Kyocera DP-420, PF-420, DF-420, JS-420 Service manual
DP-420/PF-420
DF-420/JS-420
FAX System (R)
SERVICE
MANUAL
Published in May 2009
3MZSM060
First Edition
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 INSTRUCTIONS DONNEES.
Il peut être illégal de jeter les batteries dans des eaux d’égout municipales. Vérifiez avec les fonctionnaires municipaux de votre région pour les détails concernant des déchets solides et une mise
au rebut appropriée.
Revision history
Revision Date Replaced pages Remarks
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 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. .....................................................................................................................
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. .............
• 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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DP-420
First Edition
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 ............................................................................................................................1-1-3
1-2 Installation
1-2-1 Installation environment ..........................................................................................................................1-2-1
1-2-2 Unpacking ...............................................................................................................................................1-2-2
(1) Unpacking .........................................................................................................................................1-2-2
(2) Removing the tapes and the spacer..................................................................................................1-2-3
1-3 Maintenance Mode
1-3-1 Maintenance mode (operation panel is a 7-segment type) .....................................................................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
1-3-2 Maintenance mode (operation panel is an LCD type)...........................................................................1-3-15
(1) Executing a maintenance item ........................................................................................................1-3-15
(2) Maintenance mode item list.............................................................................................................1-3-16
(3) Contents of maintenance mode items.............................................................................................1-3-17
3MX
1-4 Troubleshooting
1-4-1 Original misfeed detection ......................................................................................................................1-4-1
(1) Original misfeed indication ................................................................................................................1-4-1
(2) Original misfeed detection conditions................................................................................................1-4-1
(3) Paper misfeeds .................................................................................................................................1-4-3
1-4-2 Self-diagnosis .........................................................................................................................................1-4-4
(1) Self-diagnostic function (operation panel is a 7-segment type).........................................................1-4-4
(2) Self diagnostic codes (operation panel is a 7-segment type)............................................................1-4-4
(3) Self-diagnostic function (operation panel is an LCD type) ................................................................1-4-4
(4) Self diagnostic codes (operation panel is an LCD type)....................................................................1-4-4
1-4-3 Electric problems ....................................................................................................................................1-4-5
1-4-4 Mechanical problems ..............................................................................................................................1-4-6
1-5 Assembly and Disassembly
1-5-1 Precautions for assembly and disassembly............................................................................................1-5-1
(1) Precautions .......................................................................................................................................1-5-1
1-5-2 Original feed section ...............................................................................................................................1-5-2
(1) Detaching and refitting the DP forwarding pulley and DP feed pulley...............................................1-5-2
(2) Detaching and refitting the DP separation pad..................................................................................1-5-5
1-5-3 Image adjustment ...................................................................................................................................1-5-6
(1) Adjusting the angle of leading edge ..................................................................................................1-5-6
(2) Adjusting the angle of trailing edge ...................................................................................................1-5-8
2-1 Mechanical construction
2-1-1 Mechanical construction .........................................................................................................................2-1-1
(1) Operation of original switchback .......................................................................................................2-1-3
2-2 Electrical Parts Layout
2-2-1 Electrical parts layout..............................................................................................................................2-2-1
(1) PWBs ................................................................................................................................................2-2-1
(2) Switches and sensors .......................................................................................................................2-2-2
(3) Motors ...............................................................................................................................................2-2-3
(4) Solenoids...........................................................................................................................................2-2-4
2-3 Operation of the PWBs
2-3-1 DP main PWB .........................................................................................................................................2-3-1
3MX
2-4 Appendixes
List of maintenance parts........................................................................................................................2-4-1
Periodic maintenance procedures ..........................................................................................................2-4-2
Wiring diagram........................................................................................................................................2-4-4
1-1 Specifications
1-1-1 Specifications
Type................................................Duplex sheet-through document feeder
Original feed method ......................Automatic feed
Original weight ................................Single-sided original mode: 45 to 160 g/m
Double-sided original mode: 50 to 120 g/m
Original type....................................Sheet originals
Original size .................................... A3 to A5R/Ledger to StatementR
Original No. of sheets .....................50 sheets or less (50 to 80 g/m
Mixed original sizes: 30 sheets or less (50 to 80 g/m2)
Original scanning speed .................53.5 to 107 mm/s
Power source..................................Electrically connected to the machine
Dimensions .....................................559 (W) x 487 (D) x 131 (H) mm
22" (W) x 19
3/16" (D) x 5 3/16" (H)
Weight.............................................7 kg/15.4 lbs or less
NOTE: These specifications are subject to change without notice.
2
)
3MX
2
2
1-1-1
3MX
1-1-2 Parts names
4
2
1
6
2
Figure 1-1-1
1. Original table
2. Original width guides
3. Original eject table
4. Document processor top cover
5. Original stopper
6. Cleaning cloth compartment
3
5
1-1-2
1-1-3 Machine cross section
3MX
2
1
Original path
3
Figure 1-1-2 Machine cross section
1. Original feed section
2. Original conveying section
3. Original switchback section
1-1-3
3MX
This page is intentionally left blank.
1-1-4
3MX
1-2 Installation
1-2-1 Installation environment
Installation location (Be based on the machine establishment place.)
Avoid direct sunlight or bright lighting. Ensure that the photoconductor 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 photoconductor, such as mercury, acidic
of alkaline vapors, inorganic gasses, NOx, SOx gases and chlorine-based organic solvents.
Select a well-ventilated location.
°).
1-2-1
3MX
1-2-2 Unpacking
(1) Unpacking
1. Document processor
2. Outer case
3. Inner case
4. Rear upper pad
5. Rear lower pad
6. Front pad
7. Spacer
8. Plastic sheet
Caution: See the Installation Guide for installation.
1-2-2
Figure 1-2-1 Unpacking
9. Plastic bag
10. Cleaning cloth
11. Tray spacer
12. Plastic bag
13. Original mat
14. Plastic bag
15. M4 x 14 screws
16. Pins
17. Angle adjusting plate
18. Plastic bag
19. Installation guide
20. Film
21. Label A
22. Label B (220 V - 240 V
specifications only)
(2) Removing the tapes and the spacer
3MX
Procedure
1. Remove two tapes.
2. Open the document processor top cover.
3. Raise the DP feed pulley unit.
4. Open the spacer.
5. Raise the original table.
6. Remove the spacer.
7. Remove the plastic bag.
Ta pe
Document processor
top cover
DP feed pulley unit
Ta pe
Figure 1-2-2
Original table
Plastic bag
Spacer
Figure 1-2-3
1-2-3
3MX
This page is intentionally left blank.
1-2-4
1-3 Maintenance Mode
1-3-1 Maintenance mode (operation panel is a 7-segment type)
The machine is equipped with a maintenance function which can be used to maintain and service the machine.
(1) Executing a maintenance item
Start
3MX
Yes
Enter “10871087” using
the numeric keys.
Enter the maintenance item
number using the zoom
+/- keys or numeric keys.
Press the start key.
The selected maintenance item is run.
Press the stop/clear key.
Repeat the same
maintenance item?
Maintenance mode is entered.
The maintenance item is
selected.
Yes
No
Run another maintenance
item?
No
Enter “001” using the
or numeric keys
+/- keys
zoom
and press the start key.
End
Maintenance mode is exited.
1-3-1
3MX
(2) Maintenance mode item list
Section
Item
No.
Content of maintenance item
Initial
setting*
General U019 Displaying the ROM version -
Optical U068 Adjusting the scanning position for originals from the DP 0
U070 Adjusting the DP magnification 0/0
U071 Adjusting the DP scanning timing 0/0/0/0
U072 Adjusting the DP center line 0/0
U074 Adjusting the DP input light luminosity 1
U076 Adjusting the DP automatically -
U087 Setting DP reading position modification operation ON/35
Operation
panel and
support
equipment
Image
U203 Checking DP operation -
U243 Checking the operation of the DP motors -
U244 Checking the DP switches -
U404 Adjusting margins for scanning an original from the DP 2.0/3.0/2.0/2.0
processing
Other U905 Checking/clearing counts by optional devices -
U942 Setting of deflection for feeding from DP 0/0
*1
*1
*1
*1
*1
*1
*1
*1
*Initial setting for executing U020, *1: The item initialized for executing U020, *2: The item initialized for executing U021
1-3-2
(3) Contents of maintenance mode items
3MX
Maintenance
item No.
U019
Description
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.
2. Select the item to be displayed using the image mode selection key and exposure adjustment keys.
Image mode LEDs
Exposure
indicator
Exp. 1 (lit)
Exp. 2 (lit)
Exp. 3 (lit)
Exp. 4 (lit)
Exp. 1 (lit)
Exp. 2 (lit)
Exp. 3 (lit)
Exp. 4 (lit)
Exp. 5 (lit)
Exp. 1 (flashing)
Exp. 1 (lit)
Exp. 2 (lit)
Exp. 3 (lit)
Exp. 4 (lit)
Exp. 5 (lit)
Copy quantity display
“A” Part Code: Main PWB
Change history of the main PWB
Number of the main ROM
Number of the main ROM sub
“E” Part Code: Engine PWB
Change history of the engine PWB
Number of the engine ROM
Number of the engine ROM sub
Change history of the engine PWB BOOT
Number of the engine PWB BOOT
“L” Part Code: Language
Change history of the standard language
Number of the standard language ROM
Change history of the optional language
Number of the optional language ROM
Exp. 1 (lit)
Exp. 2 (lit)
Exp. 3 (lit)
Exp. 4 (lit)
Exp. 1 (lit)
Exp. 2 (lit)
Exp. 1 (lit)
Exp. 2 (lit)
Exp. 3 (lit)
: Off, : On, : Flashing
When the optional equipment is not installed, [non] is displayed.
Completion
Press the stop/clear key. The screen for selecting a maintenance item No. is displayed.
“C” Part Code: Cassette
Number of the optional first paper feeder ROM
Number of the optional second paper feeder ROM
Number of the optional third paper feeder ROM
“d” Part Code: DP
Number of the DP ROM
“P” Part Code: Printer
Change history of the optional printer
Number of the optional printer ROM
1-3-3
3MX
Maintenance
item No.
U068
Description
Adjusting the scanning position for originals from the DP
Description
Adjusts the position for scanning originals from the DP.
Purpose
Used when the image fogging occurs because the scanning position is not proper when the DP is used. Run
U071 to adjust the timing of DP leading edge when the scanning position is changed.
Setting
1. Press the start key.
2. Change the setting using the zoom +/- keys.
Description Setting range Initial setting Change in value per step
Scanning position -17 to 17 0 0.17 mm
Increasing the value moves the image backward, and decreasing it moves the image forward.
Supplement
While this maintenance item is being executed, copying from an original is available in interrupt copying mode
(which is activated by pressing the interrupt key).
Completion
Press the stop/clear key. The screen for selecting a maintenance item No. is displayed.
1-3-4
3MX
Maintenance
item No.
U070
Description
Adjusting the DP magnification
Description
Adjusts the DP original scanning speed.
Purpose
Make the adjustment if the magnification is incorrect in the auxiliary scanning direction when the optional DP
is used.
Adjustment
1. Press the start key.
2. Select the item using the exposure adjustment keys.
Display Description Setting
range
Exp. 1 Magnification in the auxiliary scan-
-25 to 25 0 0.2 mm
Initial
setting
Change in
value per step
ning direction (first page)
Exp. 2 Magnification in the auxiliary scan-
-25 to 25 0 0.2 mm
ning direction (second page)
3. Press the interrupt key.
4. Place an original on the DP and press the start key to make a test copy.
5. Change the setting value using the zoom +/- keys.
For copy example 1, increase the value.
For copy example 2, decrease the value.
Original Copy
example 1
Copy
example 2
Figure 1-3-1
6. Press the start key. The value is set.
Caution
Check the copy image after the adjustment. If the image is still incorrect, perform the following adjustments in
maintenance mode.
U070
U071
(P.1-3-6)
U404
(P.1-3-13)
Completion
Press the stop/clear key. The screen for selecting a maintenance item No. is displayed.
1-3-5
3MX
Maintenance
item No.
U071
Description
Adjusting the DP scanning timing
Description
Adjusts the DP original scanning timing.
Purpose
Make the adjustment if there is a regular error between the leading or trailing edges of the original and the
copy image when the optional DP is used.
Method
1. Press the start key.
2. Select the item using the exposure adjustment keys.
Exposure
indicator
Exp. 1 DP leading edge registration
Description Setting
range
-32 to 32 0 0.2 mm
Initial
setting
Change in
value per step
(first side)
Exp. 2 DP trailing edge registration
-42 to 32 0 0.2 mm
(first side)
Exp. 3 DP leading edge registration
-32 to 32 0 0.2 mm
(second side)
Exp. 4 DP trailing edge registration
-42 to 32 0 0.2 mm
(second side)
3. Press the interrupt key.
4. Place an original on the DP and press the start key to make a test copy.
5. Change the setting value using the zoom +/- keys.
For copy example 1, decrease the value of exp.1.
For copy example 2, increase the value of exp.1.
Original Copy
example 1
Copy
example 2
Figure 1-3-2
6. Press the start key. The value is set.
Caution
Check the copy image after the adjustment. If the image is still incorrect, perform the following adjustments in
maintenance mode.
U071
U404
(P.1-3-13)
Completion
Press the stop/clear key. The screen for selecting a maintenance item No. is displayed.
1-3-6
3MX
Maintenance
item No.
U072
Description
Adjusting the DP center line
Description
Adjusts the scanning start position for the DP original.
Purpose
Make the adjustment if there is a regular error between the centers of the original and the copy image when
the optional DP is used.
Adjustment
1. Press the start key.
2. Select the item using the exposure adjustment keys.
Exposure
indicator
Description
Setting
range
Initial
setting
Change in
value per step
Exp. 1 DP center line (first side) -6.6 to 6.6 0 0.15 mm
Exp. 2 DP center line (second side) -3.0 to 3.0 0 0.15 mm
3. Press the interrupt key.
4. Place an original on the DP and press the start key to make a test copy.
5. Change the setting value using the zoom +/- keys.
For copy example 1, increase the value.
For copy example 2, decrease the value.
Original Copy
example 1
Copy
example 2
Figure 1-3-3
6. Press the start key. The value is set.
Caution
Check the copy image after the adjustment. If the image is still incorrect, perform the following adjustments in
maintenance mode.
U072
U404
(P.1-3-13)
Completion
Press the stop/clear key. The screen for selecting a maintenance item No. is displayed.
1-3-7
3MX
Maintenance
item No.
U074
Description
Adjusting the DP input light luminosity
Description
Adjusts the luminosity of the exposure lamp for scanning originals from the DP.
Purpose
Used if the exposure amount differs significantly between when scanning an original on the platen and when
scanning an original from the DP.
Setting
1. Press the start key.
2. Change the setting using the zoom +/- keys.
Description Setting range Initial setting
DP input light luminosity 0 to 8 1
Increasing the setting makes the luminosity higher, and decreasing it makes the luminosity lower.
3. Press the start key. The value is set.
Supplement
While this maintenance item is being executed, copying from an original is available in interrupt copying mode
(which is activated by pressing the interrupt key).
Completion
Press the stop/clear key. The screen for selecting a maintenance item No. is displayed.
1-3-8
3MX
Maintenance
item No.
U076
Description
Adjusting the DP automatically
Description
Uses a specified original and automatically adjusts the following items in the DP scanning section.
Adjusting the DP magnification (U070)
Adjusting the DP scanning timing (U071)
Adjusting the DP center line (U072)
When you run this maintenance mode, the preset values of U070, U071 and U072 will also be updated.
Purpose
To perform automatic adjustment of various items in the DP scanning section.
Method
1. Set a specified original (P/N: 302AC68243) in the DP.
Cut the trailing edge of the original.
F
5 mm
149 ± 1 mm
R
74 ± 1 mm
Figure 1-3-4
2. Press the start key. "on" appears.
3. Press the start key. Auto adjustment starts. When adjustment is complete, "Gd" appears.
4. Display each setting value after adjustment using the exposure adjustment keys.
Exposure indicator Description
Exp. 1 Execution result
Exp. 2 DP scanning timing
Exp. 3 DP center line
Exp. 4 DP magnification
If a problem occurs during auto adjustment, "nG" is displayed and operation stops. Determine the details
of the problem and either repeat the procedure from the beginning, or adjust the remaining items manually by running the corresponding maintenance items.
Completion
Press the stop/clear key after auto adjustment is complete.The screen for selecting a maintenance item No. is
displayed.
If the stop/clear key is pressed during auto adjustment, adjustment stops and no settings are changed.
1-3-9
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