Kyocera PF-510 Service Manual
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Kyocera PF-510 Service Manual

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PF-510
PF-500
SERVICE
MANUAL
Published in March 2009
3K8SM061
Rev. 1

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Summary of Contents for Kyocera PF-510

  • Page 1 PF-510 PF-500 SERVICE MANUAL Published in March 2009 3K8SM061 Rev. 1...
  • Page 2 CAUTION RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECT TYPE. DISPOSE OF USED BATTERIES ACCORDING TO THE INSTRUCTIONS. It may be illegal to dispose of this battery into the municipal waste stream. Check with your local solid waste officials for details in your area for proper disposal. ATTENTION IL Y A UN RISQUE D’EXPLOSION SI LA BATTERIE EST REMPLACEE PAR UN MODELE DE TYPE INCORRECT.

  • Page 3: Revision History

    Revision history Revision Date Replaced pages Remarks 5 March 2009 1-3-4, 1-3-5, 1-3-6, 1-3-7...
  • Page 4 This page is intentionally left blank.

  • Page 5: Safety Precautions

    Safety precautions This booklet provides safety warnings and precautions for our service personnel to ensure the safety of their customers, their machines as well as themselves during maintenance activities. Service personnel are advised to read this booklet carefully to familiarize themselves with the warnings and precautions described here before engaging in maintenance activities.

  • Page 6: Safety Warnings And Precautions

    Safety warnings and precautions Various symbols are used to protect our service personnel and customers from physical danger and to prevent damage to their property. These symbols are described below: DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol.

  • Page 7: Installation Precautions

    1.Installation Precautions WARNING • Do not use a power supply with a voltage other than that specified. Avoid multiple connections to one outlet: they may cause fire or electric shock. When using an extension cable, always check that it is adequate for the rated current....................•...

  • Page 8: Precautions For Maintenance

    2.Precautions for Maintenance WARNING • Always remove the power plug from the wall outlet before starting machine disassembly....• Always follow the procedures for maintenance described in the service manual and other related brochures............................• Under no circumstances attempt to bypass or disable safety features including safety mechanisms and protective circuits.
  • Page 9 • Do not remove the ozone filter, if any, from the copier except for routine replacement..... • Do not pull on the AC power cord or connector wires on high-voltage components when removing them; always hold the plug itself...................... •...
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  • Page 11 CONTENTS 1-1 Specifications 1-1-1 Specifications............................1-1-1 1-1-2 Parts names............................1-1-2 1-1-3 Machine cross section ..........................1-1-4 1-2 Installation 1-2-1 Installation environment ..........................1-2-1 1-2-2 Unpacking ...............................1-2-2 (1) Unpacking ............................1-2-2 (2) Attaching the sub-cursors (Multi purpose feeder only)..............1-2-4 1-3 Troubleshooting 1-3-1 Paper misfeed detection .........................1-3-1 (1) Paper misfeed indication ........................1-3-1 (2) Paper misfeed detection........................1-3-2 1-3-2 Self-diagnostic function...........................1-3-3...
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  • Page 13: Specifications

    3K8/3K9 1-1 Specifications 1-1-1 Specifications Paper feeder (Normal) Paper weight........60 to 120 g/m Paper size........A5, B5, ISO B5, A4, Executive, Letter, Legal, Oficio II, Statement, Folio, Custom Paper capacity ........ 500 sheets, plain paper (80 g/m Dimension (W × H × D) ....345 mm × 115 mm × 478 mm "...

  • Page 14: Parts Names

    3K8/3K9 1-1-2 Parts names Paper feeder (Normal) Figure 1-1-1Paper feeder (Normal) Cassette Paper size dial window Paper gauge Paper size dial Paper width guide Paper length guide Positioning pins Paper feeder 1-1-2...
  • Page 15 3K8/3K9 Multi purpose feeder Figure 1-1-2Multi purpose feeder Cassette Positioning pins Paper size dial window Paper feeder Paper gauge AC inlet Paper size dial 10. AC outlet Paper width guide 11. Right sub-cursor Paper length guide 12. Left sub-cursor 1-1-3...

  • Page 16: Machine Cross Section

    3K8/3K9 1-1-3 Machine cross section Paper feeder (Normal) Paper path Figure 1-1-3Paper feeder (Normal) Multi purpose feeder Paper path Figure 1-1-4 Multi purpose feeder 1-1-4...

  • Page 17: Installation Environment

    3K8/3K9 1-2 Installation 1-2-1 Installation environment Installation location (Must comply with the same environment as the main unit installation.) Avoid direct sunlight or bright lighting. Ensure that the photo-conductor will not be exposed to direct sunlight or other strong light when removing paper jams. Avoid locations subject to high temperature and high humidity or low temperature and low humidity;...
  • Page 18 3K8/3K9 1-2-2 Unpacking (1) Unpacking Paper feeder (Normal) Figure 1-2-1Paper feeder (Normal) Paper feeder Plastic bag 600 × 800 Left pad Right pad Front pad Outer case Caution: Place the machine on a level surface. See the Installation Guide for installation. 1-2-2...
  • Page 19 3K8/3K9 Multi purpose feeder Figure 1-2-2Multi purpose feeder Paper feeder Junction cable Plastic bag 600 × 800 Right sub-cursor Left pad Left sub-cursor 10. Plastic bag 120 × 250 Right pad Front pad 11. Paper type label 12. Plastic bag 70 × 280 Outer case Caution: Place the machine on a level surface.
  • Page 20 3K8/3K9 (2) Attaching the sub-cursors (Multi purpose feeder only) To load A4-size coated paper, a sub-cursor must be used. Procedure 1. Attach the right and left sub-cursors to the cassette. Right sub-cursor Right sub-cursor Left sub-cursor Cassette Left sub-cursor Figure 1-2-3 1-2-4...

  • Page 21: Paper Misfeed Detection

    3K8/3K9 1-3 Troubleshooting 1-3-1 Paper misfeed detection (1) Paper misfeed indication If the paper jammed in the paper transport system, or no paper sheets were fed at all, the “Paper jam” message appears and the location of the paper jam (the component where the paper jam has occurred) is also indicated. The printer auto- matically goes off-line when this message is displayed.
  • Page 22 3K8/3K9 (2) Paper misfeed detection PF paper feed sensor PF paper sensor 1, 2 Figure 1-3-2 1-3-2...

  • Page 23: Self-Diagnostic Function

    3K8/3K9 1-3-2 Self-diagnostic function (1) Self-diagnostic function The printer is equipped with self-diagnostic function. When a problem is detected, the printer stops printing and display an error message on the operation panel. An error message consists of a message prompting a contact to service personnel, total print count, and a four-digit error code indicating the type of the error.
  • Page 24 3K8/3K9-1 (3) Self diagnostic codes Remarks Code Contents Causes Check procedures/corrective measures 0420 Paper feeder communication error Improper installation Follow installation instruction carefully Communication error between paper feeder. again. printer’s engine PWB and paper Defective harness Reinsert the connector. Also check for con- feeder.
  • Page 25 3K8/3K9-1 Remarks Code Contents Causes Check procedures/corrective measures 1500 PF warm air heater (upper blower) The inlet of upper Check visually and remove it, if any (See 1520 high temperature error* blower assembly is page 2-1-3). 1540 (Option paper feeder) blocked by paper pieces 1560 or the like.
  • Page 26 3K8/3K9-1 Remarks Code Contents Causes Check procedures/corrective measures 1600 PF warm air heater (upper blower) Defective harness Reinsert the connector. Also check for con- 1620 low temperature error* between PF warm air tinuity within the connector harness. If 1640 (Option paper feeder) heater 2 and PF warm none, remedy or replace the harness (See 1660...
  • Page 27 3K8/3K9-1 Remarks Code Contents Causes Check procedures/corrective measures 1610 PF warm air heater (side blower) Defective harness Reinsert the connector. Also check for con- 1630 error* between PF warm air tinuity within the connector harness. If 1650 (Option paper feeder) heater 1 and PF warm none, remedy or replace the harness (See 1670...

  • Page 28: Electric Problems

    3K8/3K9 1-3-3 Electric problems Problem Causes Check procedures/corrective measures Actuators of PF paper feed Repair or replace. Defective paper jam sensor does not operate detecting. smoothly. A piece of paper torn from a Check visually and remove it, if any. sheet is caught around actuator of PF paper feed sensor.

  • Page 29: Mechanical Problems

    3K8/3K9 1-3-4 Mechanical problems Problem Causes/check procedures Corrective measures Check if the surfaces of the following rollers Clean with isopropyl alcohol. No primary paper feed. are dirty with paper powder: pickup roller and paper feed roller. Check if the pickup roller and paper feed roller Check visually and replace any deformed are deformed.
  • Page 30 3K8/3K9 This page is intentionally left blank. 1-3-10...

  • Page 31: Precautions For Assembly And Disassembly

    3K8/3K9 1-4 Assembly and Disassembly 1-4-1 Precautions for assembly and disassembly (1) Precautions Be sure to turn the power switch of the machine off and disconnect the power cable before starting disassembly of the paper feeder. For the multi purpose feeder, remove also the power cord/junction cable (refer to the figure below). When handling PWBs, do not touch connectors with bare hands or damage the PWB.

  • Page 32: Paper Feed Section

    3K8/3K9 1-4-2 Paper feed section (1) Detaching and refitting the paper feed holder assembly (paper feed roller and pickup roller) Procedure 1. Remove the cassette from the paper feeder. Cassette Figure 1-4-2 2. While pressing the lever A and slide the feed roller pin.
  • Page 33 3K8/3K9 (2) Detaching and refitting the retard assembly (retard roller) Procedure 1. Remove the cassette from the paper feeder. Cassette Figure 1-4-4 2. Release the two hooks and then remove the retard guide. Cassette Hook Hook Retard guide Figure 1-4-5 1-4-3...
  • Page 34 3K8/3K9 3. Remove the retard assembly from the pro- jections. Retard assembly 4. Check or replace the retard assembly (retard roller) and refit all the removed parts. Caution: Before refitting the retard assem- Projection bly, firmly install the retard roller spring onto the projection of the retard assembly.
  • Page 35 3K8/3K9 1-4-3 Warm air blowing section (Multi purpose feeder only) (1) Detaching and refitting the PF thermistor 1, PF thermostat 1, PF warm air heater 1 and PF warm air fan motor 1 Procedure 1. Remove the cassette from the paper feeder. 2.
  • Page 36 3K8/3K9 6. Pull the lever and then remove the wire cover. Wire cover Lever Figure 1-4-9 7. Remove the two connectors form the PF warm air heater driver PWB. 8. Remove the wires from the three clamps. Warm air heater driver PWB Connector (YC3) Connector...
  • Page 37 3K8/3K9 9. Remove the three connectors A. 10. Draw the three connectors A out through the opening. 11. Remove the connector B. 12. Remove the screw. Connector B Opening Screw PF main PWB Connector A (YC12) Connector A (YC11) Connector A (YC13) Figure 1-4-11 13.
  • Page 38 3K8/3K9 16. Remove the four screws. 17. Release the hook and then remove the top Screw frame assembly. Screw Top frame Screw assembly Screw Hook Figure 1-4-13 18. Remove the screw and then remove the side blower assembly. Side blower assembly Screw Top frame assembly Figure 1-4-14...
  • Page 39 3K8/3K9 19. Remove the wires from the four clamps. Clamp Clamp Wires Clamps Figure 1-4-15 20. Remove the two connectors. Connector Connector Figure 1-4-16 21. Remove the screw. 22. Turn the PF thermostat 1 to the 45 degrees. 23. Remove the PF thermostat 1. Screw PF thermostat 1 Figure 1-4-17...
  • Page 40 3K8/3K9 24. Remove the wires from the six clamps. Wires Clamps Clamps Clamps Figure 1-4-18 25. Remove the screw and then remove the side duct cover. Screw Side duct cover Figure 1-4-19 26. Remove the connector. 27. Remove the screw. 28.
  • Page 41 3K8/3K9 29. Remove the PF warm air heater 1. Caution: The heater plate spring must be installed in the specified position. 30. Remove the connector. PF warm air heater 1 Connector Heater plate spring Figure 1-4-21 31. Remove the side fan duct. 32.
  • Page 42 3K8/3K9 (2) Detaching and refitting the PF warm air fan motor 2, PF thermistor 2, PF thermostat 2 and PF warm air heater 2 Procedure 1. Remove the paper feeder from the printer. 2. Turn the paper feeder with the bottom side 3.
  • Page 43 3K8/3K9 6. Pull the lever and then remove the wire cover. Wire cover Lever Figure 1-4-25 7. Remove the connector. 8. Remove the PF warm air fan motor 2. PF warm air fan motor 2 Connector Figure 1-4-26 1-4-13...
  • Page 44 3K8/3K9 9. Remove the connector. Spring 10. Remove the spring. Connector Figure 1-4-27 11. Remove the screw and then remove the thermostat base. 12. Remove the two connectors. Connector Screw Thermostat base Connector Figure 1-4-28 1-4-14...
  • Page 45 3K8/3K9 13. Remove the screw. 14. Remove the thermistor spring and PF ther- Screw mistor 2. Thermistor spring 15. Remove the two screws and then remove the PF thermostat 2. PF thermistor 2 Caution: When mounting PF thermistor 2 again, ensure that the temperature detection sec- tion keeps securely in contact with PF warm air fan heater 2.
  • Page 46 3K8/3K9 (3) Detaching and refitting the PF warm air heater driver PWB Procedure 1. Remove the paper feeder from the printer. 2. Turn the paper feeder with the bottom side 3. Remove the two screws. Hook 4. Release the two hooks and then remove the fan cover.
  • Page 47 3K8/3K9 6. Remove the screw. 7. Remove the PF warm air heater driver PF warm air heater driver PWB PWB. Screw 8. Check or replace the PF warm air heater driver PWB and refit all the removed parts. Hook Hook Figure 1-4-33 1-4-17...
  • Page 48 3K8/3K9 1-4-4 (1) Detaching and refitting the PF main PWB Procedure 1. Remove the paper feeder from the printer. Upper cover 2. Turn the paper feeder with the bottom side 3. Release the two hooks and then remove the upper cover. Hook Hook PF main PWB...
  • Page 49 3K8/3K9 5. Remove the screw. 6. Release the three hooks and then remove PF main PWB Screw the PF main PWB. 7. Check or replace the PF main PWB and refit all the removed parts. Hook Hook Hook Figure 1-4-36 1-4-19...
  • Page 50 3K8/3K9 This page is intentionally left blank. 1-4-20...
  • Page 51 3K8/3K9 2-1 Mechanical Construction 2-1-1 Paper feed section (1) Paper feed section The paper feeder conveys paper from the cassette to the printer. Cassette can hold up to 500 sheets of plain paper (80 g/m ). Paper is fed from the paper feeder by the rotation of the pickup roller and paper feed roller. Paper feeder (Normal) 15,7 Multi purpose feeder...
  • Page 52 3K8/3K9 PF lift PF paper PF paper limt sensor sensor 1 sensor 2 PF cassette PF main PWB size switch PAPSIZ2-0 YC2-1,3,4 TRANSW YC1-3 PF paper FEEDCL feed sensor YC9-3 TMOTDRVN PF paper YC6-5 TMOTCLK feed clutch YC6-4 PF paper TMOTGAIN YC6-3 feed motor...
  • Page 53 3K8/3K9 (2) Warm air blowing section (Multi purpose feeder only) PF warm air fan motor 1 in the side blower assembly blows warm air from near the leading edge of the paper to assist sep- aration of paper, and PF warm air fan motor 2 in the upper blower assembly blows warm air into the cassette to dehumidity the whole paper.
  • Page 54 3K8/3K9 This page is intentionally left blank. 2-1-4...

  • Page 55: Electrical Parts Layout

    3K8/3K9 2-2 Electrical Parts Layout 2-2-1 Electrical parts layout (1) Electrical parts layout Paper feeder (Normal) Figure 2-2-1 Electrical parts layout: Paper feeder (Normal) PF main PWB ..........Controls electrical components in the paper feeder and serial communi- cations with the printer. PF paper sensor 1 (PH1) ......
  • Page 56 3K8/3K9 Multi purpose feeder 20 21 Machine left Machine inside Machine right Figure 2-2-2 Electrical parts layout: Multi purpose feeder PF main PWB ..........Controls electrical components in the paper feeder and serial communi- cations with the printer. PF warm air heater driver PWB ....Controls the PF warm air heater 1 and 2. PF paper sensor 1 (PH1) ......
  • Page 57 3K8/3K9 11. PF thermostat 2 ........... Shuts off the power source to the warm air heater 2 when the warm air heater 2 reaches extremely high temperature. 12. PF paper feed motor ........Drives the paper feed mechanism in the paper feeder. 13.
  • Page 58 3K8/3K9 This page is intentionally left blank. 2-2-4...

  • Page 59: Pf Main Pwb

    3K8/3K9 2-3 Operation of the PWBs 2-3-1 PF main PWB PF main PWB PF paper feed motor Driver Multi purpose feeder only PF paper AC power feed clutch Driver source Driver PF warm air heater drive signal PF warm air conveying heater driver Driver...

  • Page 60: Connector Pin

    3K8/3K9 YC11 YC10 Figure 2-3-2 PF main PWB silk-screen diagram Connector Signal Voltage Description 5 V DC 5 V DC power source Connected Ground to the PF TRANSW 0/5 V DC PF paper feed sensor: On/Off paper feed sensor PAPSIZ2 0/5 V DC PF paper size switch: On/Off Connected...
  • Page 61 3K8/3K9 Connector Signal Voltage Description Ground Connected OPSCLK 0/5 V DC (pulse) Serial communication clock signal to the inter- OPRDYN 0/5 V DC Ready signal face con- OPSDI 0/5 V DC (pulse) Serial communication data signal nector OPSDO 0/5 V DC (pulse) Serial communication data signal 5 V DC 5 V DC power source...
  • Page 62 3K8/3K9 Connector Signal Voltage Description YC11* +24V 24 V DC 24 V DC power source Connected FAN1 0/24 V DC PF warm air fan motor 1: On/Off to the PF +24V 24 V DC 24 V DC power source warm air fan FAN2 0/24 V DC PF warm air fan motor 2: On/Off...
  • Page 63 3K8/3K9 2-4 Appendixes 2-4-1 Appendixes (1) Wiring diagram 2-4-1...
  • Page 64 3K8/3K9 This page is intentionally left blank. 2-4-2...

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Pf-500

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