Mita-Kyocera KM-1620 Service Manual
DP-410
SERVICE
MANUAL
Published in May ’03
843HL110
CAUTION
Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent
type recommended by the manufacturer. Dispose of used batteries according to the
manufacturer’s instructions.
CAUTION
Double-pole/neutral fusing.
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) Parts names ................................................................................................................................... 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) Unpacking ....................................................................................................................................... 1-2-1
1-3 Maintenance Mode
1-3-1 Maintenance mode ............................................................................................................................... 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
1-4 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) Original misfeeds ............................................................................................................................ 1-4-3
1-4-2 Self-diagnosis ....................................................................................................................................... 1-4-5
(1) Self-diagnostic function .................................................................................................................. 1-4-5
(2) Self-diagnostic codes ..................................................................................................................... 1-4-5
1-4-3 Image formation problems ................................................................................................................... 1-4-6
(1) There is a regular error between the centers of the original and copy image. ............................... 1-4-7
(2) There is a regular error between the leading edges of the original and copy image. ..................... 1-4-7
1-4-4 Electrical problems ............................................................................................................................... 1-4-8
(1) The machine does not operate when the power switch is turned on. ............................................. 1-4-8
(2) The original feed motor does not operate. ...................................................................................... 1-4-8
(3) The original conveying motor does not operate. ............................................................................ 1-4-8
(4) The switchback feedshift solenoid does not operate. ..................................................................... 1-4-8
(5) The switchback pressure solenoid does not operate. .................................................................... 1-4-8
(6) The original size is not detected correctly. ..................................................................................... 1-4-8
(7) A original jam in the DP is indicated when the power switch is turned on. ..................................... 1-4-9
(8) The message requesting cover to be closed is displayed when the DP original
cover is closed. ............................................................................................................................... 1-4-9
(9) Others. ............................................................................................................................................ 1-4-9
1-4-5 Mechanical problems ......................................................................................................................... 1-4-10
(1) No primary original feed. .............................................................................................................. 1-4-10
(2) Multiple sheets of original are fed at one time. ............................................................................. 1-4-10
(3) Originals jam. ................................................................................................................................ 1-4-10
(4) Abnormal noise is heard. .............................................................................................................. 1-4-10
3HL
1-5 Assembly and Disassembly
1-5-1 Precautions for assembly and disassembly ......................................................................................... 1-5-1
(1) Precautions ..................................................................................................................................... 1-5-1
(2) Running a maintenance item .......................................................................................................... 1-5-2
1-5-2 Paper feeder ........................................................................................................................................ 1-5-3
(1) Detaching and refitting the DP forwarding pulley and DP paper feed pulley .................................. 1-5-3
(2) Detaching and refitting the DP separation pad ............................................................................... 1-5-5
(3) Adjusting the DP magnification ....................................................................................................... 1-5-6
(4) Adjusting the DP center line ........................................................................................................... 1-5-7
1-1-1
3HL
(5) Adjusting the DP scanning timing ................................................................................................... 1-5-8
(5-1) Adjusting the DP leading edge registration ........................................................................... 1-5-8
(5-2) Adjusting the DP trailing edge registration ............................................................................ 1-5-9
(6) Adjusting the margins for scanning the original from the DP ........................................................ 1-5-10
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) PCBs .............................................................................................................................................. 2-2-1
(2) Switches and sensors ..................................................................................................................... 2-2-2
(3) Motors and solenoids ..................................................................................................................... 2-2-3
2-3 Operation of the PCBs
2-3-1 DP driver PCB ...................................................................................................................................... 2-3-1
2-4 Appendixes
Maintenance parts list..................................................................................................................................... 2-4-1
Periodic maintenance procedures .................................................................................................................. 2-4-2
Timing chart No. 1 .......................................................................................................................................... 2-4-3
Timing chart No. 2 .......................................................................................................................................... 2-4-4
Wiring diagram ............................................................................................................................................... 2-4-5
1-1-2
1-1-1 Specifications
Type ............................................... Machine mounted type duplex sheet-through document processor
Original feed system ...................... Automatic feed
Originals ......................................... Sheets
Original weights.............................. Single-sided original mode: 45 – 160 g/m
Double-sided original mode: 50 – 120 g/m
Original paper................................. Plain paper, recycled paper, thermal paper, art paper and colored paper
1
Original sizes.................................. A3 – A5R/11" × 17" – 5
No. of originals ............................... 50 sheets (50 – 80 g/m
/2" × 81/2"
2
)
30 sheets in the auto selection mode
Original processing speed.............. Original replacement: Max. 20 sheets/min (A4/11" × 8
Original scanning: 100 mm/s (100%)
Power source ................................. Electrically connected to the copier
Dimensions .................................... 552 (W) × 483 (D) × 120 (H) mm
213/4" (W) × 19" (D) × 43/4" (H)
Weight ............................................Approx. 6.0 kg/13.2 lbs
2
2
1
/2")
3HL
1-1-1
3HL
1-1-2 Parts names and their functions
(1) Parts names
Figure 1-1-1
1 Original table
2 Original insert guides
3 DP original cover
4 Switchback tray
5 Ejection extension
1-1-2
1-1-3 Machine cross section
3HL
Original path
Figure 1-1-2 Machine cross section
1 Original feed section
2 Original conveying section
3 Original switchback section
1-1-3
3HL
1-1-4 Drive system
• Original conveying motor
• Inside front of machine • Inside rear of machine
• Original feed motor
Figure 1-1-3 Drive system
1 Original conveying motor gear
2 Gear 16
3 Idle gear 49/13
4 Gear 24/30
5 Belt 174S2M
6 Pulley
7 Conveying pulley 40
8 Exit gear 16
9 Idle gear 15
0 Idle gear 15
! Exit gear 16
@ Gear 40
# Gear 30
$ Original feed motor gear
% Gear 42/29
^ Gear 20
& Gear 30
1-1-4
Figure 1-1-4 Drive system
1-2-1 Unpacking and installation
(1) Unpacking
3HL
Figure 1-2-1 Unpacking
1 Document processor
2 Fixing fitting
3 Pin
4 Bronze TP screw M3x06
5 Chrome TP screw M4x10
6 Outer case
7 Spacer
8 Supports
9 Front pad
0 Rear bottom pad
! Rear upper pad
@ Air cap bag (70 × 280)
# Plastic sheet (1300 × 1300)
$ Bar code labels
% Plastic bag (70 × 110)
^ Plastic bag (240 × 350)
& Caution lavel
* Installation guide
1-2-1
1-3-1 Maintenance mode
The copier is equipped with a maintenance function which can be used to maintain and service the machine.
(1) Executing a maintenance item
Start
3HL
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
+/- keys
or numeric keys
and press the start key.
End
zoom
Maintenance mode is exited.
1-3-1
3HL
(2) Maintenance mode item list
Section
DP U019 Displaying the ROM version —
Item
No. setting*
U068 Adjusting the scanning position for originals from the DP 0
U070 Adjusting the DP magnification 0
U071 Adjusting the DP scanning timing
• DP leading edge registration 0
• DP trailing edge registration 0
U072 Adjusting the DP center line 0
U074 Adjusting the DP input light luminosity 1
U087 Turning the DP scanning position adjust mode on/off 35
U203 Operating DP separately —
U243 Checking the operation of the DP motors and solenoids —
U244 Checking the DP switches —
U404 Adjusting margins for scanning an original from the DP —
Maintenance item contents
Initial
* Initial setting for executing maintenance item U020
1-3-2
(3) Contents of maintenance mode items
3HL
Maintenance
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. A selection item appears.
2. Select the item to be displayed using the image mode selection key and copy exposure adjustment keys.
Image mode LEDs
Description
Copy exposure
indicator
Exp. 1 number of the main ROM
Exp. 2 number of the main ROM sub
Exp. 1 number of the engine ROM
Exp. 2 number of the engine ROM sub
Exp. 1 number of the first paper feeder ROM
Exp. 2 number of the second paper feeder ROM
Exp. 3 number of the third paper feeder ROM
Copy quantity display
Exp. 1 number of the DP ROM
: Off, : On, : Flashing
Completion
Press the stop/clear key. The indication for selecting a maintenance item No. appears.
U068 Adjusting the scanning position for originals from the DP
Description
Adjusts the position for scanning originals from the DP.
Purpose
Used when there is a regular error between the leading edges of the original and the copy image when the DP
is used.
Method
Press the start key.
Setting
1. Change the setting using the zoom +/– keys.
Description Setting range Initial setting Change in value per step
Scanning position –17 to +17 0 0.254 mm
Increasing the setting moves the image backward, and decreasing it moves the image forward.
2. Press the start key. The value is set.
Completion
Press the stop/clear key. The indication for selecting a maintenance item No. appears.
1-3-3
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