3-BIN SORTER
(Machine Code: A566)
Service Manual
25 April 1997 SPECIFICATIONS
1. SPECIFICATIONS
Paper Size for Bins: Sort/Stack Modes:
Maximum: A3, 11 x 17"
Minimum: A6 lengthwise, 5
1/2
x 8
1/2
"
Paper Weight for Bins: Face up:
2
1st bin: 52 ~ 157 g/m
2nd/3rd bins: 52 ~ 105 g/m
(14 ~ 42 lb)
2
(14 ~ 28 lb)
Face down:
2
All bins: 64 ~ 105 g/m
(17 ~ 28 lb)
Bin Capacity: 1st bin:
1/2
A4, 8
x 11" : 500 copies
A3, 11 x 17" : 250 copies
2nd/3rd bins:
1/2
A4, 8
x 11" : 250 copies
A3, 11 x 17" : 125 copies
Number of Bins: 3 copy trays
1 inverter tray
Power Source: DC 24 V, 5 V (from the main machine)
Power Consumption: Average: Less than 30 W
Weight: 13 kg (28.7 lb)
Dimensions (W x D x H): 361 x 483 x 427 mm (14.2" x 19.0" x 16.8")
A566-1
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COMPONENT LAYOUT 25 April 1997
2. COMPONENT LAYOUT
2.1 MECHANICAL COMPONENT LAYOUT
1
15
12
1. Tray Lift Belt
2. 2nd Bin Gate
14
13
11
10
2
3
4
5
6
9
7
8
A566V001.wmf
9. Inverter Sensor
10. 3rd Exit Sensor
3. 2nd Exit Sensor
4. 3rd Bin Gate
5. Entry Sensor
6. Junction Gate
7. Feed Roller
8. Return Pinch Roller
11. Inverter Bin
12. 3rd Bin
13. 2nd Bin
14. Tray Lower Limit Sensor
15. 1st Bin
A566-2
25 April 1997 COMPONENT LAYOUT
2.2 DRIVE LAYOUT
1
4
9
5
6
3
1. Entry Roller
2. Feed Roller
3. Entrance Motor
4. 1st Exit Roller
5. 2nd Exit Roller
2
A566V002.wmf
8
7
A566V003.wmf
6. 3rd Exit Roller
7. Inverter Roller
8. Return Pinch Roller
9. Exit Motor
A566-3
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COMPONENT LAYOUT 25 April 1997
2.3 ELECTRICAL COMPONENT DESCRIPTION
Refer to the electrical component layout on the reverse side of the point-topoint diagram (on waterproof paper).
Symbol Index No. Descriptio n Note
Motors
M1 13
M2 14
M3 18 Tray Shift Moves the 1st bin from side to side.
M4 16 Tray Lift Moves the 1st bin up or down.
Solenoids
SOL1 4
SOL2 5
SOL3 6
SOL4 7
Sensors
S1 2
S2 17
S3 1 1st Exit Detects paper jams at the 1st bin.
S4 8 2nd Exit Detects paper jams at the 2nd bin.
S5 9 3rd Exit Detects paper jams at the 3rd bin.
S6 10
S7 11
S8 15
Switches
SW1 3
Circuit Board
PCB1 12 Control Controls all sorter fu nct i ons.
Entrance Drives the feed roll er and the entry
roller.
Exit Drives the inverter roller and the exit
rollers.
2nd Bin Gate Opens and closes the 2nd bin gate to
direct the copies i nt o either the 2nd
bin or 1st bin.
3rd Bin Gate Opens and close s the 3rd bin gate to
direct the copies i nt o either the 3rd bin
or the other bins .
Junction Gate Opens and close s the junction gate t o
direct copies into either the inverter
area or other exits.
Pinch Roller In face down mode, contacts the
return pinch roller with the copy to
deliver the copy to bin 1, 2, or 3.
Stack Height Detects when the copy paper stack is
at the correct height, and detects
when the 1st bin i s at its upper limit
position.
Tray Half-turn Detects complete side-to-side
movement of the 1 st bi n.
Inverter Detects misfeeds and synchronizes
the inverter gate.
Entry Detects misfee ds and copy paper
entry.
Tray Lower Lim i t Detects when the 1st bin i s at i ts lo w er
limit position.
Sorter Set Detects when the sorter is attached to
the main machine.
A566-4
25 April 1997 DETAILED SECTION DESCRIPTIONS
3. DETAILED SECTION DESCRIPTIONS
3.1 BASIC OPERATION
3.1.1 Face-up Mode
[D]
[C]
[E]
[A]
[B]
A566D001.wmf
A566D002.wmf
Copies exiting the copier pass through the entrance guide plate [A]. The entry
roller will send copies either to the inverter bin or to each bin, depending on
the selected mode.
When the sorter receives the feed-out signal from the main machine, the
entrance motor and exit motor energize to rotate the all rollers in the sorter.
During copying, all rollers transport the paper at a speed which depends on
the copier. When the leading edge of the copy passes the entry sensor [B],
the speed of the rollers changes to 550 mm/s.
- 1st, 2nd and 3rd bins -
When the junction gate [C] is closed as shown above, the copies pass
through the upper part of the junction gate. For 1st bin output mode, the copy
goes straight up from the junction gate directly to the bin. For the 2nd and 3rd
bins, the copies from the junction gate are delivered to these bins, as directed
by the 2nd bin gate [D] and 3rd bin gate [E].
A566-5
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DETAILED SECTION DESCRIPTIONS 25 April 1997
3.1.2 Face-down mode
[A]
[B]
[D]
A566D003.wmf
[C]
When the junction gate [A] is opened, the copy goes to the inverter bin [B]
through the lower part of the junction. When the trailing edge of the copy
passes through the inverter sensor [C], the return pinch rollers [D] lower to
contact the copy, then the copy is fed back in by the rollers. The copy is fed
out to any output bin and it arrives face down.
A566D004.wmf
A566-6
25 April 1997 DETAILED SECTION DESCRIPTIONS
3.2 1ST BIN UP/DOWN MECHANISM
[C]
[E]
[A]
[D]
[B]
A566D005.wmf
The tray lift motor (a dc motor) [A] controls the vertical position of the 1st bin
[B] through gears. When the main switch is turned on, the 1st bin is initialized
at the upper position. The bin’s upper position is detected by the stack height
sensor [C]. The 1st bin activates the stack height sensor, then the 1st bin
lowers until it is at the correct height to receive the copy. This initialization is
performed before every copy job.
During coping, when the stack height sensor is activated by the stack of
paper, the 1st bin lowers until the stack height sensor is deactivated.
When the 1st bin reaches its lower limit, actuator [D] enters the lower limit
sensor [E], and copying stops. After copying ends, the machine stops.
A566-7
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DETAILED SECTION DESCRIPTIONS 25 April 1997
3.3 1ST BIN SIDE-TO-SIDE SHIFT MECHANISM
[A]
[B]
[E]
[B]
[D]
[H]
[E]
A566D006.wmf
[G] [F]
[C]
A566D007.wmf
In the sort/stack mode, the 1st bin [A] moves from side-to-side to stagger and
separate the sets of copies.
The horizontal position of the shift tray is controlled by the tray shift motor (a
dc motor) [B] and the shift cam [C]. After one set of copies is delivered to the
bin, the tray shift motor starts rotating, driving the shift cam through gears.
The link [D] connected between the shift cam and the tray shift plate [E] is
creating the side-to-side movement required to stagger the copies.
When the shift cam has rotated 180 degrees (when the tray is fully shifted
across), the tray half-turn sensor [F] is activated by the slot [G] in the actuator
plate [H], which is fixed to the shift cam, and the tray shift motor stops. The
next set of copies is then delivered. The motor rotates, repeating the same
process and moving the bin back to the previous position.
A566-8
25 April 1997 DETAILED SECTION DESCRIPTIONS
3.4 PAPER FEED AND MISFEED DETECTION TIMING
– Normal Mode –
* 1
312 4560
J4
550 mm/s
J4
J2
J3
J3
J1
J3 J4
(Sec.)
Normal Mode [A4 sideways, 3 pages, 40 CPM (200 mm/s)]
Feed Out Signal
Entrance Motor
Entry Sensor
Junction Gate Sol.
3rd Exit Sensor
2nd Exit Sensor
1st Exit Sensor
300 mm/s 550 mm/s * 1
Exit Motor
*1: This speed depends on the copier.
A566-9
A566D008.wmf
Options
DETAILED SECTION DESCRIPTIONS 25 April 1997
– Inverter Mode –
312 4560
* 1
300 mm/s
J9
J7J6
550 mm/s
J8
J5
(Sec.)
Inverter Mode [A4 sideways, 3 pages, 40 CPM (200 mm/s)]
Feed Out Signal
Entrance Motor
Entry Sensor
Junction Gate Sol.
Inverter Sensor
Pinch Roller Sol.
1st Exit Sensor
J9
J8
550 mm/s
Exit Motor
J9
J8
2nd Exit Sensor
A566D009.wmf
3rd Exit Sensor
*1: This speed depends on the copier.
A566-10
25 April 1997 DETAILED SECTION DESCRIPTIONS
3.5 JAM DETECTION
– Paper Jams –
J1: The entry sensor does not turn on within 2 s after the feed out signal has
turned on.
J2: The entry sensor does not turn off within 610 ms after the feed out signal
has turned off or the entry sensor stays on over 2.8 s.
J3: The following exit sensors do not turn on within the specified time after the
entry sensor has turned on.
1st exit sensor: 2.4 s
2nd exit sensor: 1.4 s
3rd exit sensor: 740 ms
J4: The following exit sensors do not turn off within the specified time after the
entry sensor has turned off.
1st exit sensor: 870 ms
2nd exit sensor: 500 ms
3rd exit sensor: 270 ms
J5: The inverter sensor does not turn off within 4.56 s after the inverter
senosr has turned on.
J6: The inverter sensor does not turn on again within 380 ms after the
inverter sensor has turned off.
J7: The inverter sensor does not turn off within 1.14 s after the inverter
sensor has turned on again.
J8: The following exit sensors do not turn on within the specified time after the
inverter sensor has turned on again.
1st exit sensor: 770 ms
2nd exit sensor: 430 ms
3rd exit sensor: 250 ms
J9: The following exit sensors do not turn off within the specified time after the
inverter sensor turned off again.
1st exit sensor: 770 ms
2nd exit sensor: 430 ms
3rd exit sensor: 250 ms
Options
A566-11
INSTALLATION PROCEDURE 25 April 1997
4. INSTALLATION PROCEDURE
4.1 ACCESSORY CHECK
Check the quantity and condition of the accessories in the box against the
following list.
1. New Equipment Condition Report...........................1
2. Installation Procedure...... .................. ......................1
3. Front Connecting Bracket......... .................. .............1
4. Rear Connecting Bracket ........................ ................1
5. Bottem Bracket........................................................1
6. Copy Tray................................................................4
7. Decal - Paper Size Detector....................................1
7. Philips Screw - M4X12 ............................................6
9. Tapping Screw - M4X10..........................................2
10. Snap Ring...................... .................. ......................2
A566-12
25 April 1997 INSTALLATION PROCEDURE
4.2 INSTALLATION PROCEDURE
A566I500.wmf
A566I501.wmf
[F]
[A]
[E]
[C]
CAUTION
+
[B]
A566I502.wmf
[D]
A566I503.wmf
Unplug the copier power cord before star ting the follo wing procedure.
1. Remove the strips of tape.
2. Install the front connecting bracket [A] (2 screws) and the rear connecting
bracket [B] (2 screws).
3. Install the bottom bracket [C].
4. Remove the front cover [D] (3 screws) and rear cover [E] (3 screws).
5. Install the tray [F] with 2 tapping screws - M4 x 10.
A566-13
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INSTALLATION PROCEDURE 25 April 1997
[I]
[C]
[A]
[B]
[G]
[E]
[D]
A566I504.wmf
[H]
[F]
A566I505.wmf
A566I506.wmf
6. Install the sorter unit [A] on the frame with 1 clip [B].
7. Mount the arm bracket [C] with 1 clip [D].
8. Install the trays [E].
9. Reinstall the front and rear covers.
10. Connect the cable [F] and the optic cable [G].
NOTE:
If the main machine is 115V version, perform the following. In
other case, skip step 11.
11. Remove the slider [H] from the copier’s paper tray and attach the paper
size detection decal [I].
12. Reinstall the slider.
13. Turn the copier’s main switch on and check the sorter operation.
A566-14
25 April 1997 REPLACEMENT AND ADJUSTMENT
5. REPLACEMENT AND ADJUSTMENT
5.1 EXTERIOR COVER AND BIN REMOVAL
[A]
[D]
[C]
[B]
A566R006.wmf
1. Rear Cover [A] (3 screws)
2. Front Cover [B] (3 screws)
3. Top Cover [C] (2 screws)
4. Bins [D] (1st bin: 2 screws)
Options
A566-15
REPLACEMENT AND ADJUSTMENT 25 April 1997
5.2 TRAY LIFT/TRAY SHIFT MOTOR ASSEMBLY REMOVAL
[A]
[B]
A566R007.wmf
1. Remove the rear cover (see Exterior Cover and Bin Removal).
2. Remove the clip [A].
3. Remove the motor assembly [B] (3 screws, 3 connectors).
A566-16
25 April 1997 REPLACEMENT AND ADJUSTMENT
5.3 ENTRANCE MOTOR REPLACEMENT
[A]
[B]
A566R008.wmf
[C]
A566R009.wmf
1. Remove the rear cover (see Exterior Cover and Bin Removal).
2. Remove the control board [A] (9 connectors, 4 clamps).
3. Remove the motor bracket [B] (2 screws).
4. Remove the exit motor [C] (2 screws).
Options
A566-17
REPLACEMENT AND ADJUSTMENT 25 April 1997
5.4 EXIT MOTOR REPLACE MENT
[B]
[A]
A566R010.wmf
1. Remove the rear cover (see Exterior Cover and Bin Removal).
2. Remove the motor bracket [A] (2 screws, 1 connector).
3. Remove the exit motor [B] (2 screws, 1 connector).
A566-18
25 April 1997 REPLACEMENT AND ADJUSTMENT
5.5 STACK HEIGHT SENSOR AND 1ST EXIT SENSOR
REPLACEMENT
[C]
[B]
A566R001.wmf
[A]
A566R002.wmf
1. Remove the front, rear, and top covers (see Exterior Cover and Bin
Removal).
2. Remove all bins (see Exterior Cover and Bin Removal).
3. Remove the 3-bin sorter.
4. Remove the middle guide plate [A] (1 clip).
5. Remove the motor assembly [B] (see Tray Lift/Tray Shift Motor Assembly
Removal).
6. Remove the upper guide plate [C] (4 screws).
A566-19
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REPLACEMENT AND ADJUSTMENT 25 April 1997
[D]
[E]
[F]
A566R003.wmf
7. Remove the middle shift guide plate [D] (3 screws).
8. Remove the stack height sensor [E] (1 connector).
9. Remove the 1st exit sensor [F] (1 screw, 1 connector).
A566-20
25 April 1997 REPLACEMENT AND ADJUSTMENT
5.6 2ND / 3RD EXIT SENSOR AND INVERTER SENSOR
REPLACEMENT
[A]
[B]
[D]
[E]
[G]
[F]
[C]
A566R004.wmf
[H]
A566R005.wmf
1. Remove the front cover and rear cover (see Exterior Cover Removal).
2. Remove all bins.
3. Remove four tray brackets [A] (1 screw each).
4. Remove the upper exit cover [B] (2 screws).
5. Remove the lower exit cover [C] (2 screws).
6. Remove the sensor bracket [D] (1 screw) and replace the 2nd exit sensor
[E] (1 screw, 1 connector).
7. Remove the sensor bracket [F] (1 screw) and replace the 3rd exit sensor
[G] (1 screw, 1 connector).
8. Replace the inverter sensor [H] (1 screw, 1 connector).
Options
A566-21
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