Kyocera PE-MF2 User manual

Model PE-MF2
Machine Code:
M018/M019 Copiers
SERVICE MANUAL
November 2008
Subject to change

Safety Notices
Important Safety Notices
Prevention of Physical Injury
1. Before disassembling or assembling parts of the machine and peripherals, make sure that the machine
power cord is unplugged.
2. The wall outlet should be near the machine and easily accessible.
3. If any adjustment or operation check has to be made with exterior covers off or open while the main
switch is turned on, keep hands away from electrified or mechanically driven components.
4. The machine drives some of its components when it completes the warm-up period. Be careful to keep
hands away from the mechanical and electrical components as the machine starts operation.
5. The inside and the metal parts of the fusing unit become extremely hot while the machine is operating.
Be careful to avoid touching those components with your bare hands.
Health Safety Conditions
Toner is non-toxic, but if you get either of them in your eyes by accident, it may cause temporary eye
discomfort. Try to remove with eye drops or flush with water as first aid. If unsuccessful, get medical attention.
Observance of Electrical Safety Standards
The machine and its peripherals must be serviced by a customer service representative who has completed
the training course on those models.
Safety and Ecological Notes for Disposal
1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly when exposed to an
open flame.
2. Dispose of used toner, the maintenance unit which includes developer or the organic photoconductor
in accordance with local regulations. (These are non-toxic supplies.)
3. Dispose of replaced parts in accordance with local regulations.
• To prevent a fire or explosion, keep the machine away from flammable liquids, gases, and aerosols.
A fire or an explosion might occur.
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• The Controller board on the MF model contains a lithium battery. The danger of explosion exists if a
battery of this type is incorrectly replaced. Replace only with the same or an equivalent type
recommended by the manufacturer. Discard batteries in accordance with the manufacturer's
instructions and local regulations.
Laser Safety
The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units
in the field. The optical housing unit can only be repaired in a factory or at a location with the requisite
equipment. The laser subsystem is replaceable in the field by a qualified Customer Engineer. The laser
chassis is not repairable in the field. Customer engineers are therefore directed to return all chassis and
laser subsystems to the factory or service depot when replacement of the optical subsystem is required.
• Use of controls, or adjustment, or performance of procedures other than those specified in this manual
may result in hazardous radiation exposure.
WARNING
WARNING:
Turn off the main switch before attempting any of the procedures in the Laser Optics Housing Unit section.
Laser beams can seriously damage your eyes.
CAUTION MARKING:
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Symbols, Abbreviations and Trademarks
This manual uses several symbols and abbreviations. The meaning of those symbols and abbreviations are
as follows:
*See or Refer to
Clip ring
Screw
Connector
Clamp
E-ring
SEF Short Edge Feed
LEF Long Edge Feed
Trademarks
Microsoft®, Windows®, and MS-DOS® are registered trademarks of Microsoft Corporation in the United
States and /or other countries.
PostScript® is a registered trademark of Adobe Systems, Incorporated.
PCL® is a registered trademark of Hewlett-Packard Company.
Ethernet® is a registered trademark of Xerox Corporation.
PowerPC® is a registered trademark of International Business Machines Corporation.
Other product names used herein are for identification purposes only and may be trademarks of their
respective companies. We disclaim any and all rights involved with those marks.
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TABLE OF CONTENTS
Safety Notices.....................................................................................................................................................1
Important Safety Notices...............................................................................................................................1
Laser Safety.....................................................................................................................................................2
Symbols, Abbreviations and Trademarks.........................................................................................................3
Trademarks.....................................................................................................................................................3
1. Product Information
Specifications......................................................................................................................................................9
Machine Overview..........................................................................................................................................10
Component Layout.......................................................................................................................................10
Paper Path....................................................................................................................................................12
Drive Layout..................................................................................................................................................13
Machine Configuration....................................................................................................................................15
Guidance for Those Who are Familiar with Predecessor Products..............................................................16
2. Installation
Installation Requirements.................................................................................................................................17
Environment..................................................................................................................................................17
Machine level...............................................................................................................................................18
Machine Space Requirement.....................................................................................................................18
Power Requirements....................................................................................................................................18
Installation Procedure..................................................................................................................................19
3. Preventive Maintenance
Preventive Maintenance..................................................................................................................................21
4. Replacement and Adjustment
Before You Start...............................................................................................................................................23
Special Tools....................................................................................................................................................24
Exterior Covers.................................................................................................................................................25
Rear Cover...................................................................................................................................................25
Operation Panel...........................................................................................................................................26
Right Cover...................................................................................................................................................27
Left Cover......................................................................................................................................................27
Front Cover Unit...........................................................................................................................................28
Laser Optics......................................................................................................................................................30
Caution Decal Location...............................................................................................................................30
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Laser Optics Housing Unit...........................................................................................................................30
AIO Cartridge..................................................................................................................................................35
AIO Cartridge (All In One Cartridge) .......................................................................................................35
Black AIO Motor.........................................................................................................................................35
Color AIO Motor.........................................................................................................................................38
Image Transfer..................................................................................................................................................40
Image Transfer Belt Unit..............................................................................................................................40
ITB (Image Transfer Belt) Cleaning Unit.....................................................................................................41
Agitator Motor.............................................................................................................................................42
ITB (Image Transfer Belt) Contact Motor...................................................................................................44
ITB (Image Transfer Belt) Contact Sensor..................................................................................................45
TM (Toner Mark) Sensor Base....................................................................................................................46
Waste Toner Bottle Set Sensor...................................................................................................................47
Waste Toner Overflow Sensor...................................................................................................................48
Paper Transfer..................................................................................................................................................50
Transfer Unit.................................................................................................................................................50
Transfer Roller..............................................................................................................................................50
Registration Roller........................................................................................................................................52
Registration Sensor......................................................................................................................................53
Registration Clutch.......................................................................................................................................53
Image Fusing....................................................................................................................................................55
Fusing Unit....................................................................................................................................................55
Fusing Lamp..................................................................................................................................................56
Transport/Fusing Motor..............................................................................................................................57
Paper Feed........................................................................................................................................................59
Paper Feed Clutch.......................................................................................................................................59
Paper Feed Roller........................................................................................................................................59
Separation Pad............................................................................................................................................60
Paper End Sensor.........................................................................................................................................61
Paper Exit..........................................................................................................................................................63
Paper Exit Roller...........................................................................................................................................63
Paper Exit Sensor.........................................................................................................................................64
Electrical Components.....................................................................................................................................66
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Controller Board..........................................................................................................................................66
EGB (Engine Board)....................................................................................................................................68
FCU...............................................................................................................................................................70
Interlock Switches........................................................................................................................................70
Fusing Fan Motor.........................................................................................................................................71
LSU Fan Motor.............................................................................................................................................72
ID Chip Board..............................................................................................................................................73
PSU................................................................................................................................................................73
High Voltage Power Supply Board............................................................................................................75
Temperature/Humidity Sensor...................................................................................................................76
Duplex Motor ..............................................................................................................................................76
Speaker .......................................................................................................................................................77
EEPROM.......................................................................................................................................................78
ADF....................................................................................................................................................................80
ADF Unit........................................................................................................................................................80
Original Tray................................................................................................................................................81
ADF Feed Unit..............................................................................................................................................82
ADF Separation Pad....................................................................................................................................82
ADF Front Cover .........................................................................................................................................83
ADF Rear Cover...........................................................................................................................................83
ADF Cover....................................................................................................................................................84
ADF Motor....................................................................................................................................................84
Original Set Sensor......................................................................................................................................86
ADF Cover Open Sensor............................................................................................................................87
ADF Feed Sensor.........................................................................................................................................87
ADF Drive Board..........................................................................................................................................88
Scanner.............................................................................................................................................................90
Scanner Unit.................................................................................................................................................90
Scanner Top Cover......................................................................................................................................92
Scanner Carriage Unit.................................................................................................................................93
Exposure Lamp.............................................................................................................................................95
Lamp Stabilizer Board.................................................................................................................................96
Scanner Motor.............................................................................................................................................97
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5. System Maintenance Reference
Service Program ..............................................................................................................................................99
Overview......................................................................................................................................................99
Configuration Page Information...................................................................................................................100
Overview....................................................................................................................................................100
Firmware Updating........................................................................................................................................101
Checking the Machine Firmware Version...............................................................................................101
Updating the Controller Firmware...........................................................................................................101
Updating Failure........................................................................................................................................106
Updating the Engine Firmware.................................................................................................................107
Boot Loader Firmware...............................................................................................................................109
6. Troubleshooting
Troubleshooting Guide..................................................................................................................................111
Image Problems.............................................................................................................................................112
Overview....................................................................................................................................................112
Checking a Sample Printout.....................................................................................................................112
INDEX...........................................................................................................................................................115
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1. Product Information
Specifications
See "Appendices" for the following information:
• "General Specifications"
• "Supported Paper Sizes"
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Machine Overview
Component Layout
Engine
1. Laser Optics Housing Unit
2. Print Cartridge (AIO)
3. Development Roller (AIO)
4. Paper Exit
5. Fusing Unit
6. Fusing Lamp
7. Duplex Path
8. Transfer Roller
9. Registration Roller
10. By-pass
11. Paper Feed Roller
12. ITB (Image Transfer Belt) Unit
13. OPC (AIO)
14. Tray 1
15 EGB/Controller
1. Product Information
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ADF
1. Feed Sensor
2. Feed Roller
3. Separation Roller
4. Pick-up Roller
5. Exit Roller
6. Original Set Sensor
7. DF Exposure Glass
Scanner
1. Scanner Carriage Unit
2. DF Exposure Glass
3. Exposure Glass
4. Carriage Drive Bar
5. White Plate
Machine Overview
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Paper Path
Engine
1. Paper path from tray 1
2. Duplex path
3. By-pass tray
4. Paper path from tray 2 (optional)
ADF
1. Product Information
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1. Original path
Drive Layout
1. Color AIO Motor
2. Black AIO Motor
3. Duplex Motor
4. Transport/Fusing Motor
5. Registration Clutch
6. Paper Feed Clutch
7. Agitator Motor
8. ITB (Image Transfer Belt) Contact Motor
•Color AIO Motor:
This drives the color AIOs (Cyan, Magenta and Yellow)
•Black AIO Motor:
This drives the black AIO and the ITB (Image Transfer Belt).
•Duplex Motor:
This drives the paper exit roller and the duplex roller.
•Transport/Fusing Motor:
This drives the fusing unit, paper feed roller, registration roller and paper exit roller via the paper feed
clutch, registration clutch and gears.
Machine Overview
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•Registration Clutch:
This transfers drive from the transport/ fusing motor to the registration roller.
•Paper Feed Clutch:
This transfers drive from the transport/ fusing motor to the paper feed roller.
•Agitator Motor:
This moves the agitators in the waste toner bottle.
•ITB Contact Motor:
This moves the ITB into contact with and away from the color OPCs.
1. Product Information
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Machine Configuration
Models Duplex
Unit
Optional
Memory
Optional
Tray (G849)
DDST
(GDI)
PCL
PS Fax
PE-MF2b (M018) Auto N 500x1 Y N Y
PE-MF2c (M019) Auto Y 500x1 N Y Y
Machine Configuration
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Guidance for Those Who are Familiar with
Predecessor Products
The M018/M019 series models are similar to the G181/G183/G184 series. If you have experience
with those products, the following information will be of help when you read this manual.
Different Points from Previous Products
M018/M019 G181/G183/G184
Print Cartridge (AIO) Longer life Print Cartridge (AIO) -
Operation Panel Four separated menu keys and user
tool button
One menu key and no user tool
button
1. Product Information
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2. Installation
Installation Requirements
Environment
1. Temperature Range: 10°C to 32°C (50°F to 89.6°F)
2. Humidity Range: 15% to 80% RH
3. Ambient Illumination: Less than 2,000 lux (do not expose to direct sunlight)
4. Ventilation: 3 times/hr/person
5. Do not put the machine in areas that get sudden temperature changes. This includes:
• Areas directly exposed to cool air from an air conditioner
• Areas directly exposed to heat from a heater.
6. Do not put the machine in areas that get exposed to corrosive gas.
7. Do not install the machine at locations over 2,500 m (8,125 ft.) above sea level.
8. Put the machine on a strong, level base. (Inclination on any side must be no more than 5 mm.)
9. Do not put the machine in areas with strong vibrations.
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Machine level
Front to back: Within 5 mm (0.2") of level
Right to left: Within 5 mm (0.2") of level
Machine Space Requirement
Put the machine near the power source with these clearances:
Left side: Over 20 cm (7.9")
Rear: Over 20 cm (7.9")
Right side: Over 10 cm (4")
Front: Over 70 cm (27.5")
Top: Over 24 cm (9.5")
Power Requirements
• Make sure that the plug is tightly in the outlet.
• Avoid multi-wiring.
• Make sure that you ground the machine.
2. Installation
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