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Ricoh FT4220 Service Training Manual

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FT4220/4222/4215
SERVICE TRAINING MANUAL

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Summary of Contents for Ricoh FT4220

  • Page 1 FT4220/4222/4215 SERVICE TRAINING MANUAL...

  • Page 2: Important Safety Notices

    IMPORTANT SAFETY NOTICES PREVENTION OF PHYSICAL INJURY 1. Before disassembling or assembling parts of the copier and peripherals, make sure that the copier power cord is unplugged. 2. The wall outlet should be near the copier and easily accessible. 3. Note that some components of the copier and the paper tray unit are supplied with electrical voltage even if the main switch is turned off.

  • Page 3: Safety And Ecological Notes For Disposal

    SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 1. Do not incinerate the toner cartridge or the used toner. Toner dust may ignite suddenly when exposed to open flame. 2. Dispose of used toner, developer, and organic photoconductors according to local regulations. (These are non-toxic supplies.) 3.
  • Page 4 MAJOR DIFFERENCES BETWEEN THE FT4220/4222 AND FT4418/4421 SERIES The FT4220/4222 were developed based on the FT4418/4421. The following table shows the major differences between the FT4220/4222 and the FT4418/4421 series. Section/Item FT4220/4222 FT4418/4421 (A110 and A111) (A048 and A054) Major Features...
  • Page 5 The optional dc power supply The optional dc power unit Unit unit (Model Code: A525) is (Model Code: A494) consists of unique to the FT4220. The the following parts: • DC power supply board optional dc power supply unit • Transformer consists of the following parts: •...
  • Page 6 Section/Item FT4220/4222 FT4418/4421 (A110 and A111) (A048 and A054) Sorter The optional dc power supply FT4418: Installation unit (A525) is not required. The optional dc power supply The interface harness is an unit (A494) is required. accessory of the sorter.
  • Page 7 Section/Item FT4220/4222 FT4418/4421 (A110 and A111) (A048 and A054) Vp Correction The interval of the grid voltage increment is changed as the drum changes. Drum Counter Vp Correction Drum Counter Vp Correction Factor Factor ±0 volt ±0 volt 0 to 1,999 copies...
  • Page 8 Section/Item FT4220/4222 FT4418/4421 (A110 and A111) (A048 and A054) Green Filter A green filter has been added ---- before the lens, to enable red originals to be copied with greater contrast. Scanner Motor The scanner motor drive circuit The main board directly controls Drive Circuit is located on the ac drive board.
  • Page 9 Section/Item FT4220/4222 FT4418/4421 (A110 and A111) (A048 and A054) Cleaning Cleaning Blade The plate on the rubber blade is ---- removed. Toner Same as FT4418 Overflow Sensor Paper Feed Paper Size The paper size switches are When the paper end guide is...
  • Page 10 This ozone filter will be used for the FT4418 series. Electrical Parts Parts Number Description Remarks A1105160 Main Board for FT4220 A1115160 Main Board for FT4222 AZ230039 DC Power Supply Board for DC power supply for FT4222 FT4222 same as FT4418...
  • Page 11 Parts Number Description Remarks A1116492 Operation Panel Ass’y - LT, FT4222 (GES) A1106292 Operation Panel Ass’y - A4, FT4220(GES) A1116292 Operation Panel Ass’y - A4, FT4222 (GES) A1106094 Operation Panel Ass’y - FT4220(Infotec) A1116094 Operation Panel Ass’y - FT4222 (Infotec)

  • Page 12: Overall Machine Information

    SECTION 1 OVERALL MACHINE INFORMATION...

  • Page 13: Specifications

    Full size 100% 100% Reduction Zoom: From 50% to 200% in 1% steps Copying Speed: (FT4220 copier) 20 copies/minute (A4/11" x 8 " sideways) 10 copies/minute (A3/11" x 17") (FT4222 copier) 22 copies/minute (A4/11" x 8 " sideways) 11 copies/minute (A3/11" x 17") Warm-Up Time: Less than 60 seconds (at 20°C)
  • Page 14 Saving the electricity consumption (Manual or manual/auto) Paper Capacity: Cassettes: 500 sheets Paper tray: 250 sheets (FT4220 copier ... 1 paper tray) (FT4222 copier ... 2 paper trays) Manual feed table: 50 sheets Toner Replenishment: Black: Cartridge exchange (370g/cartridge) YIELD 9500 COPIES Color (red, blue, &...
  • Page 15 55 dB less than 40 dB Full system less than 60 dB less than 58 dB less than 40 dB Weight: FT4220 copier FT4222 copier Copier only 55 kg (121.3 lb) 64 kg (141.1 lb) Full system 78 kg (172 lb) 83.5 kg (184 lb)

  • Page 16: Copy Processes Around The Drum

    2. COPY PROCESSES AROUND THE DRUM 2. EXPOSURE 1. DRUM CHARGE 3. ERASE 9. QUENCHING 4. DEVELOPMENT 8. CLEANING 5. PRE-TRANSFER LAMP (PTL) 7. PAPER 6. IMAGE TRANSFER SEPARATION FT4220/4222...
  • Page 17 8. CLEANING The cleaning brush removes most of the toner on the drum and loosens the remainder. Then the cleaning blade scrapes off the loosened toner. 9. QUENCHING Light from the quenching lamp electrically neutralizes the surface of the drum. FT4220/4222...
  • Page 18 Drum residual voltage (Vr) correction factor (SP67) NOTE: a) Boxed items can be adjusted by SP modes surrounded by square brackets [ ]. b) Data which determines the correction factor can be observed by SP modes surrounded by parenthesis ( ). FT4220/4222...

  • Page 19: Mechanical Component Layout

    30. Pressure Roller 14. Toner Supply Unit 31. Hot Roller 15. Optics Cooling Fans 32. Duplex Turn Guide (Option) 16. 1st Feed Roller 33. Exit Rollers 17. Manual Feed Table 34. Hot Roller Strippers 18. Pick-up Roller 35. Exhaust Blower FT4220/4222...

  • Page 20: Drive Layout

    BP2: Timing Belt Pulley G26: Relay Gear G16: Development G27: Relay Gear G29: Duplex CL Gear Transport Gear (Option) G28: Exit Roller Gear Development CL Solenoid Development Unit G17: Toner Supply CL Gear Toner Supply CL Toner Supply Unit FT4220/4222...
  • Page 21 CL Gear BP5: Timing Belt Pulley 2nd Paper Feed CL Lower Relay Roller 2nd Paper Feed Roller G31: Lower Relay Roller Gear G32: Relay Gear G33: 3rd Paper Feed CL Gear 3rd Paper Feed CL 3rd Paper Feed Roller FT4220/4222...

  • Page 22: Electrical Component Layout

    29. Auto image Density Sensor 13. Paper Lift Clutch 30. Fusing Thermistor 14. 1st Paper Feed Clutch Solenoid 31. Toner Overflow Sensor 15. Registration Clutch 32. Fusing Thermofuse 16. Right Cover Switch 33. Exit Sensor 17. Relay Roller Clutch 34. Lens Motor FT4220/4222 1-10...
  • Page 23 58. Main Board 45. Main DC Power Supply Board 59. TC/SC Power Pack 46. Option DC Power Supply Board 60. CC/Grid/Bias Power Pack (FT4220 copier only) 61. Platen Cover Position Sensor 47. Option Transformer (FT4222 copier only) (FT4220 copier only) 62.

  • Page 24: Electrical Component Descriptions

    SOL3 Development Drives the development unit. Clutch Solenoid Switches Main Switch Supplies power to the copier. Cover Safety Switch Cuts the ac power line when the front cover or/and exit cover is open. FT4220/4222 1-12...
  • Page 25 Informs CPU when the lower paper tray runs Sensor out of paper. (FT4222 copier only) Relay Sensor Detects misfeeds. (FT4222 copier only) Platen Cover Detects when the platen cover is positioned Position Sensor about 10 cm (4") above the exposure glass. (FT4222 copier only) 1-13 FT4220/4222...
  • Page 26 Rectifies 26 and 10 Vac input and outputs Supply Board dc voltages. This board is required when the document feeder or/and duplex unit is installed. (FT4220 copier only) Lamps Exposure Lamp Applies high intensity light to the original for exposure.
  • Page 27 10 Vac. Option Transformer Steps down the wall voltage to 26 Vac and 10 Vac. This transformer is required when the document feeder or/and duplex unit is installed. (FT4220 copier only) Others Fusing Thermistor Monitors the fusing temperature. Fusing Thermofuse Provides back-up overheat protection in the fusing unit.
  • Page 28 8. AC POWER AND DC POWER DISTRIBUTION FT4220/4222 1-16...
  • Page 29 (dc battery) for the service program mode and misfeed job recovery. (FT4220) When the main switch is turned on, the ac power supply to the anti-condensation heater is cut off and ac power is supplied to the ac drive board.
  • Page 30 When the main switch is turned off, power is cut off to the main board and to RA401, and the drum and optional anticondensation heaters are turned on. The exposure lamp and the fusing lamp power lines are completely disconnected from the line voltage. FT4220/4222 1-18...
  • Page 31 SECTION 2 DETAILED SECTION DESCRIPTIONS...

  • Page 32: Opc Drum Characteristics

    4. Being less sensitive to changes in temperature (when compared to selenium F type drums). 5. During the drum’s life, drum residual voltage gradually increases and the photoconductive surface becomes worn. Therefore, some compensation for these characteristics is required. FT4220/4222...
  • Page 33 The drum is driven by the main motor [E] through the main motor gear [F], a relay gear and the drum drive gear [G]. The pick-off pawls are always in contact with the drum surface. The ID sensor is electrically connected to the ID sensor connector [H]. FT4220/4222...

  • Page 34: Drum Charge

    The flow of air around the charge corona wire may deposit paper dust or toner particles on the corona wire. These particles may interfere with charging and cause low density bands on copies. The wire cleaner cleans the corona wire when the operator slides the corona unit in and out. FT4220/4222...

  • Page 35: Charge Corona Wire Cleaner Mechanism

    The pads move away from the wire when the charge unit is fully inserted and the cleaning bracket is pushed against the front block [D]. After copier installation the key operator should be instructed how to use this mechanism when copies have white streaks. FT4220/4222...

  • Page 36: Charge Corona Circuit

    The grid trigger pulse applied to CN1-5 is a pulse width modulated signal (PWM signal). This signal is not only a trigger signal; it also changes the voltage level of the grid. As the width of the pulse applied increases, the voltage of the grid also increases. FT4220/4222...
  • Page 37 The CPU increases the development bias voltage depending on the Vr ratio to prevent dirty background on copies. (See page 2-33 for more information.) The CPU also increases the grid voltage to ensure proper image density depending on the Vr ratio. (See page 2-8.) FT4220/4222...
  • Page 38 –20 volts after 2,000 copies (see page 2-8). The drum counter is displayed by SP69. The counter must be reset by SP66 when the drum is replaced with a new one. FT4220/4222...
  • Page 39 Standard ID sensor grid voltage (–560 volts [SP62 = 5]) Vp correction factor Drum counter Vp correction factor ± 0 to 1,999 (copies) 0 (volt) Over 2,000 (copies) –20 (volts) 2.5.3 Vr Detection Grid Voltage = –500 volts (Fixed) FT4220/4222...
  • Page 40 The thermoswitch can be reset manually when the exposure lamp area cools. A green color filter [E] is located just in front of the lens to enable the OPC to more effectively reproduce red image areas. FT4220/4222...

  • Page 41: Scanner Drive

    This relationship can be expressed as: = 2 (V2r) = VD/r where r = Reproduction ratio = First scanner velocity (when the reproduction ratio is "r") = Second scanner velocity (when the reproduction ratio is "r") = Drum peripheral velocity (120 mm/s) FT4220/4222 2-10...

  • Page 42: Lens Drive

    [G]. When the lens moves in the reduction direction, the groove cams move the shading plates closer together. The plate blocks part of the light passing through the lens to keep the intensity of the light on the drum even. 2-11 FT4220/4222...
  • Page 43 The lens always stops while moving from left to right (as viewed from the front) to minimize the error caused by mechanical play in the drive gears [D]. FT4220/4222 2-12...
  • Page 44 3.4.2 Positioning The positioning mechanism is similar to that of lens positioning, as shown in the above positioning chart. The scanner always stops while moving from right to left (as viewed from the front). 2-13 FT4220/4222...

  • Page 45: Original Size Detection In Platen Mode

    The second check is done when the platen cover (or DF) is closed and the platen cover closed switch [F] is actuated. The platen cover closed switch is a lead switch. A magnet [G] mounted on the platen cover (or DF) actuates the lead switch. FT4220/4222 2-14...
  • Page 46 When a copy is made with the platen cover (DF) open, the CPU uses the original size data detected when the Start key is pressed. When an original is fed to the exposure glass through the DF, the CPU uses the original size data from the DF. 2-15 FT4220/4222...

  • Page 47: Automatic Image Density Sensing

    RAM. It then computes the image density of the original from the maximum sample voltage and changes the development bias accordingly. (See page 2-31 for details.) The exposure lamp voltage is constant regardless of the image density of the original. FT4220/4222 2-16...
  • Page 48 (see page 2-21). 3.7.3 Reproduction Ratio Correction To compensate for the change in the concentration of light on the drum, the exposure lamp voltage increases depending on the selected reproduction ratio (see page 2-21). 2-17 FT4220/4222...

  • Page 49: Exposure Lamp Voltage Control

    69.0 128.1 83.9 155.6 69.6 129.2 84.4 156.7 70.2 130.2 85.0 157.8 70.8 131.3 85.6 158.8 71.3 132.4 NOTE: Exposure lamp rating: 115 V machine: 97 V/280 W 220/230/240 V machine: 180 V/310 W Default data value: 126 FT4220/4222 2-18...
  • Page 50 Auto image density level SP data (SP34) Exposure lamp data Development bias shift Same as level 4 ±0 volts Normal (Vo ±0) Same as level 4 Darker +40 volts (Vo ±0) Same as level 5 ±0 volts Lighter (Vo +4) 2-19 FT4220/4222...
  • Page 51 SP94 should be performed to clear V correction. correction clear (SP94) SP data (SP94) correction Not clear Clear NOTE: When "1" is input in SP94, the machine on time (SP57) data is cleared. Perform SP94 whenever optics parts are cleaned. FT4220/4222 2-20...
  • Page 52 Change of exposure lamp data 50 to 61% ±0 62 to 139% 140 to 159% 160 to 179% 180 to 200% The exposure lamp data increases depending on the selected reproduction ratio as shown in the above table. 2-21 FT4220/4222...

  • Page 53: Exposure Lamp Control Circuit

    The voltage applied to the exposure lamp can be changed with SP48 (Light Intensity Adjustment). The ADS voltage adjustment (SP56) must be done whenever the light intensity adjustment is done. FT4220/4222 2-22...
  • Page 54 The erase lamp has four functions: lead edge erase, side erase, trail edge erase and editing mode erase (erase edge or/and erase center). Trail edge erase begins after the trailing edge of the copy paper; therefore, the trailing edge of the copy will not be erased. 2-23 FT4220/4222...
  • Page 55 (Vr detection). 4.1.2 Side Erase Based on the combination of copy paper size and the reproduction ratio data, the LEDs turn on in blocks (labeled "a" – "p" above). This reduces toner consumption and drum cleaning load. FT4220/4222 2-24...
  • Page 56 Erase center and edge..Press "8" a) Center Erase The erase margin of the center is done through the timing of when the entire line of LEDs turns on. The margin can be changed by SP26 as shown. 2-25 FT4220/4222...
  • Page 57 12 mm 6 mm 8.5" x 11", 8.5" x 5.5" A4R, A5, 8" x 13", 11 mm 6 mm 8" x 10.5", 8" x 10" B5R, B6 10 mm 5 mm (Factory setting: SP13 = 0) Non-standard paper size FT4220/4222 2-26...
  • Page 58 A hole, fitted with a filter [F], has been added to the top of the unit to relieve air pressure and to minimize toner scattering. 2-27 FT4220/4222...

  • Page 59: Drive Mechanism

    The knob has a one-way clutch inside. The one-way clutch prevents the development roller from turning in the wrong direction. The development clutch solenoid energizes each copy cycle after image development is completed. This stops the rollers, thereby reducing developer fatigue. FT4220/4222 2-28...

  • Page 60: Cross-Mixing

    [F]. The agitator moves the developer slightly to the front as it turns, so the developer stays level in the development unit. 2-29 FT4220/4222...

  • Page 61: Development Bias For Image Density Control

    ID level. The voltage applied at each ID level is shown in the above table. The base exposure lamp voltage also varies depending on the manual ID level as shown in the table. (See page 2-19 for more information.) FT4220/4222 2-30...
  • Page 62 –280 volts TL4 > K ≥ TL5 –360 volts –320 volts TL5 > K –380 volts –340 volts ADS Output Voltage (Peak Hold Voltage ) ADS Reference Voltage (SP56) TL1 to TL5: Threshold level (see the following table) 2-31 FT4220/4222...
  • Page 63 The above table gives the base bias voltage for each SP mode setting. This adjustment should be done only when the exposure lamp voltage adjustment (SP48) fails to achieve the desired image density. FT4220/4222 2-32...
  • Page 64 Vrp: ID sensor output for Vr correction pattern Vsg: ID sensor output for bare drum When the Vr correction is made every 1,000 copies, all blocks of erase lamps turn on and the development bias becomes 0 volt to develop the Vr correction pattern. 2-33 FT4220/4222...

  • Page 65: Development Bias Circuit

    As the width of the trigger pulses increase, the voltage of the development roller also increases. The CPU monitors the development bias voltage at CN1-6 and controls the width of the bias trigger pulses based on this feedback. FT4220/4222 2-34...
  • Page 66 [B] at the rear side of the development unit. The color switch has two microswitches (SW6-1 [C] and 6-2 [D]) inside. The CPU receives a LOW signal from the microswitch activated by the screw and determines which color unit has been installed. 2-35 FT4220/4222...

  • Page 67: Detect Supply Mode

    The toner is not added all at once. The CPU energizes the toner supply clutch for the proper amount of time to add a selected amount of toner over the next 10 cycles. When a color development unit is used, the CPU automatically selects fixed toner supply mode. 2-36 FT4220/4222...
  • Page 68 (See page 2-43 for more information.) When the data of SP35 is set to "1" (factory setting = "0"), the CPU changes the interval of the ID check from every 10 copies to every 5 copies for the black development unit. FT4220/4222 2-37...

  • Page 69: Fixed Supply Mode

    In this case, a fixed amount of toner is added every copy cycle depending on the selected toner supply ratio (SP32 (black toner), SP70 (color toner)), the paper size in use, and the color data. (See page 2-45 for more information.) 2-38 FT4220/4222...
  • Page 70 CPU stops supplying toner. Toner supply resumes when Vsp rises above the threshold level again. Vsg 4V Low Density Threshold Level High Density [COLOR] The threshold level (a percentage) for each color can be monitored in SP80 (Red), 81 (Green) and 82 (Blue). FT4220/4222 2-39...
  • Page 71 SP33 or SP75. This adjustment should be used only when the exposure lamp voltage adjustment (SP48) and the base bias adjustment (SP37 or SP79) for copy image can not achieve the desired image density. 2-40 FT4220/4222...
  • Page 72 More than 500 copies ±0 volts ±0 volts 12 to 15 ±0 volts 0 to 7 –40 volts ±0 volts 8 to 11 –20 volts ±0 volts 16 to 21 +20 volts ±0 volts More than 22 +40 volts FT4220/4222 2-41...
  • Page 73 The toner agitator [H] mechanism, which is contained in the toner cartridge, prevents toner from blocking. The toner agitator gear [I] turns whenever the toner supply clutch solenoid is engaged. Rotation passes through the toner cartridge casing to the agitator junction [J]. 2-42 FT4220/4222...

  • Page 74: Toner Supply Amount

    Paper size is A4 or LT. The paper size data = 1. Toner Supply Clutch ON Time = I x T x P = 29 x 2 x 1 = 58 (pulses) = 232 (m sec.) (1 pulse = 4.0 m sec.) FT4220/4222 2-43...
  • Page 75 4. Detect Toner Supply Ratio Data (SP31) SP data (SP31) Toner supply ratio Toner supply ratio data Paper Size Data Paper size Paper size data Paper size ≤ A4 or LT Paper size > A4 or LT 2-44 FT4220/4222...
  • Page 76 Black toner is used. The color data = 1. Toner Supply Clutch ON Time = T x P x 2 x C = 2 x 29 x 2 x 1 = 116 (pulses) = 464 (m sec.) (1 pulse = 4.0 m sec.) FT4220/4222 2-45...
  • Page 77 21.0% 28.0% Paper Size Data Paper size Paper size data 11" x 17" " x 14" " x 11" " x 8 " Universal ( Paper size not detected Color Data Color Color data Black Blue or Green 2-46 FT4220/4222...
  • Page 78 16th ~ 20th copies 16th copy 22.6 Add Toner indicator 21st copy 21st copy 22.6 starts blinking (near toner end condition) Add Toner indicator blinks (near toner end condition) Add Toner indicator 71st copy — — — lights (toner end condition) FT4220/4222 2-47...
  • Page 79 If the toner end or near end condition is not cleared, copying is inhibited. This prevents the customer from clearing the near end or toner end condition by simply opening and closing the front cover or turning off and on the main switch. 2-48 FT4220/4222...

  • Page 80: Color Toner End Detection

    When the toner end lever releases the toner end arm, the toner end plate lowers and the actuator [G] on the toner end arm moves into the toner end sensor. The CPU receives a single pulse from the toner end sensor. FT4220/4222 2-49...
  • Page 81 3 seconds to supply toner to the empty toner supply unit from the toner cartridge. A toner end detection is also done during this 3 second period. The CPU performs this operation a maximum of 3 times (9 seconds) to clear the toner end condition. 2-50 FT4220/4222...

  • Page 82: Image Transfer And Paper Separation

    In addition, the paper is held against the drum by the positive counter charge on the drum. FT4220/4222 2-51...

  • Page 83: Paper Separation

    The two pick-off pawls [E] ensure that thin, low stiffness paper and upward curled paper separate completely. The spurs [F] prevents the unfused toner on the paper from being smeared by the pick-off pawls. 2-52 FT4220/4222...
  • Page 84 When the main switch is turned off and on, or the front cover or the exit cover is opened and closed, this condition is cleared. FT4220/4222 2-53...

  • Page 85: Drum Cleaning

    [E] neutralizes any charge remaining on the drum in preparation for the next copy cycle. The cleaning blade releases when the release knob is pressed. This cleans the edge of the cleaning blade using the blade scraper [F], which is mounted under the cleaning blade. 2-54 FT4220/4222...

  • Page 86: Drive Mechanism

    The gear [D] driven by the cleaning drive gear passes the rotation to the toner collection roller gear [E] and to the cleaning brush gear [F] through the idle gears [G]. The cleaning blade [H] is mounted in the center of the blade and is tilted to apply even pressure. FT4220/4222 2-55...

  • Page 87: Toner Overflow Detection

    [C], the CPU starts to blink "E70" on the operation panel. After the "E70" starts to blink, 250 copies can be made. Then, after 250 copies the "E70" stops blinking (stays on) and copying is inhibited. 2-56 FT4220/4222...
  • Page 88 In preparation for the next copy cycle, light from the quenching lamp (QL) [A] neutralizes any charge remaining on the drum [B]. The neon lamp is used for quenching and it is turned on whenever the main motor rotates. FT4220/4222 2-57...

  • Page 89: Paper Feed And Registration

    10. PAPER FEED AND REGISTRATION 10.1 OVERVIEW FT4220 copier has two paper feed stations (1 cassette + 2 paper trays) and manual feed table [A]. FT4222 copier has three paper feed stations (1 cassette + 2 paper trays) and manual feed table.

  • Page 90: Frr Feed System

    The reverse roller, however, is driven through a slip clutch (torque limiter clutch) which allows it to turn in either direction depending on the friction between the rollers. A spring keeps the reverse roller in contact with the feed roller. FT4220/4222 2-59...
  • Page 91 If two or more sheets are fed between the rollers, the forward force on the second sheet (F3), becomes less than F1 because the coefficient of friction between the two sheets is small. So, the reverse roller starts turning clockwise and drives the second sheet back to the cassette. 2-60 FT4220/4222...
  • Page 92 Under the following conditions, the CPU checks the paper lift sensor [H] to see if the paper is at the feed position: 1. When the Start key is pressed. 2. When the warm-up condition changes to the ready condition. 3. When the manual feed table is closed. FT4220/4222 2-61...
  • Page 93 The paper end sensor then sends a HIGH signal to the main board. The Add Paper indicator then turns on. The Wait indicator keeps turning on and the machine stops after the copy cycle is finished. 2-62 FT4220/4222...
  • Page 94 This prevents the paper end feeler from being damaged by the paper tray. When the paper tray is closed, the projection [K] on the paper tray pushes the release arm to release the paper end actuator and the paper end feeler. FT4220/4222 2-63...

  • Page 95: Paper Size Detection

    The paper size switch is actuated by an actuator plate [B] on the rear of the cassette. Each paper size has its own unique combination of notches in the plate. The CPU receives a LOW signal from the microswitches activated by the actuator and determines which cassette was inserted. 2-64 FT4220/4222...
  • Page 96 0 0 0 1 1 8" x 10" 0 1 0 1 1 " x 8 " 1 1 0 1 1 0 0 1 1 1 No Cassette 1 1 1 1 1 — 0: Actuated (Low) 1: Not Actuated (High) FT4220/4222 2-65...
  • Page 97 Each paper size has its own unique combination of holes in the block. The CPU receives a LOW signal from the microswitches activated by the block and determines which paper size is used in the paper tray. 2-66 FT4220/4222...
  • Page 98 0: Actuated (Low) 1: Not Actuated (High) NOTE: 1. SP96 (special paper size setting) sets the appropriate paper size for special paper when setting the " " mark on the paper size detection block. 2. Duplex modes cannot be selected. FT4220/4222 2-67...

  • Page 99: Paper Feed Drive Mechanism

    [H]. After the trailing edge of the paper passes under the pick-up roller, the pick-up roller release solenoid is de-energized and the pick-up roller drops back onto the paper stack in preparation for the next copy cycle. 2-68 FT4220/4222...
  • Page 100 2nd feed roller shaft and turns the 2nd feed rollers [G]. The 2nd feed rollers stop turning when the 2nd feed clutch gear completes one rotation. The relay roller clutch stays energized until the leading edge of the paper reaches the registration rollers. FT4220/4222 2-69...
  • Page 101 The relay roller clutch stays energized until the leading edge of the paper reaches the registration rollers. The relay sensor [I] is located just after the lower relay roller [J]. This sensor is used for paper misfeed detection. 2-70 FT4220/4222...

  • Page 102: Slip Clutch Mechanism

    The hubs and spring are precisely machined, and the output hub and spring slip when a single sheet of paper feeds between the feed roller and reverse roller. FT4220/4222 2-71...
  • Page 103 The manual feed table switch sends a LOW signal to the main board so that the Manual Feed indicator turns on and the pick-up roller is lifted up. When paper is loaded onto the manual feed table, the manual feed is selected automatically. 2-72 FT4220/4222...

  • Page 104: Paper Registration

    The CPU energizes the registration clutch 1.4 seconds (1st feed station) after the Start key is pressed. The registration rollers then feed the paper to the image transfer section. FT4220/4222 2-73...

  • Page 105: Paper Feed And Misfeed Detection Timing

    2285 (LTS) Release Solenoid 2010 2010 2010 120ms 120ms 120ms Registration Sensor 2000 2000 2000 Registration Clutch 1433 (FT4220 copier) 2183→1433 2933→1433 3683→1433 1557 (FT4222 copier) 2252→1557 2947→1557 3642→1557 <2nd Feed Station> 2010 2010 2010 Relay Roller Clutch 500ms 500ms 500ms...
  • Page 106 2.75 (A4 sideways) or 2.80 (Letter sideways) seconds after the exit sensor has been actuated. (FT4222 copier only) Checks whether the relay sensor is actuated within 267 pulses (1.07 seconds) after the 3rd feed clutch turns on. FT4220/4222 2-75...

  • Page 107: Image Fusing

    When the sorter is installed, the paper sensor on the sorter also functions as a misfeed detector. 2-76 FT4220/4222...
  • Page 108 When the front cover and/or the exit cover is opened, the actuator plate [C] pulls release wire [D] and the fusing unit drive gear is disengaged. The actuator plate also releases the cover safety switch [E] removing all power from the copier and the optional peripherals. FT4220/4222 2-77...

  • Page 109: Fusing Lamp Control

    If the fusing lamp (780 W) is turned on or off when the exposure lamp is on, the power supplied to the exposure lamp will fluctuate, possibly degrading the copy image. To prevent this, the fusing lamp does not switch during scanning; it stays either on or off. 2-78 FT4220/4222...

  • Page 110: Energy Saver Function

    3. Opening the platen cover (FT4222 copier only), 4. Opening the DF or setting original on it. When the auto energy saver mode (SP78) is selected, the copier automatically goes to the energy saver mode at the auto reset time selected by SP15. FT4220/4222 2-79...

  • Page 111: Fusing Lamp Control Circuit

    This trigger pulse allows maximum ac power to be applied to the fusing lamp. When the operating temperature is reached, the CPU stops outputting the trigger pulse (trigger goes HIGH) and the fusing lamp turns off. 2-80 FT4220/4222...
  • Page 112 The amount of time that power is applied to the fusing lamp [D] depends on the temperature of the hot roller. The trigger pulse (LOW part) is wider [C1] when the hot roller temperature is lower, and it is narrower [C2] when the hot roller is near the operating temperature. FT4220/4222 2-81...
  • Page 113 At the same time "E53" lights on the operation panel and the power relay (RA401) turns off. Even if the thermistor overheat protection fails, a thermofuse is installed in series with the fusing lamp. If the thermofuse temperature reaches 169°C, the thermofuse opens, removing power from the fusing lamp. 2-82 FT4220/4222...

  • Page 114: Document Feeder

    SECTION 3 DOCUMENT FEEDER...

  • Page 115: Specifications

    One flat belt Copy Speed: 20 copies/minute for A4/8 " x 11" sideways Power Consumption: 20 W Dimensions (W x D x H): 670 x 460 x 103 mm (26.4" x 18.1" x 4.1") Weight: Approximately 9.0 kg (19.916 lb) FT4220/4222...

  • Page 116: Component Layout

    3. Pulse Generator Sensor 11. Inverter Solenoid 4. Original Width Sensor 12. Feed-out Sensor 5. Pick-up Solenoid 13. Original Select Switch 6. Belt Drive Motor 14. Feed-in Solenoid 7. Indicator Panel 15. DF Position Sensor 8. Lift Switch (FT4222 copier only) FT4220/4222...

  • Page 117: Electrical Component Descriptions

    DF Position Sensor Detects when the document feeder is positioned about 10 cm above exposure glass. (FT4222 copier only) Printed Circuit Boards PCB1 DF Main Board Controls all DF functions. PCB2 Indicator Panel Contains operator indicators. Board FT4220/4222...

  • Page 118: Overall Machine Control

    LEDs directly. The belt drive motor and the inverter motor are controlled by the DF CPU through their respective driver ICs. The exchanged signals are shown in the tables on the next page. FT4220/4222...
  • Page 119 Requests the DF to feed-out the original Invert Original Requests the DF to invert the original Auto Feed Shifts the DF to the auto feed mode Original Stay Attempt to use DF but the original from the previous copy run remains on the exposure glass FT4220/4222...

  • Page 120: Basic Operation

    At this time, the scanner begins returning to the home position. When the scanner comes to the return position after scanning the last original, the copier CPU only sends the feed-out signal in order to feed-out the last original. FT4220/4222...
  • Page 121 Auto Feed indicator. The Auto Feed indicator remains on for five seconds after the copier main motor stops. If another original is inserted within that five-second period, it is automatically fed and copied. FT4220/4222...

  • Page 122: Power Distribution

    6. POWER DISTRIBUTION 6.1 FT4220 COPIER +12V +24V Option DC Option 115Vac +24V (VA) Regulator AC Drive 26Vac Power Supply Transformer Board Board (TR2) (PCB2) (PCB6) 220/230/240Vac +5V (VC) 10Vac DF Main Board (PCB1) The DF uses three DC power levels: +24 volts, +12 volts, and +5 volts.
  • Page 123 10 volts ac input to +5 volts dc and the 31 volts ac input to +24 volts. Then, those two dc voltages are supplied to the DF main board through the copier main board. The regulator IC on the DF main board further steps down the 24 volts to +12 volts. FT4220/4222...

  • Page 124: Original Feed

    DF will be used. When the Start key is pressed, the pick-up solenoid [B] is energized. The original stack is then pressed between the pick-up lever [C] and pick-up roller [D]. The rotation of the pick-up roller advances the bottom original. FT4220/4222 3-10...
  • Page 125 The friction belt prevents multiple feeds because the resistance of the friction belt is greater than the friction between original sheets. 3-11 FT4220/4222...

  • Page 126: Original Feed-In Mechanism

    The pulse generator disc [G] always turns when the belt drive motor is on. Slightly after the original trailing edge passes the registration sensor, the relay rollers and the transport belt stop turning. FT4220/4222 3-12...
  • Page 127 After the exposure cycle is completed, the copier sends the feed-out signal to the DF CPU and the belt drive and feed out motors start turning. At this time, the copied original feeds out and the next original feeds in. 3-13 FT4220/4222...

  • Page 128: Original Size Detection

    [A], registration sensor, and pulse generator sensor [B]. The original’s length is calculated by counting the number of pulses from the pulse generator while the registration sensor is on. Original size detection is necessary for the feed-in/feed-out timing of the DF. FT4220/4222 3-14...

  • Page 129: Original Inversion Mechanism

    DF registration sensor [A]. The feed-out motor [B] and the inverter solenoid [C] turn on 100 milliseconds after the original trailing edge passes the registration sensor. When the inverter solenoid turns on, the inverter pawls [D] rotate counterclockwise. 3-15 FT4220/4222...
  • Page 130 5) The original is fed onto the exposure glass again as in step 3 above. The front side of the original is then copied. 6) After the front side of the original has been exposed, the original is fed out from the DF. FT4220/4222 3-16...

  • Page 131: Original Feed-Out Mechanism

    220 milliseconds and then stops. The lower speed prevents uneven stacking of originals. For A3 or double letter size originals, the feed-out motor speed does not change due to the length of the originals. 3-17 FT4220/4222...
  • Page 132 An encoder in the servomotor has two magnetic sensors that generate two pulse signals (phase A and B). The driver IC monitors the belt speed and direction by these pulse signals and uses this data to regulate the motor’s speed. FT4220/4222 3-18...
  • Page 133 The frequency generator of the feed-out motor makes a very low voltage ac current which is fed back to the driver IC. The driver IC monitors the frequency of this ac current and based on the frequency it regulates the motor speed. 3-19 FT4220/4222...

  • Page 134: Input And Output Circuits

    +12 volts or +5 volts. To energize a solenoid or indicator, the CPU drops the connected trigger line from +24 volts to LOW. The CPU monitors the input lines of the sensors and switch to determine when they are activated. FT4220/4222 3-20...

  • Page 135: Lift Mechanism

    [F]. The lift switch is turned off during this condition, so the DF does not function. The tension of spring [G] returns the DF to the normal condition after copying a thick original. 3-21 FT4220/4222...

  • Page 136: Original Misfeed Sensing

    Original Misfeed indicator also lights if the feed-out sensor is not actuated within 1,250 milliseconds after the feed-out motor starts turning (ON check) or if the feed-out sensor does not turn off within 1,250 milliseconds after the feed-out sensor is actuated (OFF check). FT4220/4222 3-22...
  • Page 137 (OFF check). If a previous original remains on the exposure glass after manual copying and DF feed is attempted, the original misfeed indicator lights. When the DF is lifted and the previous original is removed, DF copying is permitted. 3-23 FT4220/4222...
  • Page 138 SECTION 4 SORTER...

  • Page 139: Specifications

    (Non-Sort/Stack Mode) Power Source: +5 volts and +24 volts from the copier Power Consumption: 7.7 W Dimensions: 402 mm x 443 mm x 217 mm (W x D x H) (15.8" x 17.4" x 8.5") Weight: 7.5 kg (16.5 lb) FT4220/4222...

  • Page 140: Component Layout

    4. Upper Paper Guide 5. Lower Paper Guide 6. Bin Guide – Electrical Components – 1. Sorter Main Board 5. Sorter Switch 2. Paper Sensor 6. Bin Drive Motor 3. Wheel Switch 7. Home Position Switch 4. Roller Drive Motor FT4220/4222...

  • Page 141: Electrical Component Descriptions

    Paper Sensor Serves as the misfeed sensor for the sorter and also sets exit roller and bin drive timing. Printed Circuit Board PCB1 Sorter Main Board Serves as the communication board between the copier main board and the sorter. FT4220/4222...
  • Page 142 IC outputs the status of the sensor and switches as the scan output signal. The copier main board also sends the sorter drive signal to the drive IC on the sorter main board. After receiving the drive signal, the drive IC turns on the appropriate motors. FT4220/4222...

  • Page 143: Basic Operation

    250 milliseconds after the last copy of the original has gone through the paper sensor. If the Sorter key is pressed during stack mode, all bins shift to home position. FT4220/4222...
  • Page 144 [D]. The shaft of the lower exit roller is a cylindrical cavity type which rotates around the transfer wheel shaft [E]. The paper sensor is positioned just in front of the exit rollers. The paper sensor detects misfeeds in the sorter. FT4220/4222...
  • Page 145 Using the scan output signal, the copier main board determines the status of the sensor. For safety reasons, the CPU limits the operation time of the roller drive motor to 5 seconds. FT4220/4222...

  • Page 146: Bin Drive Mechanism

    The bins sit on each other with the lower bin resting on the permanently-mounted 10th bin. The upper and lower paper guides pivot up and down depending on the height of the bin to be picked up or released. FT4220/4222...
  • Page 147 [J]. The actuator cam has two flat sides that are 180 degrees apart and is mounted behind the rear transfer wheel. A pulse is generated each time one of the lobes of the actuator cam passes the wheel switch. FT4220/4222...

  • Page 148: Bin Drive Circuit

    The CPU monitors the on-time of the bin drive motor to detect a malfunction of the bin drive motor. If the bin drive motor continues to rotate more than twelve seconds, the CPU stops machine operation. FT4220/4222 4-10...

  • Page 149: Misfeed Detection

    In misfeed condition, the "Check Paper Path" and "Misfeed Location" indicators lights and copier operation is inhibited. To recover the sorter from the misfeed condition, the sorter has to be slide away from the copier, then, after misfed paper removal, returned to its original position. 4-11 FT4220/4222...

  • Page 150: Installation Procedure

    4. Philips Pan Head Screw - M4 x 8 ............8 5. Philips Pan Head Screw - M4 x 8 ............1 6. Screw M4 x 8 ...................1 7. Snap Ring ..................1 8. Toothed Washer ................1 9. Spring Washer .................1 10. Interface Harness ................1 FT4220/4222 4-12...
  • Page 151 3. Remove the receiving tray [E]. 4. Remove the rear cover [F] (4 screws). 5. Remove the caps [G] on the upper left side cover with the pliers. 6. Install the magnet catch [H] on the exit unit [I] (2 screws). 4-13 FT4220/4222...
  • Page 152 9. Remove the ac harness [E] from the wire clamp [F] as shown. 10. Install the sorter harness bracket [G] with the harness (2 screws). 11. Reinstall the ac harness into the wire clamp. 12. Install the sorter holder bracket cover [H] (1 screw). FT4220/4222 4-14...
  • Page 153 [I]) on the bottom plate as shown. 17. Plug in the copier power supply cord. 18. Change the SP71 data to "1" (sorter instruction). 19. Reinstall the rear cover and turn on the main switch. 20. Check the operation of the sorter. 4-15 FT4220/4222...

  • Page 154: Preparation For Transportation

    1. If the bins are not at the home position, turn on the main switch of the copier to move the bins to the home position. 2. Secure the bins with strips of tape as shown in the illustration. 3. Remove the sorter from the copier. (See the Installation Procedure [Sorter] section.) FT4220/4222 4-16...

  • Page 155: Roller Drive Belt Replacement

    NOTE: Be careful not to damage the sorter home position switch actuator [H] when reassembling. 6. Remove the transfer wheel [I], spacer [J], pin [K] and bushing [L] (1 C-ring). 7. Slide the wheel shaft [M] towards the front and remove the roller drive belt. 4-17 FT4220/4222...

  • Page 156: Bin Guide Lubrication

    2. Remove all bins [A] from the bin guides [B]. 3. Apply Grease 501 to the grooves of the bin guides. NOTE: There are three kinds of bins. Therefore, when installing the bins, be sure that they are installed in the correct order. FT4220/4222 4-18...
  • Page 157 SECTION 5 DUPLEX...

  • Page 158: Specifications

    (16 to 28 lb) Paper Stack: 50 sheets Dimension 516 x 529 x 90 mm (W x D x H): (20.4" x 20.9" x 3.6") Weight: Approximately 5 kg (11 lb) • Specifications are subject to change without notice. FT4220/4222...
  • Page 159 6. Paper End Feeler – Electrical Components – 1. Duplex Main Board 5. Duplex Entrance Sensor 2. Jogger Motor 6. Duplex Paper End Sensor 3. Jogger HP Sensor 7. Duplex Turn Sensor 4. Duplex Gate Solenoid 8. Duplex Feed Motor FT4220/4222...

  • Page 160: Electrical Component Description

    Duplex Turn Sensor Detects copy in the turn section. Duplex Paper End Detects copy in the duplex tray. Sensor Jogger Home Detects whether the jogger fences are at Position Sensor home position. Printed Circuit Board PCB1 Duplex Main Board Controls all duplex unit functions. FT4220/4222...
  • Page 161 4. POWER DISTRIBUTION AND OVERALL MACHINE CONTROL FT4220 COPIER Option DC Power Option Transformer AC Drive Board (PCB2) (TR2) Supply Board (PCB6) 115Vac 26Vac 220/230/240Vac 10Vac +24V (VA) (VC) +24V (VA) Mortors Solenoid Reset Signal +5V (VC) Sensors Copier Main Board (PCB1)
  • Page 162 All motors and solenoid operate on +24 volts and all sensors operate on +5 volts. The duplex main board has its own CPU which controls all functions in the duplex unit. The duplex CPU communicates with the copier main board using a serial interface. FT4220/4222...

  • Page 163: Duplex Stacking

    (front view) to feed the copy to the relay rollers [G]. Second side copying is then done with the copy following the second feed station paper path. FT4220/4222...
  • Page 164 [D] through the duplex transport gear [E]. A rubber belt [F] on the end of the duplex gate roller shaft drives the transport rollers [G]. The duplex feed motor also drives the duplex bottom plate up and down. FT4220/4222...
  • Page 165 The copy is then directed to the duplex turn guide, where it is fed by the transport rollers [C] to the entrance rollers [D]. The leading edge of the copy activates the duplex entrance sensor [E], which is monitored by the duplex CPU to detect misfeeds. FT4220/4222...
  • Page 166 [F]. The paper flatteners [G] correct curl on the leading edge of the copies. The leading edge of the copy actuates the duplex turn sensor [H], which is monitored by the duplex CPU to detect misfeeds. FT4220/4222...
  • Page 167 [A] rotates to drive the jogger fences [B] inward to square the paper stack, then the fences move back 10 mm. After the last copy of the first side copying run enters the duplex tray, the fences remain against the stack. FT4220/4222 5-10...
  • Page 168 The paper end actuator [I], which is on the same shaft as the paper end feeler, pivots into the duplex paper end sensor [J], sending a High signal to the main board to stop the next paper feeding cycle. 5-11 FT4220/4222...
  • Page 169 525 pulses (2.1 seconds) after the duplex turn sensor has been actuated. (The Misfeed Location indicator "E" turns on.) In the second side copy cycle, the misfeed detection timing is same as the one in the second feed station copying. FT4220/4222 5-12...

  • Page 170: Installation Procedure

    8. Duplex Harness .................1 NOTE: 1. When the duplex unit is installed on the copier, the DC Power Supply Unit (option) is required. (FT4220 copier only) 2. When installing the DC Power Supply Unit, please refer to the installation procedure enclosed with it.
  • Page 171 10.2 INSTALLATION PROCEDURE 1. Turn off the main switch and unplug the copier power supply cord. 2. Install the optional power supply unit (FT4220 copier only). Refer to the installation procedure enclosed with the power supply unit (A525). 3. Remove the strips and styrofoam blocks [A].
  • Page 172 7. Remove the upper paper guide [C] on the exit unit (2 screws) and remove the stubs [D] with nippers. 8. Install the three rollers [E] on the exit unit as shown. 9. Reinstall the upper paper guide plate [C] on the exit unit. 5-15 FT4220/4222...
  • Page 173 11. Reinstall the exit unit (2 screws). 12. Remove the 1st paper tray from the copier. 13. Remove the rear cover (4 screws). 14. Remove the power supply cord bracket [C] (2 screws) and support bracket [D] (1 screw) (FT4220 copier only). FT4220/4222 5-16...
  • Page 174 17. Secure the connector bracket to the rear frame (2 shoulder screws). NOTE: When installing the bracket, make sure that the cut-out [D] on the bracket faces up as shown. 18. Reinstall the power supply cord bracket and support bracket (FT4220 copier only). 5-17...
  • Page 175 [B]. 20. Connect the duplex harness connector (4P/White) [C] to CN101 on the optional power supply unit [D] (FT4220 copier only). 21. Connect the duplex harness connector (4P/White) [E] to CN150 on the main board (FT4222 copier only).

  • Page 176: Replacement And Adjustment

    7. Disconnect the sensor connector [H] from the jogger home position sensor. 8. Remove the duplex unit [I] (4 screws and grounding wire) from the tray. NOTE: Hold both sides of the duplex unit frame when lifting the duplex unit out of the tray. 5-19 FT4220/4222...
  • Page 177 NOTE: When installing the duplex unit, make sure of the following: a) Positioning pin [F] fits through hole [G] in the side plate. b) The sensor harness [H] is clamped correctly and is not caught under the unit frame. FT4220/4222 5-20...
  • Page 178 4. Replace the jogger motor [B] (2 screws). – Jogger Home Position Sensor Replacement – 3. Disconnect the sensor connector [C]. 4. Remove the sensor bracket [D] (1 screw). 5. Remove the sensor [E] from the bracket and replace it (1 screw). 5-21 FT4220/4222...
  • Page 179 1. Remove the duplex tray. 2. Raise the upper and lower paper guides [A] all the way up. 3. Disconnect the turn sensor connector [B]. 4. While lifting the sensor actuator [C], remove the sensor [D] (1 screw). FT4220/4222 5-22...

  • Page 180: Feed Motor Replacement

    2. Remove the paper feed motor bracket [A] (2 screws). 3. Replace the feed motor [B] (2 screws). NOTE: When installing the paper feed motor, make sure that the bushing [C] is properly positioned between the bracket and the motor as shown. 5-23 FT4220/4222...

  • Page 181: Paper End Sensor Replacement

    11.5 PAPER END SENSOR REPLACEMENT 1. Remove the duplex unit from the tray. (See Duplex Unit Removal.) 2. Remove the paper end sensor bracket [A] (1 screw). 3. Disconnect the sensor connector [B]. 4. Replace the sensor [C] (1 screw). FT4220/4222 5-24...

  • Page 182: Entrance Sensor Replacement

    1. Remove the duplex unit from the tray. (See Duplex Unit Removal.) 2. Turn over the duplex unit as shown. 3. Remove the entrance sensor bracket [A] (1 screw). 4. Disconnect the sensor connector [B]. 5. Replace the sensor [C]. 5-25 FT4220/4222...
  • Page 183 2. Replace the gate solenoid [A] (1 screw). NOTE: When installing a new solenoid, make sure of the following: a) Positioning pin [B] fits into the hole [C] on the gate solenoid actuator. b) Spring [D] is hooked to bracket [E]. FT4220/4222 5-26...

  • Page 184: Friction Roller Replacement

    5. Remove the roller [D] (1 snap-ring and shaft) from the bracket and replace it. NOTE: This friction roller has a one-way clutch. Be sure to install the roller so that it rotates in the direction of the arrow. (See illustration.) 5-27 FT4220/4222...

  • Page 185: Feed Roller Replacement

    7. Remove the E-ring [H] on the front side of the feed roller shaft [I]. 8. Remove the feed roller shaft (2 bushings). 9. Remove the feed support roller [J], flatter [K], paper retainer [L]; then, replace the feed roller [M] (1 E-ring and parallel pin per roller). FT4220/4222 5-28...
  • Page 186 FT4215 (A128) COPIER SERVICE TRAINING MANUAL Only the differrences from the FT4220/4222 (A110/A111) copier are described in the following pages. Refer to the FT4220/4222 (A110/A111) copier service manual regarding the other information.
  • Page 187 The FT4215 was developed based on the FT4415. The following table shows the major differences between the FT4215 and the FT4415 series. Section/Item FT4215 FT4415 Major Features Copy Speed FT4220: FT4418: 15 copies/minute 15 copies/minute (A4/11" x 8 " sideways) (A4/11" x 8 " sideways) 10 copies/minute (A3/11"...
  • Page 188 The sorter interface harness is an accessory of the optional dc power supply unit. DF Installation FT4220: FT4415: The optional dc power supply The optional dc power supply unit (A525) is required. unit (A494) is required.
  • Page 189 Section/Item FT4215 FT4415 Dirty To prevent the dirty backgrounds ---- Background on copies caused by dust Copy accumulated on optics parts, the following items are modified. 1) The toner shield glass is removed and a green color filter is installed on the lens unit.
  • Page 190 Section/Item FT4215 FT4415 Toner Density Detection And Toner Supply Black Toner The ID sensor is used for black The toner end sensor is used for End Detection toner end detection. both black and color toner end The black development unit for detection.
  • Page 191 1. SPECIFICATIONS Configuration: Desk top Copy Process: Dry electrostatic transfer system Originals: Sheet/Book, object Original Size: Maximum: A3, 11" x 17" Copy Paper Size: Maximum: A3, 11" x 17" Minimum: A6, 5 " x 8 " (lengthwise) Copy Paper Weight: 52 to 157 g/m (14 to 42 lb) Reproduction Ratios:...
  • Page 192 Energy Saver Function: Reduces electricity consumption (Manual or manual/auto) Paper Capacity: Cassettes: 500 sheets (A4, 8 " x 11") 250 sheets (A3, 11" x 17") Manual feed table: 50 sheets Toner Replenishment: Black: Cartridge exchange (370g/cartridge) Yield 9500 COPIES Color (red, blue, & green): Cartridge exchange (310 g/cartridge) Yield 6000 COPIES Developer...
  • Page 193 Dimensions: Width Depth Height Copier only 672 mm (1130 mm)* 600 mm 363 mm (417 mm)* (1255 mm)** 23.7" 14.1" (16.4")* 26.5" (44.5")* (49.4")** Full system 1274 mm 600 mm 466 mm 49.1" 23.7" 18.3" )* : When the A4 cassette and platen cover are installed and the copy tray is extended.
  • Page 194 2. COPY PROCESSES AROUND THE DRUM 2. EXPOSURE 1. DRUM CHARGE 3. ERASE 9. QUENCHING 4. DEVELOPMENT 8. CLEANING 5. PRE-TRANSFER LAMP (PTL) 7. PAPER 6. IMAGE TRANSFER SEPARATION CLEANING The cleaning blade removes any toner remaining on the drum. (A cleaning brush is not used in the FT4215 (A128) copier).
  • Page 195 3. MECHANICAL COMPONENT LAYOUT 10 11 12 13 14 1. Third Mirror 16. 1st Feed Roller 2. Second Mirror 17. Manual Feed Table 3. First Mirror 18. Pick-up Roller 4. Exposure Lamp 19. Separation Roller 5. Ozone Filter 20. Registration Rollers 6.
  • Page 196 4. DRIVE LAYOUT BP2 G16 G18 G22 G23 G24 G1: Main Motor Gear G20: Relay Gear G21: Cleaning Drive Cleaning G2: Relay Gear G18: Relay Gear G3: Timing Belt Drive G19: Drum Drive Gear G22: Relay Gear Gear Drum Fusing and Exit Section BP1: Timing Belt Pulley G23: Relay Gear Development...
  • Page 197 Paper Feed Section BP3: Timing Belt Pulley G11: Registration CL G4: Relay Gear Gear G5: Relay Gear Registration CL Registration Roller Paper Feed CL G6: 1st Paper Feed CL Gear G7: Relay Gear Paper Feed Gear G8: Paper Lift CL Gear Paper Feed Rollers Paper Lift CL G9: Paper Lift Gear...
  • Page 198 5. ELECTRICAL COMPONENT LAYOUT 1. Scanner H.P. Sensor 17. Paper End Sensor 2. Lens H.P. Sensor 18. Paper Lift Sensor 3. Scanner Motor 19. Registration Sensor 4. Main Motor 20. Total Counter 5. Development Clutch Solenoid 21. Pre-transfer Lamp (PTL) 6.
  • Page 199 32. Operation Panel Board 41. Option Transformer 33. Optics Thermoswitch 42. Main Transformer 34. Exposure Lamp 43. AC Drive Board 35. Cover Safety Switch 44. Main Motor Capacitor 36. Main Switch 45. Main Board 37. Exhaust Blower Motor 46. TC/SC Power Pack 38.
  • Page 200 6. ELECTRICAL COMPONENT DESCRIPTIONS Symbol Name Function Index No. Motors Main Motor Drives all the main unit components except for the optics unit and fans. (115/220/230/240 Vac) Scanner Motor Drives the scanners (1st and 2nd). (dc stepper) Lens Motor Positions the lens according to the selected magnification.
  • Page 201 Symbol Name Function Index No. Lens Home Informs the CPU when the lens is at the Position Sensor home position (full size position). 4th/5th Mirror Home Informs the CPU when the 4th/5th mirror Position Sensor assembly is at the home position (full size position).
  • Page 202 Symbol Name Function Index No. TC/SC Power Pack Provides high voltage for the transfer and separation coronas. Heaters Drum Prevents moisture around the drum. Anti-condensation Heater Optics Prevents moisture from forming on the Anti-condensation optics. Heater (Option) Counters Total Counter Keeps track of the total number of copies made.
  • Page 203 7. AC POWER AND DC POWER DISTRIBUTION AC Power (115V or 220/230/240V) Anti-condensation Heater Main SW - Drum - Optics (Option) Cover Safety SW Scan FU401 Operation Panel Board Signal 24V (VA) 5V (VC) Power Relay Sensors/Switches (RA401) Exhaust Blower Motor (L) Solenoids 24V (VA)
  • Page 204 When this copier is plugged in and the main switch is turned off, ac power is supplied via the ac drive board to the anti-condensation heater. When the front cover and/or the exit cover is open, the cover safety switch completely cuts off power to all ac and dc components.
  • Page 205 When the Start key is pressed, the main board energizes the main motor relay (RA402). Then, the main motor and the quenching lamp turn on and the exhaust blower starts rotating at high speed. When the main switch is turned off, power is cut off to the main board and to RA401, and the drum and optional anticondensation heaters are turned on.

  • Page 206: Detailed Section Descriptions

    8. DETAILED SECTION DESCRIPTIONS 8.1 DRUM CLEANING 8.1.1 Overview The cleaning blade [A] removes any toner remaining on the drum [B] after the image is transferred to the paper. The removed toner falls into the cleaning unit. The toner collection roller [C] carries the used toner to the used toner tank.
  • Page 207 8.1.2 Drive Mechanism The rotation of the main motor is transmitted to the cleaning unit through the main motor gear [A], the relay gear [B], and the cleaning drive gear [C]. The gear [D] driven by the cleaning drive gear passes the rotation to the toner collection roller gear [E].
  • Page 208 8.2 PAPER FEED AND MISFEED DETECTION TIMING Timing Pulse 1500 2000 2500 3000 3500 4000 (4 ms/pulse) 400 ms Start Key Main Motor 1750 1750 1750 1st Feed Clutch 1877 2273 (A4 S) 1877 2273 (A4 S) 1877 Pick-up Roller 2285 (LT S) 2285 (LT S) Release Sol.

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