Toshiba 4560 User manual

SERVICE MANUAL
PLAIN PAPER COPIER
4560/70
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Copyright TOSHIBA CORPORATION 1995
ALL RIGHTS RESERVED

GENERAL PRECAUTIONS REGARDINGTHE INSTALLATION
AND SERVICE FORTHE COPIER 4560/4570
The installation and service should be done by a qualified service technician.
1. Transportation/Installation
• When transporting/installing the copier, use two persons and be sure to use the positions as
indicated below.
The copier is fairly heavy and weighs approximately 95kg (210lb), therefore pay full attention
when handling it.
2. Installation
• Be sure to use a dedicated outlet with AC 115V/15A (220V, 230V, 240V/10A) or more for its power
source.
• The copier must be grounded for safety.
Never ground it to a gas pipe or a water pipe.
• Select a suitable place for installation.
Avoid excessive heat, high humidity, dust, vibration and direct sunlight.
• Also provide proper ventilation as the copier emits a slight amount of ozone.
• To insure adequate working space for the copying operation, keep a minimum clearance of 80 cm
(32”) on the left, 80 cm (32”) on the right and 10 cm (4”) in the rear.
• After having installed the copier, be sure to push the carrying handles into the copier and fasten
them with screws.
3. Service of Machines
• Basically, be sure to turn the main switch off and unplug the power cord during service.
• Be sure not to touch high-temperature sections such as the exposure lamp, the fuser unit, the
damp heater and their periphery.
• Be sure not to touch high-voltage sections such as the chargers and the high-voltage transformer.
• Be sure not to touch rotating/operating sections such as gears, belts, pulleys, etc.
• When servicing the machines with the main switch turned on, be sure not to touch live sections
such as the lamp terminal, etc. and rotating/operating sections.
• Use suitable measuring instruments and tools.

4. Main Service Parts for Safety
• The breaker, door switch, fuse, thermostat, thermofuse, thermistor, etc. are particularly important
for safety. Be sure to handle/install them properly.
5. CautionaryLabels
• During servicing be sure to check the rating plate and the cautionary labels such as “Unplug the
power cord during service”, “Hot area” etc. to see if there is any dirt on their surface or whether
they are properly stuck to the copier.
6. Disposition of Consumable Parts/Packing Materials
• Regarding the recovery and disposal of the copier, supplies, consumable parts and packing mate-
rials, it is recommended to follow the relevant local regulations or rules.
7. Whenpartsaredisassembled,reassembly is basically the reverse of disassembly unless other-
wise noted in this manual or other related documents. Be careful not to reassemble small parts
such as screws, washers, pins, E-rings, toothed washers in the wrong places.
8. Basically,the machine should not be operated with any parts removed or disassembled.
9. Precautions Against Static Electricity
• The PC board must be stored in an anti-electrostatic bag and handled carefully using a wristband,
because the ICs on it may become damaged due to static electricity.
Caution: Beforeusingthe wrist band,pull out thepowercord plug ofthecopier and makesurethat
there is no uninsulated charged objects in the vicinity.

Nov. 1997 © TOSHIBA 1 - 1 4560/4570 SPECIFICATIONS
Copy paper
Cassette Duplexing Manual Note
Size A3~A5-R A3~A6-R Adjustable to
(Ledger~Statement-R) Unfixed, Arbitary sizes
Thickness 64~80 64~130 Unit: g/m2
(Weight) (17~22) (17~34) (Unit: lb.)
Special _ _ OHP film Toshiba recommended
paper etc.
Copy process Indirect electrophotographic process (dry)
Type Desk top (console when the pedestal is used)
Exposure Type Slit exposure with fixed table
Acceptable originals Kind Sheets, books, and 3-dimensional objects.
When the document feeder is used:
Sheet originals only (60 g/m2~90 g/m2) (16 lb.~24 lb.)
Maximum size A3 (Ledger)
1. SPECIFICATIONS • ACCESSORIES • OPTIONS • SUPPLIES
1.1 Specifications

4560/4570 SPECIFICATIONS 1 - 2 Nov.1997 © TOSHIBA
Copy speed
System copy speed
(BLI format)
First copy Approx.3.3sec. (Actual-size A4 or Letter from large capacity feeder)
Warm-up time Approx. 240sec.
Multiple copying 1~999, keyboard entry
Reproduction ratio
Actual ratio 100% or 101% (Setting mode)
Zoom ratio 50~200% (Multiple reduction and enlargement in 1% steps)
*Ten originals (A4) are set in the RADF.This includes the first
copy time.
Manual feeding represents the value when the size is set.
CPM
Paper size Cassette Manual LCF
A4, B5, A5-R 45 40 45
LT, ST-R
A4-R, B5-R 34 34 —
LT-R
B4, FOLIO 29 29 —
LG, Computer
A3 24 24 —
LD
Reduction/ 23 23 23
Enlargement
Mode CPM
Original Copy Numberof copies
1 1 1 set 36
3 set 42
5 set 43
1 2 1 set 13
3 set 25
5 set 30
2 2 1 set 10
3 set 21
5 set 27
2 1 1 set 18
3 set 30
5 set 35

Nov. 1997 © TOSHIBA 1 - 3 4560/4570 SPECIFICATIONS
Paper supply Automatic feeding:
Upper deck: Automatic duplexing unit (ADU)
Lower deck: Front loading cassette (600 sheets)
Manual feeding: 50 sheets
Toner supply Automatic density detection and replenishment
Toner cartridge replacement
Exposure Automatic control and manually selectable (9 steps)
Weight Copier: 95kg
Power source 115 V ~ 60 Hz, 12A For the U.S.A. and Canada
220-240 V ~ 50/60 Hz, 8A For Europe
Power consumption 1.5 kW (115 V), 1.7 kW (220 V/240 V)
Counter 7-digit total counter
Machine size
601 mm
676 mm
540 mm
660 mm

4560/4570 SPECIFICATIONS 1 - 4 Nov.1997 © TOSHIBA
Paper feed pedestal: PFP KD-1003A (1 cassette), KD-2009A (2 cassettes)
Paper feed unit (cassette modular unit) MY-1006
Large capacity feeder: LCF MP-1501
MP-4001
Sorter MG-2009A (20 bins, hanging type)
MG-2010 (20 bins, stapler)
MG-2012 (20 bins, stapler, hanging type)
MG-2015 (20 bins, multi position stapler)
Sorter kit KN-2060S02 (For MG-2009A)
KN-3560S01 (For MG-2012)
Sorter staple cartridge STAPLE-400 (For MG-2010, 12)
STAPLE-700 (For MG-2015)
Work tray KK-2060
Key copy counter MU-8/MU-10 (6 digit)
1.2 Accessories
Copyreceiving tray : 1 pc.
Operator’s manual : 1 pc.
Set-up report : 1 pc.
Drum : 1 pc.
Developer : 1 bottle
Toner : 1 pc.
*Accessories vary according to the destination.
1.3 Options
1.4 Supplies
Drum OD-4560
Developer D-4560
Toner T-3560
*Options vary according to the destination.

Nov. 1997 © TOSHIBA 2 - 1 4560/4570 GENERAL
2. OUTLINE OFTHE MACHINE
2.1 SectionalViews and Electrical Parts Location Diagram
2.1.1 Sectional view
[A] Front view
Front view (For details of the ADU and RADF, refer to chapter 13, ADU and chapter 18,RADF .)
2
7
8
6
17
68
67
20
69
60 55
54315 16 14 19 18 21 28 12 13
10 9
1
11
39
45
40
62
44
46
63
47
42
41
43
66
64
65
37
25
23
22
70
71
24 36
38
33
48
49
50
2926
27
30
59
61
52
59 56 58 54
53 57
51
72
32 31 34 35

4560/4570 GENERAL 2 - 2 Nov. 1997 © TOSHIBA
No. Name
37 Cassette
38 Manual feed separation pad
39 Manual feed roller
40 Manual pickup roller
41 Cassette separation roller
42 Cassette feed roller
43 Cassette pickup roller
44 Upper transport roller
45 Manual feed switch (S6)
46 Paper guide
47 Lower transport roller
48 Aligning switch (S8)
49 Aligning roller (U)
50 Aligning roller (L)
51 Thermistor-2 (THMS2)
52 Thermostat (THERMO)
53 Heater lamp
54 Heat roller (upper side)
55 Pressure roller (lower side)
56 Separation claw (for heat roller)
57 Cleaning roller
58 Cleaning felt roller
59 Fuser exit roller
60 Separation claw
61 Fuser cover
62 Paper stop switch-1 (S7)
63 Paper stop switch-2 (S16)
64 Paper-empty switch-2 (S14)
65 Cassette tray
66 Cassette size switch-2 (S15)
67 Exit/ADU selection gate
68 Exit roller
69 ADU
70 Exit fan-1 (M7)
71 Exit fan-2 (M15)
72 Exit switch (S9)
No. Name
1 Carriage 1
2 Mirror 1
3 Reflector
4 Light distribution adjustment plates
5 Exposure lamp
6 Carriage 2
7 Mirror 2
8 Mirror 3
9 Mirror unit
10 Mirror 4
11 Mirror 5
12 Mirror 6
13 Slit glass
14 Auto exposure sensor
15 Lens
16 Original glass
17 Ozone filter
18 Main charger
19 Discharge lamp
20 Receiving tray
21 LED eraser array
22 Main blade
23 Recovery blade
24 Toner recovery auger
25 Separation claw (for drum)
26 Transfer charger
27 Separation charger
28 Drum
29 Bias guide
30 Transport belt
31 Magnetic roller
32 Leveller (doctor)
33 Auto-toner sensor
34 Mixer 1
35 Mixer 2
36 Sheet bypass guide

Nov. 1997 © TOSHIBA 2 - 3 4560/4570 GENERAL
[B] Rear side view
80
84 7885
9186
98
93
92
97
90
89 88 79 83
99
94
76
82 9581 87 77 96

4560/4570 GENERAL 2 - 4 Nov. 1997 © TOSHIBA
No. Name
76 Scanning motor (M2)
77 Carriage drive wire
78 Drum gear
79 Aligning motor (M17)
80 Drum driving gear
81 Drum belt
82 Belt-1 for fuser drive
83 Belt-2 for fuser drive
84 Main motor (M1)
85 Lens motor (M3)
86 Mirror motor (M4)
87 Thermistor-1 (THMS1)
88 Developer unit drive gear
89 Aligning roller
90 Paper feed belt
91 Manual feed clutch (CLT4)
92 Transport roller clutch (CLT6)
93 Transport roller drive belt
94 Cassette feed clutch (CLT3, 5)
95 Optical fan (M6,12, 18)
96 Document motor (M11)
97 Transport motor (M16)
98 Transport roller clutch (CLT7)
99 Transport roller clutch (CLT1)

Nov. 1997 © TOSHIBA 2 - 5 4560/4570 GENERAL
2.1.2 Electrical parts layout
[A] DC electrical parts (except motors)
37
22
27
4
1
10
20
2
7
8
12
26
24
17
19
3932 29
34
531
30
13 38 9
35
36
33 18
16
11 25
6
21
23 14
15
Front side
Rear side
3

4560/4570 GENERAL 2 - 6 Nov. 1997 © TOSHIBA
No. Name
1 Control panel key PC board (PWA-KEY2)
2 Key PC board (PWA-KEY1)
3 Liquid crystal module (LCD)
4 Total counter (T-CTR)
5 Logic PC board (PWA-LGC)
6 Auto paper sensor-2 (APS-R)
7 Auto paper sensor-3 (APS-C)
8 Auto paper sensor-4 (APS-F)
9 Toner-full switch (T-FUL-SW) (S13)
10 Control panel PC board (PWA-PNL)
11 Discharge lamp PC board (PWA-ERS)
12 LED eraser array PC board (K-DCH)
13 High-voltage power supply (PS-HVT)
14 Home switch (HOME-SW) (S10)
15 Platen switch (PTN-SW) (S27)
16 Manual feed switch (M-FED-SW) (S6)
17 Aligning switch (PSTPO-SW) (S8)
18 Paper stop switch 1 (PSTP1-SW) (S7)
19 Side door switch (U-COV-SW) (S4)
No. Name
20 Auto paper sensor-1 (APS-3B)
21 Drum separation claw solenoid (SCRP-SOL) (SOL1)
22 Exit switch (EXIT-SW) (S9)
23 Heat-roller thermistor 1 (THMS1-HTR)
24 Toner sensor (TNR-ATC)
25 Lens switch (LNS-SW) (S11)
26 Mirror switch (MRR-SW) (S12)
27 Automatic exposure PC board (PWA-AES)
29 Transport-roller clutch (RGT1-CLT) (CLT1)
30 Transport-roller clutch (RGT2-CLT) (CLT6)
31 Transport-roller clutch (RGT3-CLT) (CLT7)
32 Manual-feed roller clutch (MFED-CLT) (CLT4)
33 Size switch 2 (SIZE2-SW) (S15)
34 Feed-roller clutch 2 (FED2-CLT) (CLT5)
35 Paper-empty switch 2 (EMP2-SW) (S14)
36 Paper stop switch 2 (PSTP2-SW) (S16)
37 Heat-roller thermistor-2 (THMS2-HTR)
38 Drum thermistor (DRM-THMS)
39 Tray-up switch (T-UP2-SW) (S29)

Nov. 1997 © TOSHIBA 2 - 7 4560/4570 GENERAL
[B] DC electrical parts (motors)
No. Name
41 Main motor (MAIN-MOT) (M1)
42 Scanning motor (SCN-MOT) (M2)
43 Lens motor (LNS-MOT) (M3)
44 Mirror motor (MRR-MOT) (M4)
45 Toner motor (TNR-MOT) (M9)
46 Document motor (DCM-MOT) (M11)
47 Aligning motor (RGT-MOT) (M17)
48 Tray-up motor-2 (T-UP2-MOT) (M14)
No. Name
49 Optical fan-F (OPT-FAN-F) (M12)
50 Optical fan-R1 (OPT1-FAN-R) (M6)
51 Optical fan-R2 (OPT2-FAN-R) (M18)
52 Exit fan (EXIT1-FAN) (M15)
53 Exit fan (EXIT2-FAN) (M7)
55 Developer unit fan (DEV-FAN) (M19)
56 Transport motor (FEED-MOT) (M16)
46
42
50
53
41
55
47
56 48
43
44
45
Front side
Rear side
52
49
51

4560/4570 GENERAL 2 - 8 Nov. 1997 © TOSHIBA
[C] AC electrical parts
No. Name
64 Thermostat (Option)
65 Damp heater U1 (D-HTR-U1) (Option)
66 Exposure lamp (EXPO-LAMP)
67 Thermofuse (FU-EXPO)
68 Fuse PC board (PWA-FUS) (Option)
69 Damp heater U2 (D-HTR-U2) (Option)
No. Name
57 SW power supply (PS-ACC)
58 Door switch (DOOR-SW) (S2)
59 Main switch (MAIN-SW) (S1)
60 Lamp regulator PC board (PWA-LRG)
61 Heater lamp (HTR-LAMP)
62 Damp heater L (D-HTR-L) (Option)
63 Thermostat (K-THERMO)
69
67
58
65
60
64
68
66
63
59
61
57
62
Front side
Rear side

Nov. 1997 © TOSHIBA 2 - 9 4560/4570 GENERAL
Parts list
Page Item
M1 MAIN-MOT (Main motor) Drives the drum, developer, IC motor 10 37
heat roller and transport belt
M2 SCN-MOT (Scanning motor) Scans the optical system Pulse motor 5 23
M3 LNS-MOT (Lens motor) Drives the lens unit Pulse motor 11 23
M4 MRR-MOT (Mirror motor) Drives the mirror unit Pulse motor 11 23
M6 OPT1-FAN-R (Optics fan-R1) Cools the optical system IC motor: 80 5 8
M7 EXIT2-FAN (Exit2-fan) Cools the drum and cleaner IC motor: 60 4 14
M9 TNR-MOT (Toner motor) Replenishes the toner Brush motor 24 30
M11 DCM-MOT (Document motor) Drives copy-area indicators Pulse motor 9 2
M12 OPT-FAN-F (Optical fan-F) Cools the optical system IC motor: 60 4 14
M14 T-UP2-MOT (Tray-up motor-2) Drives the lower cassette tray to Brush motor 12 36
move it up/down
M15 EXIT1-FAN (Exit1-fan) Cools the drum and cleaner IC motor: 60 4 14
M16 FEED-MOT Drives transport roller IC motor 14 20
(Transport motor)
M17 RGT-MOT (Aligning motor) Drives aligning roller Pulse motor 6 42
M18 OPT2-FAN-R (Optical fan-R2) Cools the optical system IC motor: 80 5 8
M19 DEV-FAN (Developer fan) Developer unit suction IC motor 6 36
2.2 Symbol and Function of Electrical Parts
(1) Motors
Symbol Code name Remarks
Function

4560/4570 GENERAL 2 - 10 Nov. 1997 © TOSHIBA
Parts list
Page Item
CLT1 RGT1-CLT Transmits transport-roller-1 drive. 13 29
(Transport-roller clutch-1)
CLT4 MFED-CLT Transmits manual-feed roller 15 17
(Manual-feed roller clutch) clutch drive.
CLT5 FED2-CLT Transmits feed-roller clutch 12 24
(Feed-roller clutch-2) drive. (Lower cassette)
CLT6 RGT2-CLT Transmits transport-roller-1 13 29
(Transport-roller clutch-2) drive.
CLT7 RGT3-CLT Transmits transport-roller-2 10 30
(Transport-roller clutch-3) drive.
SOL1 SCRP-SOL Drum separation claw drive 4 42
(Drum separation claw solenoid)
(2) Electromagnetic spring clutches and solenoid
(3) Counters
Symbol Code name Function Remarks
Symbol Code name Function Remarks Parts list
Page Item
T T-CTR (Total counter) Total counter 7-digit 3 32
K K-CTR (Key-copy counter) Individual counter 6-digit (option) 101 5

Nov. 1997 © TOSHIBA 2 - 11 4560/4570 GENERAL
Parts list
Page Item
S1 MAIN-SW (Main switch) Power supply Tumbler type 6 3
S2 DOOR-SW (Door switch) For safety, cancels abnormal Push switch 6 4
condition
S4 U-COV-SW For safety, detects open/closed Push switch 2 27
(Side door switch) condition of paper jam release cover
S6 M-FED-SW Detects manual feeding Photointerruptor 15 3
(Manual-feed switch)
S7 PSTP1-SW Detects paper in front of the Photointerruptor 14 15
(Paper stop switch-1) upper transport roller
S8 PSTP0-SW Detects paper in front of the Photointerruptor 16 20
(Aligning switch) aligning roller
S9 EXIT-SW (Exit switch) Detects exiting paper Photointerruptor 29 8
S10 HOME-SW (Home switch) Detects home position of the Photointerruptor 11 8
optical system
S11 LNS-SW (Lens switch) Detects home position of the lens Photointerruptor 11 8
unit
S12 MRR-SW (Mirror switch) Detects home position of the mirror Photointerruptor 11 8
unit
S13 T-FUL-SW Detects when the used toner bag Push switch 10 2
(Toner-full switch) is full
S14 EMP2-SW Detects lack of paper in the lower Photointerruptor 12 32
(Paper-empty switch-2) cassette
S15 SIZE2-SW Detects lower cassette size Push switch 14 31
(Size switch-2)
S16 PSTP2-SW Detects paper in front of the lower Photointerruptor 2 26
(Paper stop switch-2) transport roller
S27 PTN-SW Detects open/closed condition of Photointerruptor 5 38
(Platen switch) the platen cover
S29 T-UP2-SW Detects the position of the lower Photointerruptor 12 32
(Tray-up-2 switch) cassette tray
(4) Switches
Symbol Code name Function Remarks

4560/4570 GENERAL 2 - 12 Nov. 1997 © TOSHIBA
Parts list
Page Item
LGC PWA-LGC (Logic PC board) Controls the entire copier 8 15
PNL PWA-PNL Controls the control panel 3 33
(Control panel PC board)
KEY1 PWA-KEY1 Controls operation keys 3 11
(Key PC board-1)
KEY2 PWA-KEY2 Controls operation keys 3 14
(Key PC board-2)
LRG PWA-LRG Controls exposure lamp 5 20
(Lamp regulator PC board)
DCH K-DCH Turns ON and drives the LEDs 4 10
(LED eraser array PC board) during reduction
ERS PWA-ERS Discharge lamp 4 12
(Discharge lamp PC board)
AES PWA-AES Reads dark/light of the original 18 37
(Automatic exposure PC board)
FUS PWA-FUS (Fuse PC board) Fuse for the damp heater circuit 7 31
(5) Heaters and lamps
(6) PC boards
Symbol Code name Function Remarks
Symbol Code name Function Remarks
Parts list
Page Item
EXP EXPO-LAMP Exposes the original Halogen lamp 19 13
(Exposure lamp) 300W
HTR HTR-LAMP (Heater lamp) Fixing Halogen lamp 26 22
900W
(100V series)
1100W
(200V series)
ERS ERS-LAMP Discharges the drum Fuse type 4 12
(Discharge lamp)
DCH DCH-LED To interrupt the charge LED 4 10
(LED eraser array)
DHU1 D-HTR-U1 (Damp heater U1) Keeps optical system warm (option) Cement resistor 11 39
DHU2 D-HTR-U2 (Damp heater U2) Keeps optical system warm (option) Cement resistor 11 37
DHL D-HTR-L (Damp heater L)
Keeps the drum and transfer/separation Cement resistor 7 30
charger case warm (option)

Nov. 1997 © TOSHIBA 2 - 13 4560/4570 GENERAL
(7) Transformers
Parts list
Page Item
HVT PS-HVT (Charging transformer) Generates high voltage electricity
Mono unit type 727
for charging (negative voltage)
(Transfer/separation Generates high voltage electricity
transformer) for transfer/separation and
developing bias voltage
(Transfer bias Generates bias voltage to raise
transformer) transfer efficiency
ACC PS-ACC Power supply for entire copier 8 7
(Power supply for all) power
(8) Others
Parts list
Page Item
ATS SNR-ATC Reads toner density with a magnetic 24 33
(Auto-toner sensor) sensor
THMS1 THMS1-HTR Detects temperature of the heat roller 26 6
(Heat-roller thermistor-1)
THMS2 THMS2-HTR Detects the temperature of the heat roller 26 6
(Heat-roller thermistor-2) end
THERMO K-THERMO Prevents abnormal heating of heat roller 26 20
(Thermostat)
FU FU-EXPO (Thermofuse) Prevents abnormal heating of the 19 12
exposure lamp
Symbol Code name Function Remarks
Symbol Code name Function Remarks