, the resistance is reduced, and the drum surface becomes a
conductor.
• The more a technician knows about each phase of the copy process, the better she or he will be able to identify the source of Print Quality problems.
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4. What is the charge of the toner particles that are attracted to the latent image? A. Positive B. Negative C. Neutral D. AC
5. Which of the following accurately states the order of the nine phases of the copy process? A. Main Charge
Data Reading Data Writing Development First Transfer Second Transfer (If color device) Fusing Cleaning Discharging
B. Main Charge
Data Reading Development Data Writing First Transfer Second Transfer (If color device) Fusing Cleaning Discharging
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SECTION TWO

The Copy Process
(A Closer Look)

Goals

Upon completion of this section, you will:
• Have a detailed understanding of each phase of the copy process.
• Know the major components associated with each phase of the copy process.
• Know the basic preventive maintenance principles associated with each phase of the copy process
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Toshiba’s Organic Photoconductor (OPC)
A photoconductor is defined as a light sensitive material which acts as a conductor when exposed to light and an insulator in the dark. Toshiba’s Organic Photoconductor meets that definition.
The drum consists of a photoconductive layer on the outside and an aluminum base material on the inside. Changes in the intensity of light falling on the drum create changes in the electrical resistance of the drum surface. When exposed to light, the electrical resistance is reduced, and the drum becomes a conductor. The greater the intensity of light, the less the resistance and the better conductor the surface becomes. In the dark, conductivity does not change. As light changes the conductive and insular characteristics of the drum, electrons can move more freely or less freely between the photosensitive material on the surface and the aluminum base material, thus changing the charge potential on the surface.
By first applying a uniform negative charge to the surface of the drum, and then exposing the drum to light from the LASER or LED assembly, a change in the surface charge takes place which corresponds to the details of the original document or print job. The high intensity of the light (which represents the image) causes the drum surface to become more conductive in those areas and the negative charge dissipates. Essentially the LASER
or LED assembly is “Writing” an invisible image on the surface of the drum. The amount of charges that is
dissipated on the drum surface is directly proportional to the intensity of the light. The higher the intensity, more charge is dissipated. The lower the intensity, less charge is dissipated from the drum. In this way, many different levels of density can be reproduced.
This invisible image is called the “Latent Image”. When toner particles with a negative charge are attracted to
the “more positive” areas of the drum surface (this is the area of the drum which was exposed to an intensity of
light), it becomes a visible image that can be transferred either to a transfer belt or directly to paper.
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The diagram shows the changes in electrical charge on the drums surface in relation to the light from the LASER or LED assembly. As you can see, the areas on the drum corresponding to colored areas on the original are deprived of negative charge, while the areas on the drum corresponding to white areas retain the negative charge. Thus, it forms a negative charge image on the drum surface. This negative charge image is called an “electrostatic latent image.”
Service Tips (for the drum)
• If the condition of the drum surface deteriorates, print quality will of course be negatively affected.
• The drum is temperature as well as light sensitive.
• Store the drum in a cool dry place.
• Exposure to light for an extended period may cause light shock, which could cause permeant damage
to the drum. The drum may recover if placed in the dark.
The following are also potential causes of damage to the drum, and thus, to the quality of the drum.
Fatigue Occurs over time with wear. The drum’s ability to accept a charge potential
decreases.
Physical Damage Scratching or touching the surface will cause imperfections on the copy or print. Surface Contamination If the equipment is not properly cleaned and maintained, contaminants can coat
the drum causing print quality problems.
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Review: OPC Drum
1. True or False: The photoconductor most frequently used in Toshiba’s products – OPC – consists of a photoconductive material and an aluminum base. A. True B. False
2. True or False: When exposed to light the electrical resistance of the drum surface is increased. A. True B. False
3. True or False: The greater the intensity of the light to which the drum is exposed, the less the resistance and the better conductor the surface becomes. A. True B. False
4. True or False: In the dark, the resistance of the drum remains unchanged. A. True B. False
Memory
Put the following important items into “memory”
• Electrical resistance of the drum surface decreases in direct proportion to the intensity of light to which it is exposed.
• The drum insulates in the dark and conducts in the light.
• The shift in charge potential over the surface of the drum is what enables the system to
create a latent image.
• If the condition of the drum surface deteriorates, print quality will be negatively affected.
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5. If the OPC is exposed to ambient light for a long period of time, what is the best action to take to restore the drum? A. Put the drum in a dark place and let it recover. B. Turn the machine OFF and back ON. C. Wipe it off. D. Open the windows.
6. Wear on the drum over time can cause ________________ condition which can decrease the ability of the OPC to accept charge. A. Filming B. Oxidation C. Radioactive D. Fatigue
7. Why is it a good idea for a technician to know as much as possible about the construction and dynamics of the OPC? A. Because of the raise you will get. B. It makes you a better person. C. It will better enable you to diagnose and correct print quality problems. D. So, you can march to the beat of a different drummer.
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Main Charge

The copy process begins when the main charger creates a negative charge on the drum surface. The high voltage transformer generates a high negative voltage to the needle electrode. A strong negative charge inside the housing of the main charger is created. The grid has two functions: first, it regulates how much negative charge is allowed to the drum. Secondly, it ensures a uniform charge across the surface of the drum.
The strong negative charge on the drum surface is balanced by the positive charges that are formed in the aluminum core beneath the photosensitive layer. Since the main charge takes place in the dark, the drum maintains a high resistance which prevents any kind of conductivity from neutralizing the ions. As a result, a uniform negative charge is established and maintained across the entire surface of the OPC drum.
The ultimate purpose of the Main Charge is to prepare the photoconductive layer for the LASER exposure which will follow.
Photosensitive Layer
The HVT generates a negative voltage to charge the needle electrode and the grid. The charge is dissipated through the grid to the drum surface.
Aluminum Base
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Service Tips for Charging System
Any contamination (dirt, toner, oxidation, etc.) or deformation (bending or breaking) of the needle electrode or grid will result in degrading print quality. The following are print quality problems that are sometimes associated with a Main Charger that has not been maintained properly.
Malfunction
Effect on System
Effect on Copies
Broken Needle Electrode
No Main Charge
Solid copies
Worn or dirty Needle Electrode or Grid
Uneven Charge
Uneven Image Density
Charge potential higher than factory spec.
Excessive charge on drum
Charge potential lower than factory spec.
Insufficient charge on drum
Proper Maintenance
Replace needle electrode and grid at specified PM intervals and clean the housing on schedule.
Memory
Put the following important items into “memory”
• The copy process begins when the Main Charger places a uniform negative charge over the photosensitive layer of the OPC.
• The components used to create the Main Charge are the HVT, Needle Electrode, Grid and the OPC.
• The Main Charge is executed in total darkness which preserves the insular character of the OPC and thus “holds” the charge.
• The Main Charge prepares the drum surface to receive the light produced from the LASER or LED assembly.
• If the condition of the Main Charger is not well maintained, print quality will be negatively affected. The Charger should always be cleaned or changed according to the PM schedule.
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Review: Main Charge
1. The potential of the OPC after the Main Charge is executed is: A. Positive B. Negative
2. List the primary components used to execute Main Charge. __________________________________________________________________________________
__________________________________________________________________________________
3. True or False: Since the Main Charge is executed in the dark, the electrical resistance at the surface of the OPC is decreased and a positive charge is created. A. True B. False
4. What will happen to copy quality if the Needle Electrode is not installed?
__________________________________________________________________________________
5. What will happen to the copy quality if the Main Charge is less than what the factory specifies?
__________________________________________________________________________________
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Exposure

The exposure process enables the machine to illuminate the original document and transport the reflected light to the Charged Couple Device (CCD).
Carriage 1 shown here consists of the Exposure lamp, Lamp inverter, Reflector, and Mirror 1. On newer systems, the Exposure Lamp has been changed from a Xenon lamp to an LED lamp. When the LED lamp was introduced, this eliminated the need for the Lamp inverter. So, on most newer systems you will not see a Lamp inverter.
Mirror 1 directs the light reflected from the original to the carriage 2 described below.
Carriage 2 consists of mirror 2 and mirror 3 and directs the reflected light from mirror 1 through the mirrors 2 and 3 to the lens. This carriage is driven by the same scan motor as that for the carriage 1 at half the scanning speed of the carriage 1 (The scanning distance is also half that of the carriage 1).
The light reflected from the mirror 3 described above is led to the CCD placed at the focal point of the lens which is in a fixed position.
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Service Tips for Exposure
Any contamination (dirt, moisture, film etc.) or deformation (cracks) of the optical system will of course obstruct the reflected light and degrade quality of the scan. The following are copy quality problems that are sometimes associated with Optics and Exposure problems.
Malfunction
Effect on System
Effect on Copies
Broken Exposure Lamp
No light, the CCD does not receive any light therefore there is no image data.
Solid copies
Dirt, dust, etc.
Reduced light causes the CCD to interpret the image incorrectly
Uneven Image Density or backgrounding
Obstruction in optical path
Light will not be reflected properly
Line or background band
Mirror out of position
Light will not be reflected properly
Skewed image
Proper Maintenance
Clean reflecting surfaces, lens and original glass at specified PM intervals.
Memory
Put the following important items into “memory”
• In the scanning section, the surface of the original is irradiated with a direct light and the reflected light is led through mirrors, a lens and a slit to CCD.
• A lens and a slit to CCD is where optical–to–electrical conversion is performed, converting the optical image data into an electrical (analog) signal.
• The analog signal is changed to a digital signal, which then undertakes various corrective processes necessary for image formation.
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Data Reading

This device is a digital camera. Although a little different than the one you have on your smart phone. Rather than having a square sensor, it utilizes an inline sensor. The inline sensor is taking pictures line by line as the scanner moves underneath the original. Just like a digital camera, the CCD driving PC board processes signal amplification, signal integration and Analog to Digital conversion.
Reflected Light to Electrical Signal
During the scanning process, the reflected light from the original document is transmitted – one line at a time – to a Charged Coupled Device (CCD). The CCD consist of an array of light sensitive elements which can sense the incoming light and convert it to an analog voltage. Each output of each picture element on the CCD is an analog voltage with a value that corresponds to the density of the scanned original image at a point on the line.
The denser the image (dark space), the less intense the reflected light, and the lower the output signal from the CCD. The less dense the image (white space), the more intense the reflected light, and the greater the output value of the signal.
H=High voltage analog output of CCD (non-image)
L=Low voltage analog output of CCD (image)
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Data Reading continued…
Conversion from Analog to Digital Signal
Before being stored in RAM, the analog signal from each element of the CCD must be converted to a binary number (digital signal). An Analog to Digital (A/D) converter on the controller board converts the analog voltage output from each picture element of the CCD to a binary number. The number (digital data) also corresponds to the density of the original document at a particular point on the line. The digital information is then stored in memory (RAM).
Models with a color scanner use either a 3-line CCD consisting of 3 color devices (red, green and blue) or a 4­line CCD consisting of 3 color devices (red, green and blue) plus 1 black device.
3 Line CCD example”
4 Line CCD example:
The RGB filters are used to separate the light reflected from the original into the primary colors which are then read by the CCD sensor as data of the amount of light
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