PF-2D/AD-5

SERVICE MANUAL

CONTENTS
GENERAL, MECHANICAL/ELECTRICAL
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-1
2. COMPONENT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . M-2
3. CROSS-SECTIONAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-3
4. DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-4
5. VERTICAL TRANSPORT SECTION . . . . . . . . . . . . . . . . . . . . . . . M-5
5-1. Mechanism and Control of Vertical Transport . . . . . . . . . . . . M-5
6. PAPER TAKE-UP/FEEDING MECHANISM . . . . . . . . . . . . . . . . . M-7
6-1. Mechanism and Control of Paper Take-Up . . . . . . . . . . . . . . M-7
6-2. Fixed Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-12
6-3. Detection of Drawer Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-14
6-4. Mechanism and Control of Drawer Lift-Up . . . . . . . . . . . . . . . M-15
6-5. Paper Empty Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-20

TROUBLESHOOTING
1. TYPES OF MISFEED DETECTION . . . . . . . . . . . . . . . . . . . . . . . . T-1
2. MISFEED DETECTION TIMING. . . . . . . . . . . . . . . . . . . . . . . . . . . T-2

DISASSEMBLY/ADJUSTMENTS
1. Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
1-1. Removal of Exterior Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
1-2. Removal of Guide Plates and Cover Plates. . . . . . . . . . . . . . D-2
1-3. Removal of Paper Take-Up Roll and
Feed Roll Assy from Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
1-4. Disassembly of Paper Take-Up Roll/Feed Roll Assy . . . . . . D-3
1-5. Removal of Separator Roll Assy . . . . . . . . . . . . . . . . . . . . . . . D-4
1-6. Cleaning of Paper Take-Up Roll/Feed Roll
and Separator Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5
1-7. Cleaning of Transport Roller . . . . . . . . . . . . . . . . . . . . . . . . . . D-5

CONTENTS
2. Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6
2-1. Adjustment of 3rd and 4th Drawer Reference Position . . . . . D-6
2-2. Adjustment of Vertical Transport Timing Belt Tension . . . . . D-7

WIRING DIAGRAM/CIRCUIT DIAGRAM

ELECTRICAL COMPONENT LAYOUT/CONNECTOR
LAYOUT/DESIGNATION AND FUNCTION OF SENSORS

ii

GENERAL,
MECHANICAL/
ELECTRICAL

1 SPECIFICATIONS
Name
Type
Installation
Copy Storage

:
:
:
:

Mode
Type of Paper
Paper Sizes
Paper Weight
Capacity

:
:
:
:
:

Power Requirements
Power Consumption
Dimensions

:
:
:

Weight

Paper Feed Cabinet PF-2D

Duplex Unit with a storage drawer
Fitted to copier
Horizontal Copy Storage with Moving Trailing
Gate Unit
2-sided copy
Plain paper, recycled paper
A5L to A3L, 5-1/2" 8-1/2"L to 11" 17"L
60 to 157 g/m2 or 16 to 41-3/4 lbs.
60 - 90 g/m2 or 16 - 24 lbs: 50 sheets max.
91 - 157 g/m2 or 24-1/4 - 41-3/4 lbs.: 20 sheets
max.
DC24V, 5V (supplied from copier)
PF-2D = 100W, AD-5 = 30W
PF-2D = Width ... 620 mm or 24-1/2"
Depth ... 695 mm or 27-1/4"
Height ... 390 mm or 15-1/4"
PF-2D = 42.0 kg or 92-1/2 lbs.
AD-5 = 14.2 kg or 31-1/4 lbs.

M-1

COMPONENT IDENTIFICATION/CROSS-SECTIONAL VIEW

1
2

3
6

4
8

10

11

12
13

18
17
14
16
15

1.
2.
3.
4.
5.
6.
7.

Upper Guide Plate Assy

Front/Rear Edge Guide Plate
Duplex Unit
Trailing Gate Unit
Vertical Transport Unit
Lower Left Door
Paddle Roller/Duplex Unit
Vertical Transport Roller
8. Trailing Gate Unit Gate 2
Transport Roller
9. Trailing Gate Unit Gate 1
Transport Roller

10.
11.
12.
13.
14.
15.
16.
17.
18.

M-2

Paper Take-Up Roll

Feed Roll
Vertical Transport Roller (Drive)
Vertical Transport Roller
(Driven)
Separator Roll
Roll B
Slip Roll
Release Lever
Roll A

3 DRIVE SYSTEM COMPONENT LAYOUT

G22

G23
G24

P10
PG3

B4
PG4
G12

P8
G10

B2
G19
G14
G15

G13
G20
G21

B3

P9

G8

P7
P4

G18
G17

G9

G11

B1
G16

P5 P6

G7

P3
P2

G6
G4

G5

PG2
G3

PG1
P1

G1

G2

Symbol

Gear: No.
of Teeth

Symbol

Gear: No.
of Teeth

Symbol

Gear: No.
of Teeth

Pulley: No.
of Teeth

G1

16

G13

16/19

PG1

16

16

G2

17/40

G14

24

PG2

30

16

G3

22

G15

16

PG3

100

60

G4

15/31

G16

16

PG4

19

20

G5

41/48

G17

18

P1

16

G6

31/15

G18

23

P2

16

G7

29

G19

22

P3

G8

32

G20

16

P4

G9

29

G21

16

P5

16

G10

29

G22

34

P6

16

G11

29

G23

22/18

P7

28

G12

40

G24

15

P8

22

Symbol

Length

B1

681 mm

B2

144 mm

B3

710 mm

B4

340 mm

M-3

P9

24

P10

20

4 DUPLEX UNIT DRIVE

Duplex Unit Drive Mechanism
Duplex Unit Drive Motor M31 drives the Trailing Gate Unit and Duplex

Unit Vertical Transport Section through gears, transport belts and rollers.
Duplex Unit Paper Take-Up Clutch CL31 couples motor drive force to

the paper take-up section.

When the Duplex Unit is slid into the Cabinet, Pulley Gear 1 meshes

with Gear 1 and the drive is transmitted to the Transport Section.

The figure below shows the Duplex Unit drive train.

Trailing Gate Switching Lever

Paper Take-up Assy

Duplex Unit
Rear Finger

Duplex Unit Paper

Take-Up Clutch CL31

Duplex Unit Drive

Motor M31
Duplex Unit Vertical
Transport Roller

Pully Gear

Gear 1

Paddle Roller

The Paddle Roller and Duplex Unit Vertical

Transport Roller are assembled in one unit.

M-4

 Control of Duplex Unit Drive Motor M31

A DC motor is used for M31. The M31 Remote signal from pin 31 of

IC1G of Duplex Unit Master Board PWB-G energizes and deenergizes

M31.
IC1G

M31

31
Energized (forward)

Deenergized (stopped)

M31 Energization Timing

The motor is synchronized with Main Drive Motor M1.
M31 Deenergization Timing
When a copy is to be stored in the Duplex Unit, the motor is briefly

deenergized after the storage sequence has been completed. [The

timing varies for different paper sizes, as timed after the trailing edge of
the paper moves past Duplex Unit Trailing Edge Sensor PC14 (which
goes HIGH).] It is then reenergized for the Duplex paper take-up
sequence.
At the end of the copy process, the motor is deenergized 1.5 seconds

after Paper Exit Switch S53 has detected the trailing edge of the paper.
(It is synchronized with Main Drive Motor M1.)

4444C06MAA

M-5

 MALFUNCTION DETECTION
Malfunction
Code

C0d50

Description
Duplex Unit
Drive Motor M31
failure to turn

Detecting Timing
The Motor Lock signal (L) is not detected within 1
second immediately following a 650-msec. period
after M31 has been energized.
ON
M31 OFF
Motor
Lock

650msec. 1sec. or more

H
L

4425T64MCA

C0d51

Duplex Unit
Drive Motor M31
turning at
abnormal timing

The Motor Lock signal (L) is detected for a

consecutive 1-sec. period immediately following a
100-msec. period after M31 has been
deenergized.
100msec.

M25

1sec. or more

ON
STOP

MOTOR
LOCK

H
L

4425T65MCA

M-6

5 DUPLEX UNIT VERTICAL TRANSPORT SECTION

5-1. Middle Left Door Detection
When the Middle Left Door is closed, the Light Blocking Plate attached

to the Door blocks the Middle Left Door Sensor PC10 installed in the
Duplex Unit Vertical Transport Section of the copier.

Duplex Unit Vertical

Transport Roller 1

Middle Left Door Sensor (PC10)

Blocking Plate

Duplex Unit Vertical

Transport Roller 2

4444C07MAA

M-7

5-2. Lower Left Door Detection

When the Lower Left Door is closed, the Light Blocking Plate attached to

the Door blocks the Lower Left Door Sensor PC11 installed in the
Duplex Cabinet PF-2D.

Lower Left Door

Sensor (PC11)

Blocking Plate

4444C08MCA

M-8

5-3. Duplex Unit Turnover Mechanism

The Duplex Unit Turnover Section first sends the paper to the Duplex

Unit Vertical Transport Section and then switches the direction of paper
travel with Duplex Unit Drive Motor M31 to send the paper to the Trailing
Gate Unit.
Detail of turnover operation is as follows.
Paper
Paddle
Roller
Duplex Unit
Vertical
Transport
Roller

Roll A
Release
Lever
Roll C
4425M203AA

1) Paper is transferred from the Fusing Section

to the Duplex Unit Vertical Transport Section.
The Duplex Unit Vertical Transport Roller, Roll
A, Slip Roll and Roll C turn in the direction of
the arrow.

Roll B
Slip roll

2) The Duplex Unit Vertical Transport Roller and

Roll A advance the paper downward.
The Release Lever moves in the direction of
the arrow, disengaging Roll C from the Slip
Roll.

4425M204AA

3) As the trailing edge of the paper moves past

the Vertical Transport Roller and Roll A, the
Paddle Roller catches the trailing edge and
switches its direction of travel. The Release
Lever returns to its original position to press
Roll C against the Slip Roll, allowing the paper
to move upward.
4425M205AA

4) The paper is sent to the Trailing Gate Unit by

the Duplex Unit Vertical Transport Roller/Roll
B and Slip Roll/Roll C.

4425M206AA

M-9

6 COPY STORAGE
6-1. Trailing Gate Unit Moving Mechanism/Control
The Trailing Gate Unit is moved as necessary to store paper of different
sizes.
The Trailing Gate Unit is moved as drive from Gate Motor M32 is
transmitted via a gear train to the Screw Cam and Screw Pin located at
the front of the Trailing Gate Unit.
This is done to enhance the Units paper storage performance. (See
Table 1 on p. M-14.)
The Trailing Gate Unit moves to its home position (equivalent to A4
crosswise position) if there is no copy left in Storage when Power Switch
S1 of the copier is turned ON, the Duplex Unit is slid into position, or the
Front Door of the copier is swung open and closed.
Trailing Gate Unit
Screw Pin

Screw Cam

Gate Motor M32

This ensures a given distance between the paper gate and the trailing

edge at all times. Otherwise, the incoming paper may not completely
enter the Trailing Gate Unit if the distance is shorter, or may rest on top
of the paper stack.
Trailing Gate Unit
<B4L paper>

Constant

<A3L paper>

Constant

M-10

 Control of Gate Motor M32

At the same time when the Start Key is pressed, M32 is energized to

move the Trailing Gate Unit to the position for the paper size selected.

When the 2-sided copy mode is canceled, M32 is energized to return the

Trailing Gate Unit back to the home position.

IC1G
Output Pins

Operation Order

Clock Frequency

Step 1 Step 2 Step 3 Step 4

62

61

57

56

Turns forward
Turns backward
4425T83MCA

The stepping motor M32 is controlled by the signals from pins 56, 57, 61

and 62 of IC1G of Duplex Unit Master Board PWB-G.

The order of turning ON the signals determines the turning direction of

M32.

4444C10MAA

M-11

 MALFUNCTION DETECTION
Malfunction
Code
C0d20

Description
Trailing Gate
Unit home
position
detection failure

Detecting Timing
The home position is detected only in the initial
operation sequence. (When the Power Switch is
turned ON, the Front Door is swung open and
closed, the Duplex Unit is slid into position, or the
2-sided copy mode is canceled)
1. Duplex Gate Home Position Sensor PC8 is
blocked ( L ) at the start of the initial operation
sequence.
(1) PC8 is unblocked ( H ) within 2.63 seconds.
(2) PC8 is not blocked ( L ) within 1 second
after it has been unblocked ( H ).
GATE MOTOR ON
(M32) OFF

2.63sec. or more

PC8

1sec. or more

4425T66MCA

2. Duplex Gate Home Position Sensor PC8 is

unblocked at the start of the initial operation
sequence.
(1) PC8 is not blocked ( L ) within 7.06 seconds.
GATE MOTOR ON
(M32) OFF
H

PC8

7.06sec. or more

4425T67MCA

M-12

6-2. Trailing Gate Switching Mechanism/Control

When paper is to be stored into the Duplex Unit, the Trailing Gate

Switching Lever is operated as necessary according to the paper size to

switch the Trailing Gate between Gate 1 and Gate 2.
The Trailing Gate Switching Lever is operated by Duplex Unit Gate
Switching Solenoid SL31 which is energized or deenergized according
to the paper size to select Gate 1 or Gate 2 as shown in Table 1 on the
next page.
SL31 is operated at the same time when the paper take-up sequence
starts.
When the paper to be stored is 301 mm long or more, SL31 is energized
to swing open the Trailing Gate Switching Lever to allow the paper
through Gate 2.
When the paper to be stored is 300 mm long or less, SL31 is
deenergized, allowing the paper through Gate 1.
Duplex Unit Gate Switching Solenoid
(SL31)

Trailing
Gate 1

Trailing Gate
Switching Lever

Trailing Gate 2

4444C11MAA

M-13

6-3. Trailing Gate Unit Moving and Switching Operations

Timing Chart (A3L, 2 sheets)
Start Key ON

Duplex Unit Drive Motor ON

M31 OFF

Copy Stored

GATE MOTOR
M32
Retracted Position

Paper Size
Position

Front/Rear Edge Guide

Drive Motor M33
Duplex Unit Gate
Switching Solenoid SL31

4444T20MCB

Trailing Gate Unit Travel Distance / Switching Operation

Table 1

Size

Metric Areas
Gate

Paper, Travel
Length Distance
(mm)
(mm)

Size

Travel
Paper
Length Distance
(mm)
(mm)

Gate

B5C

182

-28

A4L

297

+87

A5L

210

B4L

364

+19

A4C

210

A3L

420

+175

B5L

257

+47

Inch Areas
Gate

Paper
Length
(mm)

Travel
Distance
(mm)

10-1/2" 8"

203.2

-7

10" 8"

203.2

-7

5-1/2"8-1/2"

215.9

+6

11" 8-1/2"

215.9

+6

8" 10"

254

+44

8" 10-1/2"

266.7

+57

Size

Gate

Paper
Length
(mm)

Travel
Distance
(mm)

8-1/2" 11"

279.4

+69

8-1/4" 13"

330.2

-15

8-1/2" 13"

330.2

-15

8-1/2" 14"

355.6

+11

9" 14"

355.6

+11

11" 17"

431.8

+87

Size

*Gate 1 ... The Switching Lever remains stationary, guiding paper toward Gate 1.
*Gate 2 ... The Swing Lever swings up to guide paper through Gate 2 into the Storage.
*Travel distance ... The Trailing Gate Unit moves in the "+" direction when it slides toward the
Paddle Roller and in the "" direction when it slides toward the Paper Take-Up
Unit of the Duplex with reference to its home position.

M-14

6-4. Front/Rear Edge Guide Plate Drive Mechanism/Control

The Front/Rear Guide Plates in the Duplex Unit align the front and rear

edges of the paper being stored into the Duplex Unit.

The Rear Edge Guide Plate is moved to the front by Front/Rear Edge

Guide Drive Motor M33 through a gear and belt. The Front Edge Guide
Plate makes a flipping motion as the Cam is turned by the belt from M33.
M33 turns in steps, each step moving the Rear Edge Guide Plate a
distance of about 0.4 mm with respect to the position where Front/Rear
Edge Guide Plate Home Position Sensor PC9 is blocked. M33 is
energized to move the Plate up to the corresponding paper size position.
Front/Rear Edge Guide
Drive Motor M33
Rear Edge Guide Plate

Front Edge Guide Plate

Cam

Retracted Position
The Front Edge Guide Plate is tilted by the Cam.
The Rear Edge Guide Plate will move, according to the paper size, to

one of the six positions each of which is located at a position at least

+4mm greater than the paper width.

172mm

228mm

193mm

M-15

284mm

249mm

305mm

Light Blocking
Plate

 Operation of the Front/Rear Edge Guide Plates (for A4L)

<At Home Position>

The Front/Rear Edge Guide Plates are located at a position where
Front/Rear Edge Guide Plate Home Position Sensor PC9 is blocked.

<When storing and taking up a copy>

Select the 2-sided copy mode and press the Start Key.
M33 turns forward.
The Cam moves the Front Edge Guide Plate to a retracted (stand-by)
position. The Rear Edge Guide Plate moves to the stand-by position (paper
size position + approx. 4 mm toward rear).
Approx. 4 mm or more

After approx. 1,020 msec. the trailing edge of the paper to be stored in the
Duplex Unit has unblocked Duplex Unit Trailing Edge Sensor PC14 ( H ).
M33 turns forward to move the Front and Rear Edge Guide Plates to the
exact paper size positions.

Paper take-up operation starts when the Start Key is pressed.

When Duplex Unit Paper Empty Sensor PC15 is unblocked ( H ), M33 turns
backward, returning the Rear Edge Guide Plate to the position where it
previously blocked Front/Rear Edge Guide Plate Home Position Sensor PC9
( L ).

M-16

 Control of Front/Rear Edge Guide Drive Motor M33

<When Storing a copy>

Upon pressing the Start Key, M33 turns forward, moving the Front/Rear
Edge Guide Plates to the stand-by position.
As the paper to be stored has passed Duplex Unit Trailing Edge Sensor
PC14 ( H ), the Front Edge Guide Plate is moved to the alignment
position by the Cam. The Rear Edge Guide Plate is moved to the paper
size position.
<When taking up a copy>
When Duplex Unit Paper Empty Sensor PC15 is unblocked ( H ) after a
copy has been taken up from the Duplex Unit, the Rear Edge Guide
Plate returns to the position where it blocks Front/Rear Edge Guide
Plate Home Position Sensor PC9 ( L ).
IC1G
Output Pins

Operation Order

Clock Frequency

Step 1 Step 2 Step 3 Step 4

38

37

36

35

Turns forward
Turns backward
4425T69MCA

M33 is a stepping motor, which is driven by the output signals from pins

35 to 38 of IC1G of Duplex Unit Master Board PWB-G.

The output order of the signals determines the motor direction.

M-17

 MALFUNCTION DETECTION

4444C12MAA

Malfunction
Code
C0d00

Description
Front/Rear Edge
Guide Plate
home position
detection failure

Detecting Timing
The home position is detected only in the initial
operation sequence. Front/Rear Edge Guide Plate
Home Position Sensor PC9 is not blocked ( L )
within 2.37 seconds after the initial operation
sequence has started (when the Power Switch is
turned ON, the Front Door is swung open and
closed, the Duplex Unit is slid into position, paper
take-up sequence from the Duplex Unit is
completed, or 2-sided copy mode is canceled).

Front/rear Edge Guide

Drive Motor (M33)

2.37sec. or more

PC9

4425T70MCA

M-18

6-5. Storing of Copies in Duplex Unit

The 1-sided copy is stored into the Duplex Unit as detailed below during

the 2-sided copy mode.

<For A4C paper>
Select the 2-sided copy mode.
Press the Start Key.
Duplex Unit Master Board PWB-G
A M31 Remote signal is output from IC1G-31 (to turn M31 forward).
M32 pulse signals are output from IC1G-56 to 62 (to turn M32 forward and
backward).
M33 pulse signals are output from IC1G-33 to 38 (to turn M33 forward).
Duplex Unit Drive Motor M31:
Gate Motor M32:
Front/Rear Edge Guide Drive Motor M33:

Energized
Energized
Energized

The Trailing Gate Unit moves to the position corresponding to the set
paper size.
The Front/Rear Edge Guide Plates move to the stand-by position
(approx. +4 mm or more) preset for the set paper size.
M32, M33: Deenergized
The 1-sided copy is fed into the Duplex Unit.
The trailing edge of the 1-sided copy moves past Duplex Unit Trailing
Edge Sensor PC14 ( H ).
Approx. 1,020 msec. later
<PWB-G>

M33 pulse signals are output from IC1G-33 to 38 (to turn M33
forward).
M33: Energized
The Front/Rear Edge Guide Plates move to the predetermined paper
size position and align the copy.
NO

Is the 1-sided copy just stored in the Duplex Unit the last one?

YES
M33: Deenergized
The copy storing sequence is completed when the Front/Rear Edge Guide
Plates complete aligning the copy.

M-19

7 DUPLEX PAPER TAKE-UP UNIT

7-1. Leading Edge Guide Plate and Duplex Paper Take-Up Drive
Mechanism/Control
Copies stored in the Duplex Unit are taken up and fed back into the copier

by the Duplex Take-Up Roll and Feed Roll which are driven via Duplex Unit
Paper Take-Up Clutch CL31 by Duplex Unit Drive Motor M31. The top copy
is separated from the remaining ones by a paper separating mechanism
with a torque limiter.
The Leading Edge Guide Arms align the leading edge of the copy being
stored into the Duplex Unit.
When Duplex Unit Pick-Up Solenoid SL33 is energized to begin a paper
take-up sequence, the Leading Edge Guide Arms are unlocked by way of
the Retraction Lever. At the same time, the Duplex Paper Take-Up Roll is
pressed down against the copy to take it up.

Duplex Unit Pick-Up

Retraction Lever
Solenoid SL33
Slide Plate

Duplex Unit Paper

Take-Up Clutch CL31

Leading Edge Guide Arms

Duplex Unit Drive Motor M31

M-20

<When storing a copy>

When a copy is to be stored into the Duplex Unit, SL33 is deenergized to

release, by way of the Retraction Lever, the Duplex Paper Take-Up Roll
from the copy or copies already in the Duplex Unit.
At the same time, the Leading Edge Guide Arms are locked into position by
parts A of the Slide Plate which meet the tabs on the Guide Plate,
thereby aligning the leading edge of the copy to be stored into the Duplex
Unit.
Duplex Unit Pick-up
Solenoid SL33

Paper Take-up Roller

Slide Plate
Paper

Leading Edge
Guide Arm
A
Leading Edge
Guide Arm

4425M219AA

Leading Edge Guide Arm

<When taking up a copy>

When a copy is to be taken up from the Duplex Unit, SL33 is energized to

lower the Retraction Lever and the Duplex Paper Take-Up Roll is pressed
against the copy in the Duplex Unit by spring force.
At the same time, the Leading Edge Guide Arms are unlocked from parts
A of the Slide Plate.
When the copy is taken up and fed in, the leading edge of the copy pushes
up the Leading Edge Guide Arms in the direction of the arrow.

M-21

 Operating Timing of Duplex Unit Pick-Up Solenoid SL33 and Duplex

Unit Paper Take-up Clutch CL31 (Two 2-sided copies of A4C paper,
using Duplexing/Automatic Document Feeder)
Start Key ON

Paper Take-Up Start

Main Drive ON
Motor M1 OFF
Front/Rear Edge Guide ON
Drive Motor M33 OFF
Duplex Unit Pick-Up ON
Solenoid SL33 OFF
200ms

Paper Take-Up ON
Clutch CL31 OFF
Duplex Unit Paper
Take-Up Sensor PC16
Vertical Transport
Sensor 3 PC17

200ms
230ms

230ms

H
L
H
L

4444T21MCA

Paper Take-Up Retry Control

If the paper to be taken up does not block Duplex Unit Paper Take-Up

Sensor PC16 within a given period of time, the paper take-up cycle starts
again after SL33 and CL31 are deenergized.
<Paper Take-Up Retry>
CL31 is energized approx. 200ms after SL33 has been energized.
If PC16 is not blocked within approx. 1,230 msec. after CL31 has been
energized, the paper take-up cycle starts again.
SL33 and CL31 are deenergized.
Approx. 500 msec.
CL31 is energized approx. 200ms after SL33 has been energized. (Paper
take-up retry operation)
NOTE: The paper take-up retry sequence is not performed in the Time
Saver mode.

M-22

4444C13MAA

M-23

7-2. Paper Take-up Operation

Normal Mode

<Normal Mode with A4C Paper>

Press the Start Key to start paper take-up.
Duplex Unit Pick-Up Solenoid SL33: Energized
Approx. 200ms later
Paper Take-Up Clutch CL31: Energized
The leading edge of the paper blocks Vertical Transport Sensor 3 PC17
( L ).
SL33 and CL31: Deenergized
The trailing edge of the paper moves past Duplex Unit Paper Take-Up
Sensor PC16 ( H ).
NO

Is the Duplex Unit empty?

YES

M33 is energized and the Front/Rear Edge Guide Plates return to the home
position.

M-24

 Time Saver Mode

In the Time Saver mode, the copies stored in the Duplex Unit are taken up

and fed back into the copier in a different order from when in the normal
mode. When the number of copies remaining to be stored in the Duplex
Unit becomes N, that copy is immediately taken up and fed back to the
copier and the subsequent ones are taken up each time they have just
been stored in the Duplex Unit. This saves a given amount of time in the
overall 2-sided copying cycle, which would otherwise be lost if Duplex
take-up motion is started after all copies have been stored.
The Time Saver mode is set only when the Automatic or Duplexing
Document Feeder is being used [in the standard mode (not in the Mixed
Original Detection mode) with full-size magnification and using paper less
than 297 mm long].
When Duplex Unit Rear Finger Solenoid SL32 is energized, it turns the

Duplex Unit Rear Finger so that the Finger presses the copy or copies
stored in the Duplex Unit.
When all copies are fed out of the Duplex Unit, the Duplex Unit Rear Finger
returns to its home position.
No.

Paper Length

Time Saver Mode

139 mm to 280 mm

The number of copies remaining to be stored in the

Duplex Unit is 4

281 mm to 297 mm

The number of copies remaining to be stored in the

Duplex Unit is 3

Duplex Unit Rear Finger Solenoid

SL32
Duplex Unit Rear Finger

M-25

<Operation in Time Saver Mode: A4 crosswise paper, 10 copies>

The trailing edge of the sixth copy moves past Duplex Unit Paper Entry
Sensor PC14 ( H ).
Approx. 1,020 msec.
The Front/Rear Edge Guide Plates move to the set paper size position to
align the copy.
At the same time, Duplex Unit Rear Finger Solenoid SL32 is energized and
the Duplex Unit Rear Finger presses the copies stored in the Duplex Unit.
The trailing edge of the 7th copy moves past PC14 ( H ). (Each of the
7th and subsequent copies is taken up and fed back into the copier each
time it has just been stored.)
Approx. 1,020 msec.
The Front/Rear Edge Guide Plates move to the set paper size position to
align the copy.
Duplex paper take-up sequence starts.
Duplex Unit Pick-Up Solenoid SL33 is energized.
Approx. 200msec. later
Duplex Unit Paper Take-Up Clutch CL31 is energized.
The leading edge of the copy blocks Vertical Transport Sensor 3 PC17
( L ). At the same time, SL33 and CL31 are deenergized and the
Front/Rear Edge Guide Plates move to the stand-by position.
NO

Have all copies been taken up for Time Saver?

YES

After all copies for Time Saver have been taken up and fed in, the copies
previously stored in the Duplex Unit are taken up and fed in, one by one.
When all copies have been taken up from the Duplex Unit, the Duplex Unit
Rear Finger turns to the home position.
Duplex Unit Paper Empty Sensor PC15, which has been in the blocked
( L ) state, is unblocked ( H ).
M33 is energized and the Front/Rear Edge Guide Plates return to their
home positions.

M-26

8 VERTICAL TRANSPORT SECTION

Vertical Transport Drive Mechanism/Control
Vertical Transport Drive Motor M21 drives the Transport Rollers through a

Gear to send the paper from the Duplex Unit to the copier.

Vertical Transport Roller

Vertical Transport
Drive Motor M21
4444M024AA

Control of Vertical Transport Drive Motor M21

The stepping motor M21 is driven by the signals from pins 1, 2, 17 and 4 of

IC9A on PF-2D Master Board PWB-A which is controlled by the copier

Master Board PWB-A. The drive signals are fed into 2 windings in the
motor.
<Motor Operation>
The signals from IC9A are applied in the order of steps 1 to 4 as shown in
table below, in synchronism with the clock frequency.
IC9A
Output Pins

Operation Order

Clock Frequency

Step
1

Step
2

Step
3

Step
4

1 Pin

2 Pin

17 Pin

4 Pin

Turns
4425T72MCA

M-27

 Timing Chart: 3 Copies

Start Key ON

TRON

TRON

TRON

Main Drive Motor ON

M1 OFF
Paper Leading Edge
Detecting Sensor PC55

H
L

Paper Transport ON
Clutch CL1 OFF
Vertical Transport ON
Drive Motor M21 OFF
65ms

65ms

65ms

5ms
4444T01MCA

4444C15MAA

M-28

9 EXIT SECTION
9-1. Exit/Duplex Switching Mechanism/Control
The paper path is switched by the Exit/Duplex Switching Plate which is

operated by Exit/Duplex Solenoid SL5.

The paper path is switched according to the copying mode as detailed

below.
Copying Mode

Exit/Duplex Solenoid SL5

Normal

Deenergized

2-sided copy (when 1-sided copy is fed

into Duplex)

Energized

Operation in 2-Sided Copying Mode

Select the 2-sided copying mode.
Press the Start Key.
The Front/Rear Edge Guide Plates
and Trailing Gate Unit move
according to the set paper size.
Approx. 1,350 msec. after a TRON
signal has been output, SL5 is
energized to feed the copy into the
Duplex Unit.
The paper is fed into the Duplex Unit.
SL5 is deenergized approx. 2,770
msec. after Synchronizing
Roller Clutch CL2 has been
deenergized.

M-29

 Control of Exit/Duplex Solenoid SL5

SL5 is energized and deenergized by the SL5 Remote signal from pin 85 of

IC4A of the copier Master Board PWB-A.

<SL5 Energization Timing>
SL5 is energized approx. 1,350 msec. after the TRON ( L ) signal has
been output.
<SL5 Deenergization Timing>
SL5 is deenergized approx. 2,770 msec. after CL2 has been deenergized.
For a multi-copy cycle, it is deenergized approx. 2,770 msec. after CL2 has
been deenergized for the last paper.

4444C14MAA

M-30

DIS/REASSEMBLY,
ADJUSTMENT

1 DISASSEMBLY
1-1. Removal of Exterior Parts
1

6
2

12
3

11

No.

10

Part Name

7
9

Removal Procedure

Lower Right Door

After removing Rear Right Cover, remove 2 screws.

Rear Right Cover

Remove 2 screws.

Bottom Right Cover

After removing Front Right and Rear Right Covers, remove 2 screws.

Front Right Cover

Remove 2 screws.

Bottom Front Cover

After removing Front Left and Right Covers, remove 2 screws.

Front Left Cover

Remove 2 screws.

Lower Left Door

Remove 4 screws.

Bottom Left Cover

After removing Front Left and Rear Left Covers, remove 2 screws.

Rear Left Cover

Remove 2 screws.

10

Left Rear Cover

After removing Middle Rear Cover, remove two screws.

11

Middle Rear Cover

Remove 2 screws.

12

Right Rear Cover

After removing Middle Rear Cover, remove two scews.

D-1

1-2. Removal of Duplex Unit Drive Motor Assy

1. Slide out and remove the Duplex Unit.
2. Remove 4 screws and the Duplex Unit exterior cover.
3. Remove 2 screws and the Duplex Unit interior cover.

4. Remove 2 screws and the cover.

5. Remove 4 screws and the Duplex Unit Drive Motor

Assy.

1-3. Removal of Paper Take-Up Unit

1. Remove the Duplex Unit Drive Motor Assy.
2. Remove 3 screws and the PWB-G cover.

3. Remove 4 screws and the Duplex Unit Paper Take-Up

Unit.

D-2

4. Remove 2 connectors. Shift the Front/Rear Edge

Guide Plate Home Position Sensor to the side and
then remove the Paper Take-Up Unit.

1-4. Removal of Trailing Gate Unit

1. Remove 1 screw and the Upper Guide Plate.

2. Move the Trailing Gate Unit to the left as far as it goes

by turning the Screw Cam.
3. Remove 1 screw and the Upper Guide Plate Assy.

4. Remove the E-ring and washer. Remove the Timing

Belt from the Gear.

5. Snap off two E-rings and remove the Slide Shaft.

D-3

6. Remove 2 screws, the ground wire and the Trailing

Gate Unit.

1-5. Removal of Paper Guide Sheet

1. Remove the Trailing Gate Unit.
2. Remove 4 screws and the Paper Mounting Plate.

3. Remove 2 coil springs.

4. Remove 2 screws and the Paper Guide Sheet.

1-6. Removal of Front/Rear Guide Plate Assy

1. Remove the Paper Take-Up Unit.
2. Unplug 2 connectors.

3. Remove 2 screws and then the Front/Rear Edge

Guide Plate Assy.
CAUTION
When reinstalling the Front/Rear Edge Guide Plate
Assy, positively hook the fingers into the Mounting
Plate. Align the scale with that on the Mounting Plate.

D-4

1-7. Removal of Vertical Transport Unit

1. Open the Middle Left Door and Lower Left Door.
Remove 1 screw and then the gear Assy.

4444M019AA

2. Remove 2 screws and the Rear Left Cover.

3. Remove 4 screws and the Lower Left Door.

4. Remove 5 screws and 1 connector. Slide the Vertical

Transport Unit to the rear and remove it.

1-8. Removal of Take-Up Roll/Feed Roll Assy

1. Remove the Duplex Unit Drive Motor Assy.
2. Loosen 1 screw and remove the retainer spring.
3. Remove the C-clip and Paper Take-Up Sensor Assy.

4. Remove 1 screw and the Cover.

5. Remove 2 screws. Lift up and then remove the
Solenoid Mounting Plate Assy.
CAUTION
When reinstalling the Solenoid Mounting Plate Assy,
be sure to insert the Paper Take-Up Roll/Feed Roll
Assy bracket above the Rectraction Lever.

D-5

6. Remove 2 C-clips. Lifting up the Paper Take-Up

Roll/Feed Roll Assy, move it toward the rear and
remove.
CAUTION
When reinstalling the Paper Take-Up Roll/Feed Roll
Assy, first engage the shaft coupling at the front and
then rehook the spring.

6. Remove the bushing, E-ring, bushing, and spring.

7. Snap off 2 E-rings, pull out the shaft and then remove
the Feed Roll.

8. Remove the E-ring and lock pin and then the Paper
Take-Up Roll.
CAUTION
Save the lock pin for later use.

1-9. Removal of Separator Roll Assy

1. Remove 2 screws and then the Mounting Plate.
CAUTION
When reinstalling the Mounting Plate, align the
locking members.

D-6

2. Remove 1 C-clip and screw and then the Guide

Holder.
CAUTION
When reinstalling the screw, make sure that it is
above the Guide Holder.

3. Remove the C-clip. Remove the Separator Roll Assy

by sliding it toward the rear and then upward.

1-10. Cleaning of Vertical Transport Rollers

Using a soft cloth dampened with alcohol, wipe clean
the Transport Rollers.

1-11. Cleaning of Duplex Unit Vertical Transport Roller/Slip Roll

Using a soft cloth dampened with alcohol, wipe clean
the Duplex Unit Vertical Transport Roller/Slip Roll.

1-12. Cleaning of Paper Take-Up Roll/Feed Roll/Separator Roll

1. Pull out the Duplex Unit.
2. Remove 2 screws and then the Mounting Plate Assy.
3. Using a soft cloth dampened with alcohol, wipe clean
the Paper Take-Up Roll, Feed Roll and Separator Roll.

D-7

1-13. Cleaning of Trailing Gate Unit Transport Rollers 1 & 2

1. Pull out and remove the Duplex Unit.
2. Open the Guide Plate Assy.
3. Using a soft cloth dampened with alcohol, wipe clean
the Trailing Gate Unit Transport Rollers 1 & 2.

1-14. Parts Which Must Not Be Touched:

Duplex Unit Pick-Up Solenoid SL33

D-8

2 ADJUSTMENT
2-1. Adjustment of Magnetic Catch
1. Remove the Vertical Transport Unit.
2. Loosen two screws on the Magnetic Catch. Check that
each part marked with a circle in the fig. on the left is
in contact with the corresponding mating part and then
tighten the screws.
3. Swing open and close the Vertical Transport Unit to
check that each part is in contact with the other.

2-2. Adjustment of Clearance Between Release Lever Assy and Guide

Plate (This adjustment must be made after the adjustment of the
Magnetic Catch has been completed.)
1. Close the Vertical Transport Assy.
2. Loosen one screw on each Release Lever Assy.
3. Move the Release Lever Assy up and down as
necessary to obtain a clearance of 1 to 3.0 mm
between the Lever Assy and Guide Plate. When the
specified clearance is obtained, tighten the screw.
4. Swing open the Vertical Transport Unit and turn the
Paddle Roller one complete turn. Then, close the
Vertical Transport Unit and check for clearance again.
5. After the clearance has been checked, turn the Paddle
Roller to check to see if the Rolls in the Release Lever
turn.

2-3. Adjustment of Front/Rear Edge Guide Plate Timing Belt

1. Loosen two screws.
2. Hook a tension gage into the motor mounting hole and
then pull the gage in the direction of the arrow with a
force of 800 100g.
3. Tighten the screws.

4444M023AA

2-4. Alignment of Front/Rear Edge Guide Holder

Align the hole in the Front/Rear Edge Guide Plate
Holder with that in the Edge Guide Plate, and align the
hole in the Cam with another one in the Edge Guide
Plate. Fit an Allen wrench into the holes of the Cam
and Plate and screw the Holder into position.

D-9

2-5. Adjustment of Trailing Gate Unit Timing Belt

1. Loosen the screw that secures the tension plate. Turn
the Tension Plate right or left until the correct belt
tension is obtained.
2. Tighten the screw.

4444M022AA

2-6. Adjustment of Duplex Unit Reference Position

Requirement
Prepare a test chart (A3 size) as shown on the left.

Draw a line on the chart at a point 20 mm from the

right edge.
Dimension A on the copy should measure 20 3.0 mm.

1. Place the test chart on the Original Glass and align

the rear edge of the test chart with the reference mark
(). Lower the Original Cover.
2. Select 1 2 copy mode and make two copies of the
test chart in the full size mode (use A3 paper).
3. Compare the position of the reference line on the
second copy with that on the test chart.

4. If the copied line deviates from the reference line, pull

out the Duplex Unit and open the Upper Guide Assy.
5. Slide the Rear Edge Guide Plate forward. Loosen the
2 screws securing the Front/Rear Edge Guide Plate
Assy. Adjust the position of the Assy and then tighten
the screws.

NOTE

If copied width A < 17 mm, move the Front/Rear

Edge Guide Plate Assy toward the rear.
If copied width A > 23 mm, move the Assy toward the
front.

D-10

2-7. Adjustment of Duplex Unit Gate Switching Solenoid SL31 Position

1. Move SL31 in the direction of the arrow and then
loosen the screws.
2. Manually place SL31 in the energized position and
check that the clearance between the Switching Lever
and round shaft measures 11 mm or more. Check also
that the Switching Lever is in tight contact with the
round shaft when SL31 is in the deenergized position.

2-8. Adjustment of Duplex Unit Rear Finger Solenoid SL32 Position

1. Move SL32 in the direction of the arrow and then
loosen the screws.
2. Check that the Duplex Unit Rear Finger is operated
when SL32 is manually placed in the energized
position.

D-11

MISFEED DETECTION

1 TYPES OF MISFEED DETECTION

Seven sensors in the copier and Duplex Unit monitor paper travel through the Cabinet.
Paper Leading Edge
Detection Sensor PC55
Transport Roller Sensor
(PC54)
Duplex Vertical Transport
Sensor PC30
Vertical Transport
Sensor 3 PC17
Duplex Unit Paper Entry
Sensor PC14

Duplex Unit Paper

Take-Up Sensor PC16
Duplex Unit Paper
Empty Sensor (PC15)

1)

Duplex Vertical Transport Sensor

1 leading edge detection..................Monitors the paper which blocks PC30 after the
Synchronizing Roller has been activated.

2)

Duplex Vertical Transport Sensor

1 trailing edge detection...................Monitors the paper which first unblocks PC55 and then
unblocks PC30.

3)

Duplex Unit Paper Entry Sensor

leading edge detection.....................Monitors the paper which first blocks PC30 and then
blocks PC14.

4)

Duplex Unit Paper Entry Sensor

trailing edge detection......................Monitors the paper which first blocks and then unblocks
PC14.

5)

Storage detection .............................Duplex Unit Paper Empty Sensor PC15 monitors a copy
which has been stored.

6)

Take-up failure detection .................Monitors the paper which blocks PC17 after the Duplex
Paper Take- Up Roll has been activated.

7)

Take-up trailing edge detection .......Monitors the paper which first blocks and then unblocks
Duplex Unit Paper Take-Up Sensor PC16.

8)

Time Saver take-up failure

detection ...........................................Monitors the events from the start of the Duplex Paper
Take-Up Roll to the blocking of PC16.

9)

Transport Roller Sensor leading

edge detection..................................Monitors the paper which first blocks PC17 and then
blocks PC54.

T-1

2 MISFEED DETECTION TIMING

1) Duplex Vertical Transport Sensor 1 leading edge detection
Duplex Vertical Transport Sensor 1 (PC30) is not blocked (stays high) within 4.52 seconds after
Synchronizing Roller Clutch CL2 has been activated.

ON

CL2 OFF
About 4.52sec.
H

PC30

4444T22MCA

2) Duplex Vertical Transport Sensor 1 trailing edge detection

Duplex Vertical Transport Sensor 1 (PC30) is not unblocked (stays low) within 5.4 seconds after
Paper Leading Edge Detecting Sensor PC55 has been unblocked (stays high).

PC55

About 5.4sec.
H

PC30

4444T23MCA

3) Duplex Unit Paper Entry Sensor leading edge detection

Duplex Unit Paper Entry Sensor PC14 is not unblocked (stays high) after Duplex Vertical
Transport Sensor 1 (PC30) has been unblocked (stays low). The paper which has unblocked
PC30 should unblock PC14 within 6.13 seconds when its length is 301 mm or longer, and within
5.26 seconds when its length is 300 mm or shorter.
H

PC30 L
About 6.13sec.
About 5.26sec.
H

PC14 L
4444T24MCA

4) Duplex Unit Paper Entry Sensor trailing edge detection

Duplex Unit Paper Entry Sensor PC14 is not unblocked (stays low) within approx. [(paper length
155) + 1.5] seconds after it has been blocked.

PC14 L

Paper length
+1.5sec.
155
4444T25MCA

T-2

5) Storage detection
Duplex Unit Paper Empty Sensor PC15 is unblocked (goes low) after a copy has been stored in
the Duplex Unit.

6) Take-up failure detection

Vertical Transport Sensor 3 (PC17) is not blocked (stays high) within 2.0 seconds after Duplex
Paper Take-Up Clutch CL31 has been energized.

ON

CL31 OFF
About 2.0sec.
H

PC17

4444T26MCA

7) Take-up trailing edge detection

Duplex Unit Paper Take-Up Sensor PC16 is not unblocked (stays low) within [(paper length/162)
+ 1] seconds after it has been blocked.

PC16

Paper length
+1sec.
162

4444T27MCA

8) Time Saver take-up failure detection

Duplex Paper Take-Up Sensor PC16 is not blocked (stays high) within 1.23 seconds after
Duplex Unit Paper Take-Up Clutch CL31 has been energized for each of the copies for Time
Saver except the last.

ON

CL31 OFF
About 1.23sec.
H

PC16

4444T28MCA

9) Transport Roller Sensor leading edge detection

Transport Roller Sensor PC54 is not blocked (stays high) within 3.05 seconds after Vertical
Transport Sensor 3 (PC17) has been blocked (stays low).

PC17 L
About 3.05sec.
H

PC54 L
4444T29MCA

T-3

Copyright
1994 MINOLTA CAMERA CO., LTD
Printed in Japan
Use of this manual should
be strictly supervised to
avoid disclosure of
confidential information.

MINOLTA CAMERA CO., LTD.

PF-2D SERVICE MANUAL

4444-7993-11 94075550
Printed in Japan