Kyocera DF-780 Service Manual
DF-780/DF-780(B)
SERVICE
MANUAL
Published in August 2009
845JA112
5JASM062
Rev. 2
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
1 November 26, 2008 1-3-2, 2-4-1 -
2 August 6, 2009 CONTENTS, 1-1-1, 1-2-1, 1-3-1, 1-3-3 to 1-3-6,
1-4-2, 1-4-3
-
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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 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 ............................................................................................................................1-1-3
1-2 Installation
1-2-1 Installation environment ..........................................................................................................................1-2-1
1-2-2 Unpacking ...............................................................................................................................................1-2-2
(1) Installation procedure ........................................................................................................................1-2-2
1-3 Maintenance Mode
1-3-1 Maintenance mode (fullcolor machine) ...................................................................................................1-3-1
(1) Executing a maintenance item ..........................................................................................................1-3-1
(2) Contents of maintenance mode items...............................................................................................1-3-2
1-3-2 Maintenance mode (monochrome machine) ..........................................................................................1-3-4
(1) Executing a maintenance item ..........................................................................................................1-3-4
(2) Contents of maintenance mode items...............................................................................................1-3-5
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 .................................................................................................................................1-4-4
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 Electric problems ....................................................................................................................................1-4-9
1-4-4 Mechanical problems ............................................................................................................................1-4-12
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1-5 Assembly and Disassembly
1-5-1 Precautions for assembly and disassembly............................................................................................1-5-1
(1) Precautions .......................................................................................................................................1-5-1
1-5-2 Outer covers ...........................................................................................................................................1-5-2
(1) Detaching and refitting the front cover and rear cover ......................................................................1-5-2
(2) Gear phase adjustment for vertical driving of bundle discharge belt.................................................1-5-4
2-1 Mechanical Construction
2-1-1 Switchback section .................................................................................................................................2-1-1
(1) Switchback operation ........................................................................................................................2-1-3
2-1-2 Processing section..................................................................................................................................2-1-4
(1) Bundle discharge operation...............................................................................................................2-1-6
2-1-3 Eject tray section.....................................................................................................................................2-1-7
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 Finisher main PWB .................................................................................................................................2-3-1
2-4 Appendixes
List of maintenance parts........................................................................................................................2-4-1
Periodic maintenance procedures ..........................................................................................................2-4-1
Wiring diagram........................................................................................................................................2-4-3
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1-1 Specifications
1-1-1 Specifications
Type................................................Floor model
Number of trays .............................. One tray
Paper weight...................................64 to 105 g/m
Tray capacity...................................Paper weight 90 g/m2 or less
When not stapling:
A3, B4, Ledger, Legal, Oficio II, 8.5 x 13.5", Folio, 8K: 500 sheets
A4, A4R, B5, B5R, Letter, LetterR, ExecutiveR, 16K: 1000 sheets
When stapling 2 or 10 sheets:
A3, B4, Ledger, Legal, 8K: 30 sets
A4R, B5R, LetterR: 40 sets
A4, Letter, 16K: 45 sets
B5: 50 sets
When stapling 11 or 20 sheets:
A3, B4, Ledger, Legal, 8K: 12 sets
A4R, B5R, LetterR: 35 sets
A4, B5, Letter, 16K: 40 sets
When stapling 21 or 25 sheets:
A3, B4, Ledger, Legal, 8K: 10 sets
A4, A4R, B5, B5R, Letter, LetterR, 16K: 30 sets
When stapling 26 or 30 sheets:
A4, A4R, B5, B5R, Letter, LetterR, 16K: 30 sets
When stapling 31 or 50 sheets:
A4, A4R, B5, B5R, Letter, LetterR, 16K: 20 sets
Stapling capacity.............................Paper weight 90 g/m
A3, B4, Ledger, Legal, Oficio II, 8.5 x 13.5", Folio, 8K: 25 sheets
A4, A4R, B5, B5R, Letter, LetterR, ExecutiveR, 16K: 50 sheets
Mixed sizes: 25 sheets or less
Power source..................................Electrically connected to the machine
Dimensions .....................................634.9 (W) x 533 (D) x 1013.5 (H) mm
25" (W) x 21" (D) x 39
Weight.............................................Approx. 26.5 kg/Approx. 59 lbs
2
2
or less
7/8" (H)
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NOTE: These specifications are subject to change without notice.
1-1-1
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1-1-2 Parts names
2
6
5
13
4
1-1-2
Figure 1-1-1
1. Eject tray
2. Eject tray extension
3. Switchback unit cover
4. Finisher release button
5. Stapler cover
6. Staple holder
1-1-3 Machine cross section
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123
Paper path
Figure 1-1-2 Machine cross section
1. Switchback section
2. Processing section
3. Eject tray section
1-1-3
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1-1-4
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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
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1-2-2 Unpacking
(1) Installation procedure
Figure 1-2-1 Unpacking
1. Document finisher
2. Outer case
3. Supports
4. Hinge joints
5. Skid
6. Pad
7. Pad
8. Pad
Caution: Place the machine on a level surface. See the Installation Guide for installation.
1-2-2
9. Pad
10. Pad
11. Pad
12. Pad
13. Guide rail
14. M4 x 6 binding screws
15. M4 x 14 binding screws
1-3 Maintenance Mode
1-3-1 Maintenance mode (fullcolor machine)
The machine is equipped with a maintenance function which can be used to maintain and service the machine.
(1) Executing a maintenance item
Start
5JA-2
Yes
Enter 10871087 using
the numeric keys.
Enter the maintenance item
number using the cursor up/down keys
or numeric keys.
Press the start key.
The selected maintenance item is run.
Press the stop 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 cursor
up/down keys or numeric keys
and press the start key.
End
Maintenance mode is exited.
1-3-1
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