Kyocera ECOSYS P2035d Service Manual
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Kyocera ECOSYS P2035d Service Manual

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ECOSYS P2035d
ECOSYS P2135d
SERVICE
MANUAL
Published in Nobember 2013
842PH111
2PHSM061
Rev.1

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Summary of Contents for Kyocera ECOSYS P2035d

  • Page 1: Service Manual

    ECOSYS P2035d ECOSYS P2135d SERVICE MANUAL Published in Nobember 2013 842PH111 2PHSM061 Rev.1...
  • Page 2 Notation of products in the manual For the purpose of this service manual, products are identified by print speed at A4 and black and white modes. ECOSYS P2035d : Low model ECOSYS P2135d : High model...

  • Page 3: Revision History

    Revision history Revision Date Pages Revised contents 5 Nobember 2013 1-1-1 Change: First print time for high model Change: Warm-up time...
  • Page 4 This page is intentionally left blank.

  • Page 5: Safety Precautions

    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.
  • Page 6 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.

  • Page 7: Installation Precautions

    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...................... •...

  • Page 8: Precautions For Maintenance

    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.
  • Page 9 • 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......................•...
  • Page 10 This page is intentionally left blank.

  • Page 11: Table Of Contents

    1-5-1 Precautions for assembly and disassembly....................1-5-1 (1) Precautions ............................1-5-1 (2) Drum..............................1-5-1 (3) Toner container ..........................1-5-1 (4) How to tell a genuine Kyocera toner container..................1-5-2 1-5-2 Outer covers ............................1-5-3 (1) Detaching and refitting the top cover....................1-5-3 (2) Detaching and refitting the right and left covers ................1-5-4 1-5-3 Paper feed section ..........................1-5-6...
  • Page 12 2PG/2PH 1-5-6 Transfer/separation section ........................1-5-14 (1) Detaching and refitting the transfer roller ..................1-5-14 1-5-7 Fuser section ............................1-5-16 (1) Detaching and refitting the fuser unit....................1-5-16 (2) Switching the fuser pressure ......................1-5-18 1-5-8 PWBs ..............................1-5-19 (1) Detaching and refitting the control PWB ..................1-5-19 (2) Detaching and refitting the power source PWB................1-5-22 (3) Detaching and refitting the operation panel PWB ................1-5-24 (4) Detaching and refitting the high voltage PWB.................1-5-25...

  • Page 13: Specifications

    2PG/2PH-1 1-1 Specifications 1-1-1 Specifications Specifications Item Low model High model Type Desktop Printing method Electrophotography, laser scan Paper weight Cassette 60 to 120 g/m (Duplex: 60 to 105 g/m MP tray 60 to 220 g/m Paper type Cassette Plain, Preprinted, Bond, Recycled, Rough, Letterhead, Color (Colour), Pre- punched, High quality, Custom 1 to 8 MP tray Plain, Transparency, Preprinted, Labels, Bond, Recycled, Rough, Vellum,...
  • Page 14 2PG/2PH Specifications Item Low model High model Transfer system Transfer roller (negative-charged) Separation system Small diameter separation, discharger brush Cleaning system Drum: Counter blade Charge erasing system Exposure by eraser lamp (LED) Fusing system Heat roller system Resolution Fast 1200 mode, 600 dpi, 300 dpi Fine 1200 mode (Half speed only), Fast 1200 mode, 600 dpi, 300 dpi Operating envi-...

  • Page 15: Parts Names

    2PG/2PH 1-1-2 Parts names (1) Overall Figure 1-1-1 Top cover MP tray Paper stopper Sub tray Top tray 10. Optional interface slot cover Operation panel 11. USB interface connector Right side cover 12. Rear cover Cassette 13. Power cord connector Front cover 14.
  • Page 16 2PG/2PH (2) Operation panel Figure 1-1-2 1. Ready indicator 2. Attention indicator 3. Toner indicator 4. Data indicator 5. Paper indicator 6. Jam indicator 7. Cancel key 8. GO key 1-1-4...

  • Page 17: Machine Cross Section

    2PG/2PH 1-1-3 Machine cross section Light path Paper path Paper path (option) Figure 1-1-3 Cassette Laser scanner unit MP tray Transfer/separation section Paper feed/conveying section 10. Fuser section Toner container 11. Exit section Developing unit 12. Top tray Main charger unit 13.
  • Page 18 2PG/2PH This page is intentionally left blank. 1-1-6...

  • Page 19: Installation Environment

    2PG/2PH 1-2 Installation 1-2-1 Installation environment   1. Temperature: 10 to 32.5 C/50 to 90.5 2. Humidity: 15 to 80%RH 3. Power supply: 120 V AC, 8.0 A 220 - 240 V AC, 4.2 A   4. Power source frequency: 50 Hz 0.3%/60 Hz 0.3% 5.

  • Page 20: Unpacking

    2PG/2PH 1-2-2 Unpacking 220 - 240 V AC model 120 V AC model Figure 1-2-2 1. Printer 11. Power cord 2. Outer case 12. Pad 3. Bottom pad L 13. Plastic bag 4. Bottom pad R 14. Installation guide 5. Machine cover 15.

  • Page 21: Removing The Tapes

    2PG/2PH (1) Removing the tapes Procedure 1. Remove three tapes. Tape Tape Tape Figure 1-2-3 1-2-3...

  • Page 22: Installing The Expanded Memory (Option)

    2PG/2PH 1-2-3 Installing the expanded memory (option) Procedure 1. Turn off printer power switch. Caution: Do not insert or remove expanded memory while printer power is on. Doing so may cause damage to the printer and the expanded memory. 2. Remove the right side cover. 3.

  • Page 23: Installing The Memory Card (Option)

    2PG/2PH 1-2-4 Installing the memory card (option) Procedure 1. Turn off printer power switch. Caution: Do not insert or remove memory card while printer power is on. Doing so may cause damage to the printer and the memory card. 2. Open the rear cover. Rear cover Figure 1-2-6 3.

  • Page 24: Installing The Network Interface Card (Option)

    2PG/2PH 1-2-5 Installing the network interface card (option) Procedure 1. Turn off printer power switch. Caution: Do not insert or remove network interface card while printer power is on. Doing so may cause damage to the printer and the network interface card. 2.

  • Page 25: Maintenance Mode

    2PG/2PH 1-3 Maintenance Mode 1-3-1 Maintenance mode The product incorporates several service modes which are activated by using the keys on the operation panel or by com- manding from a PC. (1) Executing a service mode Printing a status page for service purpose........See page 1-3-2. Printing an event log (EVENT LOG) ..........

  • Page 26: Printing A Status Page

    2PG/2PH Service items Description Printing a status page Description for service purpose Prints a status page for service purpose. The status page includes various printing settings and service cumulative. Purpose To acquire the current printing environmental parameters and cumulative information. Procedure 1.
  • Page 27 2PG/2PH Service items Description Detail of service information Service information Total page 9690 [XXXXXXXX][XXXXXXXX][01/00] /t/U00/F00/N00 (6) (7) (8) /0020/0020/1061/0811/ (10) (11) (12) (13) /0000/0000/ /00/300/81/31/81/31/ (14)(15)(16)(17)(18)(19) (20) A:1234567890123456 (21) /02870284/03028003/83030286/86000086/02000000/02020202/02020202/ (22) /03030303/03030303/03030303/03030303/03000000/03030303/03030303/ SPD1:0203040508090A0B0C0D0F101112131415161718191A1B1C1D1E1F202122235E (23) (24) /00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/ /00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/ /00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/ /00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/ /00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/ /00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/ /00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/ /00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/00000000/...
  • Page 28 1 = 0: Overseas, 1: Domestic (Japan) [First byte/Second byte bit 2, 3 (Not used) (displayed in OEM model bit 4 = 0: Kyocera, 1: OEM only)] bit 5 = 0: For Europe, 1: For US bit 6 = 0: Non MICR mode, 1: MICR mode...
  • Page 29 2PG/2PH Service items Description Items Description (20) Fixed asset number (Maximum 16 characters) (21) Paper type attributes Paper type setting value from 1 to 28 (fuser, weight, duplex) (unused paper type are always 0x00.) (22) Paper type attributes Paper type setting value from 1 to 28 (density) (unused paper type are always 0x00.) (23) Memory SPD information (slot...
  • Page 30 2PG/2PH Service items Description Printing an event log Description (EVENT LOG) Prints a history list of occurrences of paper jam, self-diagnostics, toner replacements, etc. Purpose To allow machine malfunction analysis based on the frequency of paper misfeeds, self diag- nostic errors and replacements. Procedure 1.

  • Page 31: Event Log

    2PG/2PH Service items Description EVENT LOG [EB20MA001/2PH_1000.001.019] [40.00SFLB] [01] Firmware version: 2PH_30000.001.024 Released: 20/January/2010 Printed page(s) 12345 Paper Jam Log Service Call Log Count. Event Count. Service Code 9993 10.48.01.08.01.01 11234 01.6000 10000 01.6000 9992 10.48.01.08.01.01 9999 01.6000 9991 10.48.01.08.01.01 9998 01.6000 9990...
  • Page 32 [First byte/Second byte (dis- bit 2, 3 (Not used) played in OEM mode only)] bit 4 = 0: Kyocera, 1: OEM bit 5 = 0: For Europe, 1: For US bit 6 = 0: Non MICR mode, 1: MICR mode...
  • Page 33 2PG/2PH Service items Description Items Description Paper Jam (a) Cause of paper jam cont. 10: Paper does not arrive at the registration sensor. (MP tray) [42] 10: Paper does not arrive at the registration sensor. (Cassette 1) [31] 10: Paper does not arrive at the registration sensor. (Cassette 2) [31] 10: Paper does not arrive at the registration sensor.
  • Page 34 2PG/2PH Service items Description Items Description (c) Detail of paper source (Hexadecimal) Paper Jam Log cont. 00: MP tray 01: Cassette 1 (printer) 02: Cassette 2 (paper feeder 1) 03: Cassette 3 (paper feeder 2) 07: Duplex (d) Detail of paper size (Hexadecimal) 00: (Undefined) 09: B5R 20: Reply-paid postcard...
  • Page 35 2PG/2PH Service items Description Items Description (10) Maintenance Log Count. Item Remembers 1 to 8 of occur- The total page count at Code of maintenance NOTE: rence of replacement. If the the time of the replace- replacing item (1 byte, 2 It is not logged if occurrence of the previous ment of the toner con-...
  • Page 36 2PG/2PH Service items Description Items Description (12) Counter Log (g) Paper jam (h) Self diagnostic error (i) Maintenance item replacing Comprised of Indicates the log counter of Indicates the log counter Indicates the log counter three log coun- paper jams depending on of self diagnostics errors depending on the mainte- ters including...
  • Page 37 2PG/2PH Service items Description [REPLACE MAINTE- Description NANCE KIT] message [REPLACE MAINTENANCE KIT] message sheet is printed at the 1st power-up after the sheet page count exceeding 100,000 pages. Procedure Replace the maintenance kit. Low model Maintenance kit MK-182 (for 120 V specifications) Maintenance kit MK-180 (for 230 V specifications) Maintenance kit MK-184 (for 240 V specifications) High model...
  • Page 38 2PG/2PH This page is intentionally left blank. 1-3-14...

  • Page 39: Paper Misfeed Detection

    2PG/2PH 1-4 Troubleshooting 1-4-1 Paper misfeed detection (1) Paper misfeed indication If paper jams in the paper conveying system, or no paper sheets are fed at all, the printer automatically goes offline, and the jam indicator will flash rapidly. Status Monitor or COMMAND CENTER can indicate the location of the paper jam (the component where the paper jam has occurred).

  • Page 40: Paper Misfeed Detection Condition

    2PG/2PH (2) Paper misfeed detection condition Printer Peper feeder 1 (Option) (1) Registration sensor (2) Paper sensor (3) MP paper sensor (4) Paper exit sensor (5) PF paper sensor (6) PF paper feed sensor Peper feeder 2 (Option) Figure 1-4-2 1-4-2...

  • Page 41: Self-Diagnostic Function

    2PG/2PH 1-4-2 Self-diagnostic function (1) Self-diagnostic function The printer is equipped with self-diagnostic function which automatically halts the printer when an error is detected. The four indicators (Jam, Paper, Attention, Toner) are simultaneously lit, then indicate a specific error by the combination of the four indicators.

  • Page 42: Self Diagnostic Codes Indication

    2PG/2PH (2) Self diagnostic codes indication Sequence of display Indicates the occurrence of a self diagnostics error. 1.6 s 1.6 s 0.8 s 0.8 s Example of self-diagnostic code: 2610 (Refer to the following code conversion table) 0.8 s 0.8 s 0.8 s Indication example Lit (Green)

  • Page 43: Self Diagnostic Codes

    2PG/2PH (3) Self diagnostic codes Remarks Code Contents Causes Check procedures/corrective measures 0150 Control PWB EEPROM error Improper installation Check the installation of the EEPROM Detecting control PWB EEPROM control PWB EEPROM (U300) and remedy if necessary (See page (U300) communication error. (U300).
  • Page 44 2PG/2PH Remarks Code Contents Causes Check procedures/corrective measures 2610 PF paper feed motor error (Paper Defective harness Reinsert the connector. Also check for conti- feeder 1) between PF paper nuity within the connector harness. If none, The PF paper feed motor of paper feed motor and PF remedy or replace the harness (Refer to the feeder 1 ready input is not given for 2...
  • Page 45 2PG/2PH Remarks Code Contents Causes Check procedures/corrective measures 6000 Broken fuser heater lamp wire Poor contact in the Reinsert the connector (See page 1-5-16). The fuser temperature does not rise fuser thermistor con- after the fuser heater lamp has been nector terminals.
  • Page 46 2PG/2PH Remarks Code Contents Causes Check procedures/corrective measures 7990 Waste toner full Waste toner reservoir Turn the main power switch off/on to restart The waste toner sensor has detected (drum unit) is full. the printer. If the error is not resolved, that the waste toner reservoir (drum replace the drum unit (See page 1-5-12).

  • Page 47: Image Formation Problems

    2PG/2PH 1-4-3 Image formation problems (1)Completely blank (2)All-black printout. (3)Dropouts. (4)Black dots. (5)Black horizontal printout. streaks. See page 1-4-10 See page 1-4-10 See page 1-4-11 See page 1-4-11 See page 1-4-11 (6)Black vertical (7)Unsharpness. (8)Gray background. (9)Dirt on the top (10)Undulated print- streaks.

  • Page 48: All-Black Printout

    2PG/2PH (1) Completely blank printout. Print example Causes Check procedures/corrective measures Defective drum unit or developing Open the top cover and check that the drum unit and develop- unit. ing unit are correctly seated. Investigate that the terminals between the main charger unit and the drum unit are not in loose contact (See page 1-5-12 and 1-5-12).

  • Page 49: Dropouts

    2PG/2PH (3) Dropouts. Print example Causes Check procedures/corrective measures Defective developing roller (develop- If the defects occur at regular intervals of 62.8 mm/2 " (See ing unit). page 2-4-2), the problem may be the damaged developing roller (in the developing unit). Replace the developing unit (See page 1-5-11).

  • Page 50: Black Vertical Streaks

    2PG/2PH (6) Black vertical streaks. Print example Causes Check procedures/corrective measures Adhesion of oxide to main charger Remove the drum unit (See page 1-5-12). Slide the charger wire. cleaner (green) left and right 2 or 3 times to clean the charger wire, then return it to its original position (CLEANER HOME POSITION).

  • Page 51: Dirt On The Top Edge Or Back Of The Paper

    2PG/2PH (9) Dirt on the top edge or back of the paper. Print example Causes Check procedures/corrective measures Toner contamination in various parts. Dirty edges and back of the paper can be caused by toner accumulated on such parts as the paper chute guide, paper conveying paths, the bottom of the drum and developing unit, and the fuser unit inlet.

  • Page 52: Electric Problems

    2PG/2PH 1-4-4 Electric problems Problem Causes Check procedures/corrective measures No electricity at the power Measure the input voltage. The machine does outlet. not operate when the The power cord is not Check the contact between the power plug and the outlet. power switch is plugged in properly.
  • Page 53 2PG/2PH Problem Causes Check procedures/corrective measures Broken developing clutch Check for continuity across the coil. If none, replace the develop- Developing clutch coil. ing clutch. does not operate. Defective harness between Reinsert the connector. Also check for continuity within the con- developing clutch and con- nector harness.

  • Page 54: Mechanical Problems

    2PG/2PH 1-4-5 Mechanical problems Problem Causes/check procedures Corrective measures Check if the surfaces of the paper feed roller Clean with isopropyl alcohol. No primary paper feed. is dirty with paper powder. Check if the paper feed roller is deformed. Check visually and replace any deformed paper feed roller (assembly) (See page 1-5- Defective paper feed clutch installation.

  • Page 55: Assembly And Disassembly

    2PG/2PH 1-5 Assembly and Disassembly 1-5-1 Precautions for assembly and disassembly (1) Precautions Be sure to turn the power switch off and disconnect the power plug before starting disassembly. When handling PWBs, do not touch connectors with bare hands or damage the PWB. Do not touch any PWB containing ICs with bare hands or any object prone to static charge.

  • Page 56: How To Tell A Genuine Kyocera Toner Container

    A black-colored band when seen through the left side window A shiny or gold-colored band when seen through the right side window The above will reveal that the toner container is a genuine Kyocera branded toner container, otherwise, it is a counterfeit. See through the left window...

  • Page 57: Outer Covers

    2PG/2PH 1-5-2 Outer covers (1) Detaching and refitting the top cover Procedure 1. Open the top cover. 2. Remove two screws. Top cover Screw Screw Figure 1-5-3 3. Extract the boss from the hole. 4. Unhook the A hook. Top cover 5.

  • Page 58: Detaching And Refitting The Right And Left Covers

    2PG/2PH (2) Detaching and refitting the right and left covers Procedure 1. Remove the top cover (See page 1-5-3). 2. Remove the cassette (See page 1-5-6). 3. Open the front cover. 4. Unhook seven hooks and then remove the right cover. Hooks Right cover Figure 1-5-5...
  • Page 59 2PG/2PH 5. Unhook seven hooks and then remove the left cover. Left cover Hooks Figure 1-5-6 1-5-5...

  • Page 60: Paper Feed Section

    2PG/2PH 1-5-3 Paper feed section (1) Detaching and refitting the paper feed assembly (paper feed roller and pickup roller) Procedure 1. Remove the cassette. Cassette Figure 1-5-7 2. Slide the feed shaft. 3. While pressing the lever and then remove the paper feed roller assembly.
  • Page 61 2PG/2PH 4. Check or replace the paper feed assembly and refit all the removed parts. Paper feed roller Feed shaft assembly When refitting the paper feed roller assem- bly, be sure to align the paper feed roller pivot with the slotted hole on the feed shaft. Paper feed roller assembly Feed shaft...

  • Page 62: Detaching And Refitting The Retard Roller Assembly

    2PG/2PH (2) Detaching and refitting the retard roller assembly Procedure 1. Remove the cassette (See page 1-5-6). Retard guide 2. Push the bottom plate down until it locks. Hook 3. Unhook two hooks and then remove the retard guide. Hook Cassestte Bottom plate Cassette...
  • Page 63 2PG/2PH 5. Check or replace the retard roller assembly and refit all the removed parts. Retard roller Caution: Before refitting the retard roller assembly assembly, firmly install the spring onto the projection of the retard roller assembly. Projection Spring Figure 1-5-12 1-5-9...

  • Page 64: Detaching And Refitting The Mp Paper Feed Roller

    2PG/2PH (3) Detaching and refitting the MP paper feed roller Procedure 1. Open the front cover. 2. Pull the MP feed holder (lever) down (1). 3. Slide the MP feed holder (2). 4. Remove the MP paper feed roller (3). MP paper feed roller Front cover MP paper feed roller...

  • Page 65: Developing Section

    2PG/2PH 1-5-4 Developing section (1) Detaching and refitting the developing unit Procedure 1. Open the top cover. Top cover 2. Open the front cover. 3. Remove the developing unit (with toner con- tainer). 4. Check or replace the developing unit and refit all the removed parts.

  • Page 66: Drum Section

    2PG/2PH 1-5-5 Drum section (1) Detaching and refitting the drum unit Procedure 1. Remove the developing unit (See page 1-5- 11). 2. Remove the drum unit. 3. Check or replace the drum unit and refit all the removed parts. Drum unit Figure 1-5-16 1-5-12...

  • Page 67: Detaching And Refitting The Main Charger Unit

    2PG/2PH (2) Detaching and refitting the main charger unit Procedure 1. Remove the drum unit (See page 1-5-12). 2. Remove the tape. 3. While pushing on the main plate (1), slide the main charger unit (2). Tape Main charger unit Drum unit Main charger unit Main plate...

  • Page 68: Transfer/Separation Section

    2PG/2PH 1-5-6 Transfer/separation section (1) Detaching and refitting the transfer roller Procedure 1. Remove the developing unit (See page 1-5- 11). 2. Remove the drum unit (See page 1-5-12). 3. Slide the paper chute guide and unhook the hooks. 4. Remove the paper chute guide. Paper chute guide Paper chute guide Hook...
  • Page 69 2PG/2PH 5. Remove the transfer roller’s shaft from the Shaft both transfer bushes. 6. Remove the gear Z16 from the transfer roller. Transfer roller Shaft Transfer roller Transfer roller Transfer roller Gear Z16 Figure 1-5-20 7. Check or replace the transfer roller and refit all the removed parts.

  • Page 70: Fuser Section

    2PG/2PH 1-5-7 Fuser section (1) Detaching and refitting the fuser unit Procedure 1. Remove the outer covers (See page 1-5-3). 2. Remove two connectors. 3. Release the wires form wire clamps. Wires Wire clamps Connector (Fuser heater lamp) Connector (Fuser thermistor) Figure 1-5-22 4.
  • Page 71 2PG/2PH 5. Remove the rear cover. Rear cover Figure 1-5-24 6. Remove two screws and then remove the fuser unit. 7. Check or replace the fuser unit and refit all the removed parts. Fuser unit Screw Screw Figure 1-5-25 1-5-17...

  • Page 72: Switching The Fuser Pressure

    2PG/2PH (2) Switching the fuser pressure The fuser pressure may be decreased to suppress the print quality problems such as paper creases and curls. It must be cautioned that decreasing the fuser pressure could cause loose toner fusing. Procedure 1. Remove the cassette (See page 1-5-6). 2.

  • Page 73: Pwbs

    2PG/2PH 1-5-8 PWBs (1) Detaching and refitting the control PWB Procedure 1. Remove the right cover (See page 1-5-4). 2. Remove fourteen connectors form the con- trol PWB. 3. Release the wires from the wire clamps. Control PWB Wire clamps Connectors (Thirteen) Connector...
  • Page 74 2PG/2PH 4. Remove five screws. 5. Remove three connectors form the control PWB. Connectors (Three) 6. Unhook the hook and then remove the con- trol PWB assembly. Control PWB Hook Screw Screws Screws Control PWB assembly Figure 1-5-28 1-5-20...
  • Page 75 2PG/2PH 7. Remove five screws and then remove the control PWB. Screw 8. Check or replace the control PWB and refit all the removed parts. Screw To replace the control PWB, remove the Screw EEPROM (U300) from the old control PWB and mount it to the new control PWB.

  • Page 76: Detaching And Refitting The Power Source Pwb

    2PG/2PH (2) Detaching and refitting the power source PWB Procedure 1. Remove the top cover (See page 1-5-3). 2. Remove the left cover (See page 1-5-4). 3. Remove four connectors. Connector Connector Connector Connector (YC104) Figure 1-5-30 4. Remove four P tight screws, two screws and ground terminal.
  • Page 77 2PG/2PH 6. Remove four screws and then remove the Screws power source plate from the power source PWB. 7. Check or replace the power source PWB and refit all the removed parts. Caution: The power source film must be installed in the specified position. Screws Power source PWB Power source film...

  • Page 78: Detaching And Refitting The Operation Panel Pwb

    2PG/2PH (3) Detaching and refitting the operation panel PWB Procedure 1. Remove the top cover (See page 1-5-3). 2. Remove two screws and then remove the Screw panel cover. 3. Remove the operation panel PWB. 4. Remove the connector. Panel cover 5.

  • Page 79: Detaching And Refitting The High Voltage Pwb

    2PG/2PH (4) Detaching and refitting the high voltage PWB Procedure 1. Remove the developing unit (See page 1-5- 11). 2. Remove the drum unit (See page 1-5-12). 3. Remove the cassette (See page 1-5-6). Stop ring 4. Remove the outer covers (See page 1-5-3). 5.
  • Page 80 2PG/2PH 11. Remove four screws. 12. Unhook three hooks and then remove the lower base cover. Lower base cover Hook Hook Hook Screws Screws Lower base cover Figure 1-5-36 1-5-26...
  • Page 81 2PG/2PH 13. Remove the spring. 14. Remove the cassette pin. Cassette pin Spring Figure 1-5-37 15. Remove two connectors and then remove the high voltage PWB. 16. Remove the cassette pin holder from the high voltage PWB. Cassette pin holder High voltage High voltage PWB YC202...
  • Page 82 2PG/2PH 17. Check or replace the high voltage PWB and refit all the removed parts. When refitting the high voltage PWB, be High voltage PWB careful about following points. • Position the ground plate so that it is atop the high voltage PWB. Ground plate •...

  • Page 83: Others

    2PG/2PH 1-5-9 Others (1) Detaching and refitting the main motor Procedure 1. Remove the right cover (See page 1-5-4). 2. Remove the connector. Connector Figure 1-5-40 3. Remove the M3 screw and two M4 screws. 4. Remove the main motor. 5.

  • Page 84: Detaching And Refitting The Laser Scanner Unit

    2PG/2PH (2) Detaching and refitting the laser scanner unit Procedure 1. Remove the right cover (See page 1-5-4). 2. Remove the connector from the control PWB. 3. Release the wire clamp. 4. Draw in the connector inside. Connector Control PWB Clamp Connector Figure 1-5-42...
  • Page 85 2PG/2PH 5. Remove four screws and then remove the laser scanner unit. 6. Check or replace the laser scanner unit and refit all the removed parts. Screws Screws Laser scanner unit Figure 1-5-43 1-5-31...

  • Page 86: Detaching And Refitting The Eraser Lamp

    2PG/2PH (3) Detaching and refitting the eraser lamp Procedure 1. Remove the laser scanner unit (See page 1- 5-30). 2. Remove the connector. 3. Remove the eraser lamp. 4. Check or replace the eraser lamp and refit all the removed parts. Eraser lamp Connector Figure 1-5-44...

  • Page 87: Direction Of Installing The Left And Right Cooling Fan Motors

    2PG/2PH (4) Direction of installing the left and right cooling fan motors When detaching or refitting the left and/or right cooling fan motors, be careful of the airflow direction (intake or exhaust). Right cooling Left cooling fan motor fan motor Intake Exhaust Figure 1-5-45...
  • Page 88 2PG/2PH This page is intentionally left blank. 1-5-34...

  • Page 89: Firmware

    2PG/2PH 1-6 Firmware 1-6-1 Downloading firmware Firmware files are named after the following codes: Firmware file name example Compression Software ID S 2 P H _ 1 0 0 0 0 0 1 0 2 1 . c m p Product code Pause (period) 2PG: Low model...

  • Page 90: Downloading The Firmware From The Memory Card

    2PG/2PH (1) Downloading the firmware from the memory card To download data written in a memory card (CompactFlash) to the printer, proceed as explained in this section. CAUTION Downloading firmware takes several minutes. Do not turn power off during downloading. If downloading is interrupted by an accidental power failure, etc., the control PWB may have to be replaced.
  • Page 91 2PG/2PH 5. Turn printer power on. The printer starts and finishes downloading automatically. Sequence of display Indication example Off (Amber) Downloading start Lit (Green) Lit (Amber) 4.8 s Off (Amber) Supervisor Off (Green) mode Lit (Amber) 4.8 s (Repeat) Receiving data *: 0.8 s (Repeat)
  • Page 92 2PG/2PH 6. Confirm that downloading was finished nor- mally (See previous page). 7. Turn power off. 8. Remove the memory card. 9. Secure the optional interface slot cover by using two screws. Memory card slot 10. Close the rear cover. 11.

  • Page 93: Paper Feed/Conveying Section

    2PG/2PH 2-1 Mechanical Construction 2-1-1 Paper feed/conveying section Paper feed/conveying section consists of the paper feed unit that feeds paper from the cassette and the MP tray paper feed unit that feeds paper from the MP tray, and the paper conveying section that conveys the fed paper to the transfer/ separation section.

  • Page 94: Mp Tray Paper Feed Section

    2PG/2PH (2) MP tray paper feed section Figure 2-1-3 MP tray paper feed section MP paper feed roller MPF frame MPF separation pad MPF guide R/L MPF separator (10) MPF base MPF bottom plate (11) MPF middle tray MPF friction pad (12) MPF upper tray MP paper sensor (13) MPF turn guide...

  • Page 95: Paper Conveying Section

    2PG/2PH (3) Paper conveying section Figure 2-1-5 Paper conveying section Lower registration roller Upper registration roller Registration sensor Actuator (registration sensor) Feed pulley Control PWB MMOTRDYN YC305-3 MOTCLK YC305-4 Main motor REMOTEN YC305-5 REGDRN Registration YC308-2 clutch High voltage PWB Registration REGN sensor...

  • Page 96: Drum Section

    2PG/2PH 2-1-2 Drum section (1) Drum section The durable layer of organic photoconductor (OPC) is coated over the aluminum cylinder base. The OPC tend to reduce its own electrical conductance when exposed to light. After a cyclic process of charging, exposure, and development, the electrostatic image is constituted over the OPC layer.

  • Page 97: Main Charger Unit

    2PG/2PH (2) Main charger unit As the drum rotates in a “clean (neutral)” state, its photoconductive layer is given a uniform, positive (+) corona charge dis- persed by the main charger wire. Due to high-voltage scorotron charging, the charging wire can get contaminated by oxi- dization after a long run.

  • Page 98: Expose Section

    2PG/2PH 2-1-3 Expose section (1) Laser scanner unit The charged surface of the drum is then scanned by the laser beam from the laser scanner unit. The laser beam (780 nm wavelength) beam is dispersed as the polygon motor revolves to reflect the laser beam over the drum.
  • Page 99 2PG/2PH Figure 2-1-11 Laser scanner unit Polygon motor (mirror) Laser diode (APC PWB) Collimator lens Cylindrical lens F- lens F- lens PD mirror SOS lens Pin photo diode sensor (PD PWB) (10) LSU mirror 2-1-7...

  • Page 100: Developing Section

    2PG/2PH 2-1-4 Developing section The latent image constituted on the drum is developed into a visible image. The developing roller contains a 3-pole (S-NS) magnet roller and an aluminum cylinder rotating around the magnet roller. Toner attracts to the magnet sleeve since it is powdery ink made of black resin bound to iron particles.

  • Page 101: Transfer/Separation Section

    2PG/2PH 2-1-5 Transfer/separation section The transfer/separation section consists of the transfer roller, discharger brush and paper chute guide. A high voltage gen- erated by the high voltage PWB is applied to the transfer roller for transfer charging. Paper after transfer is separated from the drum.

  • Page 102: Cleaning Section

    2PG/2PH 2-1-6 Cleaning section After the transferring process, the drum needs to be physically cleaned of toner which is residual after the development process. The cleaning blade is constantly pressed against the drum and scrapes the residual toner off to the sweep roller. The waste toner is collected at the output end of the sweep roller and sent back to the toner container, into the waste toner reservoir.

  • Page 103: Fuser Section

    2PG/2PH 2-1-7 Fuser section The toner on the paper is molten and pressed into the paper as it passes between the heat roller and the press roller in the fuser unit. The heat roller has a heater lamp inside which continuously turns on and off by the fuser thermistor to maintain the constant temperature onto the heat roller surface.
  • Page 104 2PG/2PH Fuser unit High Power Control PWB voltage source PWB Fuser thermal cutout HEATN YC103-6 YC311-5 YC102-1 SLEEP YC103-7 YC311-6 ZCROSS YC102-3 YC103-8 YC311-3 Fuser heater lamp Fuser thermistor THERM YC311-16 Figure 2-1-19 Fuser section block diagram 2-1-12...

  • Page 105: Paper Exit Section

    2PG/2PH 2-1-8 Paper exit section The paper exit section transports the paper which passed the fuser unit towards the top tray. The paper which passed through the fuser unit turns on the actuator (exit sensor) in the fuser unit, and is led by the guide comprised of the rear cover, frame and the FD cover guide, finally reaching the upper FD roller.
  • Page 106 2PG/2PH Fuser unit Control PWB EXITN YC307-4 Exit sensor Figure 2-1-21 Paper exit section block diagram 2-1-14...

  • Page 107: Duplex/Conveying Section

    2PG/2PH 2-1-9 Duplex/conveying section The duplex/conveying section consists of conveying path which sends the paper sent from the exit section to the paper feed/conveying section when duplex printing. Figure 2-1-22 Duplex/conveying section DU cover B DU holder Middle pulley B DU roller DU cover A Lower base cover...
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  • Page 109: Electrical Parts Layout

    2PG/2PH 2-2 Electrical Parts Layout 2-2-1 Electrical parts layout (1) PWBs Machine left Machine inside Machine right Figure 2-2-1 PWBs Control PWB ..........Main controller: Controls the software such as the print data processing and provides the interface with computers. Engine: Controls printer hardware such as high voltage/bias output con- trol, paper conveying system control, and fuser temperature control, etc.

  • Page 110: Switches And Sensors

    2PG/2PH (2) Switches and sensors Machine left Machine inside Machine right Figure 2-2-2 Switches and sensors Power switch..........Turns ON/OFF the AC power source. Interlock switch ..........Shuts off 24 V DC power line when the top cover is opened. Cassette switch..........

  • Page 111: Other Electrical Components

    2PG/2PH (3) Other electrical components Machine left Machine inside Machine right Figure 2-2-3 Other electrical components Main motor ............Drives the paper feed/conveying section and fuser unit. Polygon motor........... Drives the polygon mirror. Right cooling fan motor ........Cools the interior of machine. Left cooling fan motor ........
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  • Page 113: Power Source Pwb

    2PG/2PH 2-3 Operation of the PWBs 2-3-1 Power source PWB Power source PWB Left +24V1 cooling fan motor ZCROSS Zero cross signal circuit Power switch SLEEP AC input Switching +5V1 regulator circuit +24V2 Fuser heater Interlock lamp control switch HEATN circuit +3.3V1 THERM...
  • Page 114 2PG/2PH YC104 YC105 YC102 YC103 YC101 Figure 2-3-2 Power source PWB silk-screen diagram Connector Pin No. Signal Voltage Description YC101 LIVE 120 V AC AC power input Connected 220 - 240 V AC to the AC NEUTRAL 120 V AC AC power input inlet 220 - 240 V AC...

  • Page 115: Control Pwb

    2PG/2PH 2-3-2 Control PWB Control PWB Engine Main controller Laser scanner unit I/F Duplex solenoid Registration clutch Operation MP paper feed panel PWB I/F solenoid Paper feed clutch USB I/F +3.3 V Developing clutch Memory card I/F Paper feed sensor Engine I/F MP paper feed KUIO I/F...
  • Page 116 2PG/2PH YC316 YC317 YC307 U300 Figure 2-3-4 Control PWB silk-screen diagram 2-3-4...
  • Page 117 2PG/2PH Connector Pin No. Signal Voltage Description LED1 3.3/0 V DC Paper indicator display: On/Off Connected LED2 3.3/0 V DC Jam indicator display: On/Off to the opera- Analog Cancel key/GO key: On/Off tion panel SGND Ground LED3 3.3/0 V DC Ready indicator display: On/Off LED4 3.3/0 V DC...
  • Page 118 2PG/2PH Connector Pin No. Signal Voltage Description YC311 +24V1 24 V DC 24 V DC power source Connected +3.3V2 3.3 V DC 3.3 V DC power source to the high ZCROSS 0/3.3 V DC (pulse) Zero cross signal voltage 0/24 V DC Left cooling fan motor: On/Off HEATN 0/3.3 V DC...
  • Page 119 2PG/2PH Connector Pin No. Signal Voltage Description YC318 +24V3 24 V DC 24 V DC power source Connected PGND Ground to the PFSI 0/3.3 V DC (pulse) Serial communication data input signal optional PFSO 0/3.3 V DC (pulse) Serial communication data output signal paper feeder PFSEL 0/3.3 V DC...
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  • Page 121: Appendixes

    2PG/2PH 2-4 Appendixes 2-4-1 Appendixes (1) Wiring diagraml 2-4-1...

  • Page 122: Repetitive Defects Gauge

    2PG/2PH (2) Repetitive defects gauge First occurrence of defect [24.99 mm/1"] Upper registration roller [37.68 mm/1 "] Lower registration roller [45.216 mm/1 "] Transfer roller [62.8 mm/2 "] Developing roller (developing unit) [73.162 mm/2 "] Heat roller (fuser unit) [78.5 mm/3 "] Press roller (fuser unit) 1/16 [94 mm/3...

  • Page 123: Self Diagnostic Codes Indication (Animation)

    2PG/2PH (3) Self diagnostic codes indication (Animation) Click the icon to play the animation of the indicator combinations. To play the animation, you have to install Adobe Flash Player and Adobe Reader (Version 6.01 or more) to your PC. If the animation is not displayed, you should get the latest version from Adobe site (http://www.adobe.com/downloads/). Indication Contents Control PWB EEPROM error...
  • Page 124 2PG/2PH Indication Contents Broken fuser thermistor wire Zero cross signal error Control PWB checksum error Control PWB RAM checksum error Control PWB general failure Control PWB engine communication error Control PWB engine checksum error Control PWB video data control error 2-4-4...

  • Page 125: Maintenance Parts List

    2PG/2PH (4) Maintenance parts list Low model Maintenance part name Alternative part Part No. Name used in service manual Name used in parts list Maintenance kit (120 V specifications) MK-182/MAINTENANCE KIT 1702PG7US0 072PG7US DK-150 DV-162(U) Maintenance kit (230 V specifications) MK-180/MAINTENANCE KIT 1702PG8NL0 072PG8NL...
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  • Page 127 Zhongshan Dist., Taipei 104, Taiwan R.O.C. Phone: +886-2-2507-6709 Level 3, 6-10 Talavera Road North Ryde N.S.W, 2113, Fax: +886-2-2507-8432 Australia Phone: +61-2-9888-9999 KYOCERA Document Solutions Korea Co., Ltd. Fax: +61-2-9888-9588 18F, Kangnam bldg, 1321-1, Seocho-Dong, Seocho-Gu, Seoul, Korea KYOCERA Document Solutions Phone: +822-6933-4050 Fax: +822-747-0084 New Zealand Ltd.
  • Page 128 KYOCERA Document Solutions South Africa (Pty) Ltd. KYOCERA Document Solutions Espana, S.A. KYOCERA House, Hertford Office Park, Edificio Kyocera, Avda. de Manacor No.2, 90 Bekker Road (Cnr. Allandale), Midrand, South Africa. 28290 Las Matas (Madrid), Spain Phone: +27-11-540-2600 Phone: +34-91-6318392...

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