Instruction/ maintenance manual of the product FS-1010 Kyocera
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SERVICE MANUAL Pub lished in Dec. ’01 Laser printer.
Version Replaced pages Remarks Date 1.0 Revision history 5-Dec-2001.
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.
indicates that action is required. The specific action required is shown inside the symbol. General action required . Remove the power plug from the wall outlet.
1. Installation Precautions WARNING •D o 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.
• Check that the power cable covering is free of damage. Check that the power plug is dust-free. If it is dirty, clean it to remove the risk of fire or electric shock. ............................................................ • Never attempt to disassemble the optical unit in machines using lasers.
• Do not pull on the AC power cord or connector wires on high-voltage components when removing them; always hold the plug itself. ...................................................................................................... •D o not route the power cable where it may be stood on or trapped.
1-1-1 Contents Chapter 1 1-1 Printer specifications ..................................................................................................... .................................. 1-3 1-2 Names of parts .......................................
Chapter 1 Product Information.
Chapter 1 Contents 1-1 Printer specifications ...................................................................................................................... 1-3 1-1-1 Specifications .............................................................
FS-1010 1-3 1-1 Printer specifications 1-1-1 Specifications (1) Engine Item Specification Print method Print speed (when printing multiple pages) Resolution (dpi) Smoothing First print (A4 or letter ,.
1-4 FS-1010 Item Specification Item S Main unit (excl. protrusions) (2) Controller (3) W eight and dimensions Item Specification CPU System ROM Font ROM Optional font ROM (Dip socket) Main (Video) RAM.
FS-1010 1-5 (4) Power requirements (5) Environmental requirements Item Specification Item S Vo ltage/current requirement W atts 220 to 240 V AC ± 10 %, 50/60 Hz ± 2 %/3.
1-6 FS-1010 1-2 Names of par ts 1-2-1 Name of parts Figure 1-2-1 Name of parts 1 T op cover 2 Face-down output tray 3 Face-up output tray 4 Side cover 5 Operator panel 6 Front cover 7 Paper cassette 8.
FS-1010 1-7 1-3 Safety inf ormation 1-3-1 Safety information (1) Laser safety This printer is certified as a Class 1 laser product under the U.S. Department of Health and Human Services (DHHS) Radiation Performance Standard according to Radiation Control for Health and Safety Act of 1968.
1-8 FS-1010 W ARNING Use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure. Figure 1-3-1 Caution labels Label on the scanner unit (Inside the printer) Label on the left cov er rear side Label on the fuser unit European countries U .
FS-1010 1-9 (4) CDRH regulations (U .S.A.) The Center of Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration implemented regulations for laser products on August 2, 1976. These regulations apply to laser products manufactured after August 1, 1976.
1-10 FS-1010 1-4 En vir onmental requirements 1-4-1 Environmental conditions The Envir onmental r equirements section on page 1-5 should be observed to ensure the optimum operation of the printer . The use of the printer in a location which does not satisfy the requirements may result in troubles and risk shortening its service life.
FS-1010 1-11 (1) Clearance Allow the necessary minimum clearance on all sides of the printer as diagrammed below . Figure 1-4-2 Clearances Ref. Clearance Dimensions 1 Left 25 cm (9-7/8 inches) 2 Front.
1-12 FS-1010 (2) Places to av oid A void installing the printer in locations exposed to: • Direct drafts of hot or cold air . • Direct drafts of outside air . (A void locations next to outside doors.) • Sudden temperature or humidity changes. • Any source of high heat, such as a radiator or stove.
FS-1010 1-13 (4) Removing the printer Observe the following precautions in removal and transportation of the printer . • Be sure to repack the printer in its original carton. • Do not leave the printer, toner container, process unit and other printer modules inside a vehicle if the outdoor temperature is more than 25 ° C.
1-14 FS-1010 1 1-5 About the toner container 1-5-1 Toner container The printer should use a TK-17 toner kit. T o ensure the high print quality and long service life, the following handling precautions should apply.
FS-1010 1-15 (2) T oner container storage The toner contained in the container is susceptible to temperature and humidity . T o ensure the high print quality, store the toner container in a place that.
Chapter 2 Installation/Operation.
Chapter 2 Contents 2-1 Unpacking .................................................................................................................. ....................... 2-3 2-1-1 Unpacking and inspection ............................................
FS-1010 2-3 2-1 Unpacking 2-1-1 Unpacking and inspection The package should contain the printer and the accessories as shown in the figure below . Remove the printer and all the accessories from the package. For unpacking, place the box containing the printer on a flat, stable surface.
2-4 FS-1010 2-2 Installing the printer Installing the printer requires several steps. Proceed as follows in sequence. If the option paper feeder is used with the printer, begin installation with connecting the printer and the paper feeder. For details, refer to the optional Paper feeder’s Service Manual .
FS-1010 2-5 3. T ake the toner container 2 from the bag. Hold it with the protective seal 3 (orange-colored) facing up. Shake the toner container 2 horizontally at least five times. This ensures that the toner is evenly distributed inside. Figure 2-2-2 Shaking the toner container 4.
2-6 FS-1010 5. Install the toner container 2 into the printer . 6. Push firmly on the top of the toner container 2 at the positions marked [PUSH HERE].
FS-1010 2-7 7. Push the lock lever #1 1 to the lock position. 8. Close the top cover 4 . Figure- 2-2-5 Locking the toner container NOTE The printer is shipped from the factory with no toner supplied in its developer (Process unit).
2-8 FS-1010 2-2-2 Expanding memory The FS-1010 printer comes standard equipped with 16 MB of main memory on the main board. Printer memory can be expanded to up to the maximum 144 MB (16 + 128 MB). (1) Minimum memory requirements Refer to the table below for minimum memory requirements in various environments.
FS-1010 2-9 (3) Notes on handling DIMM Before proceeding to install DIMM, read the following notes for handling the main board and DIMMs: • Protect the electronics by taking these precautions: • Before touching a DIMM, touch a water pipe or other lar ge metal object to discharge yourself of static electricity .
2-10 FS-1010 (4) Installing the DIMM The main board of the printer is equipped with one socket for memory expansion. Expansion memory is available in the form of DIMM (Dual In-line Memory Module). CAUTION T ake precautions that no foreign substances such as metal chips or liquid get inside the printer during the installation process.
FS-1010 2-11 Open the clips 2 on both ends of the DIMM socket 3 . Insert the DIMM 4 into the DIMM socket 3 so that the notches on the DIMM align with the corresponding protrusions in the slot.
2-12 FS-1010 (6) Installing the memory card (CompactFlash) The main board of the printer is equipped with one slot for memory card. CAUTION T ake precautions that no foreign substances such as metal chips or liquid get inside the printer during the installation process.
FS-1010 2-13 Insert the memory card 4 in the slot. Insert as shown in the figure. Push it in all the way . Close and secure the option interface slot cover (or network interface card or the serial Interface board) .
2-14 FS-1010 (7) Installing the netw ork interface card If the serial interface board kit is installed, remove it to use the network interface card. CAUTION T ake precautions that no foreign substances such as metal chips or liquid get inside the printer during the installation process.
FS-1010 2-15 2-3 Using the operator panel This section provides explanation on how to use the printer ’ s operator panel for basic operation. For details, refer to the printer ’ s User ’ s Manual . 2-3-1 Operator panel The printer ’ s operation panel has the following LED indicators and keys.
2-16 FS-1010 2-3-2 Remote operation panel The remote operation panel is a utility that allows you to make basic printer settings from the computer connected to the printer or the network. For details on installation and usage, see the printer ’ s User ’ s Manual contained as an electronic file in the CD-ROM supplied with the printer .
Chapter 3 Maintenance/Adjustments.
Chapter 3 Contents 3-1 Maintenance/Adjustments .............................................................................................................. 3-3 3-1-1 Lif e expectancy of modules .......................................................
3-3 FS-1010 3-1 Maintenance/Adjustments 3-1-1 Life expectancy of modules The table below shows the nominal life expectancy for modules. Detailed part information for each module (except toner container) can be found in Parts Catalog .
3-4 FS-1010 3-1-2 T oner container Assuming an average toner coverage of 5 % with EcoPrint mode turned off, the toner container will need replacing approximately once every 6,000 printed pages. Ta b le 3-1-2 T oner container Kit Life in pages TK-17 6,000 Based on letter or A4 size paper; average print density of 5 %.
3-5 FS-1010 (3) T oner container replacement To replace the toner container, open the top cover. Pull lock lever #1 1 to the release [UNLOCK] position, then pull lock lever #2 2 to the release (right) position. Figure 3-1-1 Releasing Loc k levers #1 and #2 Gently remove the old toner container 3 .
3-6 FS-1010 Put it in the supplied plastic bag 4 and dispose of it. Figure 3-1-3 Disposal of the old toner container NOTE Although the toner container is made from non-harmful, flammable material, be sure to dispose of it according to laws and regulations.
3-7 FS-1010 3-1-3 Cleaning the printer To avoid print quality problems, the following printer parts must be cleaned with every toner container replacement. To clean the printer , first, remove the process unit from the printer . Open the top cover 1 and front cover 2 .
3-8 FS-1010 (1) Cleaning the registration r oller Use the supplied wiper cloth 1 to clean dust and dirt away from the registration roller 2 (metal). Figure 3-1-5 Cleaning the registration r oller (2) .
3-9 FS-1010 3-1-4 Updating the firmware Updating the system (controller) firmware is possible by downloading the firmware through the parallel interface or through the memory card (CompactFlash). These firmware programs are directly overwritten in the system DIMM [board KP-893] (Flash ROM type only) on the main board.
3-10 FS-1010 (2) Downloading the firmware from the parallel interface This section explains how to download firmware data from the parallel interface. The printer system can automatically recognize whether the data to be overwritten is for controller firmware.
3-11 FS-1010 (3) Downloading the firmware fr om the memory card To download data written in a memory card (CompactFlash) to the printer , proceed as explained in this section. CA UTION Downloading firmware takes several minutes. Do not turn power off during downloading.
3-12 FS-1010 Cause Corrective action Description LED indicators LED indicators Download finished normally Convention Download err ors Slow flashing Fast flashing Lit Off Red Green Meaning Download dat.
Chapter 4 Operation Overview.
Chapter 4 Contents 4-1 Electrophotographic system ................................................................................................. ......... 4-3 4-1-1 Electrophotographic cycle .........................................................
4-3 FS-1010 4-1 Electrophotographic system Electrophotography is the technology used in laser printing which transfer data representing texts or graphics objects into a visible image which is developed on the photosensitive drum, finally fusing on paper , using light beam generated by a laser diode.
4-4 FS-1010 1 Main charger unit 2 Charger wire 3 Grid 4 Developing roller 5 Gear Z14-Z18 6 Gear Z14-Z36 7 Gear Z18-Z36 8 Free gear Z40 Process unit mechanism Figure 4-1-2 Process unit mechanism 9 Gear.
4-5 FS-1010 (1) Main charging Photo conductive drum The durable layer of or ganic 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 .
4-6 FS-1010 Charging the drum The following shows a simplified diagram of the electrophotographic components in relation to the engine system. Charging the drum is done by the main char ger unit A .
4-7 FS-1010 (2) Exposure The charged surface of the drum A is then scanned by the laser beam from the laser scanner unit B . Figure 4-1-5 Exposure The laser beam (780 nm wavelength) beam is dispersed as the polygon motor (polygon mirrors) revolves to reflect the laser beam over the drum.
4-8 FS-1010 Laser scanner unit Name Description 1 Laser diode Emits diffused, visible laser . 2 Cylindrical lens Compensates the vertical angle at which the laser beam hits a polygon mirror segment.
4-9 FS-1010 Drum surface potential The laser beam is continually switched on and of f depending on the print data. It is on for a black (exposed) dot and off for a white (blank) dot.
4-10 FS-1010 (3) Development The latent image constituted on the drum is developed into a visible image. The developing roller A contains a 3-pole (S-N-S) magnet core B and an aluminum cylinder rotating around the magnet core B . T oner attracts to the developing roller A since it is powdery ink made of black resin bound to iron particles.
4-11 FS-1010 (4) T ransfer The image developed by toner on the drum A is transferred onto the paper because of the electrical attraction between the toner itself and the transfer roller B .
4-12 FS-1010 (5) Fusing The toner on the paper is molten and pressed into the paper as it passes between the heat roller A and the press roller B in the fuser unit. Figure 4-1-10 Fusing The heat roller has a halogen lamp inside which continuously turns on and of f by the thermistor to maintain the constant temperature onto the heat roller surface.
4-13 FS-1010 1 Heat roller 2 Idle gear Z34 3 Exit gear Z23 4 Idle gear Z18 0 ! 1 2 3 4 5 6 7 8 9 @ 5 Heat gear Z33 6 Press roller 7 Heater lamp [500 ± 25 W] 8 Thermal cutout 9 Separator(s) 0 Thermist.
4-14 FS-1010 E A B C D (6) Cleaning After the transferring process, the drum needs to be physically cleaned of toner which is residual after the development process. The cleaning blade A is constantly pressed against the drum B and scrapes the residual toner off to the sweep roller C .
4-15 FS-1010 4-2 Paper feeding system The paper feeding system picks up paper from the cassette, MP tray , or if installed, the paper feeder PF-17, feeds it in the printer , and delivers in the output tray . Paper is fed at the precise timing in synchronization with data processing.
4-16 FS-1010 4-2-1 Paper feed control The following diagram shows interconnectivity of the feeding system components including the sensors and rollers. The engine board provides the signals in conjunction with the electrophotography process that is driven by the main board.
4-17 FS-1010 0 ! @ % ( & A B # $ * ) ^ 3 4 5 6 2 1 7 8 9 C A For process unit; dr um (F rom main unit) B For process unit; toner container , dev eloping roller etc.
4-18 FS-1010 4-3 Electrical control system 4-3-1 Electrical parts layout Figure 4-3-1 Electrical parts lay out 9 2 0 8 M L 5 ! # K J 4 % $ @ 7 H 3 G I 1 6 2 B A C D E F ( & ^ * 1 Main board (KP-88.
4-19 FS-1010 4-3-2 Operation of circuit boards (1) Main board Figure 4-3-2 Main board circuit block diagram Q01 Digital Transistor Q02 Digital Transistor YC03 USB I/F USBINT USBDN EDB31-16 EBIU Data b.
4-20 FS-1010 (2) Engine board Figure 4-3-3 Engine board circuit block diagram Main board (KP-888) Laser scanner unit RSTIN RSTN PLGCLK PLGRD YN PLGDRN EESCK MPFDRN EEDIO MP feed clutch Eraser lamp Era.
4-21 FS-1010 Eraser lamp control circuit The CPU (U01) turns pin #23 (ERASERN) of U01 to H level, transistors (Q16 and Q14) turns on consequently , and the 24 V DC given at pin #1 of connector YC05 applies to the eraser lamps.
4-22 FS-1010 Heater lamp control circuit Activation of the heater lamp is dominated by the HEA T signal which is derived by the engine CPU (U01) at its pin #1. When its level is high, transistor QA03-a turns on, photo-triac PC2 and triac TRC1 turn on simultaneously , and the heater lamp is applied with the primary AC voltage in turn.
4-23 FS-1010 The AC power for the heater is applied in one of the five variations of the zero cross switchings as shown in Figure 4-3-6. Each variation is constituted with the unit of ten positive and negative envelops in five cycles, as obtained by varying the duration during which TRC1 turns on.
4-24 FS-1010 Figure 4-3-6 heater lamp turn-on variations V ariation No.1 (Duty 100 %) V ariation No.2 (Duty 80 %) V ariation No.3 (Duty 60 %) On On On On On On On On On On On On On On On On On On Off Off On On Off On On Off On On Off Off On Off Off Off Off Off Off Off Off Off Off Off Off On Off Off On On Off Off + − + − + − V ariation No.
4-25 FS-1010 Polygon motor control circuit The main controller board supplies the 1700.8 Hz clock pulse (PLGCLK) via the engine board to the PLL control IC (IC1) for the polygon motor.
4-26 FS-1010 (3) P ower suppl y board The power supply board provides the AC power input and DC power and outputs. The high voltage bias generator circuit is mounted on a separate board.
4-27 FS-1010 (4) Bias boar d The bias board contains the developing bias output circuit, registration sensor , paper empty sensor, and the cassette switch. It also provides a liaison connection to the high voltage board, power supply , and the toner sensor .
4-28 FS-1010 (5) High v oltage board The high voltage board contains the high voltage output circuit, interlock switch circuit as well as providing a liaison connection with the power supply board, bias board, and the engine board.
4-29 FS-1010 Interloc k switc h The interlock switch is located on the high voltage board and opened and closed in conjunction with the front cover or the top cover via the interlock lever . This switch connects and disconnects the +24 V DC power supply line.
Chapter 5 Disassembly.
Chapter 5 Contents 5-1 General instructions ........................................................................................................................ 5-3 5-1-1 Screw/hardw are ............................................................
FS-1010 5-3 5-1 General instructions This chapter provides procedures for removal and replacement of the field replacement components. For other components not explained in this chapter , the diagrams in the Parts Catalog attached with this manual will help locate the component.
FS-1010 5-4 5-2 Disassembly Before proceeding, remove the paper cassette and the optional paper feeder, if installed. 5-2-1 Removing the process unit 1. Open the top cover 1 . 2. Open the front cover 2 . 3. Lift the process unit 3 together with the toner container out of the printer .
FS-1010 5-5 5-2-2 Removing the principal outer co vers (1) Removing the top co ver/face-down output tray 1. Open the top cover 1 . 2. Remove two screws 2 .
FS-1010 5-6 (2) Removing the right co ver 1. Remove one screw 1 . 2. Remove the side cover 2 . 3. Unlatch the six snaps 3 and one hook hole 4 on the chassis, remove the right cover 5 . Figure 5-2-3 Removing the right cover (3) Removing the left cover 1.
FS-1010 5-7 5-2-3 Removing the f eed roller CAUTION When refit the feed roller , fit the D-cut shaft into the D-shape hole of the feed roller . 1. Remove the paper cassette and the process unit. (See page 5-4) 2. Stand the machine the front side up. 3.
FS-1010 5-8 5-2-4 Removing the MP tra y feed r oller 1. Remove the engine board. (See page 5-11) 2. Remove one screw 1 . 3. Remove the grounding plate 2 .
FS-1010 5-9 6. Remove one screw 5 . 7. Remove the toner sensor 6 and spring 7 . 8. Remove two screws 8 . 9. While pressing the latch 9 by using the driver and then remove the MP feed unit 0 . Figure 5-2-7 Remo ving the MP feed unit 10. Remove the stop ring ! and then remove the MP feed roller @ .
FS-1010 5-10 5-2-5 Removing the transf er roller CAUTION Do not touch the transfer roller (sponge) surface. Oil and dust (particles of paper, etc.) on the transfer roller can significantly deteriorate the print quality (white spots, etc.). When refitting the bushes and springs, make sure to refit the black colored bush and spring on the left side.
FS-1010 5-11 5-2-6 Removing the principal cir cuit boar ds (1) Removing the engine board 1. Remove the top cover/face-down output tray and right cover (See pages 5-5 and 5-6). 2. Remove all (ten) connectors from the engine board 1 . 3. Remove three screws 2 .
FS-1010 5-12 (2) Removing the main boar d 1. Remove the process unit (See page 5-4). 2. Remove the top/face-down output tray and right cover (See pages 5-4 and 5-5). 3. Remove two connectors 1 from main board 2 . 4. Remove six screws 3 . 5. Remove the controller box (with main board) 4 .
FS-1010 5-13 6. Remove two screws 5 at the back of the main board 2 . 7. Remove three screws 6 from the parallel interface connector 7 and USB connector 8 .
FS-1010 5-14 (3) Removing the po wer supply boar d and high volta g e boar d 1. Remove the process unit (See page 5-4). 2. Remove the top cover/face-down output tray and left cover (See pages 5-5 and 5-6). 3. Remove three connectors 1 from the power supply board 2 .
FS-1010 5-15 (4) Removing the bias boar d 1. Remove the cassette and process unit (See page 5-4). 2. Remove the top cover/face-down output tray and left cover (See pages 5-5 and 5-6). 3. Remove the power supply board and high voltage board (See the previous page).
FS-1010 5-16 5-2-7 Removing the main motor and drive unit 1. Remove the cassette and process unit (See page 5-4). 2. Remove the top cover/face-down output tray and right cover (See pages 5-5 and 5-6). 3. Remove three connectors 1 from the main motor 2 .
FS-1010 5-17 5-2-16 Remo ving the cor d co ver 6. Remove the engine board (See page 5-1 1). 7. Remove wires from wire saddles 4 on the cord cover 5 . 8.
FS-1010 5-18 10. Remove one screw 6 . 11. Remove the grounding plate 7 . 12. Remove three stop rings 8 . 13. Remove MP feed clutch 9 , feed clutch 0 , and registration clutch ! .
FS-1010 5-19 14. Remove the four screws @ . 15. Remove the drive unit # . Figure 5-2-18 Remo ving the drive unit @ # @.
FS-1010 5-20 5-2-8 Removing and splitting the fuser unit W ARNING The fuser unit is hot after the printer was running. W ait until it cools down. CAUTION When refitting the fuser unit, make sure the fuser unit gear and the printer ’ s drive gear are properly meshed with each other.
FS-1010 5-21 7. Remove two screws 5 . 8. Open and split the fuser unit 4 . Figure 5-2-20 Splitting the fuser unit 5 5 4.
FS-1010 5-22 (1) Removing the separator s WARNING The separation claws are extremely hot immediately after the printer was running. Allow substantial period of time until it cools down. 1. Remove and split the fuser unit (See page 5-20). 2. Loosen the stopper screws 1 .
FS-1010 5-23 (2) Removing the heater lamp W ARNING The heater lamp is extremely hot immediately after the printer was running. Allow substantial period of time until it cools down. Also, the heater lamp is fragile: Handle it with great care. CAUTION The heater lamps are fragile.
FS-1010 5-24 (3) Removing the heat r oller W ARNING The heat roller is extremely hot immediately after the printer was running. Allow substantial period of time until it cools down. 1. Remove and split the fuser unit (See page 5-20). 2. Remove the heater lamp (See previous page).
FS-1010 5-25 3. Remove the heat gear Z33 4 , heat R bush 2 , and heat L bush 3 from the heat roller 5 . Figure 5-2-24 Remo ving the heat r oller 2 3 4 5.
FS-1010 5-26 (4) Removing the thermistor 1. Remove and split the fuser unit (See page 5-20). 2. Remove the heater lamp (See page 5-23). 3. Remove the heat roller (See page 5-24).
FS-1010 5-27 (5) Removing the thermal cutout CAUTION Do not bend the terminals of the thermal cutout. 1. Remove and split the fuser unit (See page 5-20). 2. Remove the heater lamp (See page 5-23). 3. Remove the heat roller (See page 5-24). 4. Remove the two screws 1 .
FS-1010 5-28 (6) Removing the press r oller W ARNING The press roller is extremely hot immediately after the printer was running. Allow substantial period of time until it cools down. 1. Remove and split the fuser unit (See page 5-20). 2. Remove the press roller 1 from the fuser unit 2 .
FS-1010 5-29 5-2-9 Remo ving the laser scanner unit and the eraser lamp 1. Remove the process unit (See page 5-4). 2. Remove the top cover/face-down output tray , right cover, and the left cover (See pages 5-5 and 5-6). 3. Remove four connectors 1 . 4.
FS-1010 5-30 5. Remove three screws 6 . 6. Remove one connector 7 from the laser scanner unit 8 . 7. Remove the laser scanner unit 8 . Figure 5-2-27 Removing the laser scanner unit 6 7 8.
FS-1010 5-31 8. Remove the eraser lamp 9 . 9 5-2-28 Remo ving the eraser lamp.
FS-1010 5-32 5-2-10 Remo ving the main char g er unit 1. Remove the process unit from the printer (See page 5-4). 2. Unlatch the three snaps 1 , and remove the main charger cap 2 . 3. Draw the main charger unit 3 in the direction of arrow A , then pull it out in the direction of arrow B .
Chapter 6 T roub leshooting.
Chapter 6 Contents 6-1 T roubleshooting ............................................................................................................ ................... 6-3 6-1-1 Error messages .........................................................
6-3 FS-1010 6-1 T r oubleshooting This chapter explains procedures for identifying and correcting problems. T opics covered are: 6-1-1 Error messages The printer indicates various messages using the LED indicators at its top. The indicators are lit, fast flashing, slow flashing, and off in combination to describe a specific message.
6-4 FS-1010 (1) Messages In the explanation that follows, the following diagrams are used to describe whether the indicator is lit, fast flashing, slow flashing or off.
6-5 FS-1010 Indicator Remote Operation P anel displa y Descr iption Data inside the printer is being canceled. The indicators light in sequence from the top, then go off in sequence from the bottom.
6-6 FS-1010 Indicator Remote Operation P anel displa y Descr iption Maintenance messages The paper has run out. Add paper to the paper cassette (1 or 2) or MP tray. The paper source is displayed in the Remote Operation Panel utility. The paper cassette is not closed securely.
6-7 FS-1010 Indicator Remote Operation P anel displa y Descr iption Open the printer and clear the paper jam. The location of the paper jam is also indicated in place of # ’s. For details on how to clear paper jams, see page 6-31. There is no cassette in the feeder, or the cassette is not inserted properly.
6-8 FS-1010 Indicator Remote Operation P anel displa y Descr iption The specified file is not found. Press the Go key to resume printing. You can abandon printing by pressing the Cancel key. Current print processing cannot continue. Press the Go key to resume printing.
6-9 FS-1010 Indicator Remote Operation P anel displa y Descr iption Current print processing cannot continue due to complex data. The data transferred to the printer was too complex to print on a page. Press the Go key to print data as far as it was stored.
6-10 FS-1010 6-1-2 Service error indications Service errors are represented by the alternating flashing of the indicators (LEDs). Each error is represented by the notation of four digits code and can be monitored on the Remote Operation Panel utility .
6-11 FS-1010 Ye s Ye s Ye s No No No No No No Connect oscilloscope to pin 1 (PLGCLK) and pin 3 (PLGDRN) of YC06 on engine board (KP-882). Tu rn power s witch off, then on.
6-12 FS-1010 No No Tu rn power s witch on. Replace harness (S02770) between engine board and main board. Replace engine board (KP-882). See page 5-11. OK? Ye s Ye s Tu rn power s witch on. OK? End. End. A Continued from previous page . Replace main board (KP-888).
6-13 FS-1010 Ye s Ye s No No No No No Connect oscilloscope to pin 4 (OUTPEN) of YC07 on main board (KP-888). Tu rn power s witch off, then on. Tu rn power s witch off, then on.
6-14 FS-1010 No No Tu rn power s witch on. Tu rn power s witch on. Tu rn power s witch on. Tu rn power s witch on. Replace laser scanner unit. See page 5-29. OK? Ye s OK? Ye s No OK? Ye s No OK? Ye s End. End. B Continued from previous page . Replace engine board (KP-882).
6-15 FS-1010 (4) 5300 - Eraser lamp err or Ye s Ye s No No Tu r n p o wer sw itch off , then on. Print a status page. Does pin 1(ERASPW) of YC05 on engine board (KP-882) output +24 V DC, before sho wn "5300" error ? Does pin 2 (ERASER) of YC05 on engine board (KP-882) remain low? Tu r n p o wer sw itch off , then on.
6-16 FS-1010 Ye s Ye s Ye s No No Tu rn power s witch off, and remov e power cable . Detach connector CN4 on power supply board. Detach connector CN1 on power supply board. Measure resistance between pins 1 and 2 of the detached connector . Replace thermistor.
6-17 FS-1010 Replace the waste toner sensor or engine board. Ye s Ye s No No Shake the process unit horizontally . Tu rn power s witch off, then on. Replace the process unit. "7980" error shown? Tu rn power s witch off, then on. Call service 7980:nnnnnn End.
6-18 FS-1010 (7) 7990 - W aste toner full [T otal page count more than 100,000 pages of printing] Ye s Ye s No No Shake the process unit horizontally . Tu rn power s witch off, then on. Replace the process unit. Tu rn power s witch off, then on. "7990" error shown? Call service 7990:nnnnnn End.
6-19 FS-1010 (10) F030 - Contr oller system error T urn power switch off, then on. If not solved, replace main board (See page 5-12). (11) F040 - Comm unication err or T urn power switch off, then on. If not solved, replace engine board (See page 5-12) or main board (See page 5-12).
6-20 FS-1010 6-1-3 Print quality problems Print quality problems range from uneven tone to completely blank output. The troubleshooting procedure for each type of problem is given below . ABC 123 ABC 123 ABC 123 ABC 123 (1) Completely blank printout See page 6-21.
6-21 FS-1010 (1) Completely blank printout Check the process unit. • Check that the process unit is inserted correctly . Check the transfer bias potential. • Check the transfer bias output on the high voltage board. This requires removal of the left cover and the test equipment.
6-22 FS-1010 (2) All-blac k printout Check the main charger . • Open the printer top cover and check that the process unit is correctly seated. Poor contact main charger terminal between the process unit and the printer main unit. Check the drum bias.
6-23 FS-1010 (3) Dropouts Note the spacing of the defects. Refer to Repetitive defects gauge (See page 6-29). • If the defects occur at regular intervals of 63 mm, the problem may be the damaged developing roller (in the process unit). Replace the process unit.
6-24 FS-1010 (4) Black dots Note the spacing of the defects. Use the Repetitive defects gauge ( See page 6-28). • If the defects occur at regular intervals of 94 mm, the problem may be the damaged drum (in the process unit). Replace the process unit.
6-25 FS-1010 (6) Black vertical streaks Contaminated main charger wire. • Clean the main char ger wire by pulling the green colored cleaning knob in and out several times.
6-26 FS-1010 (7) Unsharpness Check paper for property. • Paper with rugged surface or dump tends to cause unsharp printing. Replace paper with the one that satisfies the paper specifications. Check the transfer roller installation. • The transfer roller must be supported by the bushes at the both ends.
6-27 FS-1010 (8) Gray background Check the print density setting. • The print density may be set too high. T ry adjusting the print density using the Remote operation panel utility . For details refer to the printer ’ s User ’ s Manual . Check the surface potential of the drum (in the process unit).
6-28 FS-1010 (9) Dirt on the top edge or back of the paper Check 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, paper transportation paths, the bottom of the process unit, and the fuser unit inlet.
6-29 FS-1010 Repetitive defects gauge Use the following measurements for checking repetitive occurrences on the printed page. See the above section for details.
6-30 FS-1010 6-1-4 Correcting a paper jam If a paper jam occurs while you are printing, remove the jammed paper as described below . After you have removed the jammed paper , open and close the top cover once. (1) Jam at the face-down and face-up trays 1.
6-31 FS-1010 (2) Jam at the paper cassette 1. Pull out the paper cassette and remove the jammed paper . Figure 6-1-4 Jam at the paper cassette (3) Jam inside the printer 1. Open the top cover and front cover . 2. T ake the process unit together with the toner container out of the printer .
Appendix A Diagrams.
Appendix A Contents Timing c harts .................................................................................................................. ........................ A-3 1. Option paper cassette feeding, tw o A4 size papers ..................
A-3 FS-1010 Timing charts 1. Option paper cassette feeding, two A4 size papers MO TORN (Main motor) MHVDR (Main charger) THVDR (T ransfer charger) PFMDRN (Cassette feed motor) RESDRN (Registration clu.
A-4 FS-1010 2. Option paper cassette feeding, two legal size papers MO TORN (Main motor) MHVDR (Main charger) THVDR (T ransfer charger) PFMDRN (Cassette feed motor) RESDRN (Registration clutch) OUTPEN.
A-5 FS-1010 3. Option paper cassette feeding, two letter size papers MO TORN (Main motor) MHVDR (Main charger) THVDR (T ransfer charger) PFMDRN (Cassette feed motor) RESDRN (Registration clutch) OUTPE.
A-6 FS-1010 4. MP tray f eeding, two A4 size paper s MO TORN (Main motor) MHVDR (Main charger) THVDR (T ransfer charger) MPFSOL (MP feed clutch) RESDRN (Registration clutch) OUTPEN (Laser diode) BIAS .
A-7 FS-1010 5. MP tray feeding, two legal size papers MO TORN (Main motor) MHVDR (Main charger) THVDR (T ransfer charger) MPFSOL (MP feed clutch) RESDRN (Registration clutch) OUTPEN (Laser diode) BIAS.
A-8 FS-1010 6. MP tray feeding, two letter size papers MO TORN (Main motor) MHVDR (Main charger) THVDR (T ransfer charger) MPFSOL (MP feed clutch) RESDRN (Registration clutch) OUTPEN (Laser diode) BIA.
A-9 FS-1010 DGND _S/H _VIDEO _LDEN DGND +5V -IL DGND _HSYNC FPRSTN GND FPCLK FPDIR FPDA T +3.3 V YC301 High voltage board YC-T YC-M CN1 CN2 CN2 F1 : 250 V /8 A (E) 250 V /15 A (U) F2 : 250 V /1.
Appendix B Status Page.
Appendix B Contents Status page .................................................................................................................... ......................... B-3 Printing the service status page .......................................
B-3 FS-1010 Status pa ge The printer can print dif ferent types of the status page—the user (normal) status page and the service status page. This section exclusively describes information obtainable with the service status page. For information on the user (normal) status page, refer to the printer ’ s User ’ s Manual .
B-4 FS-1010 Service information on the status pa ge An example of the service status page is shown below . (Note the details born by the status page my differ from a firmware version to another .) Most of the service information are located under Service information .
B-5 FS-1010 Example Meaning Description 1 [A003] 2 [28.00C] 3 [17/05] 4 Total page 9690 5 /t Engine ROM version Boot ROM version Internal use Total count page Internal use - - - - - [A003][28.00C][17/05] Total page 9690 /t/P00/S00/F00/N00 /0020/0020/1061/8811/ 0/ 0/ 0/ /RS2/00/AI.
B-6 FS-1010 Example Meaning Description 6 P00/ 7 S00/ 8 F00/ 9 N00/ 0 /0020 ! /0020 @ /1061 # /0811 $ / 0/ 0/ 0/ % RS2 ^ /00 Parallel interface mode Serial interface error Operator panel lock (Shown o.
B-7 FS-1010 Example Meaning Description & /AI.E * /G ( /1 ) /020080000000... ⁄ /00800080/... ¤ /00000000/... ‹ SPD1:02030405... › SN:SPL9200010 Average print coverage (sum total) Average pr.
Appendix C Interface.
Appendix C Contents P arallel interface ............................................................................................................. ....................... C-3 Selecting the parallel interf ace mode ..................................
C-3 FS-1010 P arallel interface The printer uses a bidirectional parallel interface for high-speed data transmission for the host computer . This interface includes the buf fers which are compatible with the IEEE 1284 standards. The parallel interface provides support for the ECP and nibble modes in this standards.
C-4 FS-1010 Parallel interface pin assignment The pins of the parallel interface connector carry the signals listed below . The function for each signal is detailed on the following page.
C-5 FS-1010 Signal Meaning A negative-going Strobe* pulse causes the printer to read and latch the data on the Data 0 [1] to Data 7 [8] signal lines. These eight signals form the data byte sent from the host computer to the printer . Data 7 [8] is the most significant bit and Data 0 [1] is the least significant bit.
C-6 FS-1010 USB interface This printer supports the USB (Universal Serial Bus) Revision 1.1 standards. USB interface specifications and interface signals are as follows: Item Specifications Basic specification Complies with the USB Revision 1.1 standards.
C-7 FS-1010 Serial interface (Optional) The printer is equipped with an optional slot for adding a serial port. T o add a serial port, the serial interface board is equipped. The device responsible for controlling the serial interface is integrated in the gate array in the controller system.
C-8 FS-1010 Remove two thumb screws 1 then draw the serial interface board 2 . To change the serial protocol from RS-232C to RS-422A, for example, carefully remove the jumper connector 3 on the serial interface board 2 . Reconnect to the pin position as shown in the diagram.
C-9 FS-1010 Serial interface signals The following table provides details for the signals used on the serial interface board. Signal Meaning FG (Pin 1) This pin is connected directly to the printer frame. TxD (Pin 2) RS-232C only: This output carries asynchronous data sent by the printer to the computer .
C-10 FS-1010 RXD TXD DTR GND DSR RTS CTS TXD RXD RTS CTS DSR SG DTR 2 3 4 5 6 7 8 2 3 4 5 6 7 ) Computer serial por t (DB-9) Printer serial por t (DB-25) GND TXD RXD RTS CTS DSR GND DTR FG TXD RXD RTS.
C-11 FS-1010 RS-422A Frame ground Signal ground Rx terminal Tx terminal FG RD −# SG SD − SD + RD + 1 3 7 9 0 * Computer serial interface Printer serial port (DB-25) On the computer serial port, investigate pin assignments depends on the computer manufacture’s instruction.
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