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Technical Bulletin
Number: AR-650-011R Date: April 2003
Sharp Electronics Corporation Services and Support Group 1300 Naperville Drive Romeoville, IL 60446

Subject: Duplex Kit for Heavy Use. Duplex Unit adjustments / modifications 1. Model: 2. General: AR650/800 A Duplex Modification kit has been established for use in an environment where a majority of the copies are duplexed. We have listed below the details and parts included in the Duplex Kit 0N6LA55210000. ADU KIT Parts Breakdown

3. Description:

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(1) List of the parts included in this kit Procedure Item A A --A A A A A A B1 B1 B1 B2 B2 B1 A ----1 5 4 7 7 9 8 6 3 3 3 2 2 3 Part code 0N4406361050/ 0N4406361060/ 0N4408861690/ 0N6LA55193000 0N6LA55194000 0N4406355950/ 0N4406356030/ 0N4406356070/ 0N4842040370/ 0N4408844190/ 0N4407401970/ 0N4408843920/ 0N4406356080/ 0N4406356090/ 0N4406356100/ 0N6LA55137000 0N6LA55040000 0N6LA55211000 Part name Pickup roller Feed roller ROM Guide F Guide R Stopper Bracket Mylar Screw Arbor P/U Spring clutch Sleeve Sidewall F Sidewall R Sintered arbor Discharge brush CD-ROM Instruction Manual QTY 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1

0N6LA55210000 Duplex Kit

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This Duplex Kit is designed to address E-51 and E-54 Error codes, in particular for paper jams while the paper is coming into the Duplex Tray and while the paper is being picked up from the Duplex Tray. We suggest that you read the section additional adjustments and modifications before installing this update as some of these adjustments and suggestions might resolve your problem without installing this kit. If you are installing this kit, you should perform the checks mentioned in this section prior to installing the kit and order the needed parts accordingly.

1) Replacement procedure For the replacement procedures of the items marked with A on the list on page 2, refer to Page 7 for installation procedures. For the replacement procedure of the items marked with B on the previous list refer to the following replacement procedure and precautions. B1: Procedure for attaching the spring clutch 1. Refer to the Service Handbook 1.15.2 Holding gate position adjustment 1. 2. Follow the steps below to check the function of the holding gate. 1) Pull out the ADU, unscrew two screws and remove the gray- colored cover from the feed unit. Then return the ADU to its original position. 2) Use the door-switch jig and start the duplex copy operation with the leftside front cover of the main unit open. 3) Check that shaft S on the left side of the ADUs front face (shown below) turns twice at one time. Since the movement of shaft S is interlocked with the holding gate, the function of the holding gate can be checked by checking the rotation of shaft S.

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B2: Procedure for replacing the sidewall 1. Remove stack ASM. Remove the six screws and connector shown in the picture below.

2. Remove the sidewall. (Remove both sidewalls on the front and rear sides.) Remove the screws from each part shown in the picture on the next page and remove the belt-fixing bracket

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3. Install the sidewall to the support part. Replace the sidewall and assemble the unit to the original configuration in the reverse procedure above.

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When you have attached the belt to the guides, make sure that the belt is installed parralel with the guide surface. Move the guides back and forth to both extremes before reinstalling the Duplex Tray Assembly. Insure that the guides are the same point at both of the extreme settings ( Minimum and Maximum travel). Move to the next section ( procedure A) before reinstalling this Duplex Tray Assembly.

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Installation of items in section A and section C 1. Remove the Front Cover and the Feed section cover as shown:

Remove Covers

2.

Remove the wiring from the J413 PWB connector and the retaining clips all the way to the left side feed section.

Remove wiring from PWB and Clips

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3.

Removal of the Feed Section.

Remove C Clip and spring

Remove Connector

Remove C Clip Remove Shaft Remove Feed section

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4. Removing of Guide Remove the two screws at the Rear Side

Remove the two screws at the Front Side Remove Guide

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5. Removal of the Pickup and Feed Roller

Remove the Three screws that hold the bracket and remove it

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Remove the C Clip and push back the shaft

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Remove the C Clips and install the new Feed Roller (item 5) The One Way bearing side is installed at the Rear

Install the new Pickup Roller

All the parts not in the Upper Feed Section can now be reinstalled in the reverse order. The Duplex Feed Tray can then be reinstalled afterwards.

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6. Removal and installation of the Guides, Bracket and Discharge Brush

Remove the two screws holding the Bracket, Guide, Anti-static Brush

The new assembly will use a new Bracket (item 8) a new Discharge Brush and two Guides (item 7). The front guide and the back guide are similar except for the distance of the pivot points. The Stopper (item 9) is used to prevent the Guides from falling of the pivots and is mounted on top of the bracket.

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a) Install the Bracket (item 8) and the Discharge Brush on the exit of the feed section, similar to the old style assembly. b) Install the Guides F and R by hanging them on the pivots ( White side towards the Duplex Tray) c) Install the Stopper. d) Check the there is sufficient clearance between the pivots and the drive shaft. Adjust as required.

e) Reinstall the Feed section on the Duplex Unit.

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f) Realign the Duplex Tray so that the out of paper lever is properly centered in the Duplex Tray Sensor as shown below:

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Item 4 EPROM The EPROM is to be placed on the Logic PWB in the location of IC11 as shown below. This will replace the version 300F070 with version 300F07A

For the installation of item 6 ; the Mylar guide, please refer to the picture below. This shows the placement of the Mylar on ramp of the guide item 24-22 just before the separation belts. Place Mylar on the ramp before the separation belts

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Additional adjustments and modifications 1. Duplex Gate Solenoid Sticking Please refer to the Published Tech tip 2. Holding Gate Adjustment Reference FSH 1.15.2 Holding gate position adjustment 1 When the holding gate is removed for replacement, the holding gate position must be adjusted when it is installed. (1) When installing the drive gears of the holding gate, match each of the drive gear positions with the positions of the dowels on the gear. Turn only the gear on the holding gate in the direction of the arrow by 2.5 teeth, and install the drive gears. (The front side gear is installed first, and the dowels on the rear side should be aligned).

Note: Adjust the front/rear side gears by removing the central gear. The spring clutch may lock when the gear is operated. So, push the projection of the clutch unit to turn the gear. (2) Align the projection on the clutch unit of the holding gate, and fasten with an E-ring as shown below:

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Note: When it is fixed by an E-ring, be sure to check that the holding gate position is as in the illustration (correct position of holding gate). (3) Make sure that drive gear is installed correctly checking the following points. If it not installed correctly, perform the previous (1)~(2) procedures.

Note: When a new arbor is installed, perform the groove for spring installation of 1.15.3 holding gate position adjustment 2 SLEEVE-P/U-80 in "B"(center). Open the ADU feed unit 1) While the solenoid of the clutch unit is attracted (armature is pushed), turn the gear a limited small amount, release the armature. 2) Turn the gear in the direction "A" in the figure till the holding gate is stopped. 3) When the holding gate is stopped, check that B face and C or D faces are roughly parallel. B face: flat face of holding gate C face: end face of frame D face: end face of frame

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There are 3 grooves for installing the spring to SLEEVE-P/U-80. Check that the pushing gate angle is parallel to the frame. Note 1: At the time of shipping, assembly has been performed using assembly groove B. Note 2: If after performing the adjustment of the pushing gate position as in 1.15.2 the Gate angle does not become parallel or slightly advanced; the angle should be adjusted 20 using adjustment groove C. This adjustment should result in the gate being slightly advanced versus being delayed. This angle can be increased by re aligning the gears but this area should be adjusted to factory specification before attempting any additional adjustments.

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3.

Gate Binding

Its possible to have the item in section 24-22 (Assembly Guide U) adjusted in such a way that the holding gate will bind on the edge of the guide. The view shown below is with this section removed and lying upside down, the wrap spring at the lower R/H side

Elongated hole

Adjust the guide location until there is a space of about 2 sheets of paper in between the edge of the gate and the guide while in the position as shown above.

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4. Loss of drive in the lower transport section (E51, E52 codes) Its possible to have paper jams in the lower transport section due to the fact that the lower guide has been distorted. This area can be checked for excess clearance by pushing this guide (section 22) upwards while it is latched. There should be a slight clearance between top of the plastic spacer and the Duplex Unit base.

If the clearance is more than that, check the Latch for distortion. When the tray has been pulled down forcefully , the area indicated can be distorted which would allow more clearance and loss of transport roller drive.

Area of distortion

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Additional Items to check to reduce the possibility of Duplex Error codes: 1. Paper Cuts / Burrs on mechanical switch arms. Check after 100 K 2. Check for flat spots on the white idler rollers. (Section 25-16) 3. Check the condition of the three Mylar Guides. (Section 25-18, 25-19, 25-38). The Mylar guides can be damaged by customers removing paper with a sharp object. 4. Distortion of the guide (section 25-15). This guide can be damaged by the upper feed section being opened too far. 5. Feeder Latch breaking. (Section 24-6). This is usually caused by rough handling. This will not cause a problem but more of an annoyance. 6. Double feeding from the LCT. This could also show up as a Duplex Jam (most likely E-34) as there is a sheet of paper when none is expected. Check the feed rollers and torque spring limiter. 7. Check every 400 K on Duplex Counter: Clean ADU Feed Rollers. Clean ADU Separation Belts. Clean ADU Transport Rollers. Check tray for distortion. Clean ADU Registration Roller. Lubricate Wrap Spring (Gate Solenoid). 8. Suggested Paper Buckle settings 05-455 05-462 05-464 11 8 3

Section

New Part

Price Rank
CA

Description

Interchange ability
6

24

0N6LA55210000

ADU KIT

Interchangeability
1. Interchangeable 2. Current type can be used in place of new type. New type cannot be used in place of current type. 3. Current type cannot be used in place of the new type. New type can be used in place of current type. 4. Not interchangeable 5. Interchangeable if replaced with same types of related parts in use. 6. Others.

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