Kyocera PF-410 Service Manual
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Kyocera PF-410 Service Manual

Kyocera PF-410 Service Manual

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PF-410
SERVICE
MANUAL
Published in May '03
3HW70760

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Summary of Contents for Kyocera PF-410

  • Page 1 PF-410 SERVICE MANUAL Published in May ’03 3HW70760...
  • Page 2 CAUTION DANGER OF EXPLOSION IF BATTERY IS INCORRECTLY REPLACED. REPLACE ONLY WITH THE SAME OR EQUIVALENT TYPE RECOMMENDED BY THE MANUFACTURER. DISPOSE OF USED BATTERIES ACCORDING TO THE MANUFACTURER’S INSTRUCTIONS. ATTENTION IL Y A DANGER D’EXPLOSION S’IL Y A REMPLACEMENT INCORRECT DE LA BATTERIE. REMPLACER UNIQUEMENT AVEC UNE BATTERIE DU MÊME TYPE OU D’UN TYPE REC- OMMANDÉ...
  • Page 3 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 4 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 5 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 6: Specifications 1

    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 7 • Do not pull on the AC power cord or connector wires on high-voltage components when removing them; always hold the plug itself....................... • Do not route the power cable where it may be stood on or trapped. If necessary, protect it with a cable cover or other appropriate item.

  • Page 8: Table Of Contents

    CONTENTS 1-1 Specifications 1-1-1 Specifications ............................1-1-1 1-1-2 Parts names and their functions ......................1-1-2 (1) Parts names ........................... 1-1-2 1-1-3 Machine cross section .......................... 1-1-3 1-1-4 Drive system ............................1-1-4 1-2 Installation 1-2-1 Unpacking and installation ........................1-2-1 (1) Unpacking ............................1-2-1 1-3 Maintenance Mode 1-3-1 Maintenance mode ..........................
  • Page 9 2-1 Mechanical construction 2-1-1 Mechanical construction ........................2-1-1 2-2 Electrical Parts Layout 2-2-1 Electrical parts layout ........................... 2-2-1 (1) PCBs .............................. 2-2-1 (2) Switches and sensors ........................2-2-2 (3) Others ............................. 2-2-3 2-3 Operation of the PCBs 2-3-1 Drawer main PCB ..........................2-3-1 2-4 Appendixes Timing chart No.

  • Page 10: Specifications

    1-1-1 Specifications Paper feed system ......Automatic feed Paper sizes ........A3 – A5R/11" × 17" – 5 " × 8 " Copy paper ........Plain paper, recycled paper and colored paper (64 – 105 g/m Paper capacity ....... 300 sheets (80 g/m Power source .........

  • Page 11: Parts Names And Their Functions

    1-1-2 Parts names and their functions (1) Parts names Figure 1-1-1 1 Drawer left cover 2 Interface connector 3 Paper gauge 4 Paper size indication 5 Positioning pins 1-1-2...

  • Page 12: Machine Cross Section

    1-1-3 Machine cross section Paper path Figure 1-1-2 Machine cross section 1-1-3...

  • Page 13: Drive System

    1-1-4 Drive system Figure 1-1-3 Drive system 1 Drawer drive motor gear 2 Gear 26/90 3 Gear 25 4 Gear 25 5 Paper feed gear 20 6 Drawer paper feed clutch gear 1-1-4...

  • Page 14: Unpacking And Installation

    1-2-1 Unpacking and installation (1) Unpacking Figure 1-2-1 Unpacking 1 Paper feeder 7 Stay 8 Plastic sheet (1300 × 1300) 2 Outer case 3 Left bottom pad 9 Bar code labels 0 Plastic bag (240 × 350) 4 Right bottom pad 5 Left upper pad ! Installation guide 6 Right upper pad...

  • Page 15: Maintenance Mode

    1-3-1 Maintenance mode The copier is equipped with a maintenance function which can be used to maintain and service the machine. (1) Executing a maintenance item Start Enter “10871087” using Maintenance mode is entered. the numeric keys. Enter the maintenance item number using the zoom The maintenance item is +/- keys or numeric keys.

  • Page 16: Maintenance Mode Item List

    (2) Maintenance mode item list Item Initial Section Maintenance item contents setting* Paper feeder U019 Displaying the ROM version — U030 Checking motor operation — U031 Checking switches for paper conveying — U032 Checking clutch operation — U034 Setting paper timing •...

  • Page 17: Contents Of Maintenance Mode Items

    (3) Contents of maintenance mode items Maintenance Description item No. U019 Displaying the ROM version Description Displays the part number of the ROM fitted to each board. Purpose To check the part number or to decide if the ROM version is new from the last digit of the number. Method 1.
  • Page 18 Maintenance Description item No. U031 Checking switches for paper conveying Description Displays the on-off status of each paper detection switch on the paper path. Purpose To check if the switches for paper conveying operate correctly. Method 1. Press the start key. 2.
  • Page 19 Maintenance Description item No. U053 Performing fine adjustment of the motor speed Description Performs fine adjustment of the speeds of the motors. Purpose Used to adjust the speed of the respective motors when the magnification is not correct. Also speed adjustment for each paper source can be performed in group 2.
  • Page 20 Maintenance Description item No. U901 Checking/clearing copy counts by paper feed locations Description Displays or clears copy counts by paper feed locations. Purpose To check the time to replace consumable parts. Also to clear the counts after replacing the consumable parts. Method 1.

  • Page 21: Paper Misfeed Detection

    1-4-1 Paper misfeed detection (1) Paper misfeed indication When a paper misfeed occurs, the copier immediately stops copying and displays the jam location on the copier operation panel. Paper misfeed detection can be reset by opening and closing the drawer left cover to turn safety switch off and on. (2) Paper misfeed detection conditions DPFCL1 DFSW1...
  • Page 22 Section Jam code Description Conditions Paper feed No paper feed from the The registration switch (RSW)* does not turn on within 2780 section drawer 2 (first paper ms of the drawer paper feed clutch 1 (DPFCL1) turning on; feeder) the clutch is then successively held off for 1 s and turned back on once, but the switch again fails to turn on within 2780 ms.

  • Page 23: Paper Misfeeds

    (3) Paper misfeeds Problem Causes/check procedures Corrective measures Paper in the first paper Change the paper. A paper jam in the feeder is extremely curled. paper feed section Check if the paper feed Check visually and replace any deformed pulley. is indicated during pulley, separation pulley or copying (no paper...
  • Page 24 Problem Causes/check procedures Corrective measures Check if the drawer paper Run maintenance item U032 and select the drawer paper feed A paper jam in the feed clutch 3 malfunctions. clutch 3 to be turned on and off. Check the status and remedy if paper feed section necessary.
  • Page 25 Problem Causes/check procedures Corrective measures Check if the drawer paper Run maintenance item U032 and select the drawer paper feed A paper jam in the feed clutch 3 malfunctions. clutch 3 to be turned on and off. Check the status and remedy if paper conveying necessary.

  • Page 26: Self-Diagnosis

    1-4-2 Self-diagnosis (1) Self-diagnostic function When a problem is detected, copying is disabled. "C" and a number between 042 and 051. After removing the problem, the self-diagnostic function can be reset by turning safety switch off and back on. (2) Self diagnostic codes Remarks Code Contents...

  • Page 27: Image Formation Problems

    1-4-3 Image formation problems (1) The leading edge of (2) The leading edge of the image is consist- the image is sporadi- ently misaligned with cally misaligned with the original. the original. See page 1-4-8 See page 1-4-8 1-4-7...
  • Page 28 (1) The leading edge of Causes the image is consist- 1. Misadjusted leading edge registration. ently misaligned with the original. Causes Check procedures/corrective measures 1. Misadjusted leading edge registration. Readjust the leading edge registration (see pages 1-5-7). (2) The leading edge of Causes the image is sporadi- 1.

  • Page 29: Electrical Problems

    1-4-4 Electrical problems Problem Causes Check procedures/corrective measures The drawer left cover is Check the drawer left cover. The machine does not closed completely. not operate when Defective drawer left cover Check for continuity across the contacts of switch. If none, re- the power switch is safety switch.

  • Page 30: The Message Requesting Cover To Be Closed Is Displayed When The Drawer Left Cover Is Closed

    Problem Causes Check procedures/corrective measures Poor contact in the drawer Reinsert the connector. Also check for continuity within the con- The message re- left cover safety switch nector cable. If none, remedy or replace the cable. questing cover to be connector terminals.

  • Page 31: Mechanical Problems

    1-4-5 Mechanical problems Problem Causes/check procedures Corrective measures Check if the surfaces of the following roller Clean with isopropyl alcohol. No primary paper feed. or pulleys are dirty with paper powder: drawer forwarding pulley, drawer paper feed pulley, drawer separation pulley and feed roller.

  • Page 32: Precautions For Assembly And Disassembly

    1-5-1 Precautions for assembly and disassembly (1) Precautions • Be sure to turn the power switch off and disconnect the power plug before starting disassembly. • When handling PCBs, do not touch connectors with bare hands or damage the board. •...

  • Page 33: Running A Maintenance Item

    (2) Running a maintenance item Start Enter “10871087” using Maintenance mode is entered. the numeric keys. Enter the maintenance item number using the zoom The maintenance item is +/- keys or numeric keys. selected. Press the start key. The selected maintenance item is run. Press the stop/clear key.

  • Page 34: Paper Feeder

    1-5-2 Paper feeder (1) Detaching and refitting the feed roller Follow the procedure below to replace the feed roller. Procedure 1. Open the drawer left cover. 2. Remove the two stop ring, gear and spring pin from rear side of the feed roller. Stop rings * When removing the gear, take care not to lose the spring pin.

  • Page 35: Detaching And Refitting The Drawer Separation Pulley

    (2) Detaching and refitting the drawer separation pulley Follow the procedure below to replace the drawer separation pulley. Procedure 1. Pull out the drawer. Open the drawer left cover. 2. Remove the screw and then the lower paper feed unit. Lower paper feed unit Figure 1-5-2 3.

  • Page 36: Detaching And Refitting The Drawer Forwarding Pulley And Drawer Paper Feed Pulley

    (3) Detaching and refitting the drawer forwarding pulley and drawer paper feed pulley Follow the procedure below to replace the drawer forwarding pulley and drawer paper feed pulley. Procedure 1. Remove the lower paper feed unit (see page Stop ring Stop ring 1-5-4).
  • Page 37 5. Remove the springs, stop ring and bushing and then the shaft holder from the upper Shaft holder paper feed unit. Spring Spring Stop ring Upper paper feed unit Bushing Figure 1-5-6 6. Remove the drawer forwarding pulley from the upper paper feed unit. Drawer paper feed pulley 7.

  • Page 38: Adjusting The Leading Edge Registration Of Image Printing

    (4) Adjusting the leading edge registration of image printing Make the following adjustment if there is a regular error between the leading edges of the copy image and original. U066 U071 (See the service manual (See the service manual U034 of the copier.) of the copier.) Caution:...

  • Page 39: Adjusting The Center Line Of Image Printing

    (5) Adjusting the center line of image printing Make the following adjustment if there is a regular error between the center lines of the copy image and original when paper is fed from the drawer. U067 U072 (See the service manual (See the service manual U034 of the copier.)

  • Page 40: Adjusting The Amount Of Slack In The Paper

    (6) Adjusting the amount of slack in the paper Make the following adjustment if the leading edge of the copy image is missing or varies randomly, or if the copy paper is Z-folded. Procedure Start Original Copy Copy example 1 example 2 Enter maintenance mode.

  • Page 41: Mechanical Construction

    2-1-1 Mechanical construction The paper feeder conveys paper from the drawer to the copier. Drawer can hold up to 300 sheets of paper. Paper is fed from the paper feeder by the rotation of the drawer forwarding pulley and drawer paper feed pulley. The drawer separation pulley prevents multiple sheets from being fed at one time, via the torque limiter.
  • Page 42 200 ms Primary feed Scondary feed Primary feed 200 ms Scondary feed DPFCL1 DDM1 1740 ms 1740 ms RSW * 290 ms RM * 290 ms 290 ms Separation charging* 100 ms 10 ms 10 ms 670 ms Transfer charging* 2220 ms ESW * *: Copier...
  • Page 43 Primary feed 200 ms Scondary feed Primary feed 200 ms Scondary feed DPFCL2 DDM2 1420 ms 1420 ms DFSW1 DDM1 1370 ms 1370 ms RSW * 290 ms RM * 290 ms 290 ms 100 ms Separation charging* 10 ms 10 ms 670 ms Transfer...

  • Page 44: Electrical Parts Layout

    2-2-1 Electrical parts layout (1) PCBs Machine front Machine inside Machine rear Figure 2-2-1 PCBs 1. Drawer main PCB (DMPCB) ......Controls electrical components of the drawer. 2. Drawer heater PCB (DHPCB) ...... Drawer heater power relay. 2-2-1...

  • Page 45: Switches And Sensors

    (2) Switches and sensors Machine inside Machine front Machine rear Figure 2-2-2 Switches and sensors 1. Drawer left cover safety switch (DLCSSW) ........... Breaks the safety circuit when the Drawer left cover is opened. 2. Drawer feed switch (DFSW) ......Detects a paper misfeed. 3.

  • Page 46: Others

    (3) Others Machine front Machine inside Machine rear Figure 2-2-3 Others 1. Drawer drive motor (DDM) ......Drives the machine. 2. Drawer paper feed clutch (DPFCL) ..... Primary paper feed from the drawer. 3. Drawer heater (DH) ........Dehumidifies the drawer section. 2-2-3...

  • Page 47: Drawer Main Pcb

    2-3-1 Drawer main PCB Copier (Upper paper feeder) DPWSW DPLSW DFSW DPSW DMPCB DLCSSW DHPCB Motor Driver DPFCL Lower paper feeder Figure 2-3-1 Drawer main PCB block diagram The drawer main PCB (DMPCB) is controlled by the engine PCB (EPCB) in the copier, and the engine PCB (EPCB) uses serial communication to control input and output of each motor, clutch, and switch of the DP through the CPU (U1) equipped with a function of bidirectional serial/parallel conversion of 8-bit data.
  • Page 48 Figure 2-3-2 Drawer main PCB silk-screen diagram Connector Pin No. Signal Description 24 V 24 V DC power supply from copier P.GND Ground Connected to the copier 24 V 24 V DC power supply for lower paper feeder P.GND Ground Connected to the lower paper...
  • Page 49 Connector Pin No. Signal Description SEL0 SEL0 signal to lower paper feeder SCLK Clock signal to lower paper feeder Connected Serial communication reception to the Serial communication transmission copier and S.GND Ground lower paper 5 V DC power supply for lower paper feeder feeder S.GND Ground...
  • Page 50 2-4-1...
  • Page 51 2-4-2...

  • Page 52: Maintenance Parts List

    Maintenance parts list Maintenance part name Part No. Fig. No. Ref. No. Name used in service manual Name used in parts list Drawer paper feed pulley PULLEY, PAPER FEED 2AR07220 Drawer separation pulley PULLEY, SEPARATION 2AR07230 Drawer forwarding pulley PULLEY, LEADING FEED 2AR07240 Feed roller ROLLER FEED...

  • Page 53: Periodic Maintenance Procedures

    Periodic maintenance procedures Maintenance Section Method Maintenance cycle Points and cautions Page part/location Test copy and Perform at the maximum Test copy Every service test print copy size Maintenance Section Method Maintenance cycle Points and cautions Page part/location Paper feed Drawer paper feed pulley Clean or replace Clean with the rubber roller...
  • Page 54 2-4-5...

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