Chapter 6

TROUBLESHOOTING

1-1-13FS-7000+/FS-9000

CONTENTS

Chapter 6 TROUBLESHOOTINGBoard layouts ............................................................................................................ 6-1Overall boards layout (Rear view) ............................................................................... 6-1

Diagnostic .................................................................................................................. 6-2Engine diagnostics flow ............................................................................................... 6-3Logic controller diagnostics flow ................................................................................. 6-6

General error handling ............................................................................................. 6-7Panel indicator ............................................................................................................ 6-7

Error messages ......................................................................................................... 6-8Memory card errors ................................................................................................... 6-11

Call-Service person errors ..................................................................................... 6-13A1: Uninstalled waste toner conveyer ....................................................................... 6-13A2: Fuser overheating ............................................................................................... 6-15A3: Fuser heater disconnection ................................................................................ 6-16A4: Developer unit life-fuse error .............................................................................. 6-17B1 B6: Feed cassette bottom plate motor error ..................................................... 6-18C1: Duplex communication error ............................................................................... 6-19C2: Duplex printing registration error ........................................................................ 6-19C3: Void .................................................................................................................... 6-19C4: Document finisher DF-30/DF-31 IPC communication error ................................ 6-19C5: Document finisher DF-30/DF-31 backup RAM error .......................................... 6-20C6: Document finisher DF-30/DF-31 sensor error .................................................... 6-20C7: Void .................................................................................................................... 6-20C8: Document finisher DF-30/DF-31 staple unit movement motor error .................. 6-20C9: Document finisher DF-30/DF-31 staple motor error ........................................... 6-20CA: Document finisher DF-30/DF-31 alignment motor error ..................................... 6-20CB: Document finisher DF-30/DF-31 tray motor error .............................................. 6-21CC: Document finisher DF-30/DF-31 paper feed motor error ................................... 6-21CD: Document finisher DF-30/DF-31paper exit motor error/Sorter error .................. 6-21D0 D3: Firmware program errors ........................................................................... 6-21E0: Communication failure ........................................................................................ 6-22E1: Main motor error ................................................................................................. 6-23E2: Laser scanner motor error .................................................................................. 6-25E3: Laser beam detection error ................................................................................. 6-25E4: Fuser heater error ............................................................................................... 6-28E5: Eraser error ......................................................................................................... 6-29E8: Fuser unit life fuse error ...................................................................................... 6-30E9: Toner motor error ................................................................................................ 6-30F0: Controller system lock error ................................................................................ 6-31F1: Main controller ROM checksum error ................................................................. 6-31F2: RAM read/write error ........................................................................................... 6-31

1-1-14FS-7000+/FS-9000

F3: Controller system error ....................................................................................... 6-31Other errors relating to the controller board .............................................................. 6-32Option harddisk errors .............................................................................................. 6-33

Print quality problems ............................................................................................ 6-34Completely blank printout ......................................................................................... 6-34All-black printout ....................................................................................................... 6-34Dropouts ................................................................................................................... 6-35Black dots ................................................................................................................. 6-36Horizontal streaks ..................................................................................................... 6-36Black vertical streaks ................................................................................................ 6-36Unsharp printing ........................................................................................................ 6-37Gray background ...................................................................................................... 6-38Dirt on the top edge or back of the paper ................................................................. 6-39Repetitive defects gauge .......................................................................................... 6-40Drum cleaning ........................................................................................................... 6-41

Correcting a paper jam ........................................................................................... 6-42Locating and correcting paper jams .......................................................................... 6-43

Correcting paper jams ............................................................................................ 6-44Paper jam removal diagrams .................................................................................... 6-47

6-1FS-7000+/FS-9000

Board layouts

Overall boards layout (Rear view)

Symbol Board No.(above) Description FS-7000+ FS-9000

1 Main logic board KP-668 KP-6902 System ROM (Flash DIMM) KP-610 KP-6893 Engine board KP-669 KP-6694 Power supply

1

23

4

6-2FS-7000+/FS-9000

Diagnostic

The printer automatically executes its self-diagnostic test when it is powered up. Thesequence and the items to be diagnosed are explained below.When the printer locates the error with a specific item, it calls for operators attention byshowing the appropriate Call service person message on the operator panel display. TheCall service person message is followed by one of the following codes: A, Development component B, Paper cassettes C, Duplexer DU-30*/ DU-31, Bulk paper stacker ST-30, Document finisher DF-30*/

DF-31, Mail box/Sorter SO-30 D, Firmware downloading E, Engine controller F, Main controller

Flowcharts on the following pages show the order and the items diagnosed in each system.

Note: Diagnostic test is canceled if one of the user-accessible covers is opened during thetest.

*: Optional for FS-7000+ model only.

6-3FS-7000+/FS-9000

Engine diagnostics flow

Yes

No

Yes

No

Yes

No

Yes

Yes

No

No

A

Poweron

Engine ROM checksum OK? D0: Firmware program error

Fuser heater temp. normal? A2: Fuser overheating

Fuser heater normal? A3: Fuser heater disconnection

Is fuser new?

Fuser life fuse blown? E8: Fuser unit life fuse error

6-4FS-7000+/FS-9000

Yes

Yes

No

No

Yes

No

Yes

No

Yes

No

Yes

No

Is developer new?

Developer life fuse blown?

A4: Developer unit life-fuse error

Fuser thermistor normal? E4: Fuser heater error

Polygon motor normal? E2: Laser scanner motor error

Laser pin-photo detects laser? E3: Laser beam detection error

Main motor normal? E1: Main motor error

A

B

6-5FS-7000+/FS-9000

Yes

No

No

Yes

No

Yes

No

Yes

Engine ready

Toner being fed?

E9: Toner motor errorToner motor normal?

A1: Uninstalled waste toner conveyer

Waste toner conveyer normal?

E4: Fuser heater errorFuser temp. rises in normal time?

B

6-6FS-7000+/FS-9000

Logic controller diagnostics flow

Yes

Yes

Yes

No

No

No

System ROM checksum OK?

Power on

F1: System ROM error

Communication established between

engine and main CPUs?

E0: Communication error

System memory OK? F2: System memory error

Controller is ready.

6-7FS-7000+/FS-9000

General error handling

This section provides how to handle general errors as indicated on the message display.Refer to the section starting on page for errors calling for service person assistance.

Panel indicatorThe symbol mark on the front panel provides following user-handling errors. Proceed withCorrective actions indicated below.

Indicator Indication Corrective actionFlashing The printer has run low on toner. The toner

should be replaced as soon as possible.Clean the printer after replacement.

Lit Toner is low or has run out. Replace with anew toner container.

Fast flashing Paper is jammed in the location flashing.Slow flashing The paper has run out in the paper cassette

or multi-purpose tray. Add paper to thepaper feed source.

Lit This indicates either the current paper feederor the paper output point.

Flashing A paper jam has occurred in the optionalduplexer. Remove the paper jam in theduplexer DU-30*/ DU-31.

Lit An optional duplexer DU-30*/ DU-31 hasbeen attached, and the printer is printing induplex printing mode.

Flashing The printer is warming up (Please wait) orthe printer has insufficient memory available.Confirm the message indicated on themessage display.

Lit A message will be displayed in the messagedisplay. Take corrective action according tothe message displayed. The table on thefollowing pages lists the corrective action totake in response to each message.

*: Optional for FS-7000+ model only.

Low toner

Paper feeding

Duplexer

ATTENTION

6-8FS-7000+/FS-9000

Error messages

The printer indicates on its front control panel various messages ranging from user-recoverable errors to call-service person errors. The instructions below indicate how torespond to all those problems indicated by the error messages. For call-service personerrors, further reference to the descriptions including flowcharts may be required asinstructed in Corrective action below.

Message Corrective actionTop cover The top cover is open. Close it tightly.OpenFront cover The front cover is open. Close it tightly.OpenSide cover The printers side cover is open. Close it tightly.OpenPaper feeder 1 The paper feeders side cover is open. Close it tightly. If anside cover Open optional paper feeder PF-30 is installed, the paper feeder

having the problem will be indicated number in the message.If the maximum of three feeders are installed, the upperfeeder is 1, the middle feeder is 2, and the bottom feeder is 3.

Face-down tray The face-down tray has become full. You must remove allpaper full printed pages from the face-down tray. The face-down tray

can hold approximately 500 sheets.Add paper The paper source is out of paper. Add paper to the paper

cassette or multi-purpose tray.Set paper Add a sheet of paper to the multi-purpose, and press thePress CONTINUE CONTINUE key. Printing will start. This message appears

when the multi-purpose tray is in manual mode.Load paper The paper size does not match. The size of the paper in the(paper size) cassette is different to the size specified by the application

software or by PRESCRIBE II command. Put paper of thespecified size into the cassette.If the CONTINUE key is pressed, printing will be resumed.However, if more than one sheet is to be printed, the samemessage will again be displayed from the second sheetonward.You can abandon printing by pressing the CANCEL key.

Cassette The cassette is not closed securely, Close it tightly.not loadedPaper jam Paper has become jammed. Open the front cover. The loca-Open front cover tion of the paper jam is displayed in the message display.

6-9FS-7000+/FS-9000

Message Corrective actionPaper jam This message appears when the front cover is open during a############## paper jam.

Letters A through I and numbers 1 through 6 will appear inplace of the #s. For details on the meaning of the textdisplayed, see page Chapter 6-42. A label displaying thesenumber indications is also attached to the back of the frontpanel. The indicator on the front panel also flashes thelocation of the paper jam.

Warning The printers internal memory is running low. Remove anyLow memory unnecessary download fonts and/or macros. You can check

the amount of user memory currently available by printing astatus page.

Toner low TK-30*1 There is not enough toner inside the toner container. Be sure(TK-35*2) to promptly replace with a new toner as the printer will stop

printing before long. Clean the printer after replacement.Replace Toner There is no more toner in the toner container. The printer hasClean printer stopped because there is no more toner. Replace with a new

toner kit. After replacing, be sure to clean the printer.Clean printer Please clean the inside of the printer. After cleaning the insidePress CONTINUE of the printer, press the CONTINUE key and the printer will be

ready for printing. This message will be displayed whenreplacing the toner container after the message ReplaceToner Clean printer has been displayed.

Missing Toner kit No toner container is installed. Install the toner container. TheTK-30*1 (TK-35*2) printer does not operate when this message is displayed.Install MK The maintenance kit MK-33*1/ MK-35*2 needs to be replaced.

Replace the maintenance kit MK-33*1/ MK-35*2 since thetotal number of printed pages has reached 350,000. Contactthe licensed dealer of Kyocera from which you purchased theprinter or service outlet. The maintenance kit includes a drumunit, developer unit and so on.

Call service A failure requiring the attention of service personnel hasperson##:####### occurred. A failure requiring the attention of service personnel

has occurred and the printer has stopped. The correspondingerror code and total printed pages are displayed in themessage display (part indicated by #s).

Memory overflow Current print processing cannot continue due to insufficientPress CONTINUE memory. Check available user memory by printing a status

page, and either remove unnecessary download fonts and/ormacros or expand the printers memory.Press the CONTINUE key to print data as far as it was stored.You can abandon printing by the CANCEL key.

*1: FS-7000+ model*2: FS-9000 model

6-10FS-7000+/FS-9000

Message Corrective actionPrint overrun Current print processing cannot continue due to insufficientPress CONTINUE memory. The data transferred to the printer was too complex

to print on a page.Check available user memory by printing a status page, andeither remove unnecessary download fonts and/or macros orexpand the printers memory.Note: After this message has been displayed, Page protect

mode will be on. To maintain optimum use of memoryduring printing, display >Page protect from the modeselect menu, and re-select Auto.

Press the CONTINUE key to print data as far as it was stored.You can abandon printing by the CANCEL key.

MEMORY CARD err The memory card is missing. This message appears whenInsert again the memory card has been removed from the memory card

slot during memory card operations. Re-insert the samememory card in the same slot. the printer will continue withmemory card processing.

Insert the same Insert the same memory card. This message appears whenMEMORY CARD the memory card has been removed from the memory card slot

during memory card operations and replaced with a differentmemory card. Re-insert the same memory card in the sameslot. the printer will continue with memory card processing.

Warning battery The memory cards battery is low. This message appearsMEMORY CARD when the printer is in the ready state and the battery of the

memory card installed in the printer is low. You can still enterthe memory card mode, but the battery should be changed assoon as possible.

Battery error Insert a new battery in the memory card. This messageMEMORY CARD appears when the printer is in the ready state and the battery

in the memory card is missing or completely dead. Memorycard operations are not possible. Insert a new battery in thememory card. (See the Users Manual)

Format error The memory card requires formatting. This message appearsMEMORY CARD when the printer is in the ready state and the memory card is

not formatted. Be sure to format the memory card. (See theUsers Manual.)

MEMORYCARD err ## This message appears when an error occurs during accessPress CONTINUE to the memory card using the PRESCRIBE ICCD command

or from the printers control panel. Look at the error codegiven in place of ## and refer to the corresponding descriptiongiven below. Note that only error codes 09 and 11 aredisplayed due to memory card operations made from thecontrol panel.For details, see Memory card errors which follows on pageChapter 6-11.

6-11FS-7000+/FS-9000

Message Corrective actionI/F occupied The interface selected is currently being used. This message

only appears if an optional interface is installed.The interface is secured while the interface name displayedin the message display is flashing even if the printer is in theready state. How long this takes depends on the interfacerelease timeout (FRPO J2) setting.This message appears, and then the ATTENTION indicatorlights, when an attempt is made to select a secured interfacefrom the control panel or when an attempt is made to performmemory card operations while the interface indicator is flashing.Repeat operations after releasing the interface.

Processing Compressed data is printed due to insufficient memory.PAR FIT A4 Compressed data is printed due to insufficient memory when

FIT flashes in the resolution indicator. The quality of printeddata is reduced when this occurs. FIT will continue flashingeven after printing is finished. The resolution indicator willautomatically return to reading 600 dpi when any key ispressed, when a timeout occurs, or when subsequent data isreceived. Expand printer memory to avoid this error.

Processing 600 dpi processing cannot be performed due to insufficientPAR 600 A4 memory. When 300 flashes in the resolution indicator even

though the printer was set to 600 dpi, the printer automaticallyset resolution to 300 dpi due to insufficient memory andcontinued printing. The resolution indicator will automaticallyreturn to reading 600 dpi when any key is pressed, when atimeout occurs, or when subsequent data is received.

Processing Expand printer memory to avoid this error.PAR 300 A4

Memory card errors

Error Applicablecode card type Meaning

01 SRAM Card size error (An attempt was made to write data of greaterthan 32 MB in size.). Reduce the size of the data to be written fromthe host computer to 16 MB or less; or, a file name could not befound in the memory card.

02 SRAM No memory card inserted. Insert a proper memory card.03 SRAM/flash Non PCMCIA card. Replace the card with a PCMCIA card.04 SRAM Not RAM card. Use a SRAM-type card if you want to write data

to an memory card.05 SRAM Memory card battery error. Replace the memory cards internal

battery with a new one.

6-12FS-7000+/FS-9000

Error Applicablecode card type Meaning

06 SRAM Memory card protect error. Release the write protection on thememory card when you write data to the memory card.

07 SRAM Non Kyocera format. Reformat the memory card using MODESELECT (See the printers Users Manual).

08 SRAM Partition name error. Follow instructions given attempt in Chapter2 to properly name the destination.

09 SRAM Memory card data full error (An attempt was made to write dataexceeding the capacity of the memory card). Abandon the writingoperation on the host computer first. Press CONTINUE key;when the message turns to Waiting, press FORM FEED key(Ready).

10 Reserved11 SRAM Data name full (An attempt was made to write more than 127

destination data names). Press CONTINUE key (Ready).12 Reserved13 Flash Erase logic error with flash memory card. Try replacing the

memory card.14 Reserved15 Flash Non PCMCIA flash card. Replace the card with a PCMCIA flash

card.16 Reserved17 Flash Unable to write to the flash memory card due to insufficient printer

memory. Either delete unnecessary macros or fonts stored in theprinter, or extend the printers available memory.

18 Flash Writing error. Try replacing the memory card.19 Reserved

For details on memory card availability, see section Printer specifications in chapter 1-3.

6-13FS-7000+/FS-9000

Call-Service person errors

The printer does not operate when a message beginning with Call service person (A, B, C,D, E, F) is displayed. The message is categorized by an alphanumeric code. Proceed withthis section for taking a corrective action depending on the code.The Corrective action may be useful for on-site service. Follow the flowchart if one isprovided in that item for further analysis of the problem.

A1: Uninstalled waste toner conveyer

Meaning Suggested causes Corrective action Waste toner converyer is not

installed. The belt is not rotating in the

conveyer unit. Connection failure between the

engine board and the conveyerboard

Engine gate arrays (U2/U6) failure Defective LED driving circuit on the

engine board. Defective LED onthe conveyer board. Connectionfailure between the waste tonerconveyer board and the phototransistor. Defective phototransistor.

Contaminated waste tonerconveyer housing or photoreceptor.

The waste toner driving system inthe toner container is not workingproperly.

The waste toner con-veyer is not installed,or the conveyer isclogged inside withwaste toner.

Install a waste tonerconveyer or replace theconveyer and belt.Replace KP-669 orKP-574. Check cableS02359 for possibledisconnection. [If notcorrected, replace thecable.]

6-14FS-7000+/FS-9000

Yes

Yes

No

No

No

No

Yes

Yes

No

Yes

A1

Waste toner conveyer installed?

Can sweep roller in toner container

be manual rotated?

Install conveyer.

Turn power off, then on.

Remove conveyer.

Replace conveyer and tower-guide assembly.

Replace with a new toner container.

A1 shown? End

Is waste toner emitted through the waste

toner outlet?

Open waste toner outlet of drum and manipulate to turn.

Replace with a new drum unit.

Turn power off, then on.

Still A1? End

Replace KP-669. If not recovered, replace KP-574. If not recovered, replace cable S02070 between KP-669 and KP-574.

6-15FS-7000+/FS-9000

A2: Fuser overheating

Meaning Suggested causes Corrective action Defective photo-coupler (low

voltage) for heaters Defective engine gate array U2 Defective heater control circuit

(engine board) or heater tempera-ture detector

The fuser unit isoverheating.

Replace KP-669./Re-place the switchingregulator./Check orreplace S02362 cableKP-669 and the switchingregulator./Replace fuser.

Yes

No

No

Yes

A2

Temp adj pot. meter on fuser board at

fully clockwise position?

Thermistor fit tightly?

Replace fuser unit.

Replace fuser unit.

Replace KP-669. Replace the switching regulator. Check or replace S02362 cable KP-669 and the switching regulator. Replace fuser.

Remove fuse unit.

6-16FS-7000+/FS-9000

A3: Fuser heater disconnection

Meaning Suggested causes Corrective action Blown-out heater lamp(s) Defective connection between the

engine board and the low voltagesupply.

Malfunctioning engine CPU Defective heater disconnection

sensor circuit in the low voltagesupply

Defective thermo-cut (Replace thefuser unit.)

Either or both heaterlamp(s) is blown out.

Replace KP-669. Check/replace S02054 cable.Replace fuser unit.

No

Yes

A3

Less than 10? Replace fuser unit.

Replace KP-669. If not recovered, replace KP-564, power supply, S02069 cable between KP-669 and power supply, or S02362 cable between KP-669 and power supply, in the order of the above.

Remove fuser unit.

Measure the resistance across primary terminals (See right fig.) of fuser connector.

1

2

6-17FS-7000+/FS-9000

A4: Developer unit life-fuse error

Meaning Suggested causes Corrective action Defective engine gate array Defective fuse cut circuit on the

engine board

Try turning the printer offand on several times.Replace developer unit.Replace KP-669.

The life fuse wont cutin the developer unit.

6-18FS-7000+/FS-9000

B1 B6: Feed cassette bottom plate motor error

Meaning Suggested causes Corrective action Excessive torque on the motor

(activating the current protectioncircuit)

Stuck motor Defective feed board CPU (U1) Defective motor driver circuit

(transistors) or over-currentdetector circuit

No

Yes

No

Yes

B1 B6

Error still happens? Replace the cassette.

Change cassette to other cassette. Turn printer power off, then on.

Connect ckt tester to pin 5 of KP-546/U1. Measure voltage.

High level (>3.5 V)?Replace motor. If not recovered, S02088 between KP-546 and cassette. If not recovered, replace cassette or KP-546.

Replace KP-546.

Replace the motor.Check/replace S02088/S02089 cables. Tryreplacing with othercassette to see if thatcassette is faulty.Replace KP-546.

The feed cassettebottom plate motorwont revolve.

6-19FS-7000+/FS-9000

C1: Duplex communication error

Meaning Suggested causes Corrective action Defective engine gate array (U6) Defective engine CPU (U1) Duplexer CPU (U1) malfunction Defective U2, U5, U6 on duplexer

board Defective connection between

KP-669 (YC4) and KP-675 (YC1),KP-675 (YC3) and liaisonconnector, liaison connector andKP-587*2/ KP-679*3 (YC1), ordefective liaison connector

C2: Duplex printing registration error

Meaning Suggested causes Corrective action Defective registration motor Defective home position sensor Malfunctioning motor driving circuit

(U2/U6/U7)*2, (U2/U5/U6)*3 onduplexer board

Defective duplxer CPU (U1) Connection error between the

registration motor and KP-587*2/KP-679*3 (YC5), or home positionsensor and KP-587*2/ KP-679*3(YC7)

C3: Void

C4: Document finisher DF-30*/ DF-31 IPC communication error

Meaning Suggested causes Corrective action Defective IPC (intelligent protocol

controller) LSI (communicationchip)

Defective interface connector/cable

*1: Optional for FS-7000+ model only.*2: DU-30*3: DU-31

Communication errorbetween the duplexerand the printer.

Try reinstalling duplexer.Check/replace cablebetween printer andduplexer DU-30*1/ DU-31. Replace KP-679.Replace KP-669.Replace duplexer.Replace KP-675.

The duplexers regis-tration boards are notin the home position.

Check foreign objects orfractions of paper induplexer. Try manipu-lating adjusters to checkfor smooth move. Checkphoto sensor for normalconnection. Check/replace S02100 cable.Replace home positionsensor. Replace KP-587*2/ KP-679*3.Replace duplexer.

Communication errorwith the documentfinisher DF-30*/ DF-31

Check interface cablebetween document fin-isher DF-30*/ DF-31 andprinter. Replace KP-669(engine) or KP-675(CON3) in the printer.Replace S02361 cable.

6-20FS-7000+/FS-9000

C5: Document finisher DF-30*/ DF-31 backup RAM error

Meaning Suggested causes Corrective action Defective backup RAM

C6: Document finisher DF-30*/DF-31 sensor error

This error means any of the following sensors in the document finisher DF-30*/DF-31 isdefective: Input sensor Exit path sensor Inversion sensor Printer connection sensor Stack height limit sensor Stack home position sensor Offset sensor Cover sensor Stacker full sensor

C7: Void

C8: Document finisher DF-30*/DF-31 staple unit movement motor error

Meaning Suggested causes Corrective action The driver circuit for the motor is

defective. The staple unit is defective. The motor is defective.

C9: Document finisher DF-30*/DF-31 staple motor error

Perform the same procedure as C8 for the document finishers DF-30*/DF-31 staple motor.

CA: Document finisher DF-30*/DF-31 alignment motor error

Perform the same procedure as C8 for the document finishers DF-30*/DF-31 alignmentmotor except making check on connector J11.

*: Optional for FS-7000+ model only.

Backup RAM error inthe document finisherDF-30*/DF-31

Replace documentfinisher DF-30*/DF-31.

The staple unit move-ment motor does notrotate.

Check connector J8 forthe driver board. If notcorrected, replace docu-ment finisher.

6-21FS-7000+/FS-9000

CB: Document finisher DF-30*/DF-31 tray motor error

Perform the same procedure as C8 for the document finishers DF-30*/DF-31 tray motorexcept making check on connector J7.

CC: Document finisher DF-30*/DF-31 paper feed motor error

Perform the same procedure as C8 for the document finishers feed motor except makingcheck on connector J11.

CD: Document finisher DF-30*/DF-31 paper exit motor error/Sorter error

Perform the same procedure as C8 for the document finishers DF-30*/DF-31 exit motorexcept making check on connector J10.The CD error also suggests that the bulk paper stacker is defective.

D0 D3: Firmware program errors

These errors are explained in chapter 3, Downloading firmware programs.

* Optional for FS-7000+ model only.

6-22FS-7000+/FS-9000

E0: Communication failure

Meaning Suggested causes Corrective action Error with CPU and gate arrays of

either the engine or main controller Connection error between the

engine board and the main con-troller board

Program overrun in the engine ormain controller

The engine controllerdoes not respond tothe main controller.

Replace KP-669.Replace KP-668*1/ KP-690*2.

No

Yes

E0

Cable S02051 between KP-669 and

KP-536 wired properly?

Reconnect properly.

Replace KP-669. If not cured, replace KP-668*1/KP-690*2.

*1: FS-7000+ model*2: FS-9000 model

6-23FS-7000+/FS-9000

E1: Main motor error

Meaning Suggested causes Corrective action Error with CPU and gate arrays of

either the engine or main controller The motor brake circuit is activated

because of an abnormal torque ofthe motor.

Overheating protection circuit isactivated because of the over-heating main motor IC

Defective engine gate array (U2) Defective main motor driving circuit

(transistor arrays, etc.) on theengine board

Defective buffer IC for FG signaldetection on the engine board

*1: FS-7000+ model*2: FS-9000 model

The main motor wontrevolve, or will revolvetoo slow.

Replace KP-669. Replacemain motor. Check/replaceS02366*1/S02363*2 cable.Replace drive unit.

6-24FS-7000+/FS-9000

Yes

Yes

Yes

Yes

No

No

No

Yes

No

No

E1

Does motor rotate 5 seconds or more?

Can main motor be manipulated

to turn?

Turn power on and off.

Replace DRIVE ASSY.

Turn printer power off, then on.

Turn printer power off, then on.

Can drive gears for fuser,

drum, and developer be manipulated

to turn?

E1 shown again?

E1 shown again? End

End

Replace motor. If not recovered, replace S02366*1/S02363*2 cable between motor and KP-669. If not recovered KP-669.

Locate the unit preventing the motor to rotate.

Replace the unit.

Replace the failed unit.

*1: FS-7000+ model*2: FS-9000 model

6-25FS-7000+/FS-9000

E2: Laser scanner motor error

Meaning Suggested causes Corrective action Defective scanner motor (e.g., at

its axle holder) Connection error between polygon

motor and liaison connector, orliaison connector and KP-669(YC14)

Defective engine gate array (U2/U6)

Defective scanner motor drivertransistor

E3: Laser beam detection error

Meaning Suggested causes Corrective action Laser diode does not emit. Connectionerror between KP-677

(YC2) and KP-579 (YC101 [withinscanner]), KP-677 (YC1) andKP-669 (YC14), KP-572 (YC1) andKP-669 (YC14)

Defective or contaminated pin-photo IC

Malfunctioning interlock detectioncircuit on the ending board

Defective engine gate array U2

The revolution of thepolygon motor doesnot reach the prede-termined revolution.

Check/replace S02061,S02358 cables. ReplaceKP-669. Replace scannerunit.

Beam detection isfailed. The photo de-tector failed to detectlaser beam.

Check/replace S02358,S02061, S02062 cables.Replace KP-669. Replacescanner unit.

6-26FS-7000+/FS-9000

No

No

No

No

No

YesYes

Yes

Yes

Yes

Yes

E2,E3

Turn power off, then on.

Is a square wave*output?

Are the cables properlyconnected?

Is E2 or E3 displayedagain?

Is E2 or E3 displayedagain?

Replace KP-669.

Replace KP-669.

Replace KP-669.

Connect the cables correctly.

Connect ckt tester to pin 5 of KP-669/YC14. (SCCLK)

Replace S02358 cable.

Check the scanner's cables.

NoIs E2 displayedagain?

NoIs E2 displayedagain? End

End

End

End

*: f=2397 Hz (FS-9000)*: f=1770 Hz (FS-7000+)

Replace the scanner unit.

Is +24 Voutput at pin 1 ofKP669/YC14?

6-27FS-7000+/FS-9000

No

No

No

No

Yes

Yes

Yes

Yes

E3

Turn power off, then on.

Replace scanner unit.

Turn power off, then on.

Replace S02358 cable.

*: 500 s (FS-9000)*: 900 s (FS-7000+)

Is pin 14 low*?

Is pin 8 low?

E3?

E3?

End

End

Replace KP-669.

Replace KP-669.

Replace KP-572.

Connect ckt tester to pin 8 of KP-669/YC14. (LASER0)

Connect ckt tester to pin 14 of KP-669/YC14. (PDN-I)

Connect ckt tester to pin 45 of KP-544/YC2.

6-28FS-7000+/FS-9000

E4: Fuser heater error

Meaning Suggested causes Corrective action Connection error between the

engine board and the fuser unit Defective engine gate array U2 Defective comparators on the

engine board Defective thermistor (cut) Connection error between the fuser

board and the thermistor Connection error between the

engine board and the low-voltagepower supply

Defective engine gate array U2 Defective transistors, logic gate ICs,

comparators, etc. on the engineboard

Defective thermistor (showing highresistance even at heating)

The fuser heater doesnot turn on. [E4 is indi-cated immediatelyafter power is on.]

The fuser heater doesnot turn on. [E4 is indi-cated several minutesafter power is on.]

Replace KP-669. Replacefuser (temp. adjustment isrequired.) Check/replaceS 0 2 0 5 4 * 1/ S 0 2 3 6 4 * 2cable.

No

No

Yes

Yes

E4

Less than 1M W ?

E4 shown within 30 seconds since

power is on?

Replace KP-669. If not recovered, replace fuser unit.

Replace fuser unit (req. Temperature adjustment).

Measure resistance between pins 4 and 5 of KP-550/YC1.

Replace KP-669. If not recovered, replace cable between KP-669 and fuser unit.

*1: FS-7000+ model*2: FS-9000 model

6-29FS-7000+/FS-9000

E5: Eraser error

Meaning Suggested causes Corrective action Connector error between engine

board and the drum liaison board Defective connector between the

drum liaison board and the drumboard

Defective transistors and logic gateICs in the eraser controller circuiton the engine board

Connection error between drumunit board and eraser lamp

Broken eraser lamp

Yes

Yes

No

No

E5

R= ?

R= ?

Install drum unit.

Remove drum unit.

Replace drum unit.

Measure resistance between pins 1 and 7 of KP-562.

Measure resistance between pins 2 and 6 of KP-669/YC12.

Replace KP-558. If not recovered replace S02359 cable between KP-669 and KP-558.

Replace KP-669.

The eraser does notturn on.

Replace KP-669. ReplaceKP-564. Replace drumunit. Check/replaceS02359 cable.

6-30FS-7000+/FS-9000

E8: Fuser unit life fuse error

Meaning Suggested causes Corrective action Defective gate array U6 Defective fuse cut circuit on the

engine board

E9: Toner motor error

Meaning Suggested causes Corrective action Overcurrent in the toner motor

circuitry due to an excessive torque Toner motor locked Defective gate array U2 Defective toner motor driver

transistor or overcurrent detector*Also, try rotating the toner kit TK-30/ TK-30H gear (feed gear). Compare the torque witha new toner kit TK-30/ TK-30H. Replace the toner kit TK-30/ TK-30H if the torque isabnormal. Replace developer unit if the toner kit TK-30/ TK-30H is normal.

Turn printer power off andoff several times. Re-place fuser unit. ReplaceKP-669.

The fuser unit life fusewont blow out.

The toner motor doesnot revolve, or thecurrent protectioncircuit is activated.

Replace toner container.*Replace developer unit.Replace KP-669. ReplaceKP-673. Check/replaceS02366*1/S02363*2 andS02076.

Yes

Yes

No

E9

Damaged toner container

gears?

E9 shown?

Replace developer.

Turn printer off, then on.

Turn printer off, then on.

Replace toner container.

Replace KP-669. If not recovered, replace KP-673, KP-560, S02076 cable between KP-673 and KP-560 or S02366*1/S02363*2 cable between KP-669 and KP-673, in the order of priority.

No End

*1: FS-7000+ model*2: FS-9000 model

6-31FS-7000+/FS-9000

F0: Controller system lock error

Meaning Suggested causes Corrective actionConnection error between maincontroller board and engine con-troller board or engine board andfront panel board.

F1: Main controller ROM checksum error

Meaning Suggested causes Corrective actionChecksum is failed Replace KP-610*1/689*2with the system ROM (cont. ROM).

F2: RAM read/write error

Meaning Suggested causes Corrective actionChecksum is failed Replace option SIMMs.with the RAM on the Replace KP-668*1/ KP-main controller board. 690*2.

F3: Controller system error

Meaning Suggested causes Corrective actionError other than F0, Turn printer power off,F1, and F2. [privilege then on again. If notviolation, bus error, solved, replace the mainetc.] controller board.

*1: FS-7000+ model*2: FS-9000 model

Main controller can notcommunicate withcontrol panel [shownapprox. 30 secondssince OS fails tocontinue operating.]

Replace KP-668*1/ KP-690*2 (main cont.).Replace KP-669 (engine).

6-32FS-7000+/FS-9000

Other errors relating to the controller board

Symptom Suggested causes Corrective actionA situation in which OS is notable to run is occurred.

Wrong printer driver is used.Wrong emulation is used.Parameters are incorrect on theparallel interface. The surgeprotection devices on the maincontroller is defective.

Defective wiring around the frontpanel. Defective front panelboard.

Display freezes whileindicating Processing.

Printed charactersgarbled.

Harddisk error oc-curred.

No display on themessage display.

Turn power on and off. Or,replace the main controllerboard.If the parallel interface is beingused, investigate for theadequate length of theparallel cable. Also, checkthat the cable is properlyshielded. Or, replace the maincontroller board.See Option harddisk errorson page Chapter 6-33.

Check wiring between themain board and engine board;between the engine boardand front panel board.Replace the front panel boardand/or main board.

6-33FS-7000+/FS-9000

Option harddisk errors

The printer indicates Harddisk error messages on the message display when it detectserrors with the option hard disk drive HD-2 (if installed). This message is followed by a two-digit code which provides the following meaning and corrective action to the specific error.To clear the error message and continue operating the printer, press the CONTINUE key.

Harddiskerror code Meaning Corrective action

01 Turn printer power off then on again. Ifnot recovered, consider reformatting theharddisk.*[WarningFormatting erases all dataexisting in the harddisk.]

02 Ensure that the harddisk is installedproperly in the printer. For instructions,refer to the manual accompanying theharddisk kit.

03 Unlock the write-protection state byKPDL or PJL. Consult the system admin-istrator if required.

04 Free harddisk space by removingunnecessary file in the harddisk.

05 Ensure whether a file with the specifiedname exists on the harddisk. If the fileexists, ensure that correctly matchingfile name is called, i.e. case. Print out apartition list from the printer to obtain alist of the included partition names in theharddisk. (See the printers manual.)

06 Install more memory in the printer. (Seethe printers manual.)

* For instruction on how to format the harddisk, refer to the Users Manual for the printer orthe harddisk.

Format error or the harddisk isdamaged.

No harddisk installed.

Harddisk is write-protected.

Insufficient capacaity on harddisk,or the number of files stored hasexceeded 10,000.The specified file does not exist.

The memory available for use bythe file system is insufficient.

6-34FS-7000+/FS-9000

Print quality problems

Print quality problems range from uneven tone to completely blank output. The troubleshootingprocedure for each type of problem is given below.

Completely blank printoutCheck the developer unit. Check that the developer unit is inserted correctly

Check that the developers connector is connectedproperly.

Check that toner is adhered around the developingroller. If no toner appears to be on the roller, try feedingtoner into the developer using the manner described inchapter 3 (See page 3-9).

Check main charging potential. Check the main charging output on the HV board. Thisrequires removal of the left side cover and the testequipment: For information, contact Kyocera. Replacethe HV board if high voltage potential is not available onthe board.

Check the laser scanner. The scanner components within the scanner may bedisordered. Note that the laser scanner is concealed toprotect the components which are susceptible to dust.It should not be disassembled except within a dust-freechamber. Replace the scanner unit if necessary.

All-black printoutCheck the main charger unit Open the printer side cover and check that the maininstallation. charger unit is correctly seated. To do this, take out the

main charger unit from the printer; then reinstall itcarefully.

Check the grid plate (the The grid plate must be flat and fit horizontally in place.mesh metal bottom part of the Replace the main charger unit if necessary.charger unit).Check the drum bias. Make sure the bias from the HV board is correctly

arrived at the drum unit.Check high voltage potential Check the high-voltage output on the HV board. Thisat the HV board. requires removal of the left side cover and the test

equipment: For information, contact Kyocera. Replacethe HV board if high voltage potential is not available onthe board.

6-35FS-7000+/FS-9000

Dropouts

Note the spacing of the If the defects occur at regular intervals of 63 mm, thedefects. Use the Repetitive problem may be a dirty transfer roller. Clean or replacedefect gauge on page 6-40. the transfer roller.

If the defects occur at regular intervals of 94 mm, theproblem may be a damaged drum unit or fuser roller.Replace the drum unit or fuser unit accordingly.

Try changing the transfer Use the MODE SELECT key on the printers controlbias potential (Normal or panel. For details, refer to the Users ManualThick). accompanying the printer.Check paper for property. Paper with rugged surface or dump tends to cause this

type of failure.Check the paper chute The paper chute (the metallic fixture provided betweeninstallation. the transfer roller and the fuser unit for antistatic

purpose) must not be fit loose. Press the paper chutedown firmly if necessary.

Check the transfer roller The transfer roller must be supported by the axle holderinstallation. at the both ends. Clean the axle holder to remove oil

and debris. Replace the transfer roller if necessary.Check the transfer bias Check the transfer bias output on the HV board. Thispotential. requires removal of the left side cover and the test

equipment: For information, contact Kyocera. Replacethe HV board if high voltage potential is not available onthe board.

ABC123

6-36FS-7000+/FS-9000

Black dotsNote the spacing of the If the defects occur at regular intervals of 94 mm, thedefects. Use the Repetitive problem may be a damaged drum unit or fuser roller.defects gauge on page 6-40. Replace the drum unit or fuser unit accordingly.

If the defects occur at random intervals, the toner maybe leaking from the drum unit. Replace the drum unit.

If the defects occur at regular intervals of 38 mm, theproblem may be a toner lump on the developing roller.Remove the lump using a soft brush. Note that thedeveloping roller surface is fragile: Contact Kyocera forthe type of brush to use.

Horizontal streaksCheck drum ground. The drum axle and its counter partdrum grounding

tab in the printer must be in a good contact. If necessary,apply a small amount of electro-conductive greaseonto the tab. See Kyocera for which type of grease touse.

Check main charger contacts. Take out the main charger unit; check the electricterminals to see if they are clean.

The drum unit may be Replace the drum unit.defective.

Black vertical streaks

Contaminated main charger Clean the main charger wire by pulling the greenwire. colored cleaning knob in and out several times.Check the drum surface for A streak of toner remaining on drum after printinga streak of toner laying means that the cleaning blade in the drum unit is notlengthwise. working properly. Replace the cleaning blade; or replace

the drum unit.Defective developer unit. Replace the developer unit.

ABC123

6-37FS-7000+/FS-9000

Unsharp printing

Check contamination on Clean the main charger wire by pulling the green colorthe main charger wire and main charger wire cleaner know in and out severalthe grid. times.Check paper for property. Paper with rugged surface or dump tends to cause this

type of failure.Check the paper chute The paper chute (the metallic fixture provided betweeninstallation. the transfer roller and the fuser unit for antistatic

purpose) must not be fit loose. Press the paper chutedown firmly if necessary.

Try changing the transfer bias Use the MODE SELECT key on the printers controlpotential (Normal or Thick). panel. For details, refer to the instruction handbook

accompanying the printer.Check the transfer roller The transfer roller must be supported by the axle holderinstallation. at the both ends. Clean the axle holder to remove oil

and debris. Replace the transfer roller if necessary.Check the transfer bias Check contamination on the main charger wire and thepotential. grid.Check EcoPrint setting. The EcoPrint mode can provides faint, unsharp printing

because it acts to conserve toner for draft printingpurpose. For normal printing, turn the EcoPrint modeoff by using the MODE SELECT key on the printerscontrol panel.

Refresh drum. Try cleaning the drum surface using the printers built-in cleaning system specifically provided for this purpose.For details, refer to page 6-41.

6-38FS-7000+/FS-9000

Gray background

Check contamination on the Clean the main charger wire by pulling the green colormain charger wire and the grid. main charger wire cleaner know in and out several

times.Check the grid plate (the The grid plate must be flat and fit horizontally in place.mesh metal bottom part of Replace the main charger unit if necessary.the charger unit).Check the print density setting. The print density may be set too high. Try adjusting the

print density using the MODE SELECT key. For detailsrefer to the printers instruction handbook.

Check the surface potential of The drum potential should be approximately 250 V.the drum. These values may vary depending on production lots

and the measurement is possible only by using the jigand tool specifically designed for this purpose. SeeKyocera for detailes. The drum unit will have to bereplaced if it bears values far out of the allowablerange.

The developer unit may be If a developer unit which is known to work normally isdefective. available for check, replace the developer currently

used in the printer with it. If the symptom disappears,replace the developer unit with a new one.

ABC123

6-39FS-7000+/FS-9000

Dirt on the top edge or back of the paper

Check toner contamination in Dirty edges and back of the paper can be caused byvarious parts. toner accumulated on such parts as the paper chute,

paper transportation paths, the bottom of the developerunit, and the fuser inlet. Clean these areas and parts toremove toner.

Check the transfer roller. If the transfer roller is contaminated with toner, cleanthe transfer roller using a vacuum cleaner; or bycontinuously printing a low-density page until thesymptom has faded away.

ABC123

6-40FS-7000+/FS-9000

Repetitive defects gauge

Use the following measurements for checking repetitive occurrences on the printed page.See the above section for details.

FIRST OCCURRENCE OF DEFECT

32 mm: DEVELOPING ROLLER

37.5 mm: UPPER REGISTRATIONROLLER

50 mm: LOWER REGISTRATIONROLLER

66 mm: TRANSFER ROLLER/DEVELOPING PULLEY

94.3 mm: FUSER PRESSUREROLLER

116.3 mm: FUSER HEAT ROLLER

128.3 mm: DRUM UNIT

6-41FS-7000+/FS-9000

Drum cleaning

This mode is meant to provide a manual means of drum cleaning in addition to the regularcleaning procedure made automatically in a photographic cycle. In this mode, the drumturns for the period of approximately three minutes with no main charging dispersed overthe drum. Since the cleaning blade in the drum continuously attempt to scrape soils andpaper dust on its surface, the drum can be brought in a clean state.

To clean the drum using this feature, perform the following, top to bottom:press MODE then,press : repeatedly until: Others>press

s

then,press : repeatedly until: >Service>press

s

, the display should show: >>Developerpress : , the display should show: >>Drumpress ENTER, the display should show: ?press ENTER

The drum then starts turning and stops after approx. 3 minutes. The printer reverts to Ready.

6-42FS-7000+/FS-9000

Correcting a paper jamThis section describes how to remove paper when it jams in the printer. The printer will stopwhenever paper jams in the printer or paper is not fed from a cassette. The printer will gooffline and the message Paper jam Open front cover will appear in the messagedisplay.

Paper jamOpen front cover

Opening the printers front cover will cause the message display to change. It will nowindicate the coded location (A through I and 1 through 6) of the paper jam.

Example:

Paper jamC, H, 1

In this example, paper is jammed in the paper feeder (C), paper feed unit (H), and in theupper cassette (1). The corrective action to take in cases like this is explained using actualexamples beginning from page 6-46.The meanings of symbols appearing on the message display and the correspondinglocations of paper jams are given in the table on the next page. Be sure to correct paperjams according to the procedure given on the following pages.

6-43FS-7000+/FS-9000

Locating and correcting paper jams

MESSAGE DISPLAY INDICATOR AND PAPER JAM LOCATION

Ind. Meaning of Indicator Corresponding Printer LocationA Optional paper feeder

(Envelope feeder EF-1 orUniversal feeder UF-1*)

B Multi-purpose trayC Paper feeder included with

printerD Optional paper feeder PF-30E Optional paper feeder PF-30F Optional paper stacker

(Document finisher DF-30*/ DF-31 or Bulk paper stacker ST-30Mail box/Sorter SO-30)

G Face-up output trayH Paper feed unitI Optional duplex printing unit

(Duplexer DU-30*/ DU-31)1 Cassette 12 Cassette 23 Cassette 34 Cassette 45 Cassette 56 Cassette 6

*: Optional for FS-7000+ model only.

F

G

A

H

I

1

2

3

4

5

6

B

C

D

E

6-44FS-7000+/FS-9000

Correcting paper jamsWarning: Pull out the paper feed unit (See below.) and wait a while to allow the fuser unit

to cool. Do not touch the fuser unit as this may result in a burn injury.

Warning: Take care not to leave any small pieces of paper in the printer when removingpaper jams as this may result in fire.

Note: Data remaining in the printer will be lost if power is turned off while correcting a paperjam.

After checking the location of the paper jam using the table on the previous page, takecorrective action according to the table on the next page. After removing all jammed paper,the printer will automatically resume printing.

Fuser unit

6-45FS-7000+/FS-9000

Ind. Meaning of indicator Corresponding printer locationA When a paper jam occurs in the optional

feeder, pull it out carefully. (For details,read the users manual for each separateoption.)

B When a paper jam occurs in the multi-purpose tray, first completely remove alljammed paper and then open and closethe front cover.

C, D, E Open the side cover of the paper feederindicated and remove the jammed paper.See page Chapter 6-48.

F Remove the paper jammed in the paperstacker. (For details, read the paperstacker instruction manual.)

G If printing stops before a page iscompletely output, carefully remove thatsheet of paper. See Chapter 6-49.

H If printing stops before a page is completelyoutput, carefully remove that sheet of paper.Open the front cover and carefully pullout the paper feed unit as far as it will go.If paper is jammed in the registrationrollers, remove it by the easiest meanspossible. See page Chapter 6-50. Pulljammed paper out of the fuser unit in thesame manner. See page Chapter 6-50.After all paper has been completelyremoved, return the paper feed unit.Open the front cover and carefully pullout the paper feed unit as far as it will go.Open the fuser unit cover (grasp the tab[green]) and check inside the fuser unit.Jammed paper may sometimes be leftinside the fuser unit. See page Chapter6-51 or 6-53.

I Open the front cover, pull out the duplexprinting unit and remove the jammedpaper. (For details, read the duplexprinting unit users manual.)

1 6 Pull out the cassette indicated andremove the jammed paper. After all paperhas been completely removed, open andclose the front cover.

*: Optional for FS-7000+ model only.

Check the optional paper feeder(Envelope feeder EF-1 or Universalfeeder UF-1*).

Check the multi-purpose tray.

Check the optional paper feeder PF-30.(D and E are only displayed when anoptional paper feeder PF-30 is installed.)Check the optional paper stackerDocument finisher DF-30*/ DF-31,Bulk paper stacker ST-30 or Mailbox/Sorter SO-30.Check the face-up output tray.

Check the face-down output tray.

Check the paper feed unit.

Check the fuser unit.

Check the optional duplex printingunit (Duplexer DU-30*/ DU-31).(Only when installed)

Check the cassette indicated.

6-46FS-7000+/FS-9000

Example: Understanding the paper jam indication

In the example below, paper is jammed in the paper feeder (C), the upper cassette (1), andthe paper feed unit (H).

Paper jamC, H, 1

1. When paper jams in multiple locations such as in this example, begin taking correctiveaction from the location displayed at left. After the paper jam in the paper feeder (C) iscorrected, the display will change as follows.

Paper jamH, 1

2. Next, pull out the paper feed unit and remove the jammed paper. After removing thepaper the display will change as follows.

Front coverOpen

3. Close the front cover. This completes removal of this paper jam.

The page on which the paper jam occurred may not be re-printed depending on the locationof the paper jam.Frequent occurrence of paper jams may indicate you are using a paper specification whichdoes not suit the printer. If this appears to be the case, try switching to a different type ofpaper.

6-47FS-7000+/FS-9000

Paper jam removal diagrams

These diagrams are for assistance in following instructions on page Chapter 6-42.

DIAGRAM 1: PAPER FEEDER

6-48FS-7000+/FS-9000

DIAGRAM 2: FACE-UP STACK

Step 1

Step 2

6-49FS-7000+/FS-9000

Step 3

6-50FS-7000+/FS-9000

DIAGRAM 3: TRANSFER UNIT

Step 1

Step 2

Registration Roller

Open this cover first.

Registration Roller

Paper Feed Unit

6-51FS-7000+/FS-9000

DIAGRAM 4: FUSER UNIT

FS-7000+

Fuser Unit Cover

Tab (green)

Grasp the tab(green) to open.

6-52FS-7000+/FS-9000

Raise thesetwo levers(green) whenpaper is hardto pull out.

6-53FS-7000+/FS-9000

Fuser Unit Cover

Tab (green)

Grasp the tab(green) to open.

FS-9000

6-54FS-7000+/FS-9000

Press downthese twolevers (green)when paper ishard to pull.

Fuser Unit Cover

Separator

NoteWhen removing jammed paper, be careful not to touch the separator located on the backside of the fuser unit cover with your hands.