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3HW

1-5-6

5. Remove the springs, stop ring and bushing

and then the shaft holder from the upper
paper feed unit.

6. Remove the drawer forwarding pulley from

the upper paper feed unit.

7. Remove the drawer paper feed pulley from

the upper paper feed unit.

8. Replace the drawer forwarding pulley and

drawer paper feed pulley and refit all the
removed parts.

Figure 1-5-6

Figure 1-5-7

Upper paper feed unit

Bushing

Stop ring

Shaft holder

Spring

Spring

Drawer forwarding pulley

Drawer paper feed pulley

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Summary of Contents for PF-410

Page 1: ...SERVICE MANUAL Published in May 03 3HW70760 PF 410 ...

Page 2: ...TURER DISPOSE OF USED BATTERIES ACCORDING TO THE MANUFACTURER S INSTRUCTIONS ATTENTION IL Y A DANGER D EXPLOSION S IL Y A REMPLACEMENT INCORRECT DE LA BATTERIE REMPLACER UNIQUEMENT AVEC UNE BATTERIE DU MÊME TYPE OU D UN TYPE REC OMMANDÉ PAR LE CONSTRUCTEUR METTRE AU RÉBUT LES BATTERIES USAGÉES CONFORMÉMENT AUX INSTRUCTIONS DU FABRICANT ...

Page 3: ...rsonnel 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 ...

Page 4: ...ompliance 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 includi...

Page 5: ...d 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 ...

Page 6: ...e clean Dirt on them can cause abnormally high temperatures Do not remove the ozone filter if any from the copier except for routine replacement 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 att...

Page 7: ...at 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 app...

Page 8: ...awer drive motor does not operate 1 4 9 3 The drawer paper feed clutch does not operate 1 4 9 4 The message requesting paper to be loaded is shown when paper is present in the drawer 1 4 9 5 The size of paper in the drawer is not displayed correctly 1 4 9 6 A paper jam in the paper feeder is indicated when the power switch is turned on 1 4 9 7 The message requesting cover to be closed is displayed...

Page 9: ...ut 2 2 1 Electrical parts layout 2 2 1 1 PCBs 2 2 1 2 Switches and sensors 2 2 2 3 Others 2 2 3 2 3 Operation of the PCBs 2 3 1 Drawer main PCB 2 3 1 2 4 Appendixes Timing chart No 1 2 4 1 Timing chart No 2 2 4 2 Maintenance parts list 2 4 3 Periodic maintenance procedures 2 4 4 Wiring diagram 2 4 5 ...

Page 10: ...r sizes A3 A5R 11 17 51 2 81 2 Copy paper Plain paper recycled paper and colored paper 64 105 g m2 Paper capacity 300 sheets 80 g m2 Power source Electrically connected to the copier Dimensions 570 W 538 D 135 H mm 227 16 W 213 16 D 55 16 H Weight Approx 7 0 kg 15 4 lbs ...

Page 11: ...3HW 1 1 2 1 Drawer left cover 2 Interface connector 3 Paper gauge 4 Paper size indication 5 Positioning pins Figure 1 1 1 1 1 2 Parts names and their functions 1 Parts names ...

Page 12: ...3HW 1 1 3 1 1 3 Machine cross section Figure 1 1 2 Machine cross section Paper path ...

Page 13: ...3HW 1 1 4 Figure 1 1 3 Drive system 1 Drawer drive motor gear 2 Gear 26 90 3 Gear 25 4 Gear 25 5 Paper feed gear 20 6 Drawer paper feed clutch gear 1 1 4 Drive system ...

Page 14: ... Unpacking Figure 1 2 1 Unpacking 1 Paper feeder 2 Outer case 3 Left bottom pad 4 Right bottom pad 5 Left upper pad 6 Right upper pad 7 Stay 8 Plastic sheet 1300 1300 9 Bar code labels 0 Plastic bag 240 350 Installation guide Cassette size sheet ...

Page 15: ...c keys Enter 001 using the zoom keys or numeric keys and press the start key Enter the maintenance item number using the zoom keys or numeric keys The selected maintenance item is run Press the stop clear key Press the start key Start End Maintenance mode is entered The maintenance item is selected Maintenance mode is exited Repeat the same maintenance item Run another maintenance item No No Yes Y...

Page 16: ... timing Adjusting the leading edge registration 0 Adjusting the center line 0 U051 Adjusting the amount of slack in the paper 0 U053 Performing fine adjustment of the motor speed 0 U901 Checking clearing copy counts by paper feed locations Initial setting for executing maintenance item U020 Section Item Maintenance item contents Initial No setting 2 Maintenance mode item list ...

Page 17: ...p 2 number of the second paper feeder ROM Exp 3 number of the third paper feeder ROM 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 U030 Checking motor operation Description Drives each motor Purpose To check the operation of each motor Method 1 Press the start key A selection item appears 2 Select the motor...

Page 18: ...U Duplex paper conveying switch DUPPCSW Completion Press the stop clear key The indication for selecting a maintenance item No appears U032 Checking clutch operation Description Turns each clutch on Purpose To check the operation of each clutch Method 1 Press the start key A selection item appears 2 Select the clutch to be operated using the copy exposure adjustment keys 3 Press the start key The ...

Page 19: ...0 feed from optional paper feeder Exp 3 Motor speed adjustment 5 0 to 5 0 0 in duplex mode Drive motor speed adjustment unit Increasing the setting makes the image longer in the auxiliary scanning direction and decreasing it makes the image shorter in the auxiliary scanning direction Polygon motor speed adjustment unit Increasing the setting makes the image longer in the main scanning direction an...

Page 20: ...irst paper feeder copy count Exp 2 Last 3 digits of the first paper feeder copy count Exp 3 Clearing the count CLE 4 Exp 1 First 3 digits of the second paper feeder copy count Exp 2 Last 3 digits of the second paper feeder copy count Exp 3 Clearing the count CLE 5 Exp 1 First 3 digits of the third paper feeder copy count Exp 2 Last 3 digits of the third paper feeder copy count Exp 3 Clearing the c...

Page 21: ... the copier immediately stops copying and displays the jam location on the copier operation panel Paper misfeed detection can be reset by opening and closing the drawer left cover to turn safety switch off and on 2 Paper misfeed detection conditions Figure 1 4 1 DPFCL1 DFSW1 DFSW2 DPFCL2 DPFCL3 ...

Page 22: ...ccessively held off for 1 s and turned back on once but the switch again fails to turn on within 2490 ms The drawer feed switch 2 DFSW2 does not turn on within 2490 ms of the drawer paper feed clutch 3 DPFCL3 turning on the clutch is then successively held off for 1 s and turned back on once but the switch again fails to turn on within 2490 ms The registration switch RSW does not turn off within 4...

Page 23: ...ion pulley or forwarding pulley in the third paper feeder is de formed Broken drawer feed switch 2 actuator Defective drawer feed switch 2 Change the paper Check visually and replace any deformed pulley Check visually and replace registration switch if its actuator is broken Run maintenance item U031 and turn registration switch on and off manually Replace registration switch if indication of the ...

Page 24: ...he paper conveying path Broken drawer feed switch 2 actuator Defective drawer feed switch 2 Run maintenance item U032 and select the drawer paper feed clutch 3 to be turned on and off Check the status and remedy if necessary Check see page 1 4 9 Repair or replace if necessary Check visually and replace registration switch if its actuator is broken Run maintenance item U031 and turn registration sw...

Page 25: ...am code 24 Check if the drawer paper feed clutch 3 malfunctions Electrical problem with the drawer paper feed clutch 3 Check if the feed roller and feed pulley contact each other Run maintenance item U032 and select the drawer paper feed clutch 3 to be turned on and off Check the status and remedy if necessary Check see page 1 4 9 Check visually and remedy if necessary ...

Page 26: ...ve main PCB or drawer main PCB Check the installation state of the paper feeder and adjust it if it is not properly in stalled Replace the main PCB or drawer main PCB and check for correct operation Check the installation state of the paper feeder and adjust it if it is not properly in stalled Replace the main PCB or drawer main PCB and check for correct operation Check the installation state of t...

Page 27: ...4 3 Image formation problems 1 The leading edge of the image is consist ently misaligned with the original See page 1 4 8 2 The leading edge of the image is sporadi cally misaligned with the original See page 1 4 8 ...

Page 28: ...st the leading edge registration see pages 1 5 7 2 The leading edge of the image is sporadi cally misaligned with the original Causes 1 Drawer paper feed clutch installed or operating incorrectly Causes Check procedures corrective measures 1 Drawer paper feed clutch installed or operating incorrectly Check the installation position and operation of the drawer paper feed clutch If any of them opera...

Page 29: ...he cable Check visually and replace the drawer drive motor if necessary Run maintenance item U030 and check if the drawer drive motor operates when YC9 2 3 4 5 on the drawer main PCB goes low If not replace the drawer drive motor Run maintenance item U030 and check if YC9 2 3 4 5 on the drawer main PCB goes low If not replace the drawer main PCB Check for continuity across the coil If none replace...

Page 30: ...afety switch connector terminals Defective drawer left cover safety switch Wiring is broken shorted or makes poor contact Noise Reinsert the connector Also check for continuity within the con nector cable If none remedy or replace the cable Check for continuity across switch If there is no continuity when the switch is on replace it Check for continuity If none repair Locate the source of noise an...

Page 31: ...awer Check if the drawer separation pulley is worn Check if the paper is curled Check if the paper is excessively curled Deformed guides along the paper conveying path Check if the contact between the feed roller and feed pulley is correct Check if the pulleys roller and gears operate smoothly Check if the following electromagnetic clutche are installed correctly drawer paper feed clutche Clean wi...

Page 32: ...CBs do not touch connectors with bare hands or damage the board Do not touch any PCB containing ICs with bare hands or any object prone to static charge Use the following testers when measuring voltages Hioki 3200 Sanwa MD 180C Sanwa YX 360TR Beckman TECH300 Beckman DM45 Beckman 330 Beckman 3030 Beckman DM850 Fluke 8060A Arlec DMM1050 Arlec YF1030C Capable of measuring RMS values ...

Page 33: ...e start key Enter the maintenance item number using the zoom keys or numeric keys The selected maintenance item is run Press the stop clear key Press the start key Start End Maintenance mode is entered The maintenance item is selected Maintenance mode is exited Repeat the same maintenance item Run another maintenance item No No Yes Yes ...

Page 34: ...When removing the gear take care not to lose the spring pin 3 Slide the bearings in the front and rear of the feed roller toward the inside push the feed roller once into the rear side of the machine and then remove it from the paper feeder 4 Remove the two bushing from front and rear side of the feed roller 5 Replace the feed roller and refit all the removed parts Figure 1 5 1 Gear Spring pin Fee...

Page 35: ...move the screw and then the lower paper feed unit Figure 1 5 2 3 Remove the drawer separation pulley unit from the lower paper feed unit 4 Remove the drawer separation pulley from the drawer separation pulley unit 5 Replace the drawer separation pulley and refit all the removed parts Figure 1 5 3 Lower paper feed unit Drawer separation pulley Lower paper feed unit Drawer separation pulley unit ...

Page 36: ... and drawer paper feed pulley Procedure 1 Remove the lower paper feed unit see page 1 5 4 2 Remove the drawer rear cover 3 Remove the stop ring and drawer paper feed clutch from the machine rear side Remove the stop ring and bushing 4 Remove the screw and then the upper paper feed unit Figure 1 5 5 Drawer paper feed clutch Stop ring Bushing Stop ring Upper paper feed unit ...

Page 37: ...ley from the upper paper feed unit 7 Remove the drawer paper feed pulley from the upper paper feed unit 8 Replace the drawer forwarding pulley and drawer paper feed pulley and refit all the removed parts Figure 1 5 6 Figure 1 5 7 Upper paper feed unit Bushing Stop ring Shaft holder Spring Spring Drawer forwarding pulley Drawer paper feed pulley ...

Page 38: ...leading edge registration correct Press the start key The new setting is stored Press the stop clear key to exit maintenance mode End Select the items to be adjusted using the copy exposure adjustment keys For output example 1 decrease the value using the zoom key For output example 2 increase the value using the zoom key Setting range 5 0 10 0 Initial setting 0 0 Changing the value by 1 moves the...

Page 39: ...ct Press the start key The new setting is stored Press the stop clear key to exit maintenance mode End Press the image mode selection key to light the photo and text indicators For output example 1 decrease the value using the zoom key For output example 2 increase the value using the zoom key Setting range 8 0 10 0 Initial setting 0 0 Changing the value by 1 moves the center line by 1 mm Select t...

Page 40: ...ng 0 Changing the value by 1 changes the amount of slack by 0 32 mm The greater the value the larger the amount of slack the smaller the value the smaller the amount of slack The new setting is stored Select the item to be adjusted using copy exposure adjustment keys Is the leading edge of the image missing or varying randomly copy example 1 Is the copy paper Z folded copy example 2 Increase the v...

Page 41: ...veys paper from the drawer to the copier Drawer can hold up to 300 sheets of paper Paper is fed from the paper feeder by the rotation of the drawer forwarding pulley and drawer paper feed pulley The drawer separation pulley prevents multiple sheets from being fed at one time via the torque limiter Figure 2 1 2 Block diagram DMPCB DFSW DPSW DFSW DPSW DPLSW DPLSW DPWSW DPWSW YC4 4 YC8 2 YC9 2 3 4 5 ...

Page 42: ...tion motor RM turns on to start secondary paper feed d The drawer paper feed clutch 1 DPFCL1 turns on to start primary paper feed of the second sheet e 200 ms after the registration switch RSW turns on the drawer paper feed clutch 1 DPFCL1 and drawer drive motor 1 DDM1 turns off f The drawer drive motor 1 DDM1 and the registration motor RM turns on to start secondary paper feed DPFCL1 200 ms 200 m...

Page 43: ...tion motor RM turns on to start secondary paper feed e The drawer paper feed clutch 2 DPFCL2 turns on to start primary paper feed of the second sheet f 1420 ms after the drawer paper feed clutch 2 DPFCL2 turns on the drawer feed switch 1 DFSW1 turns on e 200 ms after the registration switch RSW turns on the drawer paper feed clutch 2 DPFCL2 drawer drive motor 2 DDM2 and drawer drive motor 1 DDM1 t...

Page 44: ... Electrical parts layout 1 PCBs Figure 2 2 1 PCBs 1 Drawer main PCB DMPCB Controls electrical components of the drawer 2 Drawer heater PCB DHPCB Drawer heater power relay 1 2 Machine front Machine inside Machine rear ...

Page 45: ...ft cover is opened 2 Drawer feed switch DFSW Detects a paper misfeed 3 Drawer paper switch DPSW Detects the presence of paper in the drawer 4 Drawer paper size width switch DPWSW Detects the width of paper in the drawer 5 Drawer paper size length switch DPLSW Detects the length of paper in the drawer 1 2 3 4 5 Machine front Machine inside Machine rear ...

Page 46: ...e 2 2 3 Others 1 Drawer drive motor DDM Drives the machine 2 Drawer paper feed clutch DPFCL Primary paper feed from the drawer 3 Drawer heater DH Dehumidifies the drawer section 1 2 3 Machine front Machine inside Machine rear ...

Page 47: ... input and output of each motor clutch and switch of the DP through the CPU U1 equipped with a function of bidirectional serial parallel conversion of 8 bit data Figure 2 3 1 Drawer main PCB block diagram 2 3 1 Drawer main PCB DFSW DPSW DPWSW DLCSSW DPLSW DMPCB DDM DPFCL DH DHPCB Copier Upper paper feeder Lower paper feeder Motor Driver U2 CPU U1 ...

Page 48: ...from copier A2 S GND Ground A3 5 V I 5 V DC power supply from copier A4 S GND Ground A5 5 V I 5 V DC power supply from copier A6 S GND Ground A7 SDI I Serial communication reception A8 SDO O Serial communication transmission A9 SCLK I Clock signal from copier A10 SEL0 I SEL0 signal from copier A11 SEL1 I SEL1 signal from copier A12 SEL2 I SEL2 signal from copier A13 RDY O READY signal to copier B1...

Page 49: ... B9 5 V O 5 V DC power supply for lower paper feeder B10 S GND Ground B11 5 V O 5 V DC power supply for lower paper feeder B12 S GND Ground B13 5 V O 5 V DC power supply for lower paper feeder 1 S GND Ground 2 DLCSSW I DLCSSW on off 3 S GND Ground 4 SIZE A I DPWSW SIZE A on off 5 SIZE B I DPLSW SIZE B on off 6 SIZE C I DPLSW SIZE C on off 7 S GND Ground 8 SIZE D I DPLSW SIZE D on off 1 S GND Groun...

Page 50: ...riginal size A4 11 8 1 2 two sheets DPFCL1 Copier Primary feed Scondary feed Primary feed Scondary feed 200 ms 200 ms RSW RM Separation charging Transfer charging YC8 9 YC9 2 3 4 5 YC8 2 YC4 4 DDM1 ESW 290 ms 1740 ms 1740 ms 290 ms 290 ms 10 ms 670 ms 2220 ms 100 ms 10 ms YC9 7 YC9 11 YC15 2 ...

Page 51: ... 2 two sheets DPFCL2 Primary feed Scondary feed Scondary feed Primary feed 200 ms 200 ms DDM1 RSW DDM2 1420 ms 1370 ms 1370 ms 1420 ms 290 ms 290 ms 290 ms 10 ms 670 ms 2220 ms ESW RM DFSW1 YC8 9 YC9 7 YC9 11 YC15 2 YC4 4 10 ms 100 ms YC9 2 3 4 5 YC8 2 YC9 2 3 4 5 YC8 2 Copier Separation charging Transfer charging ...

Page 52: ...in service manual Name used in parts list Drawer paper feed pulley PULLEY PAPER FEED 2AR07220 2 16 Drawer separation pulley PULLEY SEPARATION 2AR07230 2 17 Drawer forwarding pulley PULLEY LEADING FEED 2AR07240 2 18 Feed roller ROLLER FEED 3HW06020 2 3 Feed pulley PULLEY FEED 2BL16080 1 24 ...

Page 53: ...le Points and cautions Page Paper feed Drawer paper feed pulley Clean or replace Clean with the rubber roller 1 5 5 section cleanliness Drawer separation pulley Clean or replace Clean with the rubber roller 1 5 4 cleanliness Drawer forwarding pulley Clean or replace Clean with the rubber roller 1 5 5 cleanliness Feed roller Clean or replace Clean with the rubber roller 1 5 3 cleanliness Feed pulle...

Page 54: ...B 5V SGND 5V SGND 5V SGND YC3 CZW SDI SDO SCLK SEL0 SEL1 SEL2 RDY 5V SGND 5V SGND 5V SGND SDO SDI SCLK SEL0 SEL1 SEL2 RDY 5V SGND 5V SGND 5V SGND LIVE NU 24V PGND SDO SDI SCLK SEL0 SEL1 SEL2 RDY SDI SDO SCLK SEL0 SEL1 SEL2 RDY 7 6 5 4 3 2 1 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 A B A 1 2 24V PGND 3 2 1 5V DFSW SGND YC6 CZ 1 2 3 4 5 24V A B _A _B YC9 ...

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