KIP C7800 Service Manual

Service Manual KIP C7800;
This manual is in the PDF format and have detailed Diagrams, pictures and full procedures to diagnose and repair your KIP C7800.
You can print, zoom or read any diagram, picture or page from this Service Manual. Every chapter on this manual is fully detailed and contain all theĀ  simulation codes, trouble codes, maintenance procedures, reset procedures, diagnose procedures of KIP C7800. You can find easily everything what do you need.
To see what contain, please read table of contents:

Chapter 1. INTRODUCTION
1. 1 Features
1. 2 Specifications
1. 3 Appearance
1. 3. 1 Front view
1. 3. 2 Right side view
1. 3. 3 Rear view
1. 4 Specifications for the Printing Paper
1. 4. 1 Papers not available to use
1. 4. 2 Keeping the paper in the custody
1. 4. 3 Treatment against environmental condition

Chapter 2. INSTALLATION
2. 1 Installation Requirements
2. 2 Unpacking
2. 2. 1 Unpacking
2. 2. 2 Confirmation of accessories
2. 3 Leveling KIP C7800
2. 4 Routing the LAN Cable
2. 5 Removing Tapes, Shock Absorbers and Screws
2. 6 Setting up the Process Unit (Developer, Cleaner & Drum)
2. 6. 1 Setting up the Developer Unit
2. 6. 2 Applying the toner to the Cleaning Blade
2. 6. 3 Installing the Drum
2. 6. 4 Installing the Toner Cartridge
2. 7 Installing the Web Cleaner
2. 8 Reconfirmation of Level
2. 9 Installing the Bypass Feeder Tray
2. 10 IPS Setup Wizard
2. 11 Print Format (metric/inch – if necessary)
2. 12 Supplying Toner into Developer Unit
2. 13 Setting Auto Density Control to “auto std”
2. 14 Executing Auto Adjustments
2. 15 Check and Touch-up LED Head Joint
2.15. 1 Check the result of LED Head Joint
2.15. 2 Touch-up LED Head Joint
2. 16 Check and Touch-up Color Registration
2.16. 1 Check the result of Color Registration
2.16. 2 Touch-up Color Registration
2. 17 Confirm LED Head Joint Control is set to “manual”
POWER CORD INSTRUCTION

Chapter 3. PRINT PROCESS & CONTROL
3. 1 General Outline of the Print Process
3. 1. 1 Characteristic of toner
3. 1. 2 Overall flow of print process
3. 2 Description of Each Step of Print Process
3. 2. 1 Cutting the media
3. 2. 2 Tightening the media (long print only)
3. 2. 3 Media Charging
3. 2. 4 Erasing
3. 2. 5 Drum charging
3. 2. 6 Exposure
3. 2. 7 Development
3. 2. 8 Transfer of toner image onto media
3. 2. 9 Separation of media
3. 2.10 Fusing
3. 2.11 Drum cleaning
3. 2.12 Belt cleaning
3. 3 Controlling the movement of toner in the Developer Unit
3. 4 Automatic Controls
3. 4. 1 Density Control
3. 4. 1. 1 Density Lock
3. 4. 1. 2 Density Control
3. 4. 2 Automatic Transfer Roller Voltage Adjustment

Chapter 4. ELECTRICAL
4. 1 General Information
4. 2 Electrical Components Location
4. 2. 1 Front Side
4. 2. 2 Rear Side
4. 2. 3 Right Side
4. 2. 4 Left Side
4. 2. 5 Inside
4. 2. 6 Belt Unit
4. 2. 7 Process Unit
4. 2. 8 Developer Unit
4. 2. 9 Lower Feeder Unit
4. 2.10 Fuser Unit
4. 2.11 Roll Deck
4. 2.12 LED Head
4. 2.13 Multi Tray Unit
4. 3 Check & Adjustment of HV Power Supply
4. 3. 1 Image Corona
4. 3. 1. 1 Output voltage to Image Corona
4. 3. 1. 2 Analog voltage to Image Corona
4. 3. 2 Grid Plate
4. 3. 2. 1 Output voltage to Grid Plate
4. 3. 2. 2 Analog voltage to Grid Plate
4. 3. 3 Transfer Roller
4. 3. 3. 1 Output voltage to Transfer Roller (Confirmation of Target Current)
4. 3. 3. 2 Analog voltage to Transfer Roller
4. 3. 4 Developer Bias
4. 3. 4. 1 Output voltage to Developer Roller
4. 3. 4. 2 Analog voltage to Developer Roller
4. 3. 5 Voltage gap between Developer Roller & Toner Supply Roller
4. 3. 6 Voltage gap between Developer Roller & Blade Roller (Center)
4. 3. 7 Voltage gap between Developer Roller & Blade Roller (Both sides)
4. 3. 8 Media Charge Roller
4. 3. 8. 1 Output voltage to Media Charge Roller
4. 3. 8. 2 Analog voltage to Media Charge Roller

Chapter 5. MECHANICAL
5. 1 Outer Cover
5. 1. 1 Removing Right Side Cover
5. 1. 2 Removing Left Side Door / Frame
5. 1. 3 Removing Top Cover
5. 2 Process Unit
5. 2. 1 Drawing Process Unit
5. 2. 2 Removing Drum and Cleaner Unit
5. 2. 3 Removing Developer Unit
5. 2. 4 Removing 1st Charging Unit
5. 3 Drum & Drum Cleaner Unit
5. 3. 1 Recommended Periodic Replacement
5. 4 Developer Unit
5. 4. 1 Recommended Periodic Replacement
5. 5 1st Charging Unit
5. 5. 1 Recommended Periodic Replacement
5. 6 Fuser Unit
5. 6. 1 Recommended Periodic Replacement
5. 6. 2 Removing Fuser Unit
5. 6. 3 Replacing Web Cleaner
5. 7 Filter
5. 7. 1 Replacing Filter
5. 8 Belt Unit
5. 8. 1 Replacing BC Blade
5. 8. 2 Replacing Belt
5. 9 Roll Deck
5. 9. 1 Removing Roll Deck
5. 10 Inner Feeder Unit
5. 10. 1 Removing Inner Feeder Unit
5. 11 Cutter Unit
5. 11. 1 Removing Cutter Unit
5. 12 LED Head
5. 12. 1 Removing LED Head
5. 12. 2 Replacing LED Head Lock mechanism

Chapter 6. MAINTENANCE
6. 1 Recommended Periodic Replacement Parts
6. 2 Periodical Maintenance
6. 2. 1 Cleaning of Developer Roller
6. 3 Recommended Service Tools & Devices
6. 4 Internal Battery in Embedded Controller
6. 5 Disposal of machine

Chapter 7. TROUBLESHOOTING
7. 1 Operator Call Error
7. 1. 1 Clearing Door Open Error
U-1001, 1002, 1003 Roll Deck 1/2/3 Open
U-1011, 1012, 1013 Roll Deck 1/2/3 Cutter Cover Open
U-1100 Bypass Feeder Open
U-1101 Left Side Door Open
U-1103 Rear Door Open
U-1104 Fuser Cover (Exit Door) Open
U-1201, 1202, 1203, 1204 Process Unit 1/2/3/4 Open
7. 1. 2 Clearing Jam Error
J-0101 Roll Deck 1 Jam: Power ON
J-0102 Roll Deck 2 Jam: Power ON
J-0103 Roll Deck 3 Jam: Power ON
J-0105 Bypass Feeder Jam: Power ON
J-0111 Lower Feeder Jam: Power ON
J-0112 Registration Jam: Power ON
J-0131 Fuser Jam: Power ON
J-0201 Roll Deck 1 Jam: LE Delay
J-0202 Roll Deck 2 Jam: LE Delay
J-0203 Roll Deck 3 Jam: LE Delay
J-0205 Bypass Feeder Jam: LE Delay
J-0211 Lower Feeder Jam: LE Delay
J-0231 Fuser Jam: LE Delay
J-0401 Roll Deck 1 Jam: Stay
J-0402 Roll Deck 2 Jam: Stay
J-0403 Roll Deck 3 Jam: Stay
J-0431 Fuser Jam: TE Stay
7. 1. 3 Other Operator Call Error
(1) Toner Empty
(2) Roll Empty
(3) Waste Toner Full
7. 2 Service Call Error
7. 2. 1 Clearing Service Call Error
01-11, 01-12, 01-13 Cutter Error
03-01 Dev Press Motor 1 Error
03-02 Drum Motor 1 Error
03-20 Image Corona 1 Output Error
03-21 Transfer Roller Bias 1 Output Error
03-23 Developer Bias 1 Output Error
03-30, 03-31, 03-32 LED Head 1 Error
03-36 Density Control 1 Error
03-40 Wire Cleaning Motor 1 Error
04-01 Dev Press Motor 2 Error
04-02 Drum Motor 2 Error
04-20 Image Corona 2 Output Error
04-21 Transfer Roller Bias 2 Output Error
04-23 Developer Bias 2 Output Error
04-30, 04-31, 04-32 LED Head 2 Error
04-36 Density Control 2 Error
04-40 Wire Cleaning Motor 2 Error
05-01 Dev Press Motor 3 Error
05-02 Drum Motor 3 Error
05-20 Image Corona 3 Output Error
05-21 Transfer Roller Bias 3 Output Error
05-23 Developer Bias 3 Output Error
05-30, 05-31, 05-32 LED Head 3 Error
05-36 Density Control 3 Error
05-40 Wire Cleaning Motor 3 Error
06-01 Dev Press Motor 4 Error
06-02 Drum Motor 4 Error
06-20 Image Corona 4 Output Error
06-21 Transfer Roller Bias 4 Output Error
06-23 Developer Bias 4 Output Error
06-30, 06-31, 06-32 LED Head 4 Error
06-36 Density Control 4 Error
06-40 Wire Cleaning Motor 4 Error
07-10 Media Charge Roller Set Motor Error
07-11 Transfer Roller Set Motor 1 Error
07-12 Transfer Roller Set Motor 2 Error
07-21, 07-22 Belt Skew Error
09-00 Fuser Temperature Rising Error
09-01 Fuser Abnormal High Temperature Error
09-02 Web End Error
09-03 Fuser Thermostat Error
0A-03 BUD Load Error
0A-20 Main Control PCB Communication Error
0A-21 Main Control PCB DDR Initialization Error
0C-01 Density Sensor Error
0C-11, 0C-12, 0C-13, 0C-14 Color Sensor Error
0C-21 LED Head Skew Adjustment Error
0C-22, 0C-23 LED Head Joint Adjustment Error
0C-24, 0C-25 Color Registration Calibration Error
0C-27 Cut Length Adjustment Error
0D-01, 0D-02, 0D-03, 0D-04 Cooling Fan Error
0D-05, 0D-06 DCP Cooling Fan Error
0D-07, 0D-08 IPS Cooling Fan Error
0D-09, 0D-0A Fuser Blower Error
7. 2. 2 Occurrence Condition of Service Call Error
7. 3 Troubleshooting – Image Quality
7. 3. 1 Basic Image Adjustment
7. 3. 2 Cause of Frequent Image Problem
7. 3. 3 Countermeasures – Image Quality
7. 3. 3. 1 Halftone is light (or dark)
7. 3. 3. 2 Halftone and solid images are too light
7. 3. 3. 3 Density is uneven
7. 3. 3. 4 Totally appeared foggy image
7. 3. 3. 5 Vertical thick line that looks not clear
7. 3. 3. 6 Vertical thin line that looks clear
7. 3. 3. 7 Vertical white line
7. 3. 3. 8 Void of image
7. 3. 3. 9 Dirt on the back of the print
7. 3. 3.10 Poor fusing
7. 3. 3.11 Complete white (No image)
7. 3. 3.12 Blur on dark image
7. 3 3.13 Complete solid image like “all black”
7. 3. 4 Checking for correct pressurization or Developer
7. 4 Internal Counter Error

Chapter 8. SERVICE SOFTWARE
8. 1 Service Software Overview
8. 1. 1 Launching Service Software
8. 1. 2 Service Software Home
8. 1. 3 Closing Service Software
8. 1. 4 Service Software Tree Diagram of screen menu hierarchy
8. 1. 5 Media
8. 1. 6 Density
8. 1. 7 Safely Remove Hardware
8. 1. 8 Entering Service Mode (PIN required)
8. 2 Information
8. 2. 1 Version
8. 2. 2 Configuration
8. 3 User Mode
8. 3. 1 Maintenance
8. 3. 1. 1 Cleaning
8. 3. 1. 2 Clear Web Information
8. 3. 2 Density Control
8. 3. 2. 1 Density Control
8. 3. 2. 2 Density Adjust
8. 3. 2. 3 Density Lock
8. 3. 3 Alignment Adjust
8. 3. 3. 1 LED Head Joint Control
8. 3. 3. 2 Sensor Adjust
8. 3. 3. 3 LED Head Skew
8. 3. 3. 4 LED Head Joint
8. 3. 3. 5 Color Registration
8. 3. 3. 6 Vertical Scale
8. 3. 3. 7 Cut Length
8. 4 Service Mode
8. 4. 1 Toner Setup
8. 4. 2 Setting
8. 4. 2. 1 How to change setting parameter
8. 4. 2. 2 Setting List
8. 4. 2. 3 Setting Detail
0001 iso/ansi
0019 long print trailing blank setting
0069 maximum print length
0072 tension control target
0073 tension control gain
0074 tension control offset delay
0079 web feed
0080 print end web setting
0081 to 0092 image corona current
0093 to 0104 grid bias
0113 to 0116 developer roller
(applied when pint speed is 100/120mm/sec)
0117 to 0120 supply roller bias
0125 to 0128 blade roller
(applied when pint speed is 100/120mm/sec)
0139 to 0142 developer roller bias o
(applied when pint speed is 60mm/sec)
0143 to 0146 blade roller
(applied when pint speed is 60mm/sec)
0201 flapper control solenoid pwm duty (long print)
0202 tension control target (long print)
0203 lower transfer tension control target
0204 lower transfer tension control gain
0205 mono print feed mode
0206 stacker select
0207 to 0226 flapper control solenoid pwm duty
0229 long print control change point
0241 image position vertical
0242 image position horizontal
0243 to 0250 led head joint horizontal
0251 to 0262 led head skew
0264 trailing image mask area
0265 leading image mask area
0293 to 0296 color registration horizontal
0302 / 0305 / 0308 / 0311 color registration vertical
0301 / 0303 / 0304 / 0306 / 0307 / 0309 / 0310 /
led head joint vertical
0316 to 0319 color registration vertical offset
0321 to 0324 transfer roller current
0325 to 0327 transfer roller voltage select
0361 counter-a config
0362 counter-b config
0363 counter-a data
0366 counter-b data
0369 total counter data
0441 to 0456 transfer roller voltage (K, 60mm/s plain)
0457 to 0472 transfer roller voltage (K, 60mm/s tracing)
0473 to 0488 transfer roller voltage (K, 60mm/s film)
0489 to 0504 transfer roller voltage (K, 60mm/s gloss)
0505 to 0520 transfer roller voltage (K, 60mm/s heavy)
0521 to 0536 transfer roller voltage (K, 100mm/s plain)
0537 to 0552 transfer roller voltage (K, 100mm/s tracing)
0553 to 0568 transfer roller voltage (K, 100mm/s film)
0569 to 0584 transfer roller voltage (K, 100mm/s gloss)
0585 to 0600 transfer roller voltage (K, 100mm/s heavy)
0601 to 0616 transfer roller voltage (K, 120mm/s plain)
0617 to 0632 transfer roller voltage (K, 120mm/s tracing)
0633 to 0648 transfer roller voltage (K, 120mm/s film)
0649 to 0664 transfer roller voltage (K, 120mm/s gloss)
0665 to 0680 transfer roller voltage (K, 120mm/s heavy)
0681 to 0696 transfer roller voltage (C, 60mm/s plain)
0697 to 0712 transfer roller voltage (C, 60mm/s tracing)
0713 to 0728 transfer roller voltage (C, 60mm/s film)
0729 to 0744 transfer roller voltage (C, 60mm/s gloss)
0745 to 0760 transfer roller voltage (C, 60mm/s heavy)
0761 to 0776 transfer roller voltage (C, 100mm/s plain)
0777 to 0792 transfer roller voltage (C, 100mm/s tracing)
0793 to 0800, 1481 to 1488 transfer roller voltage (C, 100mm/s film)
0801 to 0812 light intensity correction
0813 to 0816 light gain
0844 to 0852 deck motor
0853 to 0855 lower transfer motor
0917 to 0919 cut length fine (deck #1-3)
0920 time of developer reset control – after print
1401 to 1470 image enhance table
1489 to 1504 transfer roller voltage (C, 100mm/s gloss)
1505 to 1520 transfer roller voltage (C, 100mm/s heavy)
1521 to 1536 transfer roller voltage (C, 120mm/s plain)
1537 to 1552 transfer roller voltage (C, 120mm/s tracing)
1553 to 1568 transfer roller voltage (C, 120mm/s film)
1569 to 1584 transfer roller voltage (C, 120mm/s gloss)
1585 to 1600 transfer roller voltage (C, 120mm/s heavy)
1601 to 1616 transfer roller voltage (M, 60mm/s plain)
1617 to 1632 transfer roller voltage (M, 60mm/s tracing)
1633 to 1648 transfer roller voltage (M, 60mm/s film)
1649 to 1664 transfer roller voltage (M, 60mm/s gloss)
1665 to 1680 transfer roller voltage (M, 60mm/s heavy)
1681 to 1696 transfer roller voltage (M, 100mm/s plain)
1697 to 1712 transfer roller voltage (M, 100mm/s tracing)
1713 to 1728 transfer roller voltage (M, 100mm/s film)
1729 to 1744 transfer roller voltage (M, 100mm/s gloss)
1745 to 1760 transfer roller voltage (M, 100mm/s heavy)
1761 to 1776 transfer roller voltage (M, 120mm/s plain)
1777 to 1792 transfer roller voltage (M, 120mm/s tracing)
1793 to 1808 transfer roller voltage (M, 120mm/s film)
1809 to 1824 transfer roller voltage (M, 120mm/s gloss)
1825 to 1840 transfer roller voltage (M, 120mm/s heavy)
1841 to 1856 transfer roller voltage (Y, 60Ym/s plain)
1857 to 1872 transfer roller voltage (Y, 60mm/s tracing)
1873 to 1888 transfer roller voltage (Y, 60mm/s film)
1889 to 1904 transfer roller voltage (Y, 60mm/s gloss)
1905 to 1920 transfer roller voltage (Y, 60mm/s heavy)
1921 to 1936 transfer roller voltage (Y, 100mm/s plain)
1937 to 1952 transfer roller voltage (Y, 100mm/s tracing)
1953 to 1968 transfer roller voltage (Y, 100mm/s film)
1969 to 1984 transfer roller voltage (Y, 100mm/s gloss)
1985 to 2000 transfer roller voltage (Y, 100mm/s heavy)
2001 to 2016 transfer roller voltage (Y, 120mm/s plain)
2017 to 2032 transfer roller voltage (Y, 120mm/s tracing)
2033 to 2048 transfer roller voltage (Y, 120mm/s film)
2049 to 2064 transfer roller voltage (Y, 120mm/s gloss)
2065 to 2080 transfer roller voltage (Y, 120mm/s heavy)
2081 to 2096 media charge roller voltage (60mm/s plain)
2097 to 2112 media charge roller voltage (60mm/s tracing)
2113 to 2128 media charge roller voltage (60mm/s film)
2129 to 2144 media charge roller voltage (60mm/s gloss)
2145 to 2160 media charge roller voltage (60mm/s heavy)
2161 to 2176 media charge roller voltage (100mm/s plain)
2177 to 2192 media charge roller voltage (100mm/s tracing)
2193 to 2208 media charge roller voltage (100mm/s film)
2209 to 2224 media charge roller voltage (100mm/s gloss)
2225 to 2240 media charge roller voltage (100mm/s heavy)
2241 to 2256 media charge roller voltage (120mm/s plain)
2257 to 2272 media charge roller voltage (120mm/s tracing)
2273 to 2288 media charge roller voltage (120mm/s film)
2289 to 2304 media charge roller voltage (120mm/s gloss)
2305 to 2320 media charge roller voltage (120mm/s heavy)
2321 to 2340 fuser temp (60mm/s)
2341 to 2360 fuser temp (100mm/s)
2361 to 2380 fuser temp (120mm/s)
2453 to 2455 auto adjust transfer voltage target current
2468 to 2503 transfer roller voltage offset
8. 4. 3 Data Display
8. 4. 3. 1 Data Display List
8. 4. 4 Input Check
8. 4. 4. 1 Signal List
8. 4. 5 Output Check
8. 4. 5. 1 How to select item to operate
8. 4. 5. 2 Component List
8. 4. 6 Error History
8. 4. 6. 1 How to see Error History
8. 4. 6. 2 How to clear Error History
8. 4. 7 Jam History
8. 4. 7. 1 How to see Jam History
8. 4. 7. 2 How to clear Jam History
8. 4. 8 Backup Data
8. 4. 8. 1 How to backup printer setting
8. 4. 8. 2 How to restore printer setting
8. 4. 9 Program Update
8. 4. 9. 1 How to send program file to printer
8. 4. 10 Change Password
8. 5 Test Print
8. 5. 1 How to use technical Test Print

Chapter 9. ADJUSTMENTS
9. 1 Adjusting Optical Density
9. 2 Readjustment of Tension Sensor
9. 3 Belt Skew Adjustment
9. 3. 1 Before Skew Correction Adjustment
9. 3. 2 Skew Correction Adjustment

Chapter 10. APPENDIX