Chapter 10 Machine Overview

Chapter 10 Machine Overview

Table of Contents

Table of Contents
10.1 Print Process...........................................................................................................10-2
10.1.1 Print Process Overview ........................................................................................................ 10-2
10.1.2 Print Process Schematic ...................................................................................................... 10-3
10.1.3 Print Process Technical Description ..................................................................................... 10-4
10.1.3.1 Electrical charge .......................................................................................................... 10-4
10.1.3.2 Exposure ..................................................................................................................... 10-5
10.1.3.3 Development ............................................................................................................... 10-7
10.1.3.4 Primary transfer (Drum to Belt) ................................................................................. 10-10
10.1.3.5 Cleaning (Drum) ........................................................................................................ 10-11
10.1.3.6 Repetition (Complete Toner Image Formation) ......................................................... 10-11
10.1.3.7 Secondary transfer (Belt to paper) ............................................................................ 10-13
10.1.3.8 Discharge .................................................................................................................. 10-15
10.1.3.9 Cleaning .................................................................................................................... 10-15
10.1.3.10 Fusing........................................................................................................................ 10-16
10.2 Print Data Flow .....................................................................................................10-17
10.2.1 Data Flow ........................................................................................................................... 10-17
10.3 Drive Channels .....................................................................................................10-18
10.3.1 DRIVE ASSY FEED ........................................................................................................... 10-18
10.3.2 MOTOR ASSY P/R, DRIVE ASSY PRO ............................................................................ 10-19
10.3.3 MOTOR ASSY MAG, MOTOR ASSY ROT ........................................................................ 10-20
10.3.4 MOTOR ASSY DUP ........................................................................................................... 10-21
10.3.5 MOTOR ASSY FSR ........................................................................................................... 10-22
10.3.6 MOTOR-PH ........................................................................................................................ 10-23
10.4 Paper Feed ...........................................................................................................10-24
10.4.1 MSI (Multi Sheet Inserter)................................................................................................... 10-25
10.4.1.1 Primary Operations ................................................................................................... 10-25
10.4.2 Registration & FUSER........................................................................................................ 10-27
10.4.2.1 Primary Operations ................................................................................................... 10-27
10.4.2.2 Paper Lead Edge Adjustment ................................................................................... 10-29
10.4.3 500 Paper Feeder............................................................................................................... 10-30
10.4.3.1 Primary Operations ................................................................................................... 10-30
10.4.4 Duplex ................................................................................................................................ 10-33
10.4.4.1 Primary Operations ................................................................................................... 10-33
10.5 Xerographic...........................................................................................................10-34
10.5.1 Component Functions ........................................................................................................ 10-35
10.5.1.1 ROS ASSY ................................................................................................................ 10-35
10.5.1.2 XERO CRU ............................................................................................................... 10-36
10.5.1.3 Development ............................................................................................................. 10-39
10.5.1.4 2nd BTR .................................................................................................................... 10-41
10.5.1.5 FUSER ASSY............................................................................................................ 10-42
10.5.2 Process Control .................................................................................................................. 10-43
10.6 Electrical ...............................................................................................................10-46
10.6.1 Primary Operations............................................................................................................. 10-46
10.7 Operation Modes ..................................................................................................10-48

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Chapter 10 Machine Overview
10.1 Print Process

10.1 Print Process

10.1.1 Print Process Overview

This machine is a "full-color laser printer", which makes use of the electrophotographic recording
method principles. The machine has 4 toners: "Yellow, Magenta, Cyan and Black (Y, M, C, K)" and a
Drum that develops toner images. The toner image for each color is developed on the Drum and
transferred to the Belt (intermediate transfer unit). Superposing the color images on the Belt realizes
full-color printing.

This machine's print process consists of the following basic steps:

(1) Electrical charge: Charges the Drum surface with electrical charges.
(2) Exposure: Exposes the image part with laser beams.
(3) Development: Develops the image part with toners.
(4) Primary transfer: Transfers the toner image on the Drum to the Belt.
(5) Cleaning: Cleans the Drum.
(6) Repetition: Repeats steps (1) to (5) for each toner in full-color mode.
(7) Secondary transfer: Transfers the toner image on the Belt to paper.
(8) Discharge: Removes the electrical charge on the paper.
(9) Cleaning: Cleans the Belt.
(10) Fusing: Fuses the toners on the paper with heat and pressure.

Drum Belt (Intermediate Paper

transfer Belt)

1Charge

2Exposure 6Forming complete

toner image

6Repeating 3Development

41st transfer (drum to belt) 72nd transfer (belt to paper)

5Cleaning 9Cleaning 8Neutralization

Fixing

Leg_Sec06_001FA

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 Chapter 10 Machine Overview
10.1 Print Process

10.1.2 Print Process Schematic

The print process schematic is shown below.

: Laser beam
: Paper feed
1ST BTR HEAT ROLL
IBT BELT ASSY(Belt) [41st transfer (drum to belt)] [ Fixing]
PRESSURE ROLL
[41st transfer (drum to belt)] [ Fixing]
[6Repeating (forming complete toner image)]
[72nd transfer (belt to paper)]
BACK UP ROLL
Cleaning Sheet [72nd transfer (belt to paper)]
[9Cleaning (Belt)]
Cleaning Roll Detack Saw
[9Cleaning (Belt)] [8Neutralization]

Cleaning Brush
[9Cleaning (Belt)] 2ND BTR
[72nd transfer (belt to paper)]
BELT CLEANER
ASSY

Developer Assy Drum

[3Development]

Toner Cartridge
Cleaning Blade
[5Cleaning (drum)]
ROTARY
FRAME ASSY

ROS ASSY BCR

[2Exposure] [1Charge] Leg_Sec06_002EB

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Chapter 10 Machine Overview
10.1 Print Process

10.1.3 Print Process Technical Description

10.1.3.1 Electrical charge
In the "electrical charge" process, the BCR (Bias Charge Roll) evenly distributes a negative
electrical charge on the surface of the Drum that rotates at a fixed speed.

- The BCR is always in contact with the Drum and driven by the Drum rotation.
The BCR is a conductive roll that discharges the negative voltage with added AC voltage applied
to it from the HVPS to the Drum surface.
The Drum surface is evenly charged with negative electricity by DC bias voltage.
- The Drum surface is photoconductive (becomes a nonconductor when it is in a dark place and a
conductor when it receives light) and is internally composed of a conductor (aluminum cylinder).

: Negative charge
: Positive charge

Drum

Conductor

Photoconductor

HVPS

BCR

Leg_Sec06_005FA

Potential on
Drum surface drum surface
-V

Leg_Sec06_007FA
Leg_Sec06_006FA

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 Chapter 10 Machine Overview
10.1 Print Process

10.1.3.2 Exposure
In the "exposure" process, the negatively charged Drum surface is scanned with laser light to form
an invisible electrostatic latent image on the Drum surface.

- The laser light is emitted from the laser diode in the ROS ASSY to scan the Drum surface
thoroughly from end to end with the polygon mirror, fixed mirrors and lenses of the Scanner Assy
in the ROS ASSY. The laser diode emits one beam of laser light.

Drum

Mirror SOS

PWBA LD
Window

Mirror

SOS Sensor

Lens COL
PWBA SOS
Lens CYL

Scanner Assy
Lens L1
Polygon Mirror Leg_Sec06_008FA

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Chapter 10 Machine Overview
10.1 Print Process

- Emission of the laser light is triggered by the print data (image data) from the printer controller.
Laser light is output only when the print data is composed of pixels (small dots forming a text,
image, etc). (The laser diodes for the parts that will be developed with toners are lit up, while the
diodes for the parts that will not be developed are lit off.)
The Drum surface exposed to the laser light becomes a conductor, in which negative electric
charges flows towards positive side on the Drum and counteract with positive electric charges,
resulting in potential drop on the Drum surface. This lower potential parts forms an electrostatic
latent image.

Photoconductor
: Negative charge
Conductor : Positive charge

Drum

Drum surface
(Laser beam)
(Laser beam)

ROS ASSY
Electrostatic
latent image
Leg_Sec06_009FA Leg_Sec06_011FA

<Concept of drum>
Laser beam Electrostatic
latent image
Potential on
drum surface
(Laser beam)
Photoconductor
-V

Conductor
0

Leg_Sec06_010FA Leg_Sec06_012FA

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 Chapter 10 Machine Overview
10.1 Print Process

10.1.3.3 Development
In the "development" process, the electrically charged toners adhere to the electrostatic latent image
on the Drum surface to form a visible image on it.

- This machine employs the "rotary development method", which performs development by
rotating 4 developers (Developer Assy) sequentially, and the "trickle development method", which
uses 2-element (carrier and toner) developer.
The developer in the Developer Assy is beat with a spiral stirrer called Auger and supplied to the
Magnet Roll, which is placed in neighborhood on the Drum surface. Beating generates frictional
electric charges (toner becomes negative and carrier becomes positive) and they magnetize
each other and fuse.
Since the carrier is a magnetic substance, it is magnetized by the Magnet Roll and forms even
layers through the Trimmer Blade.
Negative voltage with added AC voltage from the HVPS has been applied onto the Magnet Roll.
Since the potential of the electrostatic latent image that has been formed on the Drum by
exposure is relatively positive, the negatively charged toners on the Magnet Roll are magnetized
to form a toner image.

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Chapter 10 Machine Overview
10.1 Print Process

Toner Cartridge
: Negative charge
: Positive charge
Magnet Roll
: Toner
: Carrier

Drum

Developer Assy

Auger
HVPS
Trimmer Blade

Leg_Sec06_013FA

Potential on
Drum surface drum surface
-V

Developer
bias

Toner image 0

Leg_Sec06_014FA
Leg_Sec06_015FA

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 Chapter 10 Machine Overview
10.1 Print Process

- As the number of printed sheets increases, more toners in the developer are consumed. To keep
appropriate development density, the equivalent amount of toner to the one consumed must be
filled from the Toner Cartridge to the Developer Assy. This filling is called "toner dispense".
Dispensing of toner is carried out by using two kinds of controls ("PCDC" and "ADC").
- To create a full-color image using 4 color toners, toner images for Y, M, C and K must be formed
on the Drum sequentially.
This machine has 4 Developer Assy, which are placed at 90-degree intervals on a circle. By
rotating the Rotary Frame Assy, the Developer Assy for each color is opposed to the Drum to
form a toner image for the color. This is called "Rotary Development Method".

Developer Assy M Toner Cartridge Y

Toner Cartridge M Developer Assy Y

Drum

Developer Assy C Toner Cartridge BK

Toner Cartridge C Developer Assy BK

Rotary Frame Assy Leg_Sec06_016FA

- The carrier's electrostatic charge characteristic will deteriorate due to toner contamination on the
surface or surface damage by beating.
To maintain the electrostatic charge, a small amount of carrier is mixed in toner of a Toner
Cartridge. While the toner and carrier is supplied at toner dispense, the deteriorated carrier in the
Developer Assy is collected in a separate compartment in the Toner Cartridge. This is called
"Trickle Development Method". The trickle development is performed by using the Rotary Frame
Assy rotation at rotary development.
The trickle development mechanism is shown below.
(1) A pipe is inserted in the carrier in the Developer Assy.
(2) A small amount of carrier enters the pipe hole.
(3) The carrier is taken up and moved inside the pipe.
(4) The carrier is collected in the Toner Cartridge.
Rotary Frame Assy
L shaped pipe

Drum
Toner Cartridge

Separate chamber
Leg_Sec06_017FA for collecting carrier Leg_Sec06_018FA

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10.1 Print Process

10.1.3.4 Primary transfer (Drum to Belt)

In the "primary transfer" process, the toner images formed on the Drum surface are transferred onto
the Belt surface in the XERO CRU by the 1st BTR (First Bias Transfer Roll).

- The 1st BTR is a conductive roll and has positive charge from the HVPS. The 1st BTR contacts
the rear side of the Belt and supplies positive electricity on the side.
The toner images on the Drum surface that have been negatively charged are magnetized by the
positive electricity on the rear side of the Belt and transferred from the Drum to the Belt.

1ST BTR : Negative charge

: Positive charge
: Toner

HVPS

Drum
Belt

Leg_Sec06_019FA

Drum surface Potential on Belt surface

drum surface
-V

Un-transferred
toner
0

Leg_Sec06_021FA Leg_Sec06_020FA Leg_Sec06_022FA

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 Chapter 10 Machine Overview
10.1 Print Process

10.1.3.5 Cleaning (Drum)

In the "Cleaning (Drum)" process, unnecessary toner is removed from the Drum surface.

- Cleaning a Drum
The toner that was not transferred to the Belt in the "primary transfer" process remains on the
Drum surface. Since the remaining toner on the Drum surface becomes an obstacle for the
subsequent processes, the Cleaning Blade that is in contact with the Drum sweeps off the
remaining toner and collects it in the Cleaner Box.
: Negative charge
: Positive charge
: Toner

Drum

Cleaning Blade Leg_Sec06_023FA

10.1.3.6 Repetition (Complete Toner Image Formation)

In the "Repetition (Complete Toner Image Formation)" process, the toner images for each color that
have formed on the Drum surface are transferred to the Belt sequentially, forming a complete toner
image that is composed of 4 colors on the Belt surface.

: Black toner
1ST BTR : Cyan toner
: Magenta toner
: Yellow toner

Drum

Belt
Leg_Sec06_024FA

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Chapter 10 Machine Overview
10.1 Print Process

Drum surface
(Yellow toner image)

Drum surface
(Magenta toner image)

Belt surface

Yellow
toner image
Magenta
toner image
Drum surface Cyan
(Cyan toner image) toner image
Black
toner image

Drum surface
(Black toner image)

Leg_Sec06_025FA

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10.1 Print Process

10.1.3.7 Secondary transfer (Belt to paper)

In the "secondary transfer" process, the toner image formed on the Belt surface is transferred onto
paper by the 2nd BTR (Second Bias Transfer Roll).

- The 2nd BTR gets in contact with paper only during paper transfer so that it will not damage the
toner image forming on the Belt surface. In normal situations, the 2nd BTR is in the Home
position, which is detected by the SENSOR RETRACT 2BTR. To get in contact with the paper, it
is driven and moved by the MOT ASSY MICRO.

SENSOR 2BTR RETRACT

2ND BTR ASSY MOT ASSY MICRO

Leg_Sec06_026FB

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Chapter 10 Machine Overview
10.1 Print Process

- The 2nd BTR is a conductive roll which is in contact with the back of the toner transfer paper. It
has positive charge from the HVPS.
The Back Up Roll, which is placed opposite the 2nd BTR, is grounded to the frame ground by
using a conductive roll.
The 2nd BTR positioned at the back of the paper charges the paper positively so that the
negatively charged toner images can be transferred from the Belt surface to the paper.
: Negative charge
: Positive charge
Back Up Roll Belt Paper 2nd BTR
: Toner
Detack Saw

HVPS

Back Up Roll 2nd BTR

Leg_Sec06_027FA
HVPS

Belt Paper Leg_Sec06_028FA

Belt surface Paper surface

Residual
toner

Leg_Sec06_029FA Leg_Sec06_030FA

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 Chapter 10 Machine Overview
10.1 Print Process

10.1.3.8 Discharge
In the "Discharge" process, the electrical charge on the paper is neutralized/removed by the Detack
Saw (discharge plate).
- The Detack Saw is in contact with the back of paper. The electrical charge from "the secondary
transfer" makes the toners scatter to neighboring metals. Therefore, the electricity must be
neutralized/removed.

10.1.3.9 Cleaning
In the "Cleaning (Belt)" process, the remaining toner is removed after toner images have been
transferred to paper.

- The Belt Cleaner gets in contact with the Belt only during the cleaning so that it will not damage
the toner images forming on the Belt surface. It is driven by the IBT Retract Motor when getting in
contact.

- The remaining toner on the Belt surface is absorbed by the Cleaning Roll. After that, it is
absorbed by a cleaning brush and collected in the Cleaner Box.

Cleaning Blade : Toner

Belt Cleaner Assy

Cleaning Brush

Belt

Leg_Sec06_031FB

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Chapter 10 Machine Overview
10.1 Print Process

10.1.3.10 Fusing
In the "Fusing" process, the toners are fused on the paper using heat and pressure.

- The Fuser Assy does not have a Pressure Roll and has a Fuser Belt instead.
The Heat Roll is rotated by the MOT ASSY FSR drive and the Fuser Belt starts operation by
following the friction.
The inside of the Fuser Belt is as shown in the figure below. The pressure system in the Belt nips
the Belt and Heat Roll.
- In the Fuser Assy, toners are melted in the Heat Roll by heat from the Heater Lamp. And the
pressure for nipping the Heat Roll and Fuser Belt makes the toners fuse on paper.

Heat Roll
Fuser Belt

Nip Area

Paper

Leg_Sec06_032FB

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 Chapter 10 Machine Overview
10.2 Print Data Flow

10.2 Print Data Flow

10.2.1 Data Flow

The print data (electric signals) from the Printer Controller goes through the following flow before
becoming a print image.

Host (electric signal)

Printer controller (electric signal)

ROS ASSY (laser beam)

Electrostatic latent image on drum

(invisible image)

Toner image on drum (toner image)

Toner image on belt

(intermediate transfer belt)

Toner image on paper

Printed image on paper

Leg_Sec06_033FB

REFERENCE Forming a 2-dimensional Print Image

According to the electric signals from the Printer Controller (VIDEO signals: representing
image data using high and low voltages), scanning an image while turning ON/OFF the laser
light creates a dot image for one line.
By doing the above scan for a whole image, a complete monochromatic image (2-dimensional
dot image) is created. To create a full-color image, this 2-dimensional dot image must be
created respectively for 4 colors.
The resolution is calculated as follows:
Fast scan direction: number of dots/inch
Slow scan direction: number of scan lines/inch

Number of dots/inch
Paper feeding direction

Number of scanning
lines/inch

Leg_Sec06_034FA

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Chapter 10 Machine Overview
10.3 Drive Channels

10.3 Drive Channels

10.3.1 DRIVE ASSY FEED

The DRIVE ASSY FEED rotation is transmitted through the following flow:

DRIVE ASSY FEED

CLUTCH ASSY FEED GEAR FEED

ROLL ASSY TURN 500 ROLL ASSY FEED 500

500 FEEDER ASSY

Leg_Sec06_035EB

CLUTCH ASSY FEED GEAR FEED

DRIVE ASSY FEED FRONT

Leg_Sec06_042EB

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 Chapter 10 Machine Overview
10.3 Drive Channels

10.3.2 MOTOR ASSY P/R, DRIVE ASSY PRO

The MOTOR ASSY P/R and DRIVE ASSY PRO rotations are transmitted through the following flow:

MOT ASSY P/R DRIVE ASSY PRO

FLANGE

GEAR INPUT GEAR-19

DRUM

GEAR BRUSH 22/30 CAM ASSY-IBT CL

CAM ASSY
GEAR BRUSH 32

GEAR DRIVE BRUSH

ROLL ASSY BRUSH IBT GEAR IDLE 26/40

GEAR DTR 23

ROLL DTN
XERO CRU

Leg_Sec06_036EB

GEAR DRIVE BRUSH

GEAR DTR 23
GEAR IDLE 26/40
GEAR BRUSH 22/30
GEAR BRUSH 32
IBT ASSY

MOT ASSY P/R

GEAR INPUT
GEAR-19

DRIVE ASSY PRO

FRONT

Leg_Sec06_045EC

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10.3 Drive Channels

10.3.3 MOTOR ASSY MAG, MOTOR ASSY ROT

The MOTOR ASSY MAG and MOTOR ASSY ROT rotations are transmitted through the following
flow:

MOT ASSY MAG MOT ASSY ROT

GEAR IDLE DISP INPUT GEAR FRAM ASSY-ROTARY

GEAR AUGER DISPENCE

AUGER DISPENCE GEAR MAG

GEAR IDLE GEAR AUGER SUPPLY ROLL MAG

GEAR AUGER ADMIX AUGER SUPPLY

AUGER ADMIX
HOUSING ASSY-DEVE

GEAR AGITATOR

DEVE ASSY
AGITATOR

TNR CRU
(TONER CARTRIDGE)

Leg_Sec06_037FB

MOT ASSY MAG

INPUT GEAR(C)

INPUT GEAR(K)
GEAR IDLE DISP(K)

GEAR IDLE DISP(C)

GEAR IDLE DISP(Y)

INPUT GEAR(M)
GEAR IDLE DISP(M)

INPUT GEAR(Y)

FRAM ASSY-ROTARY MOT ASSY ROT

FRONT

Leg_Sec06_044FC

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10.3 Drive Channels

10.3.4 MOTOR ASSY DUP

The MOTOR ASSY DUP rotation is transmitted through the following flow:

MOTOR ASSY DUP MOTOR ASSY DUP INV

GEAR 48H GEAR 48H

GEAR 40/42 GEAR 40/42 GEAR 20/21H

GEAR 36 GEAR 36 GEAR 36

GEAR 36 GEAR 36 GEAR 30

GEAR 30 OW GEAR 30 ROLLER ASSY INVERTER

INVERTER ASSY DUP

ROLLER ASSY DUP OUT ROLLER ASSY DUP

TRANSPORT ASSY DUP

Leg_Sec06_038FB

INVERTER ASSY DUP

GEAR 30

GEAR 36

GEAR 20/21H
GEAR 30
GEAR 48H
GEAR 36
MOTOR ASSY DUP INV
GEAR 36
GEAR 40/42
GEAR 48H
MOTOR ASSY DUP
GEAR 40/42
GEAR 36
GEAR 36
TRANSPORT ASSY DUP
GEAR 30 OW

FRONT
Leg_Sec06_041FC

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10.3 Drive Channels

10.3.5 MOTOR ASSY FSR

The MOTOR ASSY FSR rotation is transmitted through the following flow:

MOTOR ASSY FSR (Fuser Motor)

GEAR 2ND DRIVE ASSY BTR

GEAR-IDLER GEAR-27

GEAR-IDLER EXIT GEAR HR 2ND BTR ASSY

GEAR EXIT ROLL ASSY FUSER MOT ASSY MICRO

EXIT ROLLER BELT ASSY GEAR-28

FUSER ASSY
CAM ASSY-2ND

TRANSFER ASSY

Leg_Sec06_039EB

FUSER ASSY

GEAR EXIT

GEAR-IDLER EXIT

ROLL ASSY FUSER

GEAR-IDLER

BELT ASSY GEAR 2ND

GEAR HR
MOTOR ASSY FSR

DRIVE ASSY BTR

GEAR-28
GEAR-27

MOT ASSY MICRO 2ND BTR ASSY

TRANSFER ASSY
FRONT
Leg_Sec06_043EC

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10.3 Drive Channels

10.3.6 MOTOR-PH
The MOTOR -PH rotation is transmitted through the following flow:

MOTOR-PH

GEAR 21/104

GEAR 43 GEAR 43

CLUTCH ASSY REGI CLUTCH ASSY PRE REGI GEAR 28/40

ROLL REGI METAL ROLL ASSY-PRE REGI

GEAR PICK UP

ROLL REGI RUBBER

ROLL ASSY MSI

PH ASSY

HOLDER ASSY RETARD MSI

MSI

Leg_Sec06_040EB

PH ASSY

CLUTCH ASSY REGI GEAR 21/104

GEAR 43 MOTOR -PH

GEAR 28/40

GEAR 43 GEAR PICK UP

CLUTCH ASSY PRE REGI

FRONT
HOLDER ASSY RETARD MSI MSI
Leg_Sec06_046EC

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