Kyocera Pf-410 User manual

SERVICE

MANUAL

Published in May ’03

3HW70760

PF-410

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-

OMMANDÉPAR LE CONSTRUCTEUR. METTRE AU RÉBUT LES BATTERIES USAGÉES

CONFORMÉMENT AUX INSTRUCTIONS DU FABRICANT.

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.

indicates that action is required. The specific action required is shown inside the symbol.

General action required.

Remove the power plug from the wall outlet.

Always ground the copier.

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.

WARNING:Serious bodily injury or death may result from insufficient attention to or incorrect compliance

with warning messages using this symbol.

CAUTION:Bodily injury or damage to property may result from insufficient attention to or incorrect

compliance with warning messages using this symbol.

Symbols

The triangle ( ) symbol indicates a warning including danger and caution. The specific point

of attention is shown inside the symbol.

General warning.

Warning of risk of electric shock.

Warning of high temperature.

indicates a prohibited action. The specific prohibition is shown inside the symbol.

General prohibited action.

Disassembly prohibited.

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. ............................................................................................

•Connect the ground wire to a suitable grounding point. Not grounding the copier may cause fire or

electric shock. Connecting the earth wire to an object not approved for the purpose may cause

explosion or electric shock. Never connect the ground cable to any of the following: gas pipes,

lightning rods, ground cables for telephone lines and water pipes or faucets not approved by the

proper authorities. .............................................................................................................................

CAUTION:

•Do not place the copier on an infirm or angled surface: the copier may tip over, causing injury. .....

•Do not install the copier in a humid or dusty place. This may cause fire or electric shock. ..............

•Do not install the copier near a radiator, heater, other heat source or near flammable material.

This may cause fire. ..........................................................................................................................

•Allow sufficient space around the copier to allow the ventilation grills to keep the machine as cool

as possible. Insufficient ventilation may cause heat buildup and poor copying performance. ..........

•Always handle the machine by the correct locations when moving it. ..............................................

•Always use anti-toppling and locking devices on copiers so equipped. Failure to do this may

cause the copier to move unexpectedly or topple, leading to injury..................................................

•Avoid inhaling toner or developer excessively. Protect the eyes. If toner or developer is

accidentally ingested, drink a lot of water to dilute it in the stomach and obtain medical attention

immediately. If it gets into the eyes, rinse immediately with copious amounts of water and obtain

medical attention. ..............................................................................................................................

•Advice customers that they must always follow the safety warnings and precautions in the copier’s

instruction handbook. ........................................................................................................................

•Check that the power cable covering is free of damage. Check that the power plug is dust-free. If

it is dirty, clean it to remove the risk of fire or electric shock. ............................................................

•Never attempt to disassemble the optical unit in machines using lasers. Leaking laser light may

damage eyesight. ..............................................................................................................................

•Handle the charger sections with care. They are charged to high potentials and may cause

electric shock if handled improperly. .................................................................................................

CAUTION

•Wear safe clothing. If wearing loose clothing or accessories such as ties, make sure they are

safely secured so they will not be caught in rotating sections...........................................................

•Use utmost caution when working on a powered machine. Keep away from chains and belts. .......

•Handle the fixing section with care to avoid burns as it can be extremely hot. .................................

•Check that the fixing unit thermistor, heat and press rollers are clean. Dirt on them can cause

abnormally high temperatures...........................................................................................................

•Do not remove the ozone filter, if any, from the copier except for routine replacement. ...................

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. .................................................................................................

•Always use parts having the correct specifications. ..........................................................................

•Always use the thermostat or thermal fuse specified in the service manual or other related

brochure when replacing them. Using a piece of wire, for example, could lead to fire or other

serious accident. ...............................................................................................................................

•When the service manual or other serious brochure specifies a distance or gap for installation of a

part, always use the correct scale and measure carefully. ...............................................................

•Always check that the copier is correctly connected to an outlet with a ground connection. ............

•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. ..............................................................................................

•Treat the ends of the wire carefully when installing a new charger wire to avoid electric leaks........

•Remove toner completely from electronic components. ...................................................................

•Run wire harnesses carefully so that wires will not be trapped or damaged. ...................................

•After maintenance, always check that all the parts, screws, connectors and wires that were

removed, have been refitted correctly. Special attention should be paid to any forgotten

connector, trapped wire and missing screws. ..................................................................................

•Check that all the caution labels that should be present on the machine according to the

instruction handbook are clean and not peeling. Replace with new ones if necessary. ...................

•Handle greases and solvents with care by following the instructions below: ....................................

·Use only a small amount of solvent at a time, being careful not to spill. Wipe spills off completely.

·Ventilate the room well while using grease or solvents.

·Allow applied solvents to evaporate completely before refitting the covers or turning the main

switch on.

·Always wash hands afterwards.

•Never dispose of toner or toner bottles in fire. Toner may cause sparks when exposed directly to

fire in a furnace, etc...........................................................................................................................

•Should smoke be seen coming from the copier, remove the power plug from the wall outlet

immediately. ......................................................................................................................................

3. Miscellaneous

WARNING

•Never attempt to heat the drum or expose it to any organic solvents such as alcohol, other than

the specified refiner; it may generate toxic gas. ................................................................................

1-1-1

3HW

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 ............................................................................................................................... 1-3-1

(1) Executing a maintenance item ....................................................................................................... 1-3-1

(2) Maintenance mode item list ............................................................................................................ 1-3-2

(3) Contents of maintenance mode items ............................................................................................ 1-3-3

1-4 Troubleshooting

1-4-1 Paper misfeed detection ...................................................................................................................... 1-4-1

(1) Paper misfeed indication ................................................................................................................ 1-4-1

(2) Paper misfeed detection conditions................................................................................................ 1-4-1

(3) Paper misfeeds ............................................................................................................................... 1-4-3

1-4-2 Self-diagnosis ....................................................................................................................................... 1-4-6

(1) Self-diagnostic function .................................................................................................................. 1-4-6

(2) Self-diagnostic codes ..................................................................................................................... 1-4-6

1-4-3 Image formation problems ................................................................................................................... 1-4-7

(1) The leading edge of the image is consistently misaligned with the original. .................................. 1-4-8

(2) The leading edge of the image is sporadically misaligned with the original. .................................. 1-4-8

1-4-4 Electrical problems ............................................................................................................................... 1-4-9

(1) The machine does not operate when the power switch is turned on. ............................................. 1-4-9

(2) The drawer drive motor does not operate. ..................................................................................... 1-4-9

(3) The drawer paper feed clutch does not operate. ............................................................................ 1-4-9

(4) The message requesting paper to be loaded is shown when paper is present in the drawer. ....... 1-4-9

(5) The size of paper in the drawer is not displayed correctly.............................................................. 1-4-9

(6) A paper jam in the paper feeder is indicated when the power switch is turned on. ........................ 1-4-9

(7) The message requesting cover to be closed is displayed when the drawer

left cover is closed. ....................................................................................................................... 1-4-10

(8) Others. .......................................................................................................................................... 1-4-10

1-4-5 Mechanical problems ........................................................................................................................ 1-4-11

(1) No primary paper feed. ................................................................................................................. 1-4-11

(2) Skewed paper feed. ...................................................................................................................... 1-4-11

(3) Multiple sheets of paper are fed at one time. ................................................................................ 1-4-11

(4) Paper jams. .................................................................................................................................. 1-4-11

(5) Abnormal noise is heard. .............................................................................................................. 1-4-11

1-5 Assembly and Disassembly

1-5-1 Precautions for assembly and disassembly ......................................................................................... 1-5-1

(1) Precautions ..................................................................................................................................... 1-5-1

(2) Running a maintenance item .......................................................................................................... 1-5-2

1-5-2 Paper feeder ........................................................................................................................................ 1-5-3

(1) Detaching and refitting the feed roller ............................................................................................. 1-5-3

(2) Detaching and refitting the drawer separation pulley ..................................................................... 1-5-4

(3) Detaching and refitting the drawer forwarding pulley and drawer paper feed pulley ...................... 1-5-5

(4) Adjusting the leading edge registration of image printing ............................................................... 1-5-7

(5) Adjusting the center line of image printing ...................................................................................... 1-5-8

(6) Adjusting the amount of slack in the paper..................................................................................... 1-5-9

1-1-2

3HW

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. 1 .......................................................................................................................................... 2-4-1

Timing chart No. 2 .......................................................................................................................................... 2-4-2

Maintenance parts list..................................................................................................................................... 2-4-3

Periodic maintenance procedures .................................................................................................................. 2-4-4

Wiring diagram ............................................................................................................................................... 2-4-5

3HW

1-1-1

1-1-1 Specifications

Paper feed system ......................... Automatic feed

Paper sizes .................................... A3 –A5R/11" × 17" –51/2" × 81/2"

Copy paper..................................... Plain paper, recycled paper and colored paper (64 –105 g/m2)

Paper capacity ............................... 300 sheets (80 g/m2)

Power source ................................. Electrically connected to the copier

Dimensions .................................... 570 (W) × 538 (D) × 135 (H) mm

227/16" (W) × 213/16" (D) × 55/16" (H)

Weight ............................................ Approx. 7.0 kg/15.4 lbs

3HW

1-1-2

1Drawer left cover

2Interface connector

3Paper gauge

4Paper size indication

5Positioning pins

Figure 1-1-1

1-1-2 Parts names and their functions

(1) Parts names

3HW

1-1-3

1-1-3 Machine cross section

Figure 1-1-2 Machine cross section

ath

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1-1-4

Figure 1-1-3 Drive system

1Drawer drive motor gear

2Gear 26/90

3Gear 25

4Gear 25

5Paper feed gear 20

6Drawer paper feed clutch gear

1-1-4 Drive system

1-2-1

3HW

1-2-1 Unpacking and installation

(1) Unpacking

Figure 1-2-1 Unpacking

1Paper feeder

2Outer case

3Left bottom pad

4Right bottom pad

5Left upper pad

6Right upper pad

7Stay

8Plastic sheet (1300 ×1300)

9Bar code labels

0Plastic bag (240 ×350)

!Installation guide

@Cassette size sheet

3HW

1-3-1

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

Enter “10871087”using

the numeric keys.

Enter “001”using the

zoom

+/- keys

or numeric keys

and press the start key.

Enter the maintenance item

number using the zoom

+/- keys or numeric keys.

The selected maintenance item is run.

Press the stop/clear key.

Press the start key.

Start

End

Maintenance mode is entered.

The maintenance item is

selected.

Maintenance mode is exited.

Repeat the same

maintenance item?

Run another maintenance

item?

Yes

3HW

1-3-2

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

• Adjusting the leading edge registration 0

• Adjusting the center line 0

U051 Adjusting the amount of slack in the paper 0

U053 Performing fine adjustment of the motor speed 0

U901 Checking/clearing copy counts by paper feed locations —

* Initial setting for executing maintenance item U020

Section Item Maintenance item contents Initial

No. setting*

(2) Maintenance mode item list

1-3-3

3HW

(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. Press the start key. A selection item appears.

2. Select the item to be displayed using the image mode selection key and copy exposure adjustment keys.

Image mode LEDs Copy exposure Copy quantity display

indicator

Exp. 1 number of the main ROM

Exp. 2 number of the main ROM sub

Exp. 1 number of the engine ROM

Exp. 2 number of the engine ROM sub

Exp. 1 number of the first paper feeder ROM

Exp. 2 number of the second paper feeder ROM

Exp. 3 number of the third paper feeder ROM

Exp. 1 number of the DP ROM

: Off, : On, : Flashing

Completion

Press the stop/clear key. The indication for selecting a maintenance item No. appears.

U030 Checking motor operation

Description

Drives each motor.

Purpose

To check the operation of each motor.

Method

1. Press the start key. A selection item appears.

2. Select the motor to be operated using the copy exposure adjustment keys.

Display Motor

A Drive motor (DM)

2F Registration motor (RM)

F1 Drawer drive motor 1 (DDM1)

F2 Drawer drive motor 2 (DDM2)

F3 Drawer drive motor 3 (DDM3)

EJ1 Exit motor (EM) forward rotation

EJ2 Exit motor (EM) reverse rotation

3. Press the start key. The selected motor operates.

4. To stop operation, press the stop/reset key.

Completion

Press the stop/clear key after operation stops. The indication for selecting a maintenance item No. appears.

Maintenance

Description

item No.

3HW

1-3-4

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. Turn each switche on and off manually to check the status.When the on-status of a switch is detected, the

original size indicator corresponding to the operated switch lights.

Original size indicator Switch

A3R/Ledger Exit switch (ESW)

A5R/Legal Registration switch (RSW)

A4/Letter-R Drawer feed switch 1 (DFSW1)

B4R/Letter Drawer feed switch 2 (DFSW2)

B5R/Statement Feedshift switch (FSSW)

Folio/U Duplex paper conveying switch (DUPPCSW)

Completion

Press the stop/clear key. The indication for selecting a maintenance item No. appears.

U032 Checking clutch operation

Description

Turns each clutch on.

Purpose

To check the operation of each clutch.

Method

1. Press the start key. A selection item appears.

2. Select the clutch to be operated using the copy exposure adjustment keys.

3. Press the start key. The selected clutch turns on for 1 s.

Display Clutch

P1 Paper feed clutch (PFCL)

Pb Bypass paper feed clutch (BYPPFCL)

F1 Drawer paper feed clutch 1 (DPFCL1)

F2 Drawer paper feed clutch 2 (DPFCL2)

F3 Drawer paper feed clutch 3 (DPFCL3)

Completion

Press the stop/clear key. The indication for selecting a maintenance item No. appears.

U034 Adjusting the print start timing

Adjustment

See pages 1-5-7 and 8.

U051 Adjusting the amount of slack in the paper

Adjustment

See page 1-5-9.

3HW

1-3-5

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.

Method

Press the start key.

Setting

1. Select the group to be set or checked by lighting image mode LEDs using the image mode selection key.

2. Select the item by lighting a copy exposure indicator using the copy exposure adjustment keys.

3. Change the setting using the zoom +/– keys.

Image mode LED Copy exposure

Description Setting Initial

indicator range setting

Exp. 1 Drive motor speed adjustment –5.0 to +5.0 0

Exp. 2 Polygon motor speed adjustment –5.0 to +5.0 0

Exp. 3 Exit motor speed adjustment –5.0 to +5.0 0

Exp. 4 Registration motor speed adjustment –5.0 to +5.0 0

Exp. 1 Motor speed adjustment (for paper –5.0 to +5.0 0

feed from bypass tray)

Exp. 2 Motor speed adjustment (for paper –5.0 to +5.0 0

feed from optional paper feeder)

Exp. 3 Motor speed adjustment –5.0 to +5.0 0

(in duplex mode)

Drive motor speed adjustment (unit: %)

Increasing the setting makes the image longer in the auxiliary scanning direction, and decreasing it makes

the image shorter in the auxiliary scanning direction.

Polygon motor speed adjustment (unit: %)

Increasing the setting makes the image longer in the main scanning direction and shorter in the auxiliary

scanning direction; decreasing the setting makes the image shorter in the main scanning direction and

longer in the auxiliary scanning direction.

4. Press the start key. The value is set.

Interrupt copy mode

While this maintenance item is being performed, a VTC pattern shown below is output in interrupt copy mode.

Correct values for an A3/11" ×17" output are:

A= 300 ± 1.5 mm

B= 270 ± 1.35 mm

Figure 1-4-1

Adjustment

1. Output an A3/11" ×17" VTC pattern in interrupt mode.

2. Measure Aand Bon the VTC pattern (Figure 1-4-1), and perform the following adjustments if they are

different from the correct sizes:

A: Drive motor speed adjustment

B: Polygon motor speed adjustment

Completion

Press the stop/clear key while a selection item is displayed.The indication for selecting a maintenance item No.

appears.

Maintenance

Description

item No.

3HW

1-3-6

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. Press the start key.

2. Select the paper feed location (group No.) for which the count is to be checked or cleared by lighting image

mode LEDs using the image mode selection key.

3. Select the item by lighting a copy exposure indicator using the copy exposure adjustment keys.

Image mode LED Copy exposure Copy quantity display (count value)

(group No.) indicator

1 Exp. 1 First 3 digits of bypass copy count

Exp. 2 Last 3 digits of bypass copy count