LCT RT4000 Service
LCT RT4000 Service
SERVICE MANUAL
August 2007
Subject to change
Safety, Conventions, Trademarks
Conventions
Screw
Connector
E-ring
C-ring
Harness clamp
The notations "SEF" and "LEF" describe the direction of paper feed. The arrows indicate the direction of
paper feed.
In this manual, the following important symbols and notations are used.
• A Warning indicates a potentially hazardous situation. Failure to obey a Warning could result in
death or serious injury.
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• A Caution indicates a potentially hazardous situation. Failure to obey a Caution could result in minor
or moderate injury or damage to the machine or other property.
• Obey these guidelines to avoid problems such as misfeeds, damage to originals, loss of valuable
data and to prevent damage to the machine
• This information provides tips and advice about how to best service the machine.
For your safety, please read this manual carefully before you use this product. Keep this manual handy for
future reference.
Safety Information
Always obey the following safety precautions when using this product.
Safety During Operation
In this manual, the following important symbols and notations are used.
Switches and Symbols
Where symbols are used on or near switches on machines for Europe and other areas, the meaning of
each symbol conforms with IEC60417.
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Responsibilities of the Customer Engineer
Customer Engineer
Maintenance shall be done only by trained customer engineers who have completed service training for
the machine and all optional devices designed for use with the machine.
• Work carefully when lifting or moving the machine. If the machine is heavy, two or more customer
engineers may be required to prevent injuries (muscle strains, spinal injuries, etc.) or damage to the
machine if it is dropped or tipped over.
• Personnel moving or working around the machine should always wear proper clothing and footwear.
Never wear loose fitting clothing or accessories (neckties, loose sweaters, bracelets, etc. ) or casual
footwear (slippers, sandals, etc.) when lifting or moving the machine.
• Always unplug the power cord from the power source before you move the product. Before you move
the product, arrange the power cord so it will not fall under the product.
Power
• Always disconnect the power plug before doing any maintenance procedure. After switching off the
machine, power is still supplied to the main machine and other devices. To prevent electrical shock,
switch the machine off, wait for a few seconds, then unplug the machine from the power source.
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• Before you do any checks or adjustments after turning the machine off, work carefully to avoid injury.
After removing covers or opening the machine to do checks or adjustments, never touch electrical
components or moving parts (gears, timing belts, etc.).
• After turning the machine on with any cover removed, keep your hands away from electrical
components and moving parts. Never touch the cover of the fusing unit, gears, timing belts, etc.
• After installation, maintenance, or adjustment, always check the operation of the machine to make
sure that it is operating normally. This ensures that all shipping materials, protective materials, wires
and tags, metal brackets, etc., removed for installation, have been removed and that no tools remain
inside the machine. This also ensures that all release interlock switches have been restored to normal
operation.
• Never use your fingers to check moving parts causing spurious noise. Never use your fingers to
lubricate moving parts while the machine is operating.
Special Tools
During Maintenance
General
• Before you begin a maintenance procedure: 1) Switch the machine off, 2) Disconnect the power plug
from the power source, 3) Allow the machine to cool for at least 10 minutes.
• Avoid touching the components inside the machine that are labeled as hot surfaces.
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Safety Devices
• Never remove any safety device unless it requires replacement. Always replace safety devices
immediately.
• Never do any procedure that defeats the function of any safety device. Modification or removal of a
safety device (fuse, switch, etc.) could lead to a fire and personal injury. Always test the operation of
the machine to ensure that it is operating normally and safely after removal and replacement of any
safety device.
• For replacements use only the correct fuses or circuit breakers rated for use with the machine. Using
replacement devices not designed for use with the machine could lead to a fire and personal injuries.
Organic Cleaners
• During preventive maintenance, never use any organic cleaners (alcohol, etc.) other than those
described in the service manual.
• Make sure the room is well ventilated before using any organic cleaner. Use organic solvents in small
amounts to avoid breathing the fumes and becoming nauseous.
• Switch the machine off, unplug it, and allow it to cool before doing preventive maintenance. To avoid
fire or explosion, never use an organic cleaner near any part that generates heat.
• Wash your hands thoroughly after cleaning parts with an organic cleaner to contamination of food,
drinks, etc. which could cause illness.
• Clean the floor completely after accidental spillage of silicone oil or other materials to prevent slippery
surfaces that could cause accidents leading to hand or leg injuries. Use “My Ace” Silicone Oil
Remover (or dry rags) to soak up spills. For more details, please refer to Technical Bulletin “Silicone
Oil Removal” (A024-50).
• Before serving the machine (especially when responding to a service call), always make sure that the
power plug has been inserted completely into the power source. A partially inserted plug could lead
to heat generation (due to a power surge caused by high resistance) and cause a fire or other
problems.
• Always check the power plug and make sure that it is free of dust and lint. Clean it if necessary. A
dirty plug can generate heat which could cause a fire.
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• Inspect the length of the power cord for cuts or other damage. Replace the power cord if necessary.
A frayed or otherwise damaged power cord can cause a short circuit which could lead to a fire or
personal injury from electrical shock.
• Check the length of the power cord between the machine and power supply. Make sure the power
cord is not coiled or wrapped around any object such as a table leg. Coiling the power cord can
cause excessive heat to build up and could cause a fire.
• Make sure that the area around the power source is free of obstacles so the power cord can be
removed quickly in case of an emergency.
• Make sure that the power cord is grounded (earthed) at the power source with the ground wire on
the plug.
• Connect the power cord directly into the power source. Never use an extension cord.
• When you disconnect the power plug from the power source, always pull on the plug, not the cable.
• Always dispose of used items (developer, toner, toner cartridges, OPC drums, etc.) in accordance
with the local laws and regulations regarding the disposal of such items.
• To protect the environment, never dispose of this product or any kind of waste from consumables at
a household waste collection point. Dispose of these items at one of our dealers or at an authorized
collection site.
• Return used selenium drums to the service center for handling in accordance with company policy
regarding the recycling or disposal of such items.
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Safety Instructions for this Machine
Trademarks
• Microsoft®, Windows®, and MS-DOS® are registered trademarks of Microsoft Corporation in the
United States and /or other countries.
• PostScript® is a registered trademark of Adobe Systems, Incorporated.
• PCL® is a registered trademark of Hewlett-Packard Company.
• Ethernet® is a registered trademark of Xerox Corporation.
• PowerPC® is a registered trademark of International Business Machines Corporation.
• Other product names used herein are for identification purposes only and may be trademarks of their
respective companies. We disclaim any and all rights involved with those marks.
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TABLE OF CONTENTS
Safety, Conventions, Trademarks......................................................................................................................1
Conventions....................................................................................................................................................1
Warnings, Cautions, Notes...........................................................................................................................1
General Safety Instructions............................................................................................................................2
Responsibilities of the Customer Engineer....................................................................................................3
Before Installation, Maintenance..................................................................................................................3
During Maintenance......................................................................................................................................4
After Installation, Servicing............................................................................................................................6
Safety Instructions for this Machine...............................................................................................................7
1. Replacement and Adjustment
Common Procedures........................................................................................................................................11
Trays..............................................................................................................................................................11
Covers...........................................................................................................................................................12
Side Registration Adjustment.......................................................................................................................13
Paper Feed Unit................................................................................................................................................14
Rollers................................................................................................................................................................15
Paper Feed Roller........................................................................................................................................15
Motors...............................................................................................................................................................16
LCT Exit Motor..............................................................................................................................................16
Feed Motor, Grip Motor.............................................................................................................................16
Lift Motor.......................................................................................................................................................18
Sensors..............................................................................................................................................................19
LCT Exit Sensor.............................................................................................................................................19
Paper Height, Paper Width Sensors...........................................................................................................20
Boards...............................................................................................................................................................22
Main Board..................................................................................................................................................22
2. Details
Mechanical Layout...........................................................................................................................................23
Overview......................................................................................................................................................23
Drive Layout..................................................................................................................................................24
Electrical Components.................................................................................................................................25
Electrical Component Summary ................................................................................................................26
Paper Handling................................................................................................................................................29
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Paper Feed Rollers.......................................................................................................................................29
Paper Feed Motors......................................................................................................................................30
Paper Separation.........................................................................................................................................30
Paper Detection/Lift.....................................................................................................................................31
Lift Sensor......................................................................................................................................................32
Paper Size Detection...................................................................................................................................33
Remaining Paper Detection.........................................................................................................................35
Paper End Detection....................................................................................................................................36
Air-assisted Feed Mechanism.....................................................................................................................37
Paper Exit......................................................................................................................................................37
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10
1. Replacement and Adjustment
Common Procedures 1
Trays
• You do not need to remove screw for the stopper pin bracket at the back of the left rail.
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1. Replacement and Adjustment
Covers
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Common Procedures
The side-to-side registration for this LCIT can be adjusted with SP1003-8.
However, if punched hole positions are not aligned on paper fed from this LCIT, you can first adjust the
side registration by changing the tray cover position as described below, and then adjust the side
registration of the image with the SP1003-8 (Side-to-Side Reg: WIDE LCT).
1. Pull out the tray.
2. Change the screw positions at both the right [A] and left [B] sides as shown.
Adjustment range: 0±2.0 mm, Step: 0.5 mm
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1. Replacement and Adjustment
3. Remove:
[A] Paper feed unit ( x1, ( x2)
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Rollers
Rollers
Paper Feed Roller 1
1. Remove:
• Paper feed unit
2. Remove:
[A] Bracket ( x1)
[B] Pick-up roller ( x 1).
[C] Feed roller ( x 1).
[D] Separation roller ( x 1).
Note:
• Never touch the surface of the rollers with bare hands.
• The LCT pick-up and separation rollers are the same as the pick-up and separation rollers in the paper
trays of the main machine. These rollers are interchangeable.
• The feed rollers of the LCT and main machine paper trays are different because they are designed to
rotate in the opposite direction. The feed rollers of the LCT and main machine are not interchangeable.
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1. Replacement and Adjustment
Motors
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Motors
2. Use a small screwdriver to turn the shaft [A] so the pin can slip out of the keyhole.
3. Remove the motor unit [B] ( x4, x2, x2)
4. Remove:
[A] Spring x1. First, loosen screw.
[B] Spring x1. First, loosen screw.
[C] Paper feed motor ( x2, Timing belt x1)
[D] Grip motor ( x2, Timing belt x1)
Reinstallation
• First, attach the tension springs.
• Second, tighten the screws to tighten the belts.
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1. Replacement and Adjustment
Lift Motor
1. Remove:
1 • Rear cover
2. Remove:
[A] Motor unit ( x5, x1)
3. Remove:
[A] Lift motor ( x2, Clip x1, Gear x1)
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Sensors
Sensors
LCT Exit Sensor 1
5. Remove:
[A] Relay sensor bracket ( x2).
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1. Replacement and Adjustment
20
Sensors
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1. Replacement and Adjustment
Boards
1 Main Board
1. Remove:
• Rear covers
[A] Main control board ( x7, Standoff x1, x All).
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2. Details
Mechanical Layout
Overview 2
*1 The tray has 1 paper feed motor that drives the pick-up roller ¬ and paper feed roller Á, and 1 grip
motor that drives the grip roller ¯ (® is the separation roller).
23
2. Details
Drive Layout
1. Lift Motor
4. Grip Motor
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Mechanical Layout
Electrical Components
7. Grip Motor
25
2. Details
5. Lift Sensor
Heater
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Mechanical Layout
Heater
Heat elements that provide heat to keep the paper tray and paper
H Anti-Condensation Heater
stack dry.
Motors
Drives the transport rollers in the feed path that feed the paper
M Grip Motor
from the tray to the LCT exit motor.
M LCT Exit Motor Feeds the paper out the LCT and into the entrance of the copier.
M Lift Motor Raises and lowers the bottom plate of the paper tray.
Drives the pick-roller and feed roller that picks up each sheet
M Paper Feed Motor
and starts to feed it out of the 1st tray.
Board
PCB Main Board Controls the operation of all motors and sensors in the LCT unit.
Sensors
Detects jams in the paper path where the grip motor pulls the paper
S Grip Sensor
from the tray.
S LCT Exit Sensor Detects jams at the exit of the LCT unit.
Detects when the paper in the tray is at the correct height for paper
S Lift Sensor
feed and switches the lift motor off.
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2. Details
Sensors
S Paper End Sensor Detects when the last sheet feeds from the ray.
Detects the paper when it arrives at the paper feed roller and
S Paper Feed Sensor
checks for misfeeds.
2 S Paper Height Sensor 1 1st from the bottom of the 1st tray, detects stack height: 100%
S Paper Height Sensor 2 2nd from the bottom of the 1st tray, detects stack height: 75%
S Paper Height Sensor 3 3rd from the bottom of the 1st tray, detects stack height: 50%
4th from the bottom of the 1st tray, detects stack height: 25% and
S Paper Height Sensor 4
signals near-end.
1 of a set of 3 sensors that detect the width the paper in the 1st
S Paper Width Sensor 1
tray.
1 of a set of 3 sensors that detect the width the paper in the 1st
S Paper Width Sensor 2
tray.
1 of a set of 3 sensors that detect the width the paper in the 1st
S Paper Width Sensor 3
tray.
Detects the leading and trailing edge of each to detect jams in the
S Relay Sensor
horizontal paper path just before the paper exits the LCIT.
Solenoid
SOL Pick-up Solenoid Engages/disengages rotation of the pick-up roller in the tray.
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Paper Handling
Paper Handling
Paper Feed Rollers
This LCT has one paper tray feed tray. Capacity: 2,000 sheets.
The tray contains four rollers:
[A] Pick-up roller
[B] Paper feed roller
[C] Separation roller
[D] Grip roller
The pick-up roller, paper feed roller, and separation roller use the standard FRR paper feed system.
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2. Details
Two stepper motors control paper feed: Paper feed motor [A] and the grip motor [B].
The paper feed motor [A] drives the pick-up roller [C] and the paper feed roller [D].
The grip motor [B] drives the grip roller [E] that feeds the paper out of the tray, and also drives the separation
roller [F].
Paper Separation
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Paper Handling
Paper Detection/Lift
Detection
When the tray set in the machine, the tray is detected by the drawer connector on the back side of the tray.
Lift
When the machine detects that the paper tray is set in the machine:
• The tray lift motor [A] rotates forward
• Coupling gear [B] on the tray lift motor engages pin [C] of the lift drive shaft.
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2. Details
• The tray drive belts [D], connected to the tray bottom plate [E], are driven by the tray lift motor via the
lift drive shaft and tray lift pulleys [F].
• When the lift motor rotates forward, the tray bottom plate [E] rises. The tray rises until the top of the
paper stack pushes up the pick-up roller and the lift sensor in the feed unit is de-activated.
• When the actuator [G] on the rear end of the bottom plate activates the paper height sensors [H], the
remaining paper capacity is detected.
2 When the tray is pulled out:
• Coupling gear [B] separates from pin [C] and the tray bottom plate goes down.
• A damper [I] slows the descent of the bottom plate.
Lift Sensor
When the lift motor turns on, the pick-up solenoid [A] activates to lower the pick-up roller [B]. When the
top sheet of paper reaches the proper paper feed level, the paper pushes up the pick-up roller and the
actuator [C] on the pick-up roller supporter [D] de-activates the lift sensor [E] to stop the lift motor.
After several paper feeds, the paper level gradually lowers, then the lift sensor is activated and the lift motor
turns on again until the lift sensor is de-activated again.
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Paper Handling
The tray has three paper width sensors and one paper length sensor. The illustration above shows how
these sensors are arranged in the tray.
This table below describes how the three width sensors and one length sensor are used to determine the
paper size in the paper tray.
Length
Width Sensors Area
Paper Size Sensor
W1 W2 W3 L1 NA EU
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2. Details
13"×19" NO NO
320×450 mm NO NO
B5 SEF 182×257 mm H L H H NO NO
Table Key
H: Sensor OFF
L: Sensor ON
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Paper Handling
The tray has four paper height sensors. The amount of paper remaining in the tray is detected by the three
paper height photo-interrupter sensors on the left rail as the bottom plate rises. Five states, determined by
the position of the actuator [A] are possible.
1. With the actuator [A] below paper height sensor ¬, no sensor is actuated and the display indicates
100%.
2. When the actuator passes paper height sensor ¬ , the display indicates 75% of the paper supply
remaining.
3. When the actuator passes paper height sensor Á, the display indicates 50% of the paper supply
remaining.
4. When the actuator passes paper height sensor ®, the display indicates 25% of the paper supply
remaining.
5. When the actuator enters the gap of the near end sensor ¯, and then passes paper height sensor
®, the machine signals near end.
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2. Details
6. Finally, when the last sheet feeds, the paper end sensor (a photosensor) signals that the tray is empty.
The paper end sensor [A] (a photosensor) detects the top sheet of the paper in the tray by monitoring the
reflected light. After the last sheet in the tray leaves the tray, the paper end sensor does not receive the
reflected light due to cutout [B]. This causes the tray lift motor to reverse for 2 seconds and lower the tray
bottom plate.
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Paper Handling
Two air assist fans [A] and [B] comprise the air assist mechanism.
The air flow created by the opposing fans floats the first sheet off the top of the stack. This assists in the
separation of the top sheet from the sheet below and prevents double-feeding.
This only works when feeding the following paper types: Thick 2, Thick 3, Special 2.
Paper Exit
37
2. Details
The LCT exit motor [A] drives the first set of exit rollers [B] and timing belt [C] which in turn drives the second
set of exit rollers [D]. The entrance roller of the main machine [E] feeds the paper as soon as it exits the
LCIT.
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MEMO
39
MEMO
40 EN