Kyocera PF-510 User manual

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

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. METTRE AU REBUT LES BATTERIES UTILISEES SELON LES INSTRUC-
TIONS DONNEES.
Il peut être illégal de jeter les batteries dans des eaux d’égout municipales. Vérifiez avec les fonc-
tionnaires municipaux de votre région pour les détails concernant des déchets solides et une mise
au rebut appropriée.

Revision history
Revision Date Replaced pages Remarks
1 5 March 2009 1-3-4, 1-3-5, 1-3-6, 1-3-7

This page is intentionally left blank.

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.

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.
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.

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 acciden-
tally ingested, drink a lot of water to dilute it in the stomach and obtain medical attention immedi-
ately. 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. .....................................................................................................................

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 bro-
chure 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. .............
• 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. ....................
• 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 power 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 imme-
diately. ............................................................................................................................................
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. .....................................................................................

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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
(1) Self-diagnostic function .....................................................................................................................1-3-3
(2) Self diagnostic codes indication ........................................................................................................1-3-3
(3) Self diagnostic codes ........................................................................................................................1-3-4
1-3-3 Electric problems ....................................................................................................................................1-3-8
1-3-4 Mechanical problems ..............................................................................................................................1-3-9
1-4 Assembly and Disassembly
1-4-1 Precautions for assembly and disassembly............................................................................................1-4-1
(1) Precautions .......................................................................................................................................1-4-1
1-4-2 Paper feed section ..................................................................................................................................1-4-2
(1) Detaching and refitting the paper feed holder assembly (paper feed roller and pickup roller) ..........1-4-2
(2) Detaching and refitting the retard assembly (retard roller) ................................................................1-4-3
1-4-3 Warm air blowing section (Multi purpose feeder only) ............................................................................1-4-5
(1) Detaching and refitting the PF thermistor 1, PF thermostat 1, PF warm air heater 1 and
PF warm air fan motor 1....................................................................................................................1-4-5
(2) Detaching and refitting the PF warm air fan motor 2, PF thermistor 2, PF thermostat 2 and
PF warm air heater 2.......................................................................................................................1-4-12
(3) Detaching and refitting the PF warm air heater driver PWB............................................................1-4-16
1-4-4 PWB......................................................................................................................................................1-4-18
(1) Detaching and refitting the PF main PWB.......................................................................................1-4-18
2-1 Mechanical Construction
2-1-1 Paper feed section ..................................................................................................................................2-1-1
(1) Paper feed section ............................................................................................................................2-1-1
(2) Warm air blowing section (Multi purpose feeder only) ......................................................................2-1-3
2-2 Electrical Parts Layout
2-2-1 Electrical parts layout..............................................................................................................................2-2-1
(1) Electrical parts layout ........................................................................................................................2-2-1
2-3 Operation of the PWBs
2-3-1 PF main PWB .........................................................................................................................................2-3-1
2-4 Appendixes
2-4-1 Appendixes .............................................................................................................................................2-4-1
(1) Wiring diagram ..................................................................................................................................2-4-1

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3K8/3K9
1-1-1
1-1 Specific ations
1-1-1 Specifications
Paper feeder (Normal)
Paper weight................................... 60 to 120 g/m2
Paper size.......................................A5, B5, ISO B5, A4, Executive, Letter, Legal, Oficio II, Statement, Folio, Custom
Paper capacity ................................500 sheets, plain paper (80 g/m2)
Dimension (W ×H ×D)...................345 mm ×115 mm ×478 mm
13 9/16" ×4 1/2" ×18 13/16"
Weight.............................................4.0 kg/8.8 lb
Power source.................................. Electrically connected to the printer (5 V DC, 24 V DC)
Multi purpose feeder
Paper weight................................... 60 to 220 g/m2
Paper size.......................................,Executive, Letter, Legal, Custom, OufukuHagaki
Oficio II, Statement, Folio, Youkei 2, Youkei 4, 16K
Paper capacity ................................500 sheets, plain paper (80 g/m2)
(Up to height of 40 mm for envelopes and coated paper)
Dimension (W ×H ×D)...................345 mm ×115 mm ×478 mm
13 9/16" ×4 1/2" ×18 13/16"
Weight.............................................5.0 kg/11.0 lb
Power source.................................. Electrically connected to the printer (5 V DC, 24 V DC)
Power source..................................120 V AC, 220 - 240 V AC (for PF warm air heaters)
Note: These specifications are subject to change without notice.
W
D
H
W
D
H

3K8/3K9
1-1-2
1-1-2 Parts names
Paper feeder (Normal)
Figure 1-1-1Paper feeder (Normal)
1
2
8
7
7
5
5
6
4
3
1. Cassette
2. Paper size dial window
3. Paper gauge
4. Paper size dial
5. Paper width guide
6. Paper length guide
7. Positioning pins
8. Paper feeder

3K8/3K9
1-1-3
Multi purpose feeder
Figure 1-1-2Multi purpose feeder
1
2
8
7
7
5
9
10
5
11
12
6
4
3
1. Cassette
2. Paper size dial window
3. Paper gauge
4. Paper size dial
5. Paper width guide
6. Paper length guide
7. Positioning pins
8. Paper feeder
9. AC inlet
10. AC outlet
11. Right sub-cursor
12. Left sub-cursor

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

3K8/3K9
1-2-1
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; an abrupt change in
the environmental temperature; and cool or hot, direct air.
Avoid places subject to dust and vibrations.
Choose a surface capable of supporting the weight of the machine.
Place the machine on a level surface (maximum allowance inclination: 1°).
Avoid air-borne substances that may adversely affect the machine or degrade the photo-conductor, such as mercury,
acidic of alkaline vapors, inorganic gasses, NOx, SOx gases and chlorine-based organic solvents.
Select a well-ventilated location.

3K8/3K9
1-2-2
1-2-2 Unpacking
(1) Unpacking
Paper feeder (Normal)
Figure 1-2-1Paper feeder (Normal)
Caution: Place the machine on a level surface. See the Installation Guide for installation.
1
2
5
6
3
4
1. Paper feeder
2. Plastic bag 600 ×800
3. Left pad
4. Right pad
5. Front pad
6. Outer case

3K8/3K9
1-2-3
Multi purpose feeder
Figure 1-2-2Multi purpose feeder
Caution: Place the machine on a level surface. See the Installation Guide for installation.
1
2
11
12
5
6
3
10
7
8
9
4
1. Paper feeder
2. Plastic bag 600 ×800
3. Left pad
4. Right pad
5. Front pad
6. Outer case
7. Junction cable
8. Right sub-cursor
9. Left sub-cursor
10. Plastic bag 120 ×250
11. Paper type label
12. Plastic bag 70 ×280

3K8/3K9
1-2-4
(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.
Figure 1-2-3
Right sub-cursor
Right sub-cursor
Left sub-cursor
Left sub-cursor
Cassette