KIP 7970 Service Manual and Parts List Manual


Service Manual and Parts List Manual KIP 7970
This manual is in the PDF format and have detailed Diagrams, pictures and full procedures to diagnose and repair your KIP.
You can print, zoom or read any diagram, picture or page from this manual. Every chapter on this manual is fully detailed and contain all the simulation codes, trouble codes, maintenance procedures, reset procedures, diagnose procedures of KIP 7970 Service Manual and Parts List Manual.
Table of contents:

Chapter 1. Introduction
1.1 Features
1.2 Specifications
1.3 Name of Each Part
1.3.1 Front
1.3.2 Rear
1.4 Specifications for Printing Media
1. 4. 1 Available Print Size
1. 4. 2 Media not to be used
1. 4. 3 Maintaining Media
1. 4. 4 Environmental Condition – Correction
1. 4. 4 Environmental Condition – Correction

Chapter 2. Installation
2.1 Installation Requirements
2.2 Unpacking
2.3 Accessory List
2.4 Removing Shipping Tapes
2.5 Installing Floor Plates / Leveling
2.6 Releasing LED Head
2.7 Process Unit Setup
2. 7. 1 Process Frame Setup
2. 7. 2 Developer Assy Setup
2. 7. 3 Installing Toner Cartridge
2.8 Fuser Unit Setup
2.9 Installing Touch Panel
2. 9. 1 Assembling Monitor
2. 9. 2 Installing Monitor
2.10 Setting by IPS Installation Wizard
2.11 Regional Setting
2.11 Regional Setting

Chapter 3. Print Process
3.1 Characteristic of Toner
3.2 Print Processes
3.2.1 Erasing (Removal of negative electric charges)
3.2.2 Charge of Drum
3.2.3 Exposure
3.2.4 Development
3.2.5 Pre-Transfer LED
3.2.6 Transfer
3.2.7 Separation
3.2.8 Drum Cleaning (Removal of remained toner)
3.2.9 Fusing
3.3 Controlling the Movement of Toner in Developer Unit
3.4 Toner Collection Process
3.5 Density Compensation Process
3.5 Density Compensation Process

Chapter 4. Electrical
4.1 General Information
4.2 Electric Assembly Location/Function
4.2. 1 Printed Circuit Board
4.2. 2 Fans
4.2. 3 Motors, Clutches & Brake
4.2. 4 Heaters, SSR, Relays, Thermistor & Thermostats
4.2. 5 Circuit Protector, Line Filter, Micro Switches, Switches & Counter
4.2. 6 Sensors
4.3 Check & Adjustment of Analog Output from HVP
4.3. 1 Situations necessary to check the analog output
4.3. 2 Analog Current for Image Corona
4.3. 3 Analog Current for Grid Plate
4.3. 4 Analog Current for Transfer Corona
4.3. 5 AC Component for Separation Corona
4.3. 6 DC Component for Separation Corona
4.3. 7 Negative Developer Bias for Developer Roller
4.3. 8 Positive Developer Bias for Developer Roller
4.3. 9 Bias Gap between Developer Roller and Regulation Roller
4.3.10 Positive Cleaning Roller Bias (Print Cycle)
4.3.11 Negative Cleaning Roller Bias (Toner Collection Process)
4.3.11 Negative Cleaning Roller Bias (Toner Collection Process)

Chapter 5. Mechanical
General Notice for Disassembly / Assembly
5. 1 External Cover
5. 1. 1 Removing Lower Right / Left Cover
5. 1. 2 Removing Right / Left Front Cover & Side Front Covers L/R
5. 1. 3 Removing Right / Left Rear Cover
5. 1. 4 Removing Top Cover
5. 1. 5 Removing Rear Cover
5. 2 Process Unit
5. 2. 1 Opening Movable Unit
5. 2. 2 Removing Developer Unit
5. 2. 3 Replacing Photoconductive Drum
5. 2. 4 Cleaning Photoconductive Drum
5. 2. 5 Replacing LED Head
5. 2. 6 LED Head Focus Adjustment (if necessary adjust density balance among 3 LED blocks)
Check of the Test Pattern Image
Focus Adjustment with Spacers
Adjustment of density balance among 3 LED blocks (if necessary)
5. 2. 7 Replacing Eraser Lamp
5. 2. 8 Replacing LED Head Cooling Fan (Fan3A, Fan3B)
5. 2. 9 Replacing Pre-Transfer LED
5. 2.10 Replacing Main Motor (M1)
5. 2.11 Replacing Timing Belt for Pulley / P
5. 3 Main Frame
5. 3. 1 Replacing Paper Gate Brake (MC4)
5. 3. 2 Replacing Paper Gate Clutch (MC3)
5. 3. 3 Replacing Ozone Filter
5. 3. 4 Replacing Pressure Fan (Fan 2)
5. 3. 5 Replacing Main Switch (S1)
5. 4 Cutter Unit
5. 4. 1 Removing Cutter Unit
5. 4. 2 Replacing Cutter Oil Supply Solenoid (SL2)
5. 4. 3 Lubricating/Replacing Stay Assembly
5. 4. 4 Adjusting Home Position of Cutter Blade
5. 4. 5 Adjusting Installation Angle of Cutter Unit
5. 4. 6 Replacing Cutter Motor (M3)
5. 5 Image Corona Assembly
5. 5. 1 Removing Image Corona Assembly
5. 5. 2 Replacing Corona Wire, Wire Cleaner Assy
5. 5. 3 Replacing Wire Cleaning Motor (M4)
5. 6 Transfer/Separation Charger Assembly
5. 6. 1 Removing Transfer/Separation Charger Assembly
5. 6. 2 Replacing Transfer/Separation Corona Wire
5. 6. 3 Height Adjustment of Corona Wire
5. 6. 4 Replacing Corona Guard
5. 7 Fuser Unit
5. 7. 1 Removing Exit Cover
5. 7. 2 Replacing Fuser Motor
5. 7. 3 Pulling Out Fuser Unit
5. 7. 4 Replacing IR Lamp
5. 7. 5 Replacing Recommended Periodic Replacement Parts
(Fuser Roller, Pressure Roller, Separation Finger, Stripper Finger Assy)
5. 7. 6 Fuser Pressure Adjustment (Nip Width Check)
5. 7. 7 Replacing Thermistor (TH1)
5. 7. 8 Replacing Thermostat (TS1A, TS1B)
5. 7. 9 Replacing Fuser Guide Solenoid (SL2)
5. 7.10 Replacing Exit Sensor (LS2)
5. 8 Developer Unit
5. 8. 1 Removing Toner Hopper
5. 8. 2 Replacing Recommended Periodic Replacement Parts
(Developer Roller, Scraper, Spacer (2), Side Seal R/L)
5. 8. 3 Replacing Toner Supply Roller and Side Seal SU
5. 8. 4 Replacing Blade Roller and Side Seal RE
5. 8. 5 Replacing Screw Sheet
5. 8. 6 Replacing Toner Supply Motor (M6)
5. 8. 7 Replacing Toner Sensor (TLS1)
5. 8. 8 Replacing KNC PCB
5. 9 Internal Feeder Unit
5. 9. 1 Removing Internal Feeder Unit
5. 9. 2 Replacing Paper Separation Sensor (PH7)
5. 9. 3 Replacing Feed Belt
5. 9. 4 Replacing Feed Roller
5. 9. 5 Replacing Separation Fan (Fan2)
5.10 Paper Feeder Assembly
5.10. 1 Removing Roll Deck
5.10. 2 Replacing Feed Motor (M2)
5.10. 3 Replacing Roll Feed Clutch (MC2A, MC2B, MC2C, MC2D)
5.10. 4 Replacing Pick-up Roller (Roll 1, Roll 3)
5.10. 5 Replacing Pick-up Roller (Roll 2, Roll 4)
5.10. 6 Replacing Paper End Clock Sensor (PH2A, PH2B, PH2C, PH2D)
5.10. 7 Replacing Paper Set Sensor (PH1A, PH1C)
5.10. 8 Replacing Paper Set Sensor (PH1B, PH1D)
5.10. 9 Replacing Feed Sensor (PH14A, PH14B)
5.10. 9 Replacing Feed Sensor (PH14A, PH14B)

Chapter 6. Maintenance
6.1 Recommended Periodic Replacement Parts
6.2 Cleaning
6.3 Lubrication
6.4 Fuse Replacement
6.4 Fuse Replacement

Chapter 7. Troubleshooting
7.1 Error Code List
7.1.1 Operator Call Errors
7.1.2 Service Call Errors
7.2 Troubleshooting against Errors
7.2.1 Countermeasures against Operator Call Errors
(J-01) 1st Roll Jam
(J-02) 2nd Roll Jam
(J-03) 3rd Roll Jam
(J-04) 4th Roll Jam
(J-05) Bypass Jam
(J-10) Cutter Area Jam
(J-11) Internal Feeder Area Jam
(J-12) Separation Area Jam
(J-13) Exit Area Jam (Delay)
(J-14) Exit Area Jam (Stay)
(J-21) Outer Device Jam (Delay)
(J-22) Outer Device Jam (Stay)
(U-01) Upper Roll Deck Open Error
(U-02) Lower Roll Deck Open Error
(U-05) Upper Frame Unit Open Error
(U-06) Exit Cover Open Error
Toner Low
Roll Empty
7.2.2 Countermeasures against Service Call Errors
(E-01) Fuser Temperature Rising Error
(E-02) Fuser Over Temperature Error
(E-03) Main Motor Error
(E-04) Developer Error
(E-06) Counter Error
(E-07) Cutter Error
(E-14) Fuser Motor Error
(E-16) Wire Cleaning Error
(E-21) Fuser Thermostat Error
(E-27) Density Error
(E-40) Folder Error
(E-46) KNC Error
(E-51) High Voltage Power Supply Error
7.3 Troubleshooting against Image Quality Defect
7.3.1 Basic Image Adjustment
7.3.2 Troubles
(1) Too light image (Only the halftone image)
(2) Too light image (Halftone and solid black)
(3) Extremely light image (The whole image)
(4) Different copy density
(5) Totally appeared foggy image
(6) Vertically blurred or foggy black wide line
(7) Vertical Clear Black Narrow Line
(8) Vertical White Line
(9) Void of image
(10) Dirt on the back of the copy
(11) Defective fusing
(12) Incorrect Image Placement, No Leading Edge
(13) Jitter
(14) Less sharpened image
(15) Uneven image vertically
(16) Totally white (No image)
(17) Totally black
(18) Creasing
(19) Foggy Image
(20) Offset
(21) Cutter Shock
(Disturbance of image like “black belt” at about 190mm from trailing edge)
7.4 Touch Screen Calibration
7.5 Internal Counter Error
7.5 Internal Counter Error

Chapter 8. Service Mode / Utility
8. 1 General Information of Service Mode
8. 2 KIP Service Software Overview
8. 2. 1 Launching KIP Service Software
8. 2. 2 Closing KIP Service Software
8. 2. 3 Log In screen
8. 2. 4 Service Mode Home
8. 2. 5 Serial Port Setting
8. 3 Signal Status Mode
8. 3. 1 Monitoring Signal Status
8. 3. 2 Input / Output Signal List
8. 4 Information Mode
8. 4. 1 Monitoring Analog Data
8. 4. 2 List of Analog Data Monitor
8. 4. 3 Browsing Jam History
8. 4. 4 Browsing Error History
8. 5 Operation Check Mode
8. 5. 1 Checking Device Operation
8. 6 Adjustment Mode
8. 6. 1 Changing Setting Value
8. 6. 2 Setting Item List
8. 6. 3 Setting Item Explanation
General Information
(00) Metric / Inch (for size format)
(01) Maximum Cut Length
(02) Interface Board Setting
(03) LED Head Strobe Time
(05) Trailing Margin for Long Print
(06) Special Roll Size (ISO)
(08) (0a) (0c) Fusing Temperature
(0e) Temperature Gap to be Ready
(0f) Down Sequence Temperature Adjustment
(10) Fusing Temperature Cycle (Ripple)
(11) Fuser Temperature (Overshoot)
(12) Warm Up Time Setting
(13) Fuser Temperature (Idling)
(14) Fuser Temperature (Warm Sleep)
(15) (16) (17) Developer Bias
(18) Developer Temporal Bias (Front Image)
(19) Developer Temporal Bias (After Print)
(1a) (1b) (1c) Transfer Corona Analog Voltage (Roll)
(1d) (1e) Leading Registration
(1f) Grid Analog Setting
(20) (21) (22) (23) (24) (25) Cut Length Adjustment (Roll 1)
(26) (27) Trailing Margin
(28) Side Margin
(29) Transfer Corona ON Timing (Leading edge)
(2a) Transfer Corona OFF Timing (Trailing edge, Roll, Plain, A0)
(2b) (2c) (2d) Separation Corona OFF Timing
(2e) Dehumidify Setting
(2f) Hardware Counter Unit (Detail)
(30) Key Card Setting
(31) Optional Device Setting
(32) Number of Roll Deck
(33) User Mode Permission
(34) Main Motor Speed
(35) (36) (37) Feed Motor Speed
(38) (39) (3a) Fuser Motor Speed
(3b) (3c) (3d) Fuser Motor 2nd Speed Switch Timing
(3e) (3f) (40) Fuser Motor 2nd Speed
(41) (42) (43) Fuser Motor 3rd Speed Switch Timing
(44) (45) (46) Fuser Motor 3rd Speed
(47) Toner Supply Volume Adjustment
(48) Down Sequence Shift Time cause by Toner
(49) Film Mode ON/OFF
(4a) Transfer Corona ON Timing (Cut Sheet, Plain)
(4b) Transfer Corona OFF Timing (Cut Sheet)
(4c) Trailing Margin (Short Interval Mode, Roll)
(4d) Adjustment of Paper Slack at Cutter Region (Roll 1)
(4e) Fuser Motor Speed (right after Drum)
(4f) Print Wait Setting (Number of Sheet)
(50) Print Wait Setting (Time)
(51) (52) Fusing Temperature Adjustment (Side)
(53) (54) Fusing Temperature Adjustment (Center)
(56) (57) (58) Transfer Corona Analog Voltage (Cut Sheet)
(59) (5a) (5b) (5c) (5d) (5e) Cut Length Adjustment (Roll 2)
(5f) (60) (61) (62) (63) (61) Cut Length Adjustment (Roll 3)
(65) (66) (67) (68) (69) (6a) Cut Length Adjustment (Roll 4)
(6b) (6c) (6d) Fusing Temperature Compensation (Small Size)
(6e) Toner Supply Timing Adjustment
(6f) (70) (71) Adjustment of Paper Slack at Cutter Region (Roll 2/3/4)
(72) Separation Lamp ON Selection
(73) Fuser Guide Solenoid A1 Switch
(76) Toner Empty Timing Adjustment
(77) Toner Supply Roller Bias
(78) Regulation Bias
(79) Density Compensation ON/OFF
(7a) Density Sensor Standard Output
(7b) Density Sensor Analog Voltage
(7c) Density Sensor Output Monitor
(7d) Target Density
(7e) Density Measure Patch Adjustment
(7f) Density Measure Interval
(80) Developer Bias Increment for Bias Adjustment
(81) Developer Bias Increment Total
(82) Regulation Bias Increment for Bias Adjustment
(83) Regulation Bias Increment Total
(84) Regulation Bias Increment Maximum
(85) Developer Reference Bias
(86) Density Measure Extra Monitor
(87) Density Adjustment for Extra Check
(88) Regulation Temporal Bias (after Developing)
(89) Minimum Developer Bias
(8a) Maximum Developer Bias
(8b) Transfer Voltage Switch Timing at Trailing Edge
(8c) (8d) (8e) Transfer Voltage applied to Trailing Edge
(8f) Toner Supply Roller Bias (High Coverage Mode)
(90) (91) Cut Length
(92) (93) Cut Length Compensation
(94) Regulation Bias (High Coverage Mode)
(95) Hardware Counter Unit (ANSI / ISO)
(96) Fuser Motor Speed Switch Timing at Trailing Edge
(97) (98) (99) Fuser Motor Speed for Trailing Edge
(9a) Disable/enable HV error detection
(9b) Drum Reverse Time
(a4) Fuser Guide Solenoid Operation Mode
(a5) (a6) (a7) Subsidiary Toner Supply
(a8) Force Initial Cut Before Print (Cut Length)
(a9) (aa) (ab) (ac) Side Registration
(ad) (ae) (af) Fuser Motor 4th Speed Switch Timing
(b0) (b1) (b2) Fuser Motor 4th Speed
(b3) Subsidiary Toner Supply ON/OFF
(b4) (b5) Transfer Corona OFF Timing (Roll, Tracing/Film, A0)
(b6) (b7) Transfer Corona OFF Timing (Cut sheet, Tracing/Film)
(b8) (b9) (ba) Transfer Corona OFF Timing (Roll, A1)
(bb) (bc) (bd) Transfer Corona OFF Timing (Roll, A2)
(be) (bf) (c0) Transfer Corona OFF Timing (Roll, A3)
(c1) Transfer Corona OFF Timing (Roll, Plain, A0, 1/8 or less)
(c2) (c3) Auto Cut After Long Print
(c4) Fan Operation during Warm Sleep
(c5) Auto Cut After Long Print (eject length)
(c6) Force Initial Cut Before Print (Timer)
(c7) Force Initial Cut Before Print (Roll Deck Selection)
(c8) Horizontal alignment between LED blocks A & B
(c9) Horizontal alignment between LED blocks B & C
(ca) Vertical alignment between LED blocks A & B
(cb) Vertical alignment between LED blocks B & C
(cc) Leading margin given forcibly
(cd) Density of LED block A
(ce) Density of LED block B
(cf) Density of LED block C
(d0) (d1) (d2) Number of prints stacked on Upper Tray
(d3) Density compensation for the boundary between LED blocks A & B
(d4) Density compensation for the boundary between LED blocks B & C
(d5) Regional setting
(d6) Timer of Toner Collection Process during printing
(d7) Behavior of TR Guide Plate: Media type selection
(d8) Behavior of TR Guide Plate: ON timing
(d9) Behavior of TR Guide Plate: OFF timing
(da) Behavior of TR Guide Plate: Timer for action
8. 6. 4 Creating Backup
8. 6. 5 Restoring Configuration from Backup
8. 7 Running Mode (Factory Use Only)
8. 8 Jam/Error Mask Mode
8. 8. 1 Masking Jam
8. 8. 2 Masking Errors
8. 8. 2 Mask List
8. 9 Test Print Mode
8. 9. 1 Making Test Print
8. 9. 2 Built-in Test Pattern
8. 10 Factory Adjustment Mode (Factory Use Only)
8. 11 Special Operation Mode
8.11.1 Clearing Fuser Error, Jam/Error History
8.11.2 Reset of Bias Adjustment by Density Compensation Process
8.11.3 Changing Counter Value
8.11.4 Toner Supply Mode (Use only for machine initial setup)
8. 12 Send Firmware Mode
8.12.1 Sending Firmware to Printer
8.12.2 In case of transmission failure
8.12.2 In case of transmission failure

Chapter 9. Appendix

Parts List Manual