blunt essays with sharp points

Do it yourself repair of a Panasonic KX-FL511 fax machine

by Scrvpvlvs
Apr 6, 2011 1:41 PM–I solved a CALL SERVICE 3 condition by fabricating a one dollar wire for the fuser unit.

The machine reported a CALL SERVICE 3 condition and recorded a cause distinction code of 01DF, which means the heat roller temperature sensor was still at 23 °C (room temperature) 22 seconds after the heater circuit was energized. The fuser stayed cool to the touch, so I agreed with the sensor.

This could have been a fault anywhere in the heater control system. I pulled the fuser assembly because the moving parts and heater have a high potential for failure.

The multimeter showed the heater circuit had no continuity (bad), but the bulb had continuity (good). So I started removing wiring, and terminal plate wire B came out in two pieces.

The wire runs across one end of the heat roller. In my unit, it was installed wrong and was in contact with the heat roller. Over time, the heat roller sawed through the wire.

I fabricated a new wire because I did not find one in stock. I used bare solid copper wire of slightly heavier gauge than the original.

After reassembling, I cleared the CALL SERVICE 3 using service function 529.

This was my first use of the KX-FL511 service manual. It is a very good, detailed and complete manual. It has some mistakes in the cross references, some poor grammar, and some missing text cut off by the margin, all of which might have been caused by Japanese–English conversion. But it was still so good that even someone like myself who does not normally service electronics can be successful using it.


Service Manual: High Speed Laser Fax and Copier: KX-FL511 (for U.S.A.). KMF0304645C1. Panasonic, eBook. 6 Apr 2011. <>

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by Anonymous Anonymous
December 13, 2011 11:48 PM–Files for download are corrupt and do not open using zip file extractor. There is a another file "0" called pdfcreator but this installer could be malicious software since file "1" & "2" do not open with a regular zip file utility. Beware. Maybe the origial author can upload this service manual again since the zip files are unreadable.  

by Anonymous Anonymous
December 14, 2011 1:47 AM–Service manual posted on the ESP link is broken , files cannot be opened.  

by Anonymous Anonymous
December 14, 2011 1:49 AM–Service manual posted on eservice site does not work , files cannot be opened. please fix  

by Blogger Scrvpvlvs
December 14, 2011 11:17 AM–The service manual is in three parts:, Panasonic_KX-FL511_ServiceManual.z01, and Panasonic_KX-FL511_ServiceManual.z02. You must download all three parts. I was able to download them from the site just now. After I downloaded them, I used 7-Zip to open and extract the PDF. Use 7-Zip or WinZip, because they have the capability to restore a multipart ZIP file.  

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