KYOCERA FS-1010 User Manual

SERVICEMANUALPublished in Dec. ’01Laser printer

Chapter 1 Contents1-1 Printer specifications ...

FS-10105-205-2-8 Removing and splitting the fuser unitWARNING The fuser unit is hot after the printer was running. Wait until it cools down.CAUTION Wh

FS-10105-21 7. Remove two screws 5. 8. Open and split the fuser unit 4.Figure 5-2-20 Splitting the fuser unit554

FS-10105-22(1) Removing the separatorsWARNING The separation claws are extremely hot immediately after the printer was running.Allow substantial perio

FS-10105-23(2) Removing the heater lampWARNING The heater lamp is extremely hot immediately after the printer was running.Allow substantial period of

FS-10105-24(3) Removing the heat rollerWARNING The heat roller is extremely hot immediately after the printer was running. Allowsubstantial period of

FS-10105-25 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 Removing the heat roller2345

FS-10105-26(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 he

FS-10105-27(5) Removing the thermal cutoutCAUTION Do not bend the terminals of the thermal cutout. 1. Remove and split the fuser unit (See page 5-20).

FS-10105-28(6) Removing the press rollerWARNING The press roller is extremely hot immediately after the printer was running. Allowsubstantial period o

FS-10105-295-2-9 Removing the laser scanner unit and the eraser lamp 1. Remove the process unit (See page 5-4). 2. Remove the top cover/face-down outp

FS-10101-31-1 Printer specifications1-1-1 Specifications(1) EngineItem SpecificationPrint methodPrint speed (when printingmultiple pages)Resolution (d

FS-10105-30 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 Removi

FS-10105-31 8. Remove the eraser lamp 9.95-2-28 Removing the eraser lamp

FS-10105-325-2-10 Removing the main charger unit 1. Remove the process unit from the printer (See page 5-4). 2. Unlatch the three snaps 1, and remove

Chapter 6T roubleshooting

Chapter 6 Contents6-1 Troubleshooting ...

6-3FS-10106-1 TroubleshootingThis chapter explains procedures for identifying and correcting problems. Topics covered are:6-1-1 Error messagesThe prin

6-4FS-1010(1) MessagesIn the explanation that follows, the following diagrams are used to describe whether the indicator islit, fast flashing, slow fl

6-5FS-1010 IndicatorRemote Operation Panel display DescriptionData inside the printer is beingcanceled.The indicators light in sequence fromthe top,

6-6FS-1010 IndicatorRemote Operation Panel display DescriptionMaintenance messagesThe paper has run out. Add paper to thepaper cassette (1 or 2) or

6-7FS-1010 IndicatorRemote Operation Panel display DescriptionOpen the printer and clear the paperjam. The location of the paper jam isalso indicate

1-4FS-1010Item Specification Item SMain unit (excl. protrusions)(2) Controller(3) Weight and dimensionsItem SpecificationCPUSystem ROMFont ROMOptional

6-8FS-1010 IndicatorRemote Operation Panel display DescriptionThe specified file is not found. Press theGo key to resume printing. You canabandon pr

6-9FS-1010 IndicatorRemote Operation Panel display DescriptionCurrent print processing cannotcontinue due to complex data.The data transferred to th

6-10FS-10106-1-2 Service error indicationsService errors are represented by the alternating flashing of the indicators (LEDs). Each error isrepresente

6-11FS-1010Ye sYe sYe sNoNoNoNoNoNoConnect oscilloscope to pin 1 (PLGCLK) and pin 3 (PLGDRN) of YC06 on engine board (KP-882).Turn power switch off, t

6-12FS-1010NoNoTurn power switch on.Replace harness (S02770) between engine board and main board.Replace engine board (KP-882). See page 5-11.OK?Ye sY

6-13FS-1010Ye sYe sNoNoNoNoNoConnect oscilloscope to pin 4 (OUTPEN) of YC07 on main board (KP-888).Turn power switch off, then on.Turn power switch of

6-14FS-1010NoNoTurn power switch on.Turn power switch on.Turn power switch on.Turn power switch on.Replace laser scanner unit. See page 5-29.OK?Ye sOK

6-15FS-1010(4) 5300 - Eraser lamp errorYe sYe sNoNoTurn power switch off, then on.Print a status page.Does pin 1(ERASPW) of YC05 on engine board (KP-8

6-16FS-1010Ye sYe sYe sNoNoTurn power switch off, and remove power cable.Detach connector CN4 on power supply board.Detach connector CN1 on power supp

6-17FS-1010Replace the waste toner sensor or engine board.Ye sYe sNoNoShake the process unit horizontally.Turn power switch off, then on.Replace the p

FS-10101-5(4) Power requirements(5) Environmental requirementsItem Specification Item SVo ltage/current requirementWatts220 to 240 V AC ± 10 %, 50/60

6-18FS-1010(7) 7990 - Waste toner full [Total page count more than 100,000 pages of printing]Ye sYe sNoNoShake the process unit horizontally.Turn powe

6-19FS-1010(10) F030 - Controller system errorTurn power switch off, then on. If not solved, replace main board (See page 5-12).(11) F040 - Communicat

6-20FS-10106-1-3 Print quality problemsPrint quality problems range from uneven tone to completely blank output. The troubleshootingprocedure for each

6-21FS-1010(1) Completely blank printoutCheck the process unit.• Check that the process unit is inserted correctly.Check the transfer bias potential.•

6-22FS-1010(2) All-black printoutCheck the main charger.• Open the printer top cover and check that the process unit is correctly seated. Poor contact

6-23FS-1010(3) DropoutsNote the spacing of thedefects. Refer to Repetitive defects gauge (See page 6-29).• If the defects occur at regular intervals o

6-24FS-1010(4) Black dotsNote the spacing of the defects. Use the Repetitive defects gauge (See page 6-28).• If the defects occur at regular intervals

6-25FS-1010(6) Black vertical streaksContaminated main charger wire.• Clean the main charger wire by pulling the green colored cleaning knob in and ou

6-26FS-1010(7) UnsharpnessCheck paper for property.• Paper with rugged surface or dump tends to cause unsharp printing. Replace paper with the onethat

6-27FS-1010(8) Gray backgroundCheck the print density setting.• The print density may be set too high. Try adjusting the print density using the Remot

1-6FS-10101-2 Names of parts1-2-1 Name of partsFigure 1-2-1 Name of parts1 Top cover2 Face-down output tray3 Face-up output tray4 Side cover5 Operator

6-28FS-1010(9) Dirt on the top edge or back of the paperCheck toner contamination in various parts.• Dirty edges and back of the paper can be caused b

6-29FS-1010Repetitive defects gaugeUse the following measurements for checking repetitive occurrences on the printed page. See theabove section for de

6-30FS-10106-1-4 Correcting a paper jamIf a paper jam occurs while you are printing, remove the jammed paper as described below. Afteryou have removed

6-31FS-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 insi

Appendix ADiagrams

Appendix A ContentsTiming charts ...

A-3FS-1010Timing charts1. Option paper cassette feeding, two A4 size papersMOTORN(Main motor)MHVDR(Main charger)THVDR(Transfer charger)PFMDRN(Cassette

A-4FS-10102. Option paper cassette feeding, two legal size papersMOTORN(Main motor)MHVDR(Main charger)THVDR(Transfer charger)PFMDRN(Cassette feed moto

A-5FS-10103. Option paper cassette feeding, two letter size papersMOTORN(Main motor)MHVDR(Main charger)THVDR(Transfer charger)PFMDRN(Cassette feed mot

A-6FS-10104. MP tray feeding, two A4 size papersMOTORN(Main motor)MHVDR(Main charger)THVDR(Transfer charger)MPFSOL(MP feed clutch)RESDRN(Registration

FS-10101-71-3 Safety information1-3-1 Safety information(1) Laser safetyThis printer is certified as a Class 1 laser product under the U.S. Department

A-7FS-10105. MP tray feeding, two legal size papersMOTORN(Main motor)MHVDR(Main charger)THVDR(Transfer charger)MPFSOL(MP feed clutch)RESDRN(Registrati

A-8FS-10106. MP tray feeding, two letter size papersMOTORN(Main motor)MHVDR(Main charger)THVDR(Transfer charger)MPFSOL(MP feed clutch)RESDRN(Registrat

A-9FS-1010DGND_S/H_VIDEO_LDENDGND+5V-ILDGND_HSYNCFPRSTNGNDFPCLKFPDIRFPDAT+3.3 VYC301High voltage boardYC-TYC-MCN1CN2CN2F1 : 250 V /8 A (E) 250 V

Appendix BStatus Page

Appendix B ContentsStatus page ...

B-3FS-1010Status pageThe printer can print different types of the status page—the user (normal) status page and theservice status page. This section e

B-4FS-1010Service information on the status pageAn example of the service status page is shown below. (Note the details born by the status page mydiff

B-5FS-1010Example Meaning Description1 [A003]2 [28.00C]3 [17/05]4 Total page 96905 /tEngine ROM versionBoot ROM versionInternal useTotal count pageInt

B-6FS-1010Example Meaning Description6 P00/7 S00/8 F00/9 N00/0 /0020! /0020@ /1061# /0811$ / 0/ 0/ 0/% RS2^ /00Parallel interface modeSerial int

B-7FS-1010Example Meaning Description& /AI.E* /G( /1) /020080000000...⁄ /00800080/...¤ /00000000/...‹ SPD1:02030405...› SN:SPL9200010Average print

1-8FS-1010WARNING Use of controls or adjustments or performance of procedures other than thosespecified herein may result in hazardous radiation expos

Appendix CInterface

Appendix C ContentsParallel interface ...

C-3FS-1010Parallel interfaceThe printer uses a bidirectional parallel interface for high-speed data transmission for the hostcomputer. This interface

C-4FS-1010Parallel interface pin assignmentThe pins of the parallel interface connector carry the signals listed below. The function for eachsignal is

C-5FS-1010Signal MeaningA negative-going Strobe* pulse causes the printer to read and latchthe data on the Data 0 [1] to Data 7 [8] signal lines.These

C-6FS-1010USB interfaceThis printer supports the USB (Universal Serial Bus) Revision 1.1 standards. USB interfacespecifications and interface signals

C-7FS-1010Serial interface (Optional)The printer is equipped with an optional slot for adding a serial port. To add a serial port, the serialinterface

C-8FS-1010Remove two thumb screws 1 then draw the serial interface board 2. To change the serial protocolfrom RS-232C to RS-422A, for example, careful

C-9FS-1010Serial interface signalsThe following table provides details for the signals used on the serial interface board.Signal MeaningFG (Pin 1) Thi

C-10FS-1010RXDTXDDTRGNDDSRRTSCTSTXDRXDRTSCTSDSRSGDTR2345678234567)Computer serial port (DB-9)Printerserial port (DB-25)GNDTXDRXDRTSCTSDSRGNDDTRFGTXDRX

FS-10101-9(4) CDRH regulations (U.S.A.)The Center of Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administrationimplemented regula

C-11FS-1010RS-422AFrame groundSignal groundRx terminalTx terminalFGRD−#SGSD−SD+RD+13790*Computer serial interfacePrinterserial port (DB-25)On the comp

KYOCERA MITA DANMARK A/SIndustrivej 11, DK-4632 Bjæverskov,DenmarkPhone: 56871100KYOCERA MITA PORTUGAL LDA.CASCAISTOCK-Armazem nº8,Rua das Fisgas, Alc

©2001 KYOCERA MITA CORPORATION is a trademark of Kyocera Corporation is a registered trademark of KYOCERA MITA CORPOR

1-10FS-10101-4 Environmental requirements1-4-1 Environmental conditionsThe Environmental requirements section on page 1-5 should be observed to ensur

FS-10101-11(1) ClearanceAllow the necessary minimum clearance on all sides of the printer as diagrammed below.Figure 1-4-2 ClearancesRef. Clearance

Version Replaced pages RemarksDate1.0Revision history5-Dec-2001

1-12FS-1010(2) Places to avoidAvoid installing the printer in locations exposed to:• Direct drafts of hot or cold air.• Direct drafts of outside air.

FS-10101-13(4) Removing the printerObserve the following precautions in removal and transportation of the printer.• Be sure to repack the printer in i

1-14FS-101011-5 About the toner container1-5-1 Toner containerThe printer should use a TK-17 toner kit. To ensure the high print quality and long serv

FS-10101-15(2) Toner container storageThe toner contained in the container is susceptible to temperature and humidity. To ensure the highprint quality

Chapter 2Installation/Operation

Chapter 2 Contents2-1 Unpacking...

FS-10102-32-1 Unpacking2-1-1 Unpacking and inspectionThe package should contain the printer and the accessories as shown in the figure below. Removeth

2-4FS-10102-2 Installing the printerInstalling the printer requires several steps. Proceed as follows in sequence. If the option paperfeeder is used w

FS-10102-5 3. Take the toner container 2 from the bag. Hold it with the protective seal 3 (orange-colored)facing up. Shake the toner container 2 horiz

2-6FS-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].F

Safety precautionsThis booklet provides safety warnings and precautions for our service personnel to ensure the safety oftheir customers, their machin

FS-10102-7 7. Push the lock lever #1 1 to the lock position. 8. Close the top cover 4.Figure- 2-2-5 Locking the toner containerNOTE The printer is shi

2-8FS-10102-2-2 Expanding memoryThe FS-1010 printer comes standard equipped with 16 MB of main memory on the main board.Printer memory can be expanded

FS-10102-9(3) Notes on handling DIMMBefore proceeding to install DIMM, read the following notes for handling the main board andDIMMs:• Protect the ele

2-10FS-1010(4) Installing the DIMMThe main board of the printer is equipped with one socket for memory expansion. Expansion memoryis available in the

FS-10102-11Open the clips 2 on both ends of the DIMM socket 3. Insert the DIMM 4 into the DIMM socket3 so that the notches on the DIMM align with the

2-12FS-1010(6) Installing the memory card (CompactFlash)The main board of the printer is equipped with one slot for memory card.CAUTION Take precautio

FS-10102-13Insert the memory card 4 in the slot. Insert as shown in the figure. Push it in all the way. Close andsecure the option interface slot cove

2-14FS-1010(7) Installing the network interface cardIf the serial interface board kit is installed, remove it to use the network interface card.CAUTIO

FS-10102-152-3 Using the operator panelThis section provides explanation on how to use the printer’s operator panel for basic operation.For details, r

2-16FS-10102-3-2 Remote operation panelThe remote operation panel is a utility that allows you to make basic printer settings from thecomputer connect

indicates that action is required. The specific action required is shown inside the symbol.General action required.Remove the power plug from the wal

Chapter 3Maintenance/Adjustments

Chapter 3 Contents3-1 Maintenance/Adjustments ...

3-3FS-10103-1 Maintenance/Adjustments3-1-1 Life expectancy of modulesThe table below shows the nominal life expectancy for modules. Detailed part info

3-4FS-10103-1-2 Toner containerAssuming an average toner coverage of 5 % with EcoPrint mode turned off, the toner containerwill need replacing approxi

3-5FS-1010(3) Toner container replacementTo replace the toner container, open the top cover. Pull lock lever #1 1 to the release [UNLOCK]position, the

3-6FS-1010Put it in the supplied plastic bag 4 and dispose of it.Figure 3-1-3 Disposal of the old toner containerNOTE Although the toner container is

3-7FS-10103-1-3 Cleaning the printerTo avoid print quality problems, the following printer parts must be cleaned with every toner containerreplacement

3-8FS-1010(1) Cleaning the registration rollerUse the supplied wiper cloth 1 to clean dust and dirt away from the registration roller 2 (metal).Figure

3-9FS-10103-1-4 Updating the firmwareUpdating the system (controller) firmware is possible by downloading the firmware through theparallel interface o

3-10FS-1010(2) Downloading the firmware from the parallel interfaceThis section explains how to download firmware data from the parallel interface. Th

1. Installation PrecautionsWARNING•Do not use a power supply with a voltage other than that specified. Avoid multiple connections toone outlet: they m

3-11FS-1010(3) Downloading the firmware from the memory cardTo download data written in a memory card (CompactFlash) to the printer, proceed as explai

3-12FS-1010 CauseCorrective actionDescriptionLED indicatorsLED indicatorsDownload finished normally ConventionDownload errorsSlow flashingFast flashin

Chapter 4Operation Overview

Chapter 4 Contents4-1 Electrophotographic system ...

4-3FS-10104-1 Electrophotographic systemElectrophotography is the technology used in laser printing which transfer data representing textsor graphics

4-4FS-10101 Main charger unit2 Charger wire3 Grid4 Developing roller5 Gear Z14-Z186 Gear Z14-Z367 Gear Z18-Z368 Free gear Z40Process unit mechanismFig

4-5FS-1010(1) Main chargingPhoto conductive drumThe durable layer of organic photoconductor (OPC) is coated over the aluminum cylinder base.The OPC te

4-6FS-1010Charging the drumThe following shows a simplified diagram of the electrophotographic components in relation to theengine system. Charging th

4-7FS-1010(2) ExposureThe charged surface of the drum A is then scanned by the laser beam from the laser scanner unitB.Figure 4-1-5 ExposureThe laser

4-8FS-1010Laser scanner unitName Description1 Laser diode Emits diffused, visible laser.2 Cylindrical lens Compensates the vertical angle at which the

• Check that the power cable covering is free of damage. Check that the power plug is dust-free. Ifit is dirty, clean it to remove the risk of fire or

4-9FS-1010Drum surface potentialThe laser beam is continually switched on and off depending on the print data. It is on for a black(exposed) dot and o

4-10FS-1010(3) DevelopmentThe latent image constituted on the drum is developed into a visible image. The developing rollerA contains a 3-pole (S-N-S

4-11FS-1010(4) TransferThe image developed by toner on the drum A is transferred onto the paper because of the electricalattraction between the toner

4-12FS-1010(5) FusingThe toner on the paper is molten and pressed into the paper as it passes between the heat roller Aand the press roller B in the f

4-13FS-10101 Heat roller2 Idle gear Z343 Exit gear Z234 Idle gear Z180!123456789@5 Heat gear Z336 Press roller7 Heater lamp [500±25 W]8 Thermal cutout

4-14FS-1010EABCD(6) CleaningAfter the transferring process, the drum needs to be physically cleaned of toner which is residualafter the development pr

4-15FS-10104-2 Paper feeding systemThe paper feeding system picks up paper from the cassette, MP tray, or if installed, the paper feederPF-17, feeds i

4-16FS-10104-2-1 Paper feed controlThe following diagram shows interconnectivity of the feeding system components including thesensors and rollers. Th

4-17FS-10100!@%(&AB#$*)^345621789CA For process unit; drum (From main unit)B For process unit; toner container, developing roller etc. (From

4-18FS-10104-3 Electrical control system4-3-1 Electrical parts layoutFigure 4-3-1 Electrical parts layout9208ML5!#KJ4%$@7H3GI162BACDEF(&^*1 Main b

• Do not pull on the AC power cord or connector wires on high-voltage components when removingthem; always hold the plug itself. ...

4-19FS-10104-3-2 Operation of circuit boards(1) Main boardFigure 4-3-2 Main board circuit block diagramQ01Digital TransistorQ02Digital TransistorYC03

4-20FS-1010(2) Engine boardFigure 4-3-3 Engine board circuit block diagramMain board(KP-888)Laser scanner unitRSTINRSTNPLGCLKPLGRDYNPLGDRNEESCKMPFDRNE

4-21FS-1010Eraser lamp control circuitThe CPU (U01) turns pin #23 (ERASERN) of U01 to H level, transistors (Q16 and Q14) turns onconsequently, and the

4-22FS-1010Heater lamp control circuitActivation of the heater lamp is dominated by the HEAT signal which is derived by the engine CPU(U01) at its pin

4-23FS-1010The AC power for the heater is applied in one of the five variations of the zero cross switchings asshown in Figure 4-3-6. Each variation i

4-24FS-1010 Figure 4-3-6 heater lamp turn-on variationsVariation No.1(Duty 100 %)Variation No.2(Duty 80 %)Variation No.3(Duty 60 %)On On On On On On O

4-25FS-1010Polygon motor control circuitThe main controller board supplies the 1700.8 Hz clock pulse (PLGCLK) via the engine board tothe PLL control I

4-26FS-1010(3) Power supply boardThe power supply board provides the AC power input and DC power and outputs. The high voltagebias generator circuit i

4-27FS-1010(4) Bias boardThe bias board contains the developing bias output circuit, registration sensor, paper empty sensor,and the cassette switch.

4-28FS-1010(5) High voltage boardThe high voltage board contains the high voltage output circuit, interlock switch circuit as well asproviding a liais

1-1-1ContentsChapter 11-1 Printer specifications ...

4-29FS-1010Interlock switchThe interlock switch is located on the high voltage board and opened and closed in conjunctionwith the front cover or the t

Chapter 5Disassembly

Chapter 5 Contents5-1 General instructions ...

FS-10105-35-1 General instructionsThis chapter provides procedures for removal and replacement of the field replacement components.For other component

FS-10105-45-2 DisassemblyBefore proceeding, remove the paper cassette and the optional paper feeder, if installed.5-2-1 Removing the process unit 1.

FS-10105-55-2-2 Removing the principal outer covers(1) Removing the top cover/face-down output tray 1. Open the top cover 1. 2. Remove two screws 2. 3

FS-10105-6(2) Removing the right cover 1. Remove one screw 1. 2. Remove the side cover 2. 3. Unlatch the six snaps 3 and one hook hole 4 on the chassi

FS-10105-75-2-3 Removing the feed rollerCAUTION When refit the feed roller, fit the D-cut shaft into the D-shape hole of the feedroller. 1. Remove the

FS-10105-85-2-4 Removing the MP tray feed roller 1. Remove the engine board. (See page 5-11) 2. Remove one screw 1. 3. Remove the grounding plate 2. 4

FS-10105-9 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

Chapter 1Product Information

FS-10105-105-2-5 Removing the transfer rollerCAUTION Do not touch the transfer roller (sponge) surface. Oil and dust (particles of paper,etc.) on the

FS-10105-115-2-6 Removing the principal circuit boards(1) Removing the engine board 1. Remove the top cover/face-down output tray and right cover (See

FS-10105-12(2) Removing the main board 1. Remove the process unit (See page 5-4). 2. Remove the top/face-down output tray and right cover (See pages 5

FS-10105-13 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

FS-10105-14(3) Removing the power supply board and high voltage board 1. Remove the process unit (See page 5-4). 2. Remove the top cover/face-down out

FS-10105-15(4) Removing the bias board 1. Remove the cassette and process unit (See page 5-4). 2. Remove the top cover/face-down output tray and left

FS-10105-165-2-7 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 outp

FS-10105-175-2-16 Removing the cord cover 6. Remove the engine board (See page 5-11). 7. Remove wires from wire saddles 4 on the cord cover 5. 8. Remo

FS-10105-1810. 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 regis

FS-10105-19 14. Remove the four screws @. 15. Remove the drive unit #.Figure 5-2-18 Removing the drive unit@#@