Kyocera KM-3035/KM-4035/KM-5035 Parts List Manual (P/N 842FG120)

This four-PDF Kyocera Mita factory manual set covers the KM-3035 (2FD), KM-4035 (2FF), and KM-5035 (2FG). It pairs the 2003 base publications with later revisions through 2005. The service manual is written for service personnel; its maintenance-mode diagnostics, electrical tests, firmware work, and optical alignment procedures are best suited to trained copier technicians and repair shops with the proper test equipment.

• Model and revision control: Maps all three machine codes, the original and revised publications, and the BAM (Blue Angel) serial break that affects component selection.

• Exploded parts identification: Both Parts List editions organize the machine into the same 22 figure sections, with keyed views and tables for assemblies, subassemblies, spare parts, and regional power-build quantities; Revision 1 adds alternative numbers.

• Paper handling repair: Includes pulley and roller replacement, clutch checks, paper-feed and conveying diagnosis, duplex and switchback operation, plus registration, margin, center-line, and paper-slack adjustments.

• Optical and image-system work: Details scanner-wire replacement, exposure-lamp and laser-scanner removal, ISU positioning, drum and main-charger service, developing and transfer units, and fixing-unit component replacement.

• Electrical and fault diagnosis: Provides maintenance-mode motor, clutch, switch, sensor, solenoid, high-voltage, and heater checks; jam and self-diagnostic code tables; PCB layouts; connector signal tables; timing charts; and a general wiring diagram.

• Option installation and setup: Documents the paper feeder, large paper deck, document processor, printing and scanning systems, hard disk, built-in and external finishers, job separator, fax system, key counter, and drawer heater.

Publication and Build Matching

The set contains 816 PDF pages total: Service Manual 842FG110, 340 pages; Service Manual 842FG111, Revision 1, 342 pages; Parts List P/N 842FG120, 66 pages; and Parts List 842FG121, Revision 1, KMIS version, 68 pages. The October 2004 service revision identifies page 2-2-2 as the replaced page and corrects the safety-switch mapping: SSW1 is assigned to the conveying unit and SSW2 to the front cover.

The February 2005 Parts List adds BAM-specific highlights and embedded KMIS service notes. It identifies BAM machines as KM-3035 serial K3056904 and later, KM-4035 serial L3027478 and later, and KM-5035 serial M3016367 and later, with Service Bulletin 2FG-019 cited for the change. The note warns that some BAM and non-BAM parts are not interchangeable.

One procurement correction is especially important. The printed BAM engine-PCB entry 2FG68190 is marked incorrect; the embedded note substitutes 2FD68021 for KM-3035, 2FF68021 for KM-4035, and 2FG68191 for KM-5035. For non-BAM machines, 2FG68082 applies while stock lasts, followed by model-specific 2FD68010, 2FF68010, and 2FG68083 assemblies. The optical-section note likewise separates non-BAM ISU assembly 2FG93160 from BAM assembly 2FG93190.

Part tables carry separate 110V, 120V, 230V, and 240V quantity columns. This distinction reaches beyond the power cord: the listings separate 100- and 200-series power-source and noise-filter PCBs, fixing assemblies and heaters, drawer heaters, regional bypass units, and A4 versus letter cassettes. Representative exploded views include Paper Feed-In Section II, Optical Section, Laser Scanner Unit, Fixing Section, Electrical Components, and Operation Unit. A part-number index and full screw-classification table complete each Parts List.

Service and Repair Depth

The service material goes well beyond part identification. Maintenance modes isolate drive motors, paper-path switches, clutches, solenoids, scanner functions, high-voltage output, fixing control, optional equipment, and stored jam or service-call history. It also covers automatic document-processor and scanner calibration, image registration and magnification, firmware upgrades, and PCB replacement data handling. Scanner-wire repair calls out frame-securing tools P/N 2AV6808 and wire stoppers P/N 3596811; the Parts List gives the full order codes as 2AV68080 and 35968110. ISU installation specifies positioning pins P/N 1856812. Automatic scanner adjustment uses test original 2A068020, while DP automatic adjustment uses 2AC68241.

Diagnostic illustrations include drive-train views, a paper-misfeed switch map, fixing-section block diagrams, the image-adjustment procedure chart, PCB and connector layouts, eleven operating timing charts, and the general wiring diagram. Troubleshooting is divided into paper misfeeds, self-diagnostic codes, image defects, electrical failures, and mechanical problems, with component-level checks and corrective-action references.

The manual warns that strong light or contact with the drum surface can damage the photoconductor, and that bypassing the specified fixing-unit thermostat with wire can seriously damage the copier. Interrupting a printer-board firmware download can leave programming incomplete and produce checksum error F010. Disconnect the power plug before disassembly; charger sections use high potentials, the fixing section becomes extremely hot, and the laser optical unit is not to be disassembled.

Detailed internal repair for the 3000-sheet finisher, mailbox, and booklet stitcher is outside this set; related fault tables direct the technician to the separate accessory service manuals.