Text preview for : Kyocera FS--1010 Service Manual.pdf part of Kyocera FS-1010 Kyocera FS-1010 Laser Printer Service Manual



Back to : Kyocera FS--1010 Service | Home

Laser printer

SERVICE MANUAL
Published in Dec. '01

Revision history
Version 1.0 Date 5-Dec-2001 Replaced pages Remarks

Safety precautions

This booklet provides safety warnings and precautions for our service personnel to ensure the safety of their customers, their machines as well as themselves during maintenance activities. Service personnel are advised to read this booklet carefully to familiarize themselves with the warnings and precautions described here before engaging in maintenance activities.

Safety warnings and precautions
Various symbols are used to protect our service personnel and customers from physical danger and to prevent damage to their property. These symbols are described below:

DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol. WARNING:Serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol. CAUTION: Bodily injury or damage to property may result from insufficient attention to or incorrect compliance with warning messages using this symbol. Symbols The triangle ( ) symbol indicates a warning including danger and caution. The specific point of attention is shown inside the symbol. General warning. Warning of risk of electric shock. Warning of high temperature. indicates a prohibited action. The specific prohibition is shown inside the symbol. General prohibited action. Disassembly prohibited. 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. Always ground the printer.

1. Installation Precautions
WARNING Do not use a power supply with a voltage other than that specified. Avoid multiple connections to one outlet: they may cause fire or electric shock. When using an extension cable, always check that it is adequate for the rated current. ............................................................................................ Connect the ground wire to a suitable grounding point. Not grounding the printer may cause fire or electric shock. Connecting the earth wire to an object not approved for the purpose may cause explosion or electric shock. Never connect the ground cable to any of the following: gas pipes, lightning rods, ground cables for telephone lines and water pipes or faucets not approved by the proper authorities. .............................................................................................................................

CAUTION: Do not place the printer on an infirm or angled surface: the printer may tip over, causing injury. ....

Do not install the printer in a humid or dusty place. This may cause fire or electric shock. .............. Do not install the printer near a radiator, heater, other heat source or near flammable material. This may cause fire. ..........................................................................................................................

Allow sufficient space around the printer to allow the ventilation grills to keep the machine as cool as possible. Insufficient ventilation may cause heat buildup and poor copying performance. ..........

Always handle the machine by the correct locations when moving it. .............................................. Always use anti-toppling and locking devices on printers so equipped. Failure to do this may cause the printer to move unexpectedly or topple, leading to injury. ................................................ Avoid inhaling toner or developer excessively. Protect the eyes. If toner or developer is accidentally ingested, drink a lot of water to dilute it in the stomach and obtain medical attention immediately. If it gets into the eyes, rinse immediately with copious amounts of water and obtain medical attention. .............................................................................................................................. Advice customers that they must always follow the safety warnings and precautions in the printer's instruction handbook. ..........................................................................................................

2. Precautions for Maintenance
WARNING Always remove the power plug from the wall outlet before starting machine disassembly. .............

Always follow the procedures for maintenance described in the service manual and other related brochures. .........................................................................................................................................

Under no circumstances attempt to bypass or disable safety features including safety mechanisms and protective circuits. .................................................................................................

Always use parts having the correct specifications. .......................................................................... Always use the thermostat or thermal fuse specified in the service manual or other related brochure when replacing them. Using a piece of wire, for example, could lead to fire or other serious accident. ...............................................................................................................................

When the service manual or other serious brochure specifies a distance or gap for installation of a part, always use the correct scale and measure carefully. ...............................................................

Always check that the printer is correctly connected to an outlet with a ground connection. ........... 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. Leaking laser light may damage eyesight. .............................................................................................................................. Handle the charger sections with care. They are charged to high potentials and may cause electric shock if handled improperly. .................................................................................................

CAUTION Wear safe clothing. If wearing loose clothing or accessories such as ties, make sure they are safely secured so they will not be caught in rotating sections. .........................................................

Use utmost caution when working on a powered machine. Keep away from chains and belts. .......

Handle the fixing section with care to avoid burns as it can be extremely hot. .................................

Check that the fixing unit thermistor, heat and press rollers are clean. Dirt on them can cause abnormally high temperatures. .........................................................................................................

Do not remove the ozone filter, if any, from the printer except for routine replacement. ..................

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

Do not route the power cable where it may be stood on or trapped. If necessary, protect it with a cable cover or other appropriate item. ..............................................................................................

Treat the ends of the wire carefully when installing a new charger wire to avoid electric leaks. ...... Remove toner completely from electronic components. ...................................................................

Run wire harnesses carefully so that wires will not be trapped or damaged. ................................... After maintenance, always check that all the parts, screws, connectors and wires that were removed, have been refitted correctly. Special attention should be paid to any forgotten connector, trapped wire and missing screws. .................................................................................. Check that all the caution labels that should be present on the machine according to the instruction handbook are clean and not peeling. Replace with new ones if necessary. ...................

Handle greases and solvents with care by following the instructions below: .................................... Use only a small amount of solvent at a time, being careful not to spill. Wipe spills off completely. Ventilate the room well while using grease or solvents. Allow applied solvents to evaporate completely before refitting the covers or turning the main switch on. Always wash hands afterwards. Never dispose of toner or toner bottles in fire. Toner may cause sparks when exposed directly to fire in a furnace, etc. ......................................................................................................................... Should smoke be seen coming from the printer, remove the power plug from the wall outlet immediately. ......................................................................................................................................

3. Miscellaneous
WARNING Never attempt to heat the drum or expose it to any organic solvents such as alcohol, other than the specified refiner; it may generate toxic gas. ................................................................................

Contents Chapter 1
1-1 Printer specifications ....................................................................................................................................... 1-3 1-2 Names of parts ................................................................................................................................................ 1-6 1-3 Safety information ............................................................................................................................................ 1-7 1-4 Environmental requirements .......................................................................................................................... 1-10 1-5 About the toner container .............................................................................................................................. 1-14

Chapter 2
2-1 Unpacking ........................................................................................................................................................ 2-3 2-2 Installing the printer ......................................................................................................................................... 2-4 2-3 Using the operator panel ............................................................................................................................... 2-15

Chapter 3
3-1 Maintenance/Adjustments ............................................................................................................................... 3-3

Chapter 4
4-1 Electrophotographic system ............................................................................................................................ 4-3 4-2 Paper feeding system .................................................................................................................................... 4-15 4-3 Electrical control system ................................................................................................................................ 4-18

Chapter 5
5-1 General instructions ......................................................................................................................................... 5-3 5-2 Disassembly .................................................................................................................................................... 5-4

Chapter 6
6-1 Troubleshooting ............................................................................................................................................... 6-3

Appendix A
Timing charts ........................................................................................................................................................ A-3 Wiring diagram ...................................................................................................................................................... A-9

Appendix B
Status page ........................................................................................................................................................... B-3

Appendix C
Parallel interface ................................................................................................................................................... C-3 USB interface ........................................................................................................................................................ C-6 Serial interface (Optional) ..................................................................................................................................... C-7 1-1-1

Chapter 1

Product Information

Chapter 1 Contents
1-1 Printer specifications ...................................................................................................................... 1-3 1-1-1 Specifications ............................................................................................................................ 1-3 (1) Engine ................................................................................................................................. 1-3 (2) Controller ............................................................................................................................. 1-4 (3) Weight and dimensions ....................................................................................................... 1-4 (4) Power requirements............................................................................................................. 1-5 (5) Environmental requirements ................................................................................................ 1-5 1-2 Names of parts ................................................................................................................................. 1-6 1-2-1 Name of parts ............................................................................................................................ 1-6 1-3 Safety information ........................................................................................................................... 1-7 1-3-1 Safety information ...................................................................................................................... 1-7 (1) Laser safety ......................................................................................................................... 1-7 (2) Laser notice ......................................................................................................................... 1-7 (3) Laser caution label on the scanner unit ............................................................................... 1-7 (4) CDRH regulations (U.S.A.) .................................................................................................. 1-9 (5) Ozone concentration ........................................................................................................... 1-9 (6) Optional equipment ............................................................................................................. 1-9 (7) Important note on the interface connectors ......................................................................... 1-9 1-4 Environmental requirements ........................................................................................................ 1-10 1-4-1 Environmental conditions......................................................................................................... 1-10 (1) Clearance .......................................................................................................................... 1-11 (2) Places to avoid .................................................................................................................. 1-12 (3) Note on power ................................................................................................................... 1-12 (4) Removing the printer ......................................................................................................... 1-13 1-5 About the toner container ............................................................................................................. 1-14 1-5-1 Toner container ........................................................................................................................ 1-14 (1) Toner container handling ................................................................................................... 1-14 (2) Toner container storage ..................................................................................................... 1-15

1-1 Printer specifications
1-1-1 Specifications (1) Engine Item Print method Print speed (when printing multiple pages) Resolution (dpi) Smoothing First print (A4 or letter, 23 C), depends on input data Warm-up time at 23 C Maximum duty cycle (A4) Process unit life expectancy Developing Laser diode Main charger Transferring Separation Drum cleaning Drum discharging Fuser Paper Capacity of paper feed trays (80 g/m2 [0.11 mm thickness]) Capacity of output trays (80 g/m2 [0.11 mm thickness]) Specification Electrophotography laser scan 14 pages/min. (A4) 15 pages/min. (Letter) Fast 1200 mode (1800 horizontal/600 vertical) 600 horizontal/600 vertical KIR (Kyocera Image Refinement) 22 seconds or less 10 seconds or less (from sleep mode) 15 seconds or less (from power on) 100,000 pages of printing or 3 years, whichever reached first Mono component developer Visible laser Scorotron positive charging Negative charger roller Curvature separation Blade Eraser lamp (LED array) Heat roller and press roller Plain paper: Legal to A5 Cassette: 250 sheets, MP tray: 50 sheets Face-up: 30 sheets, Face-down: 150 sheets

FS-1010

1-3

(2) Controller Item CPU System ROM Font ROM Optional font ROM (Dip socket) Main (Video) RAM Expanding RAM (DIMM slot 1) Host interface Specification PowerPC405/200MHz 4 MB Flash DIMM 2 MB (16 M bit 1) 1 MB (Optional KPDL2 Upgrade kit) 16 MB (Standard-equipped on main board) Maximum 144 MB (Including the standard 16 MB main RAM) (Accepts any of 16/32/64/128 MB DIMM) Parallel: High-speed, bidirectional (IEEE1284) USB: Revision 1.1 standards Serial: Optional serial interface board, RS-232C/RS-422A, Max. speed: 115.2 Kbps KUIO-LV (3.3 V): Optional network interface card Prescribe 2e PCL6, Diablo 630, IBM proprinter X24E, Epson LQ850, Line printer, KPDL2

Page description language Standard emulation modes

(3) Weight and dimensions

Item Main unit (excl. protrusions)

Specification Width: Height: Depth: Weight: 378 mm (147/8 inches) 222 mm (83/4 inches) 375 mm (143/4 inches) 9.5 Kg (2015/16 lb.)

Item

S

FS-1010

1-4

(4) Power requirements

Item Voltage/current requirement

Watts

Specification Item S 220 to 240 V AC 10 %, 50/60 Hz 2 %/3.8 A (European countries) 120 V AC 10 %, 60 Hz 2 %/7.1 A (U.S.A/Canada) Normal operation: 265 W Maximum: 818 W Standby: 13 W Sleeping: 5 W (220 to 240 V model), 6 W (120 V model)

(5) Environmental requirements

Item Operating temperature and humidity Maximum altitude Noise emission (Excluding peaks, measured at 1 m from printer, as per ISO7779)

Specification

Item

S

10 to 32.5 C (50 to 90.5 F), 20 to 80 %RH 2,000 m (6,500 feet) 50 dB (A) maximum/28 dB (A) at standby/unmeasureably low at sleeping)

FS-1010

1-5

1-2 Names of parts
1-2-1 Name of parts
2 1 3

4 8 7 6 5

9 ! 0

@ #

1 Top cover 2 Face-down output tray 3 Face-up output tray 4 Side cover 5 Operator panel 6 Front cover 7 Paper cassette

8 MP tray 9 Option interface slot cover 0 Parallel interface connector ! USB interface connector @ Power switch # AC inlet

Figure 1-2-1 Name of parts
FS-1010

1-6

1-3 Safety information
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. This means that the printer does not produce hazardous laser radiation. Since radiation emitted inside the printer is completely confined within protective housings and external covers, the laser beam cannot escape from the printer during any phase of user operation. (2) Laser notice This printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 825. (3) Laser caution label on the scanner unit The laser scanner unit has the following label affixed atop. Observe these cautionary statements and figures when handling the laser scanner unit.

FS-1010

1-7

WARNING

Use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure.

Label on the scanner unit (Inside the printer)

Label on the left cover rear side European countries U.S.A/Canada

Label on the fuser unit

Figure 1-3-1 Caution labels

FS-1010

1-8

(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. Compliance is mandatory for products marketed in the United States. A label indicating compliance with the CDRH regulations must be attached to laser products marketed in the United States. (5) Ozone concentration The printers generate ozone gas (O3) which may concentrate in the place of installation and cause an unpleasant smell. To minimize concentration of ozone gas to less than 0.1 ppm, we recommend you not to install the printer in a confined area where ventilation is blocked. (6) Optional equipment The printer may be optionally installed with the following units: PF-17 Paper feeder (250 sheets) Serial interface board Network interface card Memory card (7) Important note on the interface connectors Be sure to turn off printer power before connecting or disconnecting an interface cable to the printer. For protection against static discharge which may be applied to the printer's internal electronics through the interface connector(s), keep any interface connector which is not in use capped using the protective cap supplied.

FS-1010

1-9

1-4 Environmental requirements
1-4-1 Environmental conditions The Environmental requirements 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. The printer will work best if it is installed in a location that is: Level and well supported (Place the printer on a table or desk.) Not exposed to sunlight or other bright light (not next to an uncurtained window). Do not place the printer on an unstable cart, stand or table. Near an AC wall outlet, preferably one that can be used for the printer alone. The outlet should have a ground slot, or an adapter should be used. If you use an extension cord, the total length of the power cord plus extension cord should be 17 feet or 5 meters or less. Well ventilated, not too hot or cold, and not too damp or dry (See section Environmental requirements on page 1-5). If you install the printer where the temperature or humidity is outside the requirements in section Environmental requirements in chapter 1, the best print quality may not be expected and there will be an increased chance of paper jams. Provide a sufficient clearances around the printer to ensure ventilation and ease of access. (See section Clearance on next page).

FS-1010

1-10

(1) Clearance Allow the necessary minimum clearance on all sides of the printer as diagrammed below.

5

4 1

2

3

Figure 1-4-2 Clearances

Ref. 1 2 3 4 5

Clearance Left Front Right Back Above

Dimensions 25 cm (9-7/8 inches) 50 cm (19-11/16 inches) 25 cm (9-7/8 inches) 40 cm (15-3/4 inches) 30 cm (11-13/16 inches)

FS-1010

1-11

(2) Places to avoid Avoid installing the printer in locations exposed to: Direct drafts of hot or cold air. Direct drafts of outside air. (Avoid locations next to outside doors.) Sudden temperature or humidity changes. Any source of high heat, such as a radiator or stove. Excessive dust. Dust and smoke may cause contamination on the laser scanner window, causing print quality problem. Vibration. Ammonia fumes or other harmful fumes. (In case of fumigating the room or saturate it with insecticide, remove the printer first.) Avoid greenhouse-like rooms. (Because of sunlight and humidity.) Avoid enclosed spaces that block ventilation. Avoid sites more than 6,500 feet or 2,000 meters above sea level. (3) Note on power Use only the power source voltage conforming to the printer's rated power voltage. Do not use other power sources. Disconnect the printer from the power source before attempting removal or replacement of an electrical component or a printed-circuit board. The printer should not be connected to a power source until the instruction is given to do so when performing tests described in this manual. In connecting the printer power, exercise an extreme care in handling the power supply or any other electric parts which may give an electric shock. Before performing maintenance or repair, power from both the power source and the associated peripheral devices (computer, sorter, etc.) should be disconnected, unless otherwise specified. To avoid possible electrical shock, extreme caution must be exercised in handling the power cord and any other electrical part. An easily accessible socket outlet must be provided near the equipment. WARNING As the disconnect device is not incorporated in the printer's AC primary circuit, an easily accessible socket outlet must be provided near the equipment.

FS-1010

1-12

(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. As unexpectedly high temperature may develop inside when a vehicle is parked for a long period of time, the drum, toner container, process unit and the supplies should be removed from the vehicle. The vehicle during transportation should be parked in the shade or with the window open to allow minimum air circulation or the adequate air conditioning should be made. Should the printer be left in a vehicle, it may not be exposed to the temperature change of more than 7 C within 30 minutes. Before removing the printer to a warm place, wrap it in a blanket, etc., before crating it. Allow approximately two to three hours after having moved after uncrated. Failure to observe the above may result in moisture condensation which will affect the performance of the printer.

FS-1010

1-13

1-5 About the toner container
1-5-1 Toner container The printer should use a TK-17 toner kit. To ensure the high print quality and long service life, the following handling precautions should apply. CAUTION As the Ecosys printers are designed to ensure the optimum print quality when used with Kyocera's proprietary toner, Kyocera do not recommend to use any refilled toner containers that may be available commercially. This is because Kyocera have no means of control over how such refilled toner could affect the print quality and the reliability of the printer.

(1) Toner container handling To loosen and mix the toner inside before use, with the label side down, thoroughly shake the toner container 1 horizontally at least five times.

1

Figure 1-5-1 Toner container handling CAUTION Do not attempt to disassemble or refill the toner container.

FS-1010

1-14

(2) Toner container storage The toner contained in the container is susceptible to temperature and humidity. To ensure the high print quality, store the toner container in a place that satisfies the following environmental conditions: Temperature: Humidity: NOTE -20 to 40 C (-4 to 104 F) 15 to 90 % RH

If the toner container is removed from the printer's developer unit, put it in a protective bag and keep it in a dark place. If the printer is shipped for return, etc., do not ship it with the toner container installed. Otherwise, toner may leak and contamination may result in the printer.

CAUTION

FS-1010

1-15

Chapter 2

Installation/Operation

Chapter 2 Contents
2-1 Unpacking ......................................................................................................................................... 2-3 2-1-1 Unpacking and inspection ......................................................................................................... 2-3 2-2 Installing the printer ........................................................................................................................ 2-4 2-2-1 Installing the toner container ..................................................................................................... 2-4 2-2-2 Expanding memory .................................................................................................................... 2-8 (1) Minimum memory requirements .......................................................................................... 2-8 (2) DIMM specifications ............................................................................................................ 2-8 (3) Notes on handling DIMM ..................................................................................................... 2-9 (4) Installing the DIMM ............................................................................................................ 2-10 (5) Testing the expansion memory .......................................................................................... 2-11 (6) Installing the memory card (CompactFlash) ...................................................................... 2-12 (7) Installing the network interface card .................................................................................. 2-14 2-3 Using the operator panel ............................................................................................................... 2-15 2-3-1 Operator panel ......................................................................................................................... 2-15 2-3-2 Remote operation panel .......................................................................................................... 2-16

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. Remove the manuals, toner kit, and other items located on top of the spacer and remove the spacer. Carefully remove the printer.

Toner container (TK-17)

Cleaning cloth

Printer Installation guide Kyocera Mita digital library CD-ROM Power cord

Figure 2-1-1 Unpacking (1) Remove the tape on the rear side of the printer, and remove the two spacers and the printed notice from the paper cassette.

Spacer

Spacer
Printed notice

Figure 2-1-2 Unpacking (2)
FS-1010

2-3

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.

2-2-1 Installing the toner container 1. Open the top cover all the way. 2. Confirm that the lock lever #1 1 is in the release (forward) position. If not, pull it forward until it is in the release position.

1

Figure 2-2-1 Confirming the lock lever #1

FS-1010

2-4

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 horizontally at least five times. This ensures that the toner is evenly distributed inside.

2

Figure 2-2-2 Shaking the toner container 4. Carefully remove the protective seal 3.

3

Figure 2-2-3 Removing the protective seal

FS-1010

2-5

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].

2

Figure 2-2-4 Installing the toner container

FS-1010

2-6

7. Push the lock lever #1 1 to the lock position. 8. Close the top cover 4.

1
LOCK UNLOCK

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). When the printer is first switched on after the toner container is installed in the manner above, there will be a delay of several minutes before the printer gets ready to print a job. This delay is necessary for the printer to fill the developer reservoir with a sufficient amount of toner to continuously support a print job. The period of time is approximately 15 minutes. If the toner low or replace toner indication does not go off after installing the new toner container, take the toner container out once, shake it well, then install again.

UNLOCK

LOCK

FS-1010

2-7

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. Resolution 300 dpi 600 dpi 2 MB 2 MB 10 MB

Printing environment (Emulation) HP LaserJet 5P (factory setting) HP LaserJet 5P with resource protection

(2) DIMM specifications Memory size in MB Number of pins Access speed Parity Bus width 16, 32, 64, 128 MB 100 pins 66 MHz None 32 bits

FS-1010

2-8

(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 large metal object to discharge yourself of static electricity. While doing the work, it is recommended that you wear an antistatic wrist strap. Touch the main board and DIMM only by the edges, not in the middle.

Figure 2-2-6 Handling DIMM

FS-1010

2-9

(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 Take precautions that no foreign substances such as metal chips or liquid get inside the printer during the installation process. Operation of the printer during the presence of a foreign substance may lead to fire or electric shock. Turn the printer's power switch off. Unplug the printer's power cable and disconnect the printer from the computer or the network.

WARNING

Remove the side cover 1 as shown in the figure below.

Step 1

Step 2

Remove one screw.

1

1

Figure 2-2-7 Removing side cover

FS-1010

2-10

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. Close the clips 5 on the DIMM slot to secure the DIMM.

Step 1

4

Step 2

2

2

5

5

3

Figure 2-2-8 Inserting the DIMM (5) Testing the expansion memory After installing DIMM in the printer, test the printer to see if the installation has been successful. To test the expansion memory, turn printer power on and print a status page. If the installation has been successful, the Available Memory item of the status page will show the expanded memory size corresponding to the amount of memory added.

FS-1010

2-11

(6) Installing the memory card (CompactFlash) The main board of the printer is equipped with one slot for memory card. CAUTION Take precautions that no foreign substances such as metal chips or liquid get inside the printer during the installation process. Operation of the printer during the presence of a foreign substance may lead to fire or electric shock. Turn the printer's power switch off. Unplug the printer's power cable and disconnect the printer from the computer or the network. Never insert or remove a memory card while the printer power is ON. Failure to turn the power switch OFF will immediately halt the printer with a Memory card err20 message (this message may not always appear). It also could result in any damage to the printer's electronic parts or the memory card. Turn the power switch ON again to restart the printer. Remove the two screws 1 from the option interface slot cover 2 and remove the option interface slot cover (or network interface card 3 or the serial Interface board) .

WARNING

1

1

2

3

Figure 2-2-9 Removing the option interface slot cover

FS-1010

2-12

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) .

4

Figure 2-2-10 installing the memory card

FS-1010

2-13

(7) Installing the network interface card If the serial interface board kit is installed, remove it to use the network interface card.

CAUTION

Take precautions that no foreign substances such as metal chips or liquid get inside the printer during the installation process. Operation of the printer during the presence of a foreign substance may lead to fire or electric shock. Turn the printer's power switch off. Unplug the printer's power cable and disconnect the printer from the computer or the network. Never insert or remove a network interface card while the printer power is ON.

WARNING

Remove the two screws 1 from the option interface slot cover 2 and remove the option interface slot cover ( or the serial Interface board) .Insert the network interface card 3 in the slot. Insert as shown in the figure. Push it in all the way. Secure the network interface card by using two screws 1.

1

1

2

3

Figure 2-2-11 installing the memory card

FS-1010

2-14

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. Note that adjustments to the printer parameters made using these keys may be overridden by those made from within the application software.
1 2 3 4 5 6

Figure 2-3-1 Operator panel Table 2-3-1 Operator panel function No. Name 1 On line indicator 2 3 4 5 6 Data indicator Paper empty/ Paper jam indicator Toner indicator Cancel key Go key Function Indicates whether the printer is on-line or off-line. Indicates that the printer is receiving data. Indicates whether the paper cassette is empty or a paper jam has occurred. Flashes when toner is low, and light when toner is exhausted. Stops printing when pressed. Switches the printer mode between on-line and off-line when pressed. If you continued to press the key for 10 or more seconds, service status page is printed. Switches between the MP tray and paper cassette when the paper runs out. Prints out any unprinted page.
FS-1010

2-15

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.

1

5

6

7

2

3

4

Figure 2-3-2 Remote operation panel Table 2-3-2 Remote operation panel function No. Name 1 Message display Function Indicates printer status, the interface currently active, the resolution, the paper size, the number of copies set in the current interface, and error messages. Makes connection settings and operation settings between the printer and the computer. Makes connection settings for new printers. Displays help message. Performs the same function as the printer's Go key. Not displayed with non-network connection. Displays printer settings and confirmation items. Changes the printer 3D image in real time according to the printer's status. For example, if you open the printer's top cover, the top cover on the 3D image else open.

2 3 4 5 6 7

SETUP button CONNECT button HELP button GO button MENU button Monitor window

FS-1010

2-16

Chapter 3

Maintenance/Adjustments

Chapter 3 Contents
3-1 Maintenance/Adjustments .............................................................................................................. 3-3 3-1-1 Life expectancy of modules ....................................................................................................... 3-3 3-1-2 Toner container .......................................................................................................................... 3-4 (1) When to replace the toner container ................................................................................... 3-4 (2) Notes on changing toner container ..................................................................................... 3-4 (3) Toner container replacement ............................................................................................... 3-5 (4) Toner saver mode (EcoPrint) ............................................................................................... 3-6 3-1-3 Cleaning the printer ................................................................................................................... 3-7 (1) Cleaning the registration roller ............................................................................................ 3-8 (2) Cleaning the main charger wire ........................................................................................... 3-8 3-1-4 Updating the firmware ............................................................................................................... 3-9 (1) Firmware program data format ............................................................................................ 3-9 (2) Downloading the firmware from the parallel interface ....................................................... 3-10 (3) Downloading the firmware from the memory card ............................................................. 3-11 (4) Downloading errors ........................................................................................................... 3-12

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. Table 3-1-1 Life expectancy of modules Kit TK-17 PU-42 Module Toner container Process unit Nominal life (pages) 6,000 100,000 Remarks User-replaceable User-replaceable

FS-1010

3-3

3-1-2 Toner 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. Table 3-1-2 Toner container Kit Life in pages TK-17 6,000 Based on letter or A4 size paper; average print density of 5 %. NOTE In the case of a new printer in which a toner kit has been installed for the first time, the number of copies that can be printed will be approximately 3,000.

(1) When to replace the toner container When the printer runs low on toner, the Toner indicator flashes on the operation panel. Be sure to promptly replace the toner container and clean the inside of the printer when this message appears. If the printer stops printing while the Toner indicator is lit, replace the toner container to continue printing.

(2) Notes on changing toner container Observe the following cautions when replacing the toner container: Do not attempt to disassemble the old toner container and reuse the waste toner inside. Keep magnetic media such as floppy disks away from the toner container. Be sure to clean the parts as instructed in this section at the same timing of replacing toner container. Use of the toner kit TK-17 is highly recommended for the optimum operation of the printer.

FS-1010

3-4

(3) Toner 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.

1

2

Figure 3-1-1 Releasing Lock levers #1 and #2 Gently remove the old toner container 3.
3

Figure 3-1-2 Removing the old toner container

FS-1010

3-5

Put it in the supplied plastic bag 4 and dispose of it.

4

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.

Proceed with the instructions provided in chapter 2, Installing the toner container on page 2-4 to complete installation of the new toner container. (4) Toner saver mode (EcoPrint) The EcoPrint enables to reduce the amount of toner consumed on the page so as to save printing costs by drastically extending the toner container life. EcoPrint mode is factory-set to off and turned on by using the Remote Operation Panel (MENU) utility. For details refer to the printer's User's Manual.

FS-1010

3-6

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. Lift the process unit 3 together with the toner container out of the printer.

1

2

3

Figure 3-1-4 Removing the process unit NOTE The drum in the process unit is sensitive to light. Never expose the drum even to normal office lighting (500 lux) for more than five minutes.

FS-1010

3-7

(1) Cleaning the registration roller Use the supplied wiper cloth 1 to clean dust and dirt away from the registration roller 2 (metal).

2

1

Figure 3-1-5 Cleaning the registration roller (2) Cleaning the main charger wire Slide the charger cleaner knob (green colored) back and forth 2 to 3 times, then return it to its [CLEANER HOME POSITION].

1

1

Figure 3-1-6 Cleaning the main charger wire After cleaning is done, install the process unit in the printer, using the reverse manner as above. Close the front cover and top cover.
FS-1010

3-8

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. The operator panel message in different languages can also be downloaded through the parallel interface or through the memory card (CompactFlash). (1) Firmware program data format Kyocera supplies the following types of data for updating firmware of the different purposes: System firmware The data to be downloaded are supplied in the following format:
System firmware file name example

A94K8000.bcmp
compression Boot program is included. Version code: Version 80.00 ID code for Kyocera Machine code: FS-1010 (A94)

Figure 3-1-9 Firmware program data format

FS-1010

3-9

(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. CAUTION Downloading the firmware takes several minutes. Do not turn power off during downloading.

NOTE

MS-DOS is required for a downloading from the parallel interface. The computer must be connected to the printer with a parallel cable.

1 Turn printer power on. Make sure the printer is ready. 2 At the DOS prompt, send the following command to the printer: echo !R! UPGR "SYS";EXIT;>prn DOS COPY (/b) the data from the host computer to the printer. 3 Confirm that downloading was finished normally by the LED indicator. (See the table below.) 4 Turn power off. 5 Turn power on again. Check the printer gets ready. Confirm the status page shows the new firmware version (See Service information on the status page on page B-4). If downloading fails, the printer indicates an error display using the LED indicators. To identify error, refer to the table on page 3-12.

FS-1010

3-10

(3) Downloading the firmware from the memory card To download data written in a memory card (CompactFlash) to the printer, proceed as explained in this section. CAUTION Downloading firmware takes several minutes. Do not turn power off during downloading. If downloading is interrupted by an accidental power failure, etc., the system DIMM may have to be replaced. The firmware program data must be stored to the root directory of the memory card (CompactFlash).

NOTE

1 Turn power switch off. 2 Remove the two screws and then remove the slot cover. Insert the memory card in the printer's memory card slot.

Memory card

Screws

Slot cover

3 Turn power switch on. 4 The printers starts and finishes downloading automatically. 5 Confirm that downloading was finished normally by the LED indicator. (See the table below.) 6 Turn power off. 7 Remove the memory card and then secure the slot cover by using two screws. 8 Turn power on again. Check the printer gets ready. Confirm the status page shows the new firmware version (See Service information on the status page on page B-4). If downloading fails, the printer indicates an error display using the LED indicators. To identify error, refer to the table on page 3-12.

FS-1010

3-11

(4) Downloading errors The following downloading errors are indicated on LED indicators when an error occurred during downloading the firmware data.
Download finished normally LED indicators LED indicators Description Download data error Download errors Cause Deficit of a file header Deficit of a data header File checksum error File header version error Data header version error System download error Incompatibility of firmware and system DIMM board Confirm whether the firmware conforms to this printer. Replace the system DIMM board. Corrective action Obtain normal firmware.

Convention Red Green Meaning Slow flashing Fast flashing Lit Off

Defective system DIMM board

Download receiving error

Improper connection of parallel cable between PC and printer Defective parallel cable

Check the contact between PC and printer's interface connector. Replace parallel cable.

If the corrective action above does not solve the problem, replace engine board (KP-882). See page 5-11.

FS-1010

3-12

Chapter 4

Operation

Overview

Chapter 4 Contents
4-1 Electrophotographic system .......................................................................................................... 4-3 4-1-1 Electrophotographic cycle ......................................................................................................... 4-3 Process unit mechanism ........................................................................................................... 4-4 (1) Main charging ...................................................................................................................... 4-5 Photo conductive drum ............................................................................................................. 4-5 Charging the drum .................................................................................................................... 4-6 (2) Exposure ............................................................................................................................. 4-7 Laser scanner unit .................................................................................................................... 4-8 Drum surface potential .............................................................................................................. 4-9 (3) Development ..................................................................................................................... 4-10 (4) Transfer ..............................................................................................................................4-11 (5) Fusing ................................................................................................................................ 4-12 Fuser unit mechanism ............................................................................................................ 4-13 (6) Cleaning ............................................................................................................................ 4-14 4-2 Paper feeding system .................................................................................................................... 4-15 4-2-1 Paper feed control ................................................................................................................... 4-16 Paper feeding mechanism ...................................................................................................... 4-17 4-3 Electrical control system .............................................................................................................. 4-18 4-3-1 Electrical parts layout .............................................................................................................. 4-18 4-3-2 Operation of circuit boards ..................................................................................................... 4-19 (1) Main board ........................................................................................................................ 4-19 (2) Engine board ..................................................................................................................... 4-20 Eraser lamp control circuit ...................................................................................................... 4-21 Polygon motor control circuit .................................................................................................. 4-25 (3) Power supply board ........................................................................................................... 4-26 (4) Bias board ......................................................................................................................... 4-27 (5) High voltage board ............................................................................................................ 4-28 Interlock switch ....................................................................................................................... 4-29

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. This section provides technical details on the printer's electrophotography system. 4-1-1 Electrophotographic cycle The electrophotography system of the printer performs a cyclic action made of six steps as follows. Each step is technically explained in the following sections.
Laser scaner unit Process unit

1 Main charging

2 Exposure
Drum

6 Cleaning

3 Developing 4 Transfer

5 Fusing
Fuser unit

Figure 4-1-1 Electrophotographic cycle The sections for main charging, exposure (drum), developing, and cleaning are modularized in one Process unit PU-42.

FS-1010

4-3

Process unit mechanism

3

2

) (

Driving power train A For drum (From main unit) B For toner container, developing roller, etc. (From main unit) C For main unit (Transfer roller) D For toner container

/



& ^

0

9

8 7

%

4 D A 6

< 1 * C $ # @ B !

5

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

9 Gear Z18-Z35H 0 MAG gear Z24H ! Mixer gear Z20 B @ Mixer gear Z20 A # DLP screw B $ DLP screw A % Drum ^ Drum gear Z35H

& Drum shaft * Drum gear Z36 ( Sweep gear Z13 ) Idle gear 18H / Cleaning blade Sweep roller < Waste toner reservoir

Figure 4-1-2 Process unit mechanism
FS-1010

4-4

(1) Main charging Photo conductive drum The durable layer of organic photoconductor (OPC) is coated over the aluminum cylinder base. The OPC tend to reduce its own electrical conductance when exposed to light. After a cyclic process of charging, exposure, and development, the electrostatic image is constituted over the OPC layer. Since the OPC is materialized by resin, it is susceptible to damage caused by sharp edges such as a screwdriver, etc., resulting in a print quality problem. Also, finger prints can cause deterioration of the OPC layer, therefore, the drum (in the process unit) must be handled with care. Substances like water, alcohol, organic solvent, etc., should be strictly avoided. As with all other OPC drums, the exposure to a strong light source for a prolonged period can cause a print quality problem. The limit is approximately 500 lux for less than five minutes. If the drum (process unit) remains removed form the printer, it should be stored in a cool, dark place.

Photo conductive layer

Aluminum base cylinder

Figure 4-1-3 Photo conductive drum

FS-1010

4-5

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 charger unit A.

High voltage board YC-M CN2-A4

Bias board

Engine board MHVDR YC12-5

Main charging output

A

B

C

Zener board KP-788

Figure 4-1-4 Charging the drum As the drum C rotates in a "clean (neutral)" state, its photoconductive layer is given a uniform, positive (+) corona charge dispersed by the main charger wire B. Due to high-voltage scorotron charging, the charging wire can get contaminated by oxidization after a long rum. Therefore, it must be cleaned periodically from time to time using the method explained in chapter 3. Cleaning the charging wire prevents print quality problems such as black streaks.

FS-1010

4-6

(2) Exposure The charged surface of the drum A is then scanned by the laser beam from the laser scanner unit B.

B

A

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. Various lenses and mirror are housed in the scanner unit, adjust the diameter of the laser beam, and focalize it at the drum surface.

FS-1010

4-7

Laser scanner unit

3

2

4 5

1 6

Diversion mirror

Figure 4-1-6 Laser scanner unit Name 1 Laser diode 2 Cylindrical lens 3 Polygon mirror (motor) Description Emits diffused, visible laser. Compensates the vertical angle at which the laser beam hits a polygon mirror segment. Has six mirror segments around its hexagonal circumference; each mirror corresponding to one scanned line width on the drum when laser beam scans on it. The f-theta lens equalizes focusing distortion on the far ends of the drum. Bends the very first shot of a laser scan towards the beam detection sensor (6). When shone by the sensor mirror above, this photo-sensor generates a trigger signal for the engine controller to start activating the paper feeding system.

4 F-theta lens 5 Sensor mirror 6 Pin photo sensor

FS-1010

4-8

Drum surface potential The laser beam is continually switched on and off depending on the print data. It is on for a black (exposed) dot and off for a white (blank) dot. Since the drum surface is evenly charged, whenever it is illuminated by the laser beam, the electrical resistance of the photoconductor is reduced and the potential on the photoconductor is also lowered. Resulted on the drum surface is an electrostatic image which represents the data to print. Note that the area to be printed black has the low potential, constituting a "positively exposed" image.

Laser beam

Exposed surface potential approximately +60 to +80 V Charged surface potential +40015 V

OPC layer

Aluminum cylinder

Drum

Figure 4-1-7 Drum surface potential

FS-1010

4-9

(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. Toner attracts to the developing roller A since it is powdery ink made of black resin bound to iron particles. Doctor blade C, magnetized by magnet D, is positioned approximately 0.3 mm above the developing roller A to constitute a smooth layer of toner in accordance with the roller revolution.

C
Magnetism 0.1 mm N S S

D

0.3 - 0.4 mm

E
N

S

A F

B

Developing bias output 2755 V DC + AC

Bias board YC-B YC302-8 HVCLK

Engine board

YC11-5

Figure 4-1-8 Development The developing roller A is applied with the AC-weighted, positive DC power source. Toner E on the developing roller A is given a positive charge. The positively charged toner E is then attracted to the areas of the drum F which was exposed to the laser light. (The gap between the drum F and the developing roller A is approximately 0.3 mm.) The non-exposed areas of the drum F repel the positively charged toner as these areas maintain the positive charge. The developing roller A is also AC-biased to ensure contrast in yielding by compensating the toner's attraction and repelling action during development.

FS-1010

4-10

(4) Transfer 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. The transfer roller is negatively biased so that the positively charged toner is attracted onto the paper while it is pinched by the drum and the transfer roller.

A

B
Transfer bias

High voltage board YC1-A5 YC1-A5 YC1-A7 YC1-A8 YC1-A8

Bias board

Engine board RTHVDR THVDR HVISEL PSEL1 PSEL2 YC11-14 YC12-2 YC11-12 YC11-9 YC11-7

YC-T

Figure 4-1-9 Transfer The nominal transfer bias is set to approximately -1.8 kV (limit) with the -6 A current. Since the ideal potential of the transfer bias depends on the thickness of paper, the bias is raised to approximately -2.5 kV/-6 A for thicker paper. On the other hand, the bias current is reduced to -1.8 kV/-6 A for thin paper.

FS-1010

4-11

(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.

A

B
Figure 4-1-10 Fusing The heat roller has a halogen lamp inside which continuously turns on and off by the thermistor to maintain the constant temperature onto the heat roller surface. The temperature is approximately 160 C while the printer is idle; approximately 175 C (Normal paper) and 185 C (Thick paper) while printing. The heat roller is resin coated by florin to prevent toner from accumulating on the roller after a long run. Care must be taken while handling the heat roller not to scratch the roller surface as doing so may result in print problems. The heat roller has four claws which are continuously in contact with its surface. These claws prevent the paper on which toner has been fused from being wound around the heat roller causing paper jam. The pressure roller is made of the heat-resistant silicon rubber. This roller is used to strongly press the paper towards the heat roller by means of coil springs. The temperature of the heat roller is constantly monitored by the engine board using the thermistor and triac. Should the temperature of the heat roller exceed the predetermined value, the thermal cutout is activated to effectively disconnect the heater (halogen) lamp from power.
FS-1010

4-12

Fuser unit mechanism

0 ! @ 1 2

9

8 7 5 4 6
1 Heat roller 2 Idle gear Z34 3 Exit gear Z23 4 Idle gear Z18 5 Heat gear Z33 6 Press roller 7 Heater lamp [50025 W] 8 Thermal cutout

3

9 Separator(s) 0 Thermistor ! Exit pulley(s) @ Lower exit roller

Figure 4-1-11 Fuser unit mechanism

FS-1010

4-13

(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. The waste toner is collected at the output end of the sweep roller C and sent back to the toner container, into the waste toner reservoir D.

E

B A

C D

Figure 4-1-12 Drum cleaning and erasing static charge After the drum B is physically cleaned, it then must be cleaned to the electrically neutral state. This is necessary to erase any residual positive charge, ready to accept the uniform charge for the next print process. The residual charge is canceled by exposing the drum B to the l