Kyocera DP-100 Service Manual

DP-100

SERVICE

MANUAL

Published in Feb. ’03

843HK110

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 main
switch on.

· Always wash hands afterwards.

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

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

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

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

3. Miscellaneous

WARNING

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

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

CONTENTS

1-1 Specifications

1-1-1 Specifications ....................................................................................................................................... 1-1-1

1-1-2 Parts names and their functions ........................................................................................................... 1-1-2

1-1-3 Machine cross section .......................................................................................................................... 1-1-3

1-1-4 Drive system ........................................................................................................................................ 1-1-4

1-2 Installation

1-2-1 Unpacking and installation ................................................................................................................... 1-2-1

1-3 Troubleshooting

1-3-1 Original misfeed detection .................................................................................................................... 1-3-1

(1) Original misfeed indication ............................................................................................................. 1-3-1

(2) Paper misfeed detection conditions ................................................................................................ 1-3-2

(3) Original misfeeds ............................................................................................................................ 1-3-3

1-3-2 Image formation problems ................................................................................................................... 1-3-4

1-3-3 Electrical problems ............................................................................................................................... 1-3-6

1-3-4 Mechanical problems ........................................................................................................................... 1-3-7

1-4 Assembly and Disassembly

1-4-1 Precautions for assembly and disassembly ......................................................................................... 1-4-1

(1) Precautions ..................................................................................................................................... 1-4-1

1-4-2 Assembly and disassembly .................................................................................................................. 1-4-2

(1) Detaching and refitting the original table, front cover, rear cover and DP original cover ................ 1-4-2

(2) Detaching and refitting the DP forwarding pulley and DP feed pulley ............................................ 1-4-3

(3) Detaching and refitting the DP conveying roller and DP eject roller ............................................... 1-4-5

1-4-3 Adjustment the maintenance mode ....................................................................................................... 1-4-7

(1) Adjusting the DP magnification ........................................................................................................ 1-4-7

(2) Adjusting the DP leading edge registration ..................................................................................... 1-4-8

(3) Adjusting the DP trailing edge registration ...................................................................................... 1-4-9

(4) Adjusting the DP center line .......................................................................................................... 1-4-10

(5) Adjusting the margins for scanning the original from the DP ......................................................... 1-4-11

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2-1 Mechanical construction

2-1-1 Mechanical construction ....................................................................................................................... 2-1-1

(1) Original feed section ....................................................................................................................... 2-1-1

(2) Original feed timing ......................................................................................................................... 2-1-3

2-2 Electrical Parts Layout

2-2-1 Electrical parts layout ........................................................................................................................... 2-2-1

2-3 Operation of the PCBs

2-3-1 DP driver PCB ...................................................................................................................................... 2-3-1

2-4 Appendixes

Timing chart No. 1 .......................................................................................................................................... 2-4-1

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

Timing chart No. 3 .......................................................................................................................................... 2-4-3

Connection diagram ....................................................................................................................................... 2-4-4

1-1-1

1-1-1 Specifications

Original feed system ...................... Automatic feed

Originals ......................................... Sheets

Original weights.............................. 50 – 120 g/m

Original sizes.................................. Folio – A5R/81/2" × 14" – 51/2" × 81/2"

No. of originals ............................... Up to 50 sheets (50 – 80 g/m

For art paper, set one sheet at a time.

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

Dimensions .................................... 455 (W) × 331 (D) × 93 (H) mm

15

/16" (W) × 131/16" (D) × 311/16" (H)

17

Weight ............................................Approx. 2.3 kg/5.06 lbs

2

2

)

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1-1-1

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1-1-2 Parts names and their functions

Figure 1-1-1

1 Original table
2 Original insert guides
3 DP opening/closing lever
4 Original eject cover
5 DP original cover
6 Ejection extension

1-1-2

1-1-3 Machine cross section

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Original path

Figure 1-1-2 Machine cross section

1-1-3

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1-1-4 Drive system

8

9

4

3

2

1

5

6

7

@

0

!

As viewed from machine front

Figure 1-1-3

1 Forwarding gear 18
2 Feed drive gear 20
3 Feed gear 18
4 Feed gear 20
5 Feed drive gear 20
6 Original feed motor (gear)

7 Gear 65/16
8 Feed drive gear 20
9 Conveying gear 33
0 Conveying V pulley
! Conveying belt
@ Eject V pulley

1-1-4

1-2-1 Unpacking and installation

2

4

3

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!

0

0

0

0

5

9

6

8

1

7

Figure 1-2-1 Unpacking

1 Document processor
2 Installation guide
3 Caution label
4 Plastic bag
5 Front pad
6 Rear pad
7 Outer case
8 Plastic sheet
9 Bottom plate
0 Supports
! Upper plate

1-2-1

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Procedure

1. Remove all of the components to the document
processor from the box.

CAUTION

Be sure to hold both sides of the document
processor when carrying it, as shown in the
illustration.
Be particularly careful NOT to touch the guide
film or the thin white surface indicated by the A
in the illustration.

2. Turn the main switch to the copier OFF (O).

A

Document processor

Figure 1-2-2

3. Open the original cover and lift it upward to
remove it from the copier.

Power switch

Figure 1-2-3

Oringinal holder

1-2-2

Figure 1-2-4

4. Attach the document processor to the copier.

CAUTION

Be sure that the connection cable does not get
caught between the document processor and the
copier when attaching the document processor to
the copier.

5. Gently close the document processor.

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Connection

cable

Figure 1-2-5

6. Attached the open end of the connection cable to
the connector on the copier.

Document
processor

Figure 1-2-6

Document

processor

Connection cable

Figure 1-2-7

1-2-3