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

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

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DP-420

First Edition

			3MX
		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
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

3MX

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/m2
	Double-sided original mode: 50 to 120 g/m2
Original type....................................	Sheet originals
Original size ....................................	A3 to A5R/Ledger to StatementR
Original No. of sheets .....................	50 sheets or less (50 to 80 g/m2)
	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.

1-1-1

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1-1-2 Parts names

4

2

1

6

3

2

5

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

1-1-2

3MX

1-1-3 Machine cross section

1

2

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

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1-1-4

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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

		Figure 1-2-1 Unpacking
1.	Document processor	9.	Plastic bag	17.	Angle adjusting plate
2.	Outer case	10.	Cleaning cloth	18.	Plastic bag
3.	Inner case	11.	Tray spacer	19.	Installation guide
4.	Rear upper pad	12.	Plastic bag	20.	Film
5.	Rear lower pad	13.	Original mat	21.	Label A
6.	Front pad	14.	Plastic bag	22.	Label B (220 V - 240 V
7.	Spacer	15.	M4 x 14 screws		specifications only)
8.	Plastic sheet	16.	Pins

Caution: See the Installation Guide for installation.

1-2-2

(2) Removing the tapes and the spacer

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.

3MX

Tape

Tape

Figure 1-2-2

Document processor top cover

Original table

Plastic bag

DP feed pulley unit

Spacer

Figure 1-2-3

1-2-3

3MX

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1-2-4

3MX

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

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.

Yes	Repeat the same
	maintenance item?
	No
Yes	Run another maintenance
	item?
	No
	Enter “001” using the zoom
	+/- keys or numeric keys
	and press the start key.

Maintenance mode is entered.

The maintenance item is selected.

Maintenance mode is exited.

End

1-3-1

3MX

(2) Maintenance mode item list

	Section	Item	Content of maintenance item	Initial
		No.		setting*
	General	U019	Displaying the ROM version	-
	Optical	U068	Adjusting the scanning position for originals from the DP	0*1
		U070	Adjusting the DP magnification	0/0*1
		U071	Adjusting the DP scanning timing	0/0/0/0*1
		U072	Adjusting the DP center line	0/0*1
		U074	Adjusting the DP input light luminosity	1*1
		U076	Adjusting the DP automatically	-
		U087	Setting DP reading position modification operation	ON/35*1
	Operation	U203	Checking DP operation	-
	panel and
		U243	Checking the operation of the DP motors	-
	support
		U244	Checking the DP switches	-
	equipment
	Image	U404	Adjusting margins for scanning an original from the DP	2.0/3.0/2.0/2.0*1
	processing
	Other	U905	Checking/clearing counts by optional devices	-
		U942	Setting of deflection for feeding from DP	0/0*1

*Initial setting for executing U020, *1: The item initialized for executing U020, *2: The item initialized for executing U021

1-3-2

3MX

(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.

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

Image mode LEDs			Exposure	Copy quantity display
			indicator
			Exp. 1 (lit)	“A” Part Code: Main PWB
			Exp. 2 (lit)	Change history of the main PWB
			Exp. 3 (lit)	Number of the main ROM
			Exp. 4 (lit)	Number of the main ROM sub
			Exp. 1 (lit)	“E” Part Code: Engine PWB
			Exp. 2 (lit)	Change history of the engine PWB
			Exp. 3 (lit)	Number of the engine ROM
			Exp. 4 (lit)	Number of the engine ROM sub
			Exp. 5 (lit)	Change history of the engine PWB BOOT
			Exp. 1 (flashing)	Number of the engine PWB BOOT
			Exp. 1 (lit)	“L” Part Code: Language
			Exp. 2 (lit)	Change history of the standard language
			Exp. 3 (lit)	Number of the standard language ROM
			Exp. 4 (lit)	Change history of the optional language
			Exp. 5 (lit)	Number of the optional language ROM
			Exp. 1 (lit)	“C” Part Code: Cassette
			Exp. 2 (lit)	Number of the optional first paper feeder ROM
			Exp. 3 (lit)	Number of the optional second paper feeder ROM
			Exp. 4 (lit)	Number of the optional third paper feeder ROM
			Exp. 1 (lit)	“d” Part Code: DP
			Exp. 2 (lit)	Number of the DP ROM
			Exp. 1 (lit)	“P” Part Code: Printer
			Exp. 2 (lit)	Change history of the optional printer
			Exp. 3 (lit)	Number of the optional printer ROM
: 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.

1-3-3

3MX

Maintenance			Description
item No.
U068 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			Description
item No.
U070 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	Initial	Change in
				range	setting	value per step
	Exp. 1		Magnification in the auxiliary scan-	-25 to 25	0	0.2 mm
			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	Copy
	example 1	example 2
6. Press the start key. The value is set.	Figure 1-3-1

Caution

Check the copy image after the adjustment. If the image is still incorrect, perform the following adjustments in maintenance mode.

U070			U071			U404
			(P.1-3-6)			(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			Description
item No.
U071 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		Description		Setting	Initial	Change in
	indicator				range	setting	value per step
	Exp. 1		DP leading edge registration		-32 to 32	0	0.2 mm
			(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	Copy
	example 1	example 2
6. Press the start key. The value is set.	Figure 1-3-2

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

Description

item No.

U072 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

Description

Setting

Initial

Change in

indicator

range

setting

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	Copy
	example 1	example 2
6. Press the start key. The value is set.	Figure 1-3-3

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		Description
item No.
U074 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	Description
	item No.
	U076 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.
					5 mm
	F					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