KIP 9000 Service Manual
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KIP 9000 Service Manual

High volume network printer
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Table of Contents

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H i g h V o l u m e
N e t w o r k P r i n t e r
Service Manual
V e r s i o n A . 0

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Summary of Contents for KIP 9000

  • Page 1 H i g h V o l u m e N e t w o r k P r i n t e r Service Manual V e r s i o n A . 0...
  • Page 2 Chapter 1 Introduction Page 1. 1 Features 1- 1 1. 2 Specifications 1- 2 1. 3 Appearance 1- 4 1. 3. 1 Front view 1- 4 1. 3. 2 Right side view 1- 5 1. 3. 3 Rear view 1- 6 1.
  • Page 3 1. 1 Features (1) New Contact Development Technology with non-magnetic mono-component toner Superior image quality High definition line, distinctive greyscale and consistent solid black can be produced. 100% toner efficiency No waste toner is generated. Neither cleaning mechanism nor waste toner receptacle is needed. It is environmentally friendly and can reduce the running cost.
  • Page 4 Film A0 / 48 inch NOTE : Longer print than the above specified maximum lengths is available. However, KIP does not guarantee any result including image quality and media feeding if the print is longer than the above specified lengths.
  • Page 5 Subject Specification Environmental Temperature 10 - 32C (50 - 89F) condition Humidity 20 - 80% RH Storage condition of Print media Keep the media surely in a plastic bag and close to consumables shut out the humidity. Toner Keep the toner cartridge away from the direct sunlight, and store it in the condition of 0 - 35 and 10 - 85% RH.
  • Page 6 Multiple cut sheet feeding (50 sheets max) is available when the size is narrower than A2 (594mm) or 24”. Operation Panel Indicates the status of KIP 9000, error, mis-feed location and so Roll Decks There are 4 Roll Decks (Drawers are 3 but Roll Spools are 4.).
  • Page 7 1. 3. 2 Right side view Toner Cartridge Fuser Handle Cutter Handle Counter A Counter B Internal Transportation Unit Lever Name of part Function Cutter Handle Can cut the roll media manually if it has not been cut yet after it was mis-fed.
  • Page 8 1. 3. 3 Rear view Dehumidify Heater Switch Interface Connector for scanner Top Rear Cover Exit Cover Power Cord Folder Port VGA Port Interface Connector for IPS USB Port Power Outlet Shut Down Diag Port for controller K115sm1e1.doc...
  • Page 9 Can access the Dehumidify Heater Switch. Outlet for Controller Unit In case you place a controller unit outside of the KIP 9000, it is possible to supply AC power from the KIP 9000 to the controller unit if you connect the power cord to this outlet. (220 - 240V, 3A...
  • Page 10 WIRE CLEAN EXP- CLEAN Name of part Function Ready Indicator Flashes green when KIP 9000 is warming up, and lights green when it is ready. Open Indicator Lights orange when any door or unit is open or unlocked. Toner Empty Flashes red when the toner is near empty.
  • Page 11 1. 3. 5 Media Indicators The Media Indicator on the right front of KIP9000 informs the size (width) and the type of roll media installed in each Roll Deck. plain paper vellum / tracing film plain paper vellum / tracing film plain paper vellum / tracing...
  • Page 12 One or two “in use” Indicator light orange when the KIP 9000 is on printing. Do not open the drawer if the concerning “in use” Indicator is lighting orange.
  • Page 13 See the following section diagram. Media feeding paths from each Roll Deck is integrated into one path in the middle drawer. When the KIP 9000 is printing with the roll media fed from the Roll Deck 1 for example, only the bottom drawer can be opened. (“in use” Indicators for top and middle drawers will light orange in this case.)

  • Page 14: Table Of Contents

    Chapter 2 Installation KIP9000 had passed the strict inspection after careful adjustment in the factory, and then it was packaged and shipped. Installation is an important work to reproduce the same machine performance at customer site. Service personnel have to understand all the detail about KIP9000 before installation.

  • Page 15: Installation Requirements

    (see certifications) Ventilate the room, if required. (8) Levelling Bolts on the bottom of the KIP 9000 should touch the floor securely. And the equipment must be levelled. Floor strength must be ample to sustain the weight of the system.

  • Page 16: Unpacking

    Unpacking 2. 2. 1 Unpacking CAUTION When the printer is to be installed in winter condensation may occur! The printer will be very cold if it has been kept in a warehouse or delivered by truck. If a cold machine is unpacked on the customer site right after it’s delivery, condensation will occur and cause issues.

  • Page 17: Confirm Accessories

    2. 2. 2 Confirm accessories Confirm the system includes the following items. Description Picture / Notes Quantity Drum (Inside of the black box) LED Head LED Cleaning Pad Monitor...
  • Page 18 Item name Picture Number of article Monitor Arm M4x10 Flush Head Screw Monitor Panel BKT M4x6 Tooth Washer Screw • 1 for securing the ground strap of Panel BKT • 2 for securing the Cover 3...
  • Page 19 Item name Picture Number of article M4x8 Tooth Washer Screw Monitor Cover 2 Monitor Cover 3 M4x10 Tooth Washer Screw...
  • Page 20 Item name Picture Number of article PC Bracket Cover 21 Cut Sheet Feeder Tray 36”x5” paper...
  • Page 21 Item name Picture Number of article Drum Stand Setup Toner Bottle (200g) Drum Cleaning Blade Drum Shading Sheet...
  • Page 22 Item name Picture Number of article Service Label IPS (PC) KIP IPS Computer in a separate box with VGA cable and Power cable Serial Cable IF Cable...
  • Page 23 Item name Picture Number of article USB Cable VGA Cable With IPS Power Supply Lead With IPS 2-10...

  • Page 24: Level The Kip9000

    Level the KIP9000 KIP9000 needs to be levelled with a water level. If it is not levelled, it may cause creasing or a poor image. Put the water level on the following 3 locations on the KIP9000 to level the printer. Turn the 4 Height Adjusters (1) on the bottom.

  • Page 25: Removal Of Tape, Screws And Shock Absorbers

    Removal of Tape, Screws and Shock Absorbers Remove the tape, screws and shock absorbers which secure some movable items. They prevent parts from being damaged during transportation. 1. Remove 2 screws with the tag (1) on the bottom of the Fuser. These screws are no longer used. NOTE The above 2 screws removes pressure during delivery to avoid damage.
  • Page 26 3. Open the Toner Cover (5) and remove the tape (6) securing the Toner Cartridge Cover. 4. Open the Right Side Door (7), and remove the tapes (8) and the shock absorber with tag (9). 5. Open the Top Rear Cover (10) and remove the shock absorber with tag (11) on the right.

  • Page 27: Setting Up The Process Unit (Led Head, Developer & Drum)

    Setting up the Process Unit (LED Head, Developer & Drum) 1. Open the Right Side Door (1). 2. Twist the Lock Lever (2) counter-clockwise to unlock the Internal Transportation Unit, bring down the Internal Transportation Unit (3), and hold its shaft with the Hook (4). 2.a Unplug the connector on the side of process frame 2-14...
  • Page 28 3. Remove 2 M4x10 screws (5). Also remove 4 M4x14 screws (6) in gray sponges. NOTE Gray sponges hold the M4x14 screws (6) and prevent them from dropping out. Sponge Machine M4x14 side 4. Hold the Handles (7) firmly and draw out the Process Unit (8). 2-15...
  • Page 29 5. Open the Top Rear Cover (9), disconnect the connector (10) on the left, remove 4 tooth washer screws (11), and remove the Top Center Cover (12). 6. Open the packaging box of LED Head, and carefully remove the wrapped LED Head (13) and small box (14).
  • Page 30 8. Remove the protection box (17) on one side of the LED Head Unit, which is protecting the Wire Cleaning Motor. 9. Insert 2 positioning bars (18) on motor side of LED Head Unit into the positioning slits (19) on the left side of the KIP9000. NOTE Be careful not to bend or break 3 pieces of Ground Plates (20).
  • Page 31 10. Fit the positioning pin (21) on another side of LED Head to the notch (22) on the right of KIP9000. Install the 2 M4x10 screws (5) removed at the former procedure 3 BUT DO NOT TIGHTEN AT THIS TIME. CAUTION It is necessary to have a correct gap (focus distance) between LED Head and Drum by a later procedure, and the LED Head Unit must be easily moved up and down at that time.
  • Page 32 11. Connect 3 connectors (23) to LED Head and 1 connector (24) of Cleaning Motor. 12. Confirm that the right side of LED Head can be easily moved up and down by hand, then push the Process Unit (8) into the machine fully. (See NOTE on the next page before closing the Process Unit.) The positioning bars (25) on the right of LED Head Unit will fit into the positioning slits (26) when Process Unit is closed, and a proper gap (focus distance) can be kept between LED...
  • Page 33 NOTE Make sure to close the Process Unit with the M4x10 screws loosed! The positioning bars (25) of the LED Head will fit into the positioning slits (26) when the Process Unit is closed. The positioning bars (25) are curved up so that they can fit into the positioning slits (26) vary smoothly.
  • Page 34 13. Secure the Process Unit tightening 4 M4x14 screws (6). After that, tighten 2 M4x10 screws (5) to secure the LED Head Unit with keeping a proper focus distance. NOTE Process Unit needs to be fixed before LED Head Unit to have correct focus distance. Do not change the order.
  • Page 35 16. Disconnect the connector (27) of the Wire Cleaning Motor, remove 2 screws (28) at both sides, and remove the Image Corona (29). 17. Remove the tapes (30) and protection paper (31) on the Developer Unit. NOTE The Developer Roller is purposely covered with the toner for smooth rotation. Do not remove it when removing the protection paper.
  • Page 36 18. Remove the screw with tag (32) on the right of Developer Unit. Also remove the screw with tag (33) on the left. (These screws are no longer used.) NOTE The screw (32) is not reused. ( this differs from the KIP 8000 ) 19. Remove 3 screws (34), and remove the Toner Hopper Cover (35). Hopper (Section drawing of Developer &...
  • Page 37 20. Put the 36”x5” paper (36) under the Sender Screw of Toner Hopper to close the toner supplying holes on the bottom of Toner Hopper. (Shift the 36”x5” paper (36) to the left side as far as possible.) This is an accessory of KIP9000. Sender Screw 21.
  • Page 38 23. Carefully remove the 36”x5” paper (36). 24. Return the Toner Hopper Cover (35) and secure it with 3 screws (34). 25. Remove the tapes on both sides of Cleaning Roller (38). Loosen the tooth washer screw (39) and hexagon head screw (40), and remove the Bracket (41) on the right.
  • Page 39 26. Remove the Cleaning Roller (38) from its operating position, and put it on its “temporary position” by fitting both bearings to the notches (42) on both sides as shown in below. (Left side) (Right side) NOTE Do not close the Process Unit with the Cleaning Roller placed on the “temporary position”. The surface of Cleaning Roller will be damaged.
  • Page 40 27. Remove the Drum (43) from the box, fit both Drum Bearings (44) into the Drum Guides (45) on both sides of Process Unit with placing the Drum Gear (46) on the left, and carefully bring down the Drum along with the Drum Guides. NOTE The Drum Shaft inside of KIP9000 has 2 Driving Pins (47), and the Drum Bearing on Drum Gear side has 2 Projections (48).
  • Page 41 28. Return the Cleaning Roller (38) to its correct position, and secure it with Bracket (41), tooth washer screw (39) and hexagon head screw (40). NOTE (1) Tighten the tooth washer screw (39) and hexagon head screw (40) when pressing down the Bracket (41).
  • Page 42 29. Return the Image Corona (29) to the Process Unit and secure it with 2 screws (28). Connect the connector (27) of the Wire Cleaning Motor. 30. Close the Process Unit (8), and secure it with 4 M4x14 screws (6). 31.
  • Page 43 32 Plug in the connector on the side of process frame 33. Close the Right Side Door (1). 2-30...
  • Page 44 Installing the Monitor 1. Open the Top Rear Cover (1). 2. Disconnect the connector (2) on the left, and remove 4 screws (3). 3. Remove the Top Center Cover (4). 4. Remove 6 screws (5), and remove the Top Front Cover (6). 2-31...
  • Page 45 5. Open the Toner Cover (7) and the Toner Cartridge Cover (8). 6. Remove 2 screws (9), and loosen 1 screw (10). NOTE The screw (10) needs to be loosened as it will interfere with Cover in the next step. 7.
  • Page 46 8. Remove the Top Right Cover (12). 9. Insert the 3 monitor cables (13) into the Arm (14). NOTE 3 monitor cables (13) are as follows. • VGA Cable • USB Cable • Power Cable 2-33...
  • Page 47 10. Install the Arm (14) to machine frame with 3 M4x10 flash head screws (15). NOTE Place 2 cut-edges (16) on the front. 11. Return the Top Right Cover (12). 2-34...
  • Page 48 12. Secure the ground strap (17) of Panel BKT Assy to the screw hole (18) on the Arm with 1 piece of M4x6 Tooth Washer Screw (19). 2-35...
  • Page 49 13. Secure the Panel BKT Assy (20) to the Arm (14) with 4 M4x8 Tooth Washer Screws (21). 2-36...
  • Page 50 14. Put 3 monitor cables (13) inside of Cover 3 Assy (22). 2-37...
  • Page 51 15. Insert the monitor cables into the square hole (23) of Cover 2 Assy (24) as the arrow shows, and secure the Cover 3 Assy (22) onto Cover 2 Assy (24) with 2 pieces of M4x6 Tooth Washer Screw (19). 2-38...
  • Page 52 16. Connect each VGA Cable (25), Power Cable (26) and USB Cable to its own terminal on the Monitor Assy (27). Power 2-39...
  • Page 53 17. Secure both Monitor Assy (27) and Cover 2 Assy (24) together with 4 M4x10 Tooth Washer Screws (28). 2-40...
  • Page 54 18. Adjust the vertical angle of monitor, and tighten the screw (29). 19. Adjust the horizontal angle of monitor, and tighten the screw (30). 2-41...
  • Page 55 20. Return the Cover (11). 21. Close the Toner Cartridge Cover (8) and the Toner Cover (7). 22. Return both Top Front Cover (6) and Top Center Cover (4). 2-42...
  • Page 56 2.7 Installing the Controller 1. Loosen 2 screws (1) and 2 screws (2) 2. Hang the PC Frame (3) to 2 screws (1), and tighten the screws (1). 2-43...
  • Page 57 3. Put the Controller Unit (4) on the PC Frame. Connect the necessary cables. Please see the following two pictures for cable connections on the printer and IPS NOTE VGA Cable IF Cable IPS Power Shut Down Cable USB Cable (Serial Cable) 2-44...
  • Page 58 NOTE IPS Power LAN Cable IF Cable VGA Cable Shut Down Cable USB Cable (Serial Cable) (any one) 2-45...
  • Page 59 4. Hang the Cover 21 Assy (5) to 2 screws (2) while holding the cables with the wire saddles. Tighten the screws (2) to secure the Cover 21 (5). NOTE Place the Power Cord of Controller Unit with the right wire saddle (6), and the other cables with left sire saddle (7).
  • Page 60 5. The power switch on the IPS should only be turned on after confirming that the IPS power supply voltage slider is set to “230”. The power outlet on the KIP 9000 is 220 - 240 VAC or the same as the wall voltage.
  • Page 61 Installing the Toner Cartridge NOTE The product does not include the Toner Cartridge. Purchase it separately. Use only KIP 9000 Toner 1. Open the Toner Cover (1), and open the Toner Cartridge Cover (2). 2. Shake the new Toner Cartridge (3) fully to loosen the toner.
  • Page 62 4. Rotate the Toner Cartridge quarter revolution. Strip off the green seal (4). 5. Rotate the cartridge quarter revolution more to place the toner supplying hole on the bottom. NOTE Be sure to place the toner supplying bole on the bottom. Otherwise the KIP9000 will show Toner Empty Error.
  • Page 63 Loading the Media into the Roll Decks NOTE The product does not include the media. Please purchase it separately. 2. 9. 1 Roll deck 1, 2 and 3 1. Open the concerning Roll Deck (1). 2. Retrieve the Roll Spool (2) to the arrow direction for 1 revolution to disengage the gears on the left, and remove it from the deck.
  • Page 64 3. Pressing down the green lever (4), insert the Roll Spool to the new roll media. NOTE Do not install the roll media with wrong direction. Correct Wrong 4. Align the edge of roll media with the concerning size guide (5), then release the green lever. The roll media is firmly fixed to the Roll Spool.
  • Page 65 5. Return the Roll Spool to the Roll Deck. NOTE The driving belt (6) inside of the Roll Deck must be flat and evenly contact on the bottom of black small roller (7) on the right of Roll Spool. If it is twisted or not contacting the black small roller properly, correctly it.
  • Page 66 6. Using the slit (8) on each drawer, cut off the leading part of roll media with a cutter knife to straighten the leading edge. DO NOT FEED ANY TAPE OR ADHESIVE INTO THE MACHINE AS IT MAY STICK TO THE DRUM. It is best to trim at least one revolution from the roll to prevent this.
  • Page 67 8. Set the Media Selector (11) correctly according to the type of media installed. If any inch size media is installed, select either “ENGINEERING” or “ARCHITECTURE” as well. (“ENGINEERING” is selected when the button is up, and “ARCHITECTURE” when it is down.) NOTE Set the Media Selector to correct media type.
  • Page 68 2. 9. 2 Roll deck 4 The method of installation to Roll 4 is a little different from the method for the other Rolls because of the different location of Roll 4’s feeding rollers. This section instructs the operation required for Roll 4. Refer to [10.1 Roll 1, 2 &...
  • Page 69 3. Return the Roll Spool to the Roll Deck 4. 4. Insert the leading edge of media under the feeding roller (2). 5. Rotate the green knob (3) clockwise to pinch the leading edge (about 1-2cm) with the feeding rollers. 6.
  • Page 70 2.10 Installing the Cut Sheet Feeder Tray Install the Tray (1) to the setting holes (2) on the front face. 2-57...
  • Page 71 220 to 240V (+6% to -10%), 16A, 50/60Hz 2. Press “|” side of Power Switch to turn on the KIP 9000. 3. KIP 9000 starts warming up the Fuser, and the Ready Indicator on the Operation Panel starts flashing. PAPER DECK...
  • Page 72 2.12 Supplying the Toner into Developer Unit 1. Press and hold the [ * ] key on the Operation Panel, and press switches in the order as [ ], [ ] and [ ] to enter the Service Mode. MENU ENTER ONLINE MENU ENTER ONLINE...
  • Page 73 4. After confirming that “- -” on 5th and 6th digits is lighting, press the [ ENTER ] Key to start supplying the toner. The 5th and 6th digits indicate “8 8” in flashing during toner supply. MENU ENTER ONLINE MENU ENTER ONLINE “8 8”...
  • Page 74 Chapter 3 Print Process Page 3. 1 Characteristic of Toner 3- 2 3. 2 Print Processes 3- 3 3. 2. 1 Erasing 3- 5 3. 2. 2 Drum Cleaning 3- 6 3. 2. 3 Charge of Drum 3- 7 3. 2. 4 Exposure 3- 8 3.

  • Page 75: Characteristic Of Toner

    3. 1 Characteristic of Toner The toner used on KIP9000 has a characteristic to be charged “negative” (like a negative object), which tends to be attracted to a relatively “positive” object. Suppose that there are objects A and B, and the situation is as follows. 1.

  • Page 76: Print Processes

    3. 2 Print Processes One print cycle consists of 9 processes. 1. Erasing (Removal of negative electric charges) 2. Drum Cleaning (Removal of remained toner) 3. Charge of Drum 4. Exposure 5. Development 6. Pre-transfer LED 7. Transfer 8. Separation 9.
  • Page 77 Processes from 1 to 8 are related with the control of electric potentials. The following graphic shows the potential on each process and the movement of toner. Voltage of Cleaning Roller +800V +700V +600V +500V +400V +300V Voltage of +200V Transfer Corona +100V -100V...

  • Page 78: Erasing

    3. 2. 1 Erasing As the first step of print cycle, the negative electric charges on the Drum are removed by Erasing process, which remained there after the former print cycle. The Drum has a characteristic to lose the negative electric charges when exposed to the light. So the Drum is rotated and evenly exposed to the light from the Eraser Lamp.

  • Page 79: Drum Cleaning

    3. 2. 2 Drum Cleaning Small amount of toner is remaining on the Drum as it was not transferred onto the printing media in the former print cycle. Drum Cleaning is a process to remove such toner from the Drum with the Cleaning Roller.

  • Page 80: Charge Of Drum

    3. 2. 3 Charge of Drum The Image Corona takes negative discharging, and the Drum surface is charged negatively with -XV evenly by this process. The Drum surface charged with -XV corresponds to the white area of the printed image pattern. The value of surface potential “-XV”...

  • Page 81: Exposure

    3. 2. 4 Exposure According to the printed image pattern, the LED Head throws light onto a certain area of the Drum that corresponds to the black area of printed image pattern. As the Drum has a characteristic to lose the negative electric charges when exposed to the light, the potential of this exposed area is increased to about -50V.

  • Page 82: Development

    3. 2. 5 Development The Developer Roller is evenly covered with the toner, and it is contacted to the Drum firmly. (The width of contacting area is about 5mm.) The Developer Roller is supplied with -YV of Developer Bias which is flexibly adjusted by the Auto Density Control. On the other hand, an Electrostatic Latent Image consisting of -XV area and -YV area exists on the Drum.
  • Page 83 Reference Very small amount of toner may be remaining on “white image area” (corresponds to -XV area) of Drum if Drum Cleaning process could not remove the toner completely. Such unnecessary toner in white image area can be removed surely by the Developer Roller because of the relationship of potential between Drum and Developer Roller.

  • Page 84: Pre-Transfer Led

    3. 2. 6 Pre-transfer LED The potential of non-toner area of the Drum is -XV even after the Development process, which is so high that the print media may not be separated smoothly from the Drum on later Separation Process as it is strongly attracted to -XV area by the static force, and may result in a jam in the worst case.

  • Page 85: Transfer

    3. 2. 7 Transfer The Transfer Corona takes positive discharging to charge the printing media positively. As the toner existing on negative Drum surface is attracted to the positive printing media, the toner image can be transferred onto the media. The voltage supplied to the Transfer Corona Wire is as follows.

  • Page 86: Separation

    3. 2. 8 Separation The printing media is stuck to the Drum after the Transfer being attracted by the static force. It is necessary for avoiding the jam to separate the media from the Drum smoothly removing the static force. The Separation Corona takes AC discharge being supplied with the AC voltage and the DC voltage.

  • Page 87: Fusing

    3. 2. 9 Fusing After Transfer / Separation Processes, the Inner Transportation Unit carries the printing media to the Fuser Unit. The Fuser Unit mainly consists of the Fuser Roller and the Pressure Roller. The toner is firmly fused onto the printing media by the heat and the pressure when the media passes through between the Fuser Roller and Pressure Roller.

  • Page 88: Controlling The Movement Of Toner In The Developer Unit

    3. 3 Controlling the Movement of Toner in the Developer Unit Developer Unit is provided with 3 rollers “Developer Roller”, “Regulation Roller” and “Toner Supply Roller”, which are provided with their own Bias respectively as the following table. The voltage of the Developer Roller (-YV) is measured against the ground, and the voltages for other items are the difference against the Developer Roller Bias (-YV).
  • Page 89 Taking advantage of the difference of potentials among these rollers, the movement of toner is controlled in the Developer Unit as follows. 1. The Toner Supply Roller carries the toner toward the Developer Roller. 2. The voltage of the Toner Supply Roller is 350V lower than that of Developer Roller. When the toner reaches the contact point of these rollers, it moves onto the Developer Roller.
  • Page 90 5. The voltage of both sides of Regulation Roller is 365V higher than the Developer Roller Bias. When the toner reaches the contact point of these rollers, it moves onto the Regulation Roller. The side areas of the Developer Roller are not covered with the toner as a result, which can prevent the toner drops into the machine from the side.

  • Page 91: Toner Collection Process

    3. 4 Toner Collection Process As explained in [3.2.2 Drum Cleaning] on page 3-6, the Cleaning Roller removes and collects the remained toner on the Drum using +800V of voltage supplied to it in the print cycle. KIP9000 takes an operation to return the collected toner to the Developer Unit in the following 3 cases. (This process to return the toner is called “Toner Collection Process”.) (1) When the KIP9000 is going to stop after printing out all the accumulated print jobs.
  • Page 92 3. The voltage supplied to the Developer Roller is also changed to +350V (+/-3V) in the Toner Collection Process. As the potential of Developer Roller becomes higher than that of Drum, toner on the Drum moves onto the Developer Roller. Then the toner is carried into the Developer Unit by both the Developer Roller and the Toner Supply Roller.
  • Page 93 Reference Voltages supplied to Regulation Roller and Toner Supply Roller are changed also as follows. Name of roller Supplied Voltage Supplied voltage (Against the ground) (Against the Developer Roller Bias) Developer Roller +350V +/-3V Toner Supply Roller -350V +/-3V Regulation Roller -100V +/-3V (Center) Regulation Roller...

  • Page 94: Automatic Controls

    3. 5 Automatic Controls 3. 5. 1 Auto Density Control If the temperature of installation site varies while the Developer Bias is always fixed to a constant level, the print image may become lighter or darker than expected. Especially when the temperature falls, the print image tends to become lighter.

  • Page 95: Density Lock

    3. 5. 1. 1 Density Lock Density Lock is a process to provide “Target Density” to KIP9000, which is performed in the factory in most of cases. (This may have to be done in the field very rarely.) This process is very important as the Target Density specified here will continue to be the expected density applied on all print/copy afterward.

  • Page 96: Auto Density Control

    3. 5. 1. 2 Auto Density Control The Auto Density Control is a process to adjust the actual density to the same level with “Target Density” in any temperature condition by increasing or decreasing the Developer Bias flexibly. The Auto Density Control can work when it is set to ON (ON1 or ON2) in the Service Mode 5-AA (or User Mode E).

  • Page 97: Auto Sp Control

    3. 5. 2 Auto SP Control A proper voltage gap must be maintained between [Bias] (Developer Bias) and [SP; white] (Surface Potential for white) for avoiding a foggy background problem. SP black Bias SP white But if the Auto Density Control increases (adjusts to more negative side) the [Bias], the voltage gap between [Bias] and [SP: white] may become so small.
  • Page 98 The value of [SP: white] adjusted by the Auto SP Control relies on the “Target Surface Potential” that is specified on the following service modes to each setting points (5 to 30 C by every 5 step) respectively. Service Mode 5-A3 : Target Surface Potential at 5 5-A4 : Target Surface Potential at 10 5-A5 : Target Surface Potential at 15 5-A6 : Target Surface Potential at 20...
  • Page 99 2. On the other hand, the Auto SP Control calculates the necessary [SP: white] based on the temperature detected by the Temperature Sensor. 3. The actual surface potential detected by Surface Potential Sensor is compared with the calculated [SP: white]. 4.
  • Page 100 Chapter 4 Electrical Systems Page 4. 1 Summary 4- 2 4. 2 Location of Electrical Components 4- 3 4. 2. 1 Printed Circuit Board 4- 3 4. 2. 2 High Voltage Power Supplies & Transformer 4-15 4. 2. 3 DC Power Supplies 4-18 4.

  • Page 101: Summary

    4. 1 Summary The microcomputer on DC Controller controls the operation of KIP9000. It reads the input signals from sensors, controls the loads of motors, SSRs, solenoid, clutches and blowers on programmed timing. Sensor Micro Computer Driver DC Load (CPU & ROM) DC Controller has an LED, meaning that 5Vdc is applied on this DC Controller safely.

  • Page 102: Location Of Electrical Components

    4. 2 Location of Electrical Components 4. 2. 1 Printed Circuit Board (Inside of Bypass Feeder) Item Symbol Signal name Name Type Function PW7771 Indication PCB B PW7771 Offers several operations and (Operation Panel PCB) information. PW7770 Indication PCB A PW7770 Indicates media size and media (Media Indicator PCB)
  • Page 103 (Top side) Item Symbol Signal name Name Type Function PW7758 LED Driver PCB PW7758 Driver of Pre-Transfer LED PW7755 DC Driver PCB PW7755 Driver of Motors, HVPs, Bias, Fans, Solenoid and Clutches PW3590 DC Translation PCB PW3590-01 Junction of LED Head (DC Terminal PCB) PW11250 DC Regulator PCB...
  • Page 104 Item Symbol Signal name Name Type Function Surface Potential Sensor ES2A-4102 Detects the potential on Drum (600mm) surface. (Always replace with SPS Sensor) K115sm4e1.doc...
  • Page 105 (Right side) K115sm4e1.doc...
  • Page 106 Item Symbol Signal name Name Type Function PW11520 Main Control PCB PW11520 Controls overall sequence of KIP9000 being related with the Interface. PW10780 Temperature & Humidity PW10780 Detects temperature and Sensor PCB humidity inside of machine PW3599 Signal Terminal PCB PW3599 Signal Junction PW7772...
  • Page 107 (Right side) Item Symbol Signal name Name Type Function PW7750 Transmission PCB PW7750 Detects the toner remaining level in the Toner Cartridge. (Throws the light) PW7751 Receiver PCB PW7751 Detects the toner remaining level in the Toner Cartridge. (Receives the light K115sm4e1.doc...
  • Page 108 (Right side of Roll Decks) Item Symbol Signal name Name Type Function PW3575UA Paper Choice PCB U PW3575 Size and type selector of Roll 1 PW3575UB Paper Choice PCB U PW3575 Size and type selector of Roll 2 PW3575UC Paper Choice PCB U PW3575 Size and type selector of Roll 3 PW3575UD...
  • Page 109 (Left side) Item Symbol Signal name Name Type Function TP0362 FUMTR Motor Controller PCB TP0362 Fuser Motor Controller TP1142 DRMTR Motor Controller PCB TP1142 Drum Motor Controller PW7756 CUTMTR Motor Controller PCB A PW7756 Cutter Motor Controller PW6125 Phase Control PCB 2 PW6125 Reduces “flicker”.
  • Page 110 (Rear side) Item Symbol Signal name Name Type Function PW2215 Filter PCB C PW2215 AC line filter PW2215 Filter PCB C PW2215 AC line filter PW6624 PC Controller PCB 2 PW6624 Shuts down the controller PC PW4211 Filter PCB PW4211 Noise filter of the controller PW5490 Reception PCB...
  • Page 111 (Process frame) Item Symbol Signal name Name Type Function PW7730 E_LAMP Eraser Lamp PCB A PW7730 Removes the electric charges from the Drum. PW7731 E_LAMP Eraser Lamp PCB B PW7731 Removes the electric charges from the Drum. 4-12 K115sm4e2.doc...
  • Page 112 Item Symbol Signal name Name Type Function PW1034 S_LAMP Eraser PCB C PW1034 Removes the electric charges to help (Separation Lamp) paper separation PW1034 S_LAMP Eraser PCB I PW1034 Removes the electric charges to help (Separation Lamp) paper separation 4-13 K115sm4e2.doc...
  • Page 113 (Backside of each Roll Deck) Item Symbol Signal name Name Type Function PW3597 DC Translation PCB P PW3597 Roll Deck 1 Roll Size Sensor PW3597 DC Translation PCB P PW3597 Roll Deck 2 Roll Size Sensor PW3597 DC Translation PCB P PW3597 Roll Deck 3 Roll Size Sensor PW3597...

  • Page 114: High Voltage Power Supplies & Transformer

    4. 2. 2 High Voltage Power Supplies & Transformer (Top side) Item Symbol Signal name Name Type Function HVP1 High Voltage Power KHKG-063 Supplies the high voltage to the Supply Image Corona. HVP5 High Voltage Power AHKG-067 Supplies the high voltage to the Supply Cleaning Roller.
  • Page 115 (Left side) Item Symbol Signal name Name Type Function HVP3 HV_TR High Voltage Power BHKG-070 Supplies the high voltage to the Supply Transfer Corona. HVP4 HV_AC High Voltage Power FHKG-046 Supplies the high voltage AC to Supply the Separation Corona. HVP6 High Voltage Power KHKG-065...
  • Page 116 (Rear side) Item Symbol Signal name Name Type Function Insulation Transformer KCT-01B Converts the inputted AC into (EUR & USA) 24VAC for Dehumidify Heater of Roll 1 and 2 4-17 K115sm4e2.doc...

  • Page 117: Dc Power Supplies

    4. 2. 3 DC Power Supplies (Right side) Item Symbol Signal name Name Type Function DCP1 DC Power Supply ZWS240PAF- Supplies +24VDC (240W). 24/J 4-18 K115sm4e3.doc...
  • Page 118 (Top side) Item Symbol Signal name Name Type Function DCP2 DC Power Supply LEA150F-5 Supplies +5VDC (150W) to sensors, LED Head, DC Controller and so on. 4-19 K115sm4e3.doc...
  • Page 119 (Rear side) Item Symbol Signal name Name Type Function DCP3 DC Power Supply ZWS150PAF- Supplying +36VDC (150W) to the 36/J Drum Motor (M1). DCP4 DC Power Supply ZWS150PAF- Supplying +36VDC (150W) to Paper 36/J Feed Motor (M2), Cutter Motor (M3) and Fuser Motor (M5).

  • Page 120: Motors

    4. 2. 4 Motors (Left side) Item Symbol Signal name Name Type Function DRMTR DC Motor TL1142 Drives both the Drum and the (Drum Motor) Developer Unit. PFMTR DC Motor TL0314 Drives the roll feeding mechanism. (Paper Feed Motor) CUTMTR Stepping Motor KT56LM4G- Drives the Cutter Unit.
  • Page 121 Item Symbol Signal name Name Type Function HOP_MTR2 DC Motor DU2711-3 Drives the Toner Hopper to Toner Supply Motor 2 supply the toner to the Developer Unit. DC Motor LA20-282BD Drives the Cleaning Pad to (LED Cleaning Motor) clean the LED Head. 4-22 K115sm4e3.doc...
  • Page 122 (Image Corona) Item Symbol Signal name Name Type Function DC Motor LA20-282BD Drives the Cleaning Pad to (Wire Cleaning Motor) clean the Image Corona Wire. 4-23 K115sm4e3.doc...
  • Page 123 (Right side) Item Symbol Signal name Name Type Function HOP_MTR1 DC Motor DME34B50G Drives the Toner Cartridge to (Toner Supply supply the toner to the Toner Motor 1) Hopper. 4-24 K115sm4e3.doc...

  • Page 124: Blowers & Fans

    4. 2. 5 Blowers & Fans (Rear side) Item Symbol Signal name Name Type Function SEPBLW Sirocco Fan TA0409 Inhales the air from the bottom of (Separation Fan) Internal Transportation Unit to help paper separation. 4 Ozone Filters are provided. BL17, 18 &...
  • Page 125 (Rear side : Fuser section) Item Symbol Signal name Name Type Function BL2 & BL3 EXBLW_L Sirocco Fan FAL-14C4RH Cools down the top of the EXBLW_H (Exhaust Blower) Fuser. 4-26 K115sm4e4.doc...
  • Page 126 (Inside of Rear Upper Cover) Item Symbol Signal name Name Type Function BL4 A-D PRESBLW_L D04R24TH33 Blows the air from the top so BL5 A-D PRESBLW_H (Pressure Blowers) as to help the paper goes into BL6 A-D the Fuser Area easily. BL7 A-D 4-27 K115sm4e4.doc...
  • Page 127 Item Symbol Signal name Name Type Function BL8 A-D COOL_FAN1 D04R24TH33 Cools down the LED Head. BL9 A-D (LED Cooling Fans 1) BL10 A-D COOL_FAN2 D04R24TH33 Cools down the LED Head. BL11 A-D (LED Cooling Fans 2) 4-28 K115sm4e4.doc...
  • Page 128 (Process frame) Item Symbol Signal name Name Type Function BL14 SEPBLW2 Sirocco Fan E0515H24B7AZ- Helps paper’s separation from the (Separation Assist Blower 2) Drum. It works always during print regardless of the paper size. BL13 & BL15 SEPBLW3 Sirocco Fan E0515H24B7AZ- Helps paper’s separation from the (Separation Assist Blower 3)
  • Page 129 (Right side) Item Symbol Signal name Name Type Function Fan Motor FBA09A24H Cools down the DCP1. (Cooling Fan 1) (Left side) Item Symbol Signal name Name Type Function Fan Motor FBA06T24H Cools down the Cutter Motor (Cooling Fan 3) Controller PCB (PW7756). Fan Motor FBA06T24H Cools down the Cutter Motor (M3)

  • Page 130: Clutches & Brakes

    4. 2. 6 Clutches & Brakes (Left side) Item Symbol Signal name Name Type Function RP_CL Electromagnetic Clutch BJ-3.5-160 (Roll Paper Feed Clutch 1) RP_CL2 Electromagnetic Clutch BJ-3.5-160 (Roll Paper Feed Clutch 2) RP_CL3 Electromagnetic Clutch BJ-3.5-160 (Roll Paper Feed Clutch 3) RP_CL4 Electromagnetic Clutch BJ-3.5-160...
  • Page 131 Item Symbol Signal name Name Type Function MF_CL Electromagnetic Clutch 2 BJ-3.5-E06 (Bypass Feed Clutch) RP_CL1 Electromagnetic Clutch BJ-3.5-166 (Roll Deck 1 Feed Clutch) 4-32 K115sm4e5.doc...
  • Page 132 (Right side) Item Symbol Signal name Name Type Function MC11 HOPPER Electromagnetic Clutch 1 BJ-3.5-E07 (Toner Supply Clutch) 4-33 K115sm4e5.doc...

  • Page 133: Solenoids

    4. 2. 7 Solenoids (Fuser Unit) Item Symbol Signal name Name Type Function FU_SL Solenoid G1247 G1247 Moves the Fuser Entrance Guide (Fuser Solenoid) Plate up and down. This solenoid is locked and does not function presently. (Cutter Unit) Item Symbol Signal name Name...
  • Page 134 Item Symbol Signal name Name Type Function T_SL1 Solenoid G-1053-K12 Moves the Bypass Feeding Roller up (Bypass Feeding Roller and down. Down Solenoid) 4-35 K115sm4e5.doc...
  • Page 135 (Inside of Bypass Feeder) Item Symbol Signal name Name Type Function T_SL2 Solenoid G-1053-K12 Moves the Bypass Reversal Roller (Bypass Reversal Roller up and down. Down Solenoid) 4-36 K115sm4e5.doc...

  • Page 136: Heaters & Ssr

    4. 2. 8 Heaters & SSR (Fuser Unit) Item Symbol Signal name Name Type Function F_LAMP1 IR Lamp QIR220- Heats up the center of the Fuser 1750KIC Roller. (EUR & USA) F_LAMP2 IR Lamp QIR220- Heats up both sides of the Fuser 1350KIAG Roller.
  • Page 137 (Left side) Item Symbol Signal name Name Type Function SSR1 Solid State Relay S5N-225HV Turns on and off the IR Lamp (H1). SSR2 Solid State Relay S5N-225HV Turns on and off the IR Lamp (H2). 4-38 K115sm4e6.doc...
  • Page 138 Item Symbol Signal name Name Type Function Heater Dehumidifies the roll media in the (Dehumidify Heater) Roll 3 (Left side). 15W (3.5 kilo ohm) Heater Dehumidifies the roll media in the (Dehumidify Heater) Roll 3 (Right side). 15W (3.5 kilo ohm) Heater Dehumidifies the roll media in the (Dehumidify Heater)
  • Page 139 (1st Roll Deck) (2nd Roll Deck) Item Symbol Signal name Name Type Function Heater Dehumidifies the roll media in the (Dehumidify Heater) Roll 2. 15W (38 ohm) Heater Dehumidifies the roll media in the (Dehumidify Heater) Roll 1. 15W (38 ohm) 4-40 K115sm4e6.doc...

  • Page 140: Terminal Block, Switches, Breaker & Counters

    4. 2. 9 Terminal Block, Switches, Breaker & Counters (Left side) Item Symbol Signal name Name Type Function Terminal Block UF1005-30A- Circuit Protector IEG-6-11-62- 20A-M 4-41 K115sm4e6.doc...
  • Page 141 Item Symbol Signal name Name Type Function Power Supply Switch AJ8R2004ZZ Turns on the printer. (Main Switch) 4-42 K115sm4e6.doc...
  • Page 142 Item Symbol Signal name Name Type Function Power Supply Switch SDDJE1 Turns on the Dehumidify Heaters. (Dehumidify Heater Switch) 4-43 K115sm4e6.doc...
  • Page 143 (Right side) Item Symbol Signal name Name Type Function CNT B CPY_CNT Electromagnetic Counter 2 SCM-2470SK Counts the number of prints. (Counter B) (Counting unit is changeable in the Service Mode.) It has 3 pins on the junction connector. CNT A LNG_CNT Electromagnetic Counter 1 SCM-2470SK...

  • Page 144: Relays

    4. 2.10 Relays (Rear side) Item Symbol Signal name Name Type Function Relay G7L-2A-BUB Supplies the power to DCP1, DCP2 (Relay 1) AC200-240 and Filter PCB (PW2215) of H2. (Does not shut it off even if the Interlock is open.) Relay G7L-2A-BUB Supplies the power to Filter PCB...
  • Page 145 (Right side) Item Symbol Signal name Name Type Function Relay JC2aF-TM- Supplies the DC power to the (Relay 4) DC24V following parts. It is shut off if the Interlock or any Roll Deck is open. (1) HVP1, 3, 4 & 6 (2) BIAS (3) M10 (4) BL4, 5, 6 &...

  • Page 146: Micro Switches

    4. 2.11 Micro Switches (Right side) Item Symbol Signal name Name Type Function RIGHT_SW1 Door Switch D2VW-5L3- Opens RY2, RY3, RY4, RY5 and (Right Side Door Switch) 1HS-191 RY6 when DS1 is open. (Interlock Switch) RIGHT_SW1_ Door Switch D2VW-01L3- Status signal of “Right Door Open” Status (Right Side Door Switch) 4-48...
  • Page 147 (Right side) Item Symbol Signal name Name Type Function RIGHT_SW2 Door Switch D2VW-5L3- Shuts of the power for Toner (Toner Cover Switch) 1HS-191 Supply Motor 1 (M7), Toner Supply Motor 2 (M6), Toner Supply Clutch (MC11) and Transmission PCB (PW7750) when DS8 is open.
  • Page 148 (Rear side) Item Symbol Signal name Name Type Function EXIT_SW Door Switch D2VW-5L3- Opens RY2, RY3, RY4, RY5 and (Exit Cover Switch) 1HS-191 RY6 when DS3 is open. EXIT_SW_ Door Switch D2VW-01L3- Status signal of “Exit Cover Open” Status (Exit Cover Switch) 4-50 K115sm4e7.doc...

  • Page 149: Paper Sensors, Thermistor, Thermostat, Toner Sensors & Sps

    4. 2.12 Paper Sensors, Thermistor, Thermostat, Toner Sensors & SPS Item Symbol Signal name Name Type Function SPS1 Surface Potential Sensor ES2A-6007 Detecting the potential of the Drum PH44 Density Sensor GP2Y40010KOF Detects the density of toner image on Drum for Automatic Density Control.
  • Page 150 Item Symbol Signal name Name Type Function PH22 CUTHP_O Cutter Home Position PW2285 Detects the Home Position of the Sensor Cutter Blade PH24 PFUNIT_ST Photo Interrupter GP1A73 Detects whether the Internal (Internal Transportation Transportation Unit is closed or not. Unit Set Sensor) 4-52 K115sm4e8.doc...
  • Page 151 (Process Unit) Item Symbol Signal name Name Type Function PH25 DEVE_HP Photo Interrupter LG283 Detects the position of the Developer (Developer Unit Position Unit (Pressed or released) Sensor) TLS1 DEV_TNR1 Toner Sensor TS15D20-37 Detects the existence of the toner in (Hopper Toner Sensor) the Hopper 4-53...
  • Page 152 (Developer Unit) Item Symbol Signal name Name Type Function PH42 TNR_LED Toner Sensor (Illuminator) KB876- Detects the existence of toner in the KD12LF Developer Unit. This throws light. PH43 TNR_SENSOR Toner Sensor (Receiver) KB874- Detects the existence of toner in the KD22LF Developer Unit.
  • Page 153 (Right side) Item Symbol Signal name Name Type Function PH45 RFID IC Tag Reader & ARWBT-RF01 Detects the Toner Cartridge. Writer PCB 4-55 K115sm4e8.doc...
  • Page 154 (On the Internal Transportation Unit) Item Symbol Signal name Name Type Function PH12 PA_ENT Photo Interrupter GP2A25 Places the roll media to the print start (Leading Edge Sensor) position. PH18 P_SEPR Actuator 2 Assy GP1S74P Detects the Separation Jam. (Separation Sensor) 4-56 K115sm4e8.doc...
  • Page 155 (Fuser Unit) Item Symbol Signal name Name Type Function Thermistor NC-F1B Controls the temperature of the Fuser Roller (Non-contacting type) Thermistor ES2U1.3B6- Shuts off the RY2 and RY3 before 20031 the Thermostat opens when over temperature is detected. (Contacting type) INT1 Thermostat Assy Protects the Fuser from over heating...
  • Page 156 (Fuser Unit) Item Symbol Signal name Name Type Function P_EXIT Lead Switch RS-801EA Detects the Exit Jam. (Exit Sensor) PH40 Web Sensor GP1A73 Detects the feeding of web 4-58 K115sm4e8.doc...
  • Page 157 (Rear side) Item Symbol Signal name Name Type Function PH40 Web Sensor GP1A73 Detects the feeding of web 4-59 K115sm4e8.doc...

  • Page 158: Sensors In Roll Decks

    4. 2.13 Sensors in Roll Decks (Roll Deck 1) Item Symbol Signal name Name Type Function RP_SET1 Photo Interrupter GP2A25 Detects the existence of roll media. (Roll Set Sensor 1) Detects 210mm, 9” & 8.5” roll media also PH5A SZDATA0 Photo Interrupter GP2A25 Detects 880mm, 890mm &...
  • Page 159 (Roll Decks 2, 3 & 4) Item Symbol Signal name Name Type Function RP_SET2 Photo Interrupter GP2A25 Detects the existence of roll media. (Roll Set Sensor 1) Detects 210mm, 9” & 8.5” roll media also RP_SET3 Photo Interrupter GP2A25 Detects the existence of roll media. (Roll Set Sensor 1) Detects 210mm, 9”...

  • Page 160: Sensors In Bypass Feeder

    4. 2.14 Sensors in Bypass Feeder (Bypass Feeder & Roll 1) Item Symbol Signal name Name Type Function PH20 MP_SRT Photo Interrupter GP2A25 Places a large cut sheet media at the (Bypass Start Sensor) print start position. (Large means 841mm, 30”, 34” and 36”.) PH31 Photo Interrupter GP2A25...

  • Page 161: Fuses

    4. 2.15 Fuses (Left side) (Left side) F101 and F102 are on the AC Circuit Board B (PW4210). Item Symbol Name Rate Type Caution for replacement F101 Fuse 250V / 2A 218002 When fuse (F101) is to be replaced, use the following specified one. Manufacturer : LITTEL FUSE INC.
  • Page 162 (Rear side) Item Symbol Name Rate Type Caution for replacement Fuse 250V / 2A 218002 When fuse (F1) is to be replaced, use the following specified one. Manufacturer : LITTEL FUSE INC. Type : 218002 (250V / 2A) F241 Fuse 250V / 3.15A 2153.15 Protects the outlet for controller...
  • Page 163 (Top side) F551 and F552 are on the DC Driver PCB (PW7755). Item Symbol Name Rate Type Caution for replacement Fuse 250V / 5A 215005 When fuse (F1) is to be replaced, use the following specified one. Manufacturer : LITTEL FUSE INC. Type : 215005 (250V / 5A) F551 Fuse...
  • Page 164 (Right side) (Left side) Item Symbol Name Rate Type Caution for replacement Fuse 250V / 4A 215004 Protects 24VDC from DCP1. Fuse 250V / 4A 215004 When fuses (F3 to F6) are to be Fuse 250V / 4A 215004 replaced, use the following specified Fuse 250V / 4A 215004...

  • Page 165: Checking & Adjustment Of Analog Output From Hvp & Bias

    4. 3 Checking & Adjustment of Analog Output from HVP & BIAS 4. 3. 1 Situations necessary to check the analog output After replacing High Voltage Power Supplies (HVP) or Bias PCB (BIAS), or when abnormal image is printed out, check if each PCB outputs correct voltage or current. The followings are the items need to be checked and readjusted.

  • Page 166: Checking & Adjustment Of Hvp1 (Image Corona)

    4. 3. 2 Checking & Adjustment of HVP1 (Image Corona) The standard value of current supplied from the HVP1 is -2.0mA +/-0.05mA. Check and adjust the HVP1 in the following way. 1. Remove the Drum from the machine for the safety. The Drum will be damaged if not removed! 2.
  • Page 167 4. Press the [ENTER] Key to output from the HVP1. Measure the voltage with multi-meter. Press the [ENTER] Key again to stop outputting when measurement is finished. Standard value of current is -2.0mA +/-0.05mA. MENU ENTER ONLINE NOTE If the multimeter shows “2.0V”, it means “-2.0mA”. (Replace “+” with “-“, and replace “V” with “mA”.) 5.

  • Page 168: Checking & Adjustment Of Hvp3 (Transfer Corona)

    4. 3. 3 Checking & Adjustment of HVP3 (Transfer Corona) The standard values of current supplied from the HVP3 are specified for each media type as follows. Plain paper 1.4mA +/-0.02mA Tracing paper 1.4mA +/-0.02mA Film 1.4mA +/-0.02mA NOTE A DC Current Meter must be connected directly to the HVP3 to measure the HVP3 output current.
  • Page 169 3. Enter the Service Mode, select the Function Checking Mode (Sub Mode No.3), and select the Signal Code “A2” (HV_TR : Transfer Corona Control Signal). MENU ENTER ONLINE 4. Press the [ENTER] Key to output from the HVP3. Measure the voltage with DC Current Meter. (It is required to be careful about the “target media type”...
  • Page 170 5. If the current from HVP3 does not satisfy the following values, readjust it to satisfy the requirement. To adjust the HVP3 current, select the Adjustment Mode 0 (Sub Mode No.4) and select the Item No.1C, 1d and 1E. 1C : Current setting for the Transfer Corona Wire (PPC) 1d : Current setting for the Transfer Corona Wire (Tracing) 1E : Current setting for the Transfer Corona Wire (Film) MENU...

  • Page 171: Checking & Adjustment Of Hvp4 (Separation Corona)

    4. 3. 4 Checking & Adjustment of HVP4 (Separation Corona) The standard values of DC Component outputted from HVP4 are as follows. DC Component : Plain paper -250V +/-3V Tracing paper -300V +/-3V Film -10V +/-3V Check and adjust the HVP4 in the following way. 1.
  • Page 172 4) Press the [ENTER] KEY to output from the HVP4. Measure the voltage with multi-meter. (It is required to be careful about the “target media type” of DC Component at this time. See the following NOTE.) Press the [ENTER] Key again to stop outputting when measurement is finished. Standard value of DC Component for each media type is as follow.
  • Page 173 5. If the voltage from HVP4 does not satisfy the following values, readjust it to satisfy the requirement. To adjust the HVP4 voltage, select the Adjustment Mode 0 (Sub Mode No.4) and select the Item No.1F, 20 and 21. 1F : Separation Corona DC component (PPC) 20 : Separation Corona DC component (Tracing) 21 : Separation Corona DC component (Film) MENU...

  • Page 174: Checking & Adjustment Of Hvp5 (Cleaning Roller)

    4. 3. 5 Checking & Adjustment of HVP5 (Cleaning Roller) The standard value of positive/negative Cleaning Roller Bias outputted from the HVP5 are as follows. Positive Cleaning Roller Bias +800V +/-3V Negative Cleaning Roller Bias -500V +/-3V Check and adjust the HVP5 in the following way. 1.
  • Page 175 2. Output both positive Cleaning Roller Bias (outputted during Print Cycle) and negative one (outputted during Toner Collection Process). Measure both positive and negative voltages with multi-meter. (Refer to the following NOTE for the way to output both Bias.) The standard value of positive Cleaning Roller Bias and negative one are as follows. Positive Cleaning Roller Bias +800V +/-3V Negative Cleaning Roller Bias...
  • Page 176 4. If the positive Cleaning Roller Bias does not satisfy +800V +-/3V, readjust it to satisfy the requirement. To adjust the positive Cleaning Roller Bias, rotate the VR2 on the HVP5 with a screwdriver. Multi-meter (DC volt range) 4-78 K115sm4ea.doc...

  • Page 177: Checking & Adjustment Of Hvp6 (Grid Plate Of Image Corona)

    4. 3. 6 Checking & Adjustment of HVP6 (Grid Plate of Image Corona) The standard value of the Grid Bias outputted from HVP6 is -780V +/-20V (About 12.2V on the Test Pin). Check and adjust the HVP6 in the following way. 1.
  • Page 178 4. Press the [ENTER] Key to output the Grid Bias from HVP6. Measure the voltage with multi-meter. Press the [ENTER] Key again to stop outputting when measurement is finished. Standard value on the Test Pin is about 12.2V. MENU ENTER ONLINE 5.
  • Page 179 6. After re-adjustment, it is necessary to confirm the actual voltage outputted from the “OUTPUT” Pin on the HVP6. To confirm it, connect “+” of the multi-meter to “OUTPUT” and “-“ to the ground. Select the DC volt range on the multi-meter. CN501 ①...
  • Page 180 9. If the voltage from HVP6 does not satisfy -780V +/-20V, readjust it to satisfy the requirement. To adjust the HVP6 voltage, select the Adjustment Mode 0 (Sub Mode No.4) and select the Item No.1b. MENU ENTER ONLINE • Refer to [8.1.5.3 Operation] on the page 8-36 for how to change the setting value. •...

  • Page 181: Checking & Adjustment Of Bias (For Developer Unit)

    4. 3. 7 Checking & Adjustment of BIAS (For Developer Unit) Each roller in the Developer Unit is supplied with its own necessary voltage respectively in the Print Cycle. These kinds of voltage supplied in the Print Cycle are called “Negative Developer Bias”.

  • Page 182: Negative Developer Bias Adjustment (Print Cycle)

    4. 3. 7. 1 Negative Developer Bias adjustment (Print Cycle) (1) Negative Developer Bias for Developer Roller The standard value of Negative Developer Bias outputted to the Developer Roller is -250V +/-3V against the ground when the Auto Density Control is set to OFF.
  • Page 183 2. Enter the Service Mode, select the Adjustment Mode 0 (Sub Mode No.4), and select the Item No.CA (Constant / Variable control of Developer Bias). If this item is set to “1” (Variable control), set it to “0” (Constant control) before starting the adjustment.
  • Page 184 5. If the Negative Developer Bias from BIAS to Developer Roller does not satisfy -250V +/-3V, readjust it to satisfy the requirement. To adjust it, select the Adjustment Mode 0 (Sub Mode No.4) and select the Item No.19 (Developer Bias). MENU ENTER ONLINE •...

  • Page 185: Negative Developer Bias For Toner Supply Roller

    (2) Negative Developer Bias for Toner Supply Roller The standard value of Negative Developer Bias outputted to the Toner Supply Roller is -350V +/-3V against the Negative Developer Bias of Developer Roller. Toner Supply Roller Check and adjust it in the following way. 1.
  • Page 186 2. Enter the Service Mode, select the Adjustment Mode 0 (Sub Mode No.4), and select the Item No.CA (Constant / Variable control of Developer Bias). If this item is set to “1” (Variable control), set it to “0” (Constant control) before starting the adjustment.
  • Page 187 5. If the Negative Developer Bias from BIAS to Toner Supply Roller does not satisfy -350V +/-3V, readjust it to satisfy the requirement. To adjust it, rotate the VR8 on the BIAS with a screwdriver. CN401 CN402 CN403 VR1 VR8 VR7 VR4 VR3 VR6 VR5 Output 2 Output 1...

  • Page 188: Negative Developer Bias For Regulation Roller (Center)

    (3) Negative Developer Bias for Regulation Roller (Center) The standard value of Negative Developer Bias supplied to the Regulation Roller (Center) is -100V +/-3V against the Negative Developer Bias of Developer Roller. Regulation Roller (Center) Check and adjust it in the following way. 1.
  • Page 189 2. Enter the Service Mode, select the Adjustment Mode 0 (Sub Mode No.4), and select the Item No.CA (Constant / Variable control of Developer Bias). If this item is set to “1” (Variable control), set it to “0” (Constant control) before starting the adjustment.
  • Page 190 5. If the Negative Developer Bias from BIAS to Regulation Roller (Center) does not satisfy -100V +/-3V, readjust it to satisfy the requirement. To adjust it, rotate the VR6 on the BIAS with a screwdriver. CN401 CN402 CN403 VR1 VR8 VR7 VR4 VR3 VR6 VR5 Output 2 Output 1...

  • Page 191: Negative Developer Bias For Regulation Roller (Side)

    (4) Negative Developer Bias for Regulation Roller (Side) The standard value of Negative Developer Bias supplied to Regulation Roller (Side) is +365V +/-3V against the Negative Developer Bias of the Developer Roller. Regulation Roller (Side) Check and adjust it in the following way. 1.
  • Page 192 2. Enter the Service Mode, select the Adjustment Mode 0 (Sub Mode No.4), and select the Item No.CA (Constant / Variable control of Developer Bias). If this item is set to “1” (Variable control), set it to “0” (Constant control) before starting the adjustment.
  • Page 193 5. If the Negative Developer Bias from BIAS to the Regulation Roller (Side) does not satisfy +365V +/-3V, readjust it to satisfy the requirement. To adjust it, rotate the VR4 on the BIAS with a screwdriver. CN401 CN402 CN403 VR1 VR8 VR7 VR4 VR3 VR6 VR5 Output 2 Output 1...

  • Page 194: Positive Developer Bias Adjustment (Toner Collection Process)

    4. 3. 7. 2 Positive Developer Bias adjustment (Toner Collection Process) (1) Positive Developer Bias for Developer Roller The standard value of Positive Developer Bias supplied to the Developer Roller is +350V +/-3V against the ground. Developer Roller Check and adjust it in the following way. 1.
  • Page 195 2. Enter the Service Mode, select the Special Mode (Sub Mode No.9), and select the Item No.7 (Developer Bias [Positive] Adjustment Mode). MENU ENTER ONLINE 3. Press the [ENTER] Key to output the Positive Developer Bias from BIAS to each roller of Developer Unit.

  • Page 196: Positive Developer Bias For Toner Supply Roller

    (2) Positive Developer Bias for Toner Supply Roller The standard value of Positive Developer Bias supplied to the Toner Supply Roller is -350V +/-3V against the Positive Developer Bias of the Developer Roller. Toner Supply Roller Check and adjust it in the following way. 1.
  • Page 197 2. Enter the Service Mode, select the Special Mode (Sub Mode No.9), and select the Item No.7 (Developer Bias [Positive] Adjustment Mode). MENU ENTER ONLINE 3. Press the [ENTER] Key to output the Positive Developer Bias from BIAS to each roller of Developer Unit.

  • Page 198: Positive Developer Bias For Regulation Roller (Center)

    (3) Positive Developer Bias for Regulation Roller (Center) The standard value of Positive Developer Bias supplied to the Regulation Roller (Center) is -100V +/-3V against the Positive Developer Bias of the Developer Roller. Regulation Roller (Center) Check and adjust it in the following way. 1.
  • Page 199 2. Enter the Service Mode, select the Special Mode (Sub Mode No.9), and select the Item No.7 (Developer Bias [Positive] Adjustment Mode). MENU ENTER ONLINE 3. Press the [ENTER] Key to output the Positive Developer Bias from BIAS to each roller of Developer Unit.

  • Page 200: Positive Developer Bias For Regulation Roller (Side)

    (4) Positive Developer Bias for Regulation Roller (Side) The standard value of Positive Developer Bias supplied to the Regulation Roller (Side) is +365V +/-5V against the Positive Developer Bias of the Developer Roller. Regulation Roller (Side) Check and adjust it in the following way. 1.
  • Page 201 2. Enter the Service Mode, select the Special Mode (Sub Mode No.9), and select the Item No.7 (Developer Bias [Positive] Adjustment Mode). MENU ENTER ONLINE 3. Press the [ENTER] Key to output the Positive Developer Bias from BIAS to each roller of Developer Unit.

  • Page 202: Compensation Of Analog Outputs By Service Mode 4-0D

    4. 4 Compensation of Analog Outputs by Service Mode 4-0d (Necessary after replacing DCP2) This operation is needed only after replacing the DC Power Supply 2 (DCP2). [Technical operation] The Main Controller PCB needs to be supplied with 5Vdc from the DC Power Supply 2 (DCP2), but in actual case there are many cases that the power from DCP2 to Main Controller PCB is lower than 5Vdc (as “4.99Vdc”...

  • Page 203: Location Of Connectors

    4. 5 Location of Connectors 4. 5. 1 Process Unit J303 J302 J311 J312 J313 J314 J301 J181 J178 J182 J183 J179 J180 4-105 K115sm4eb.doc...

  • Page 204: Base Of Machine

    4. 5. 2 Base of machine 4-106 K115sm4eb.doc...

  • Page 205: Back Of Machine

    4. 5. 3 Back of machine J341C RY2-0 RY3- 0 J 901A J 911 RY1- 1 RY2- 1 RY3-1 CN2G J 137 J134 J 136 J 135 CN 1G RY1 - 0 TB151B TB151A RY1 - 2 RY2- 2 CN1D CN2D J 72 RY3- 8...

  • Page 206: Top Of Machine

    4. 5. 4 Top of machine J125 J126 CN3F CN2F CN1F CN1A J551 J552 CN1Z J571A J573A J571 J902 J554 J572A J558 J158A CN502A CN501A J555 J901 TB581 CN2C CN1J CN1C J557 CN3C J556 J138 J581 J710 CN2Z 4-108 K115sm4eb.doc...

  • Page 207: Left Side Of Machine

    4. 5. 5 Left side of machine S2-2 S2-1 M10- 1 M10-2 CN2I CN501 CN1I J154 CN401 CN403 CN402 J173 J160 SSR2- 1 CN1B SSR2- 2 J562 SSR2- 3 SSR2- 4 SSR1 - 4 SSR1- 3 J561 SSR1 - 1 SSR1- 2 J159 J402...

  • Page 208: Right Side Of Machine

    4. 5. 6 Right side of machine 177A J174 DS5 - COM DS6 - COM DS5 - NO DS6 - NO J700 DS3-COM DS3-NO DS4-COM DS4 - NO J98 J99 J501 J208 J156 J161 J701A J207 J209 J210 J211 J206 DS1-COM DS1 - NO J205...

  • Page 209: Bypass Feeder Unit

    4. 5. 7 Bypass Feeder Unit J142 J902 J901 J140 J143 J144 J145 J146 J147 J148 4-111 K115sm4eb.doc...

  • Page 210: Top Drawer Unit

    4. 5. 8 Top Drawer Unit J88A J92A J90A J89A J175 J91A J93A J972A J94A J971A J43 J42 J751A 4-112 K115sm4eb.doc...

  • Page 211: Middle Drawer Unit

    4. 5. 9 Middle Drawer Unit J90B J88B J89B J91B J92B J93B J94B J972B J971B J751B 4-113 K115sm4eb.doc...

  • Page 212: 4. 5.10 Bottom Drawer Unit

    4. 5.10 Bottom Drawer Unit J971D J972D J72 J971C J972C J75D J90D J88D J89D J91D J92D J93D J94D J90C J88C J89C J91C J92C J93C J94C J751C 4-114 K115sm4eb.doc...
  • Page 213 Chapter 5 Mechanical Systems Page Process Unit 5- 3 5.1.1 Drawing out the Process Unit 5- 3 5.1.2 Removing Image Corona, Drum Assembly, Toner Hopper & Developer Unit 5- 6 5.1.3 Replacing Eraser Lamp A & B 5-11 5.1.4 Replacing Separation Assist Blowers (BL12 to BL16) 5-12 5.1.5 Replacing Developer Unit Position Sensor (PH25)
  • Page 214 5.8.5 Replacing Roll Set Sensor 3 (PH3) & Paper Size Sensors (PH5C to PH11C) (3rd deck) 5-103 5.8.6 Replacing Roll Set Sensor 4 (PH4) & Paper Size Sensors (PH5D to PH11D) (4th deck) 5-107 5.8.7 Replacing Paper Feed Clock Sensors (PH13 to PH16) (Common for all decks) 5-112 5.8.8 Replacing 501-3M Belt (Common for all decks)

  • Page 215: Process Unit

    Process Unit 5.1.1 Drawing out the Process Unit 1) Open the Toner Cover (1) and the Toner Cartridge Cover (2). 2) Rotate the Toner Cartridge (3) half revolution to move the opening (4) to the top position. Then, close both Toner Cover (1) and Toner Cartridge Cover (2). NOTE There is a Shutter under the opening (4).
  • Page 216 3) Open the Right Side Door (5). 4) Unlock the Internal Transportation Unit (6) rotating the Internal Transportation Unit Lever (7) counter-clockwise, bring down the unit and then lock the shaft of lever with the Hook (8). 5) Remove 4 pieces of black M4x14 screws (9) which are inside of Sponges. NOTE Even if you remove black M4x14 screws (9), sponges will hold them so as not to lose.
  • Page 217 6) Hold both Handles (10) firmly, and draw out the Process Unit (11) from the machine. K115sm5e2.doc...

  • Page 218: Removing Image Corona, Drum Assembly, Toner Hopper & Developer Unit

    5.1.2 Removing Image Corona, Drum Assembly, Toner Hopper & Developer Unit 1) Draw out the Process Unit (1) from the machine making reference to [5.1.1 Drawing out the Process Unit] on the page 5-3. 2) Disconnect the connector (2), remove 2 pieces of bind head screw (3), and then remove the Image Corona (4) holding both plastic corona heads (5).
  • Page 219 3) Catch the shaft of Cleaning Roller (6), bring it up (bring up driving side first then driven side) to remove the bearings (7) from the brackets. As there are notches (8) near the setting position, fit the bearings (7) to put the Cleaning Roller (6) temporarily.
  • Page 220 4) Catching both sides, move the Drum Assembly (9) upward along the Drum Guide in the Process Unit and remove from the machine. Keep the Drum Assembly in the Package Box if it should be out of the machine for a long time. Or stand it on the attached Drum Stand (10) temporarily if you put it back within a short time.
  • Page 221 6) Remove 4 pieces of tooth washer screws (12), and then bring up and remove the Toner Hopper (13). NOTE There are many holes on the bottom of the Toner Hopper and the toner will spill out. Please lay a large paper under the Process Unit before you remove the Toner Hopper. 7) Disconnect the connector (14) of the Developer Toner Sensor.
  • Page 222 8) Remove 2 pieces of Developer Release Brackets (15) removing 1 tooth washer screw (16) for each one. 9) Holding black side plates (17) on both sides, bring up and remove the Developer Unit (18). 5-10 K115sm5e2.doc...

  • Page 223: Replacing Eraser Lamp A & B

    5.1.3 Replacing Eraser Lamp A & B 1) Remove each Image Corona (1), Cleaning Roller (2) and Drum Assembly (3) from the Process Unit making reference to [5.1.2 Removing Image Corona, Drum Assembly, Toner Hopper & Developer Unit] on the page 5-6. NOTE Do not put the Cleaning Roller (2) temporarily on the Process Unit, but please remove it completely and put it on the paper.

  • Page 224: Replacing Separation Assist Blowers (Bl12 To Bl16)

    5.1.4 Replacing Separation Assist Blowers (BL12 to BL16) 1) Remove each Image Corona (1), Cleaning Roller (2) and Drum Assembly (3) from the Process Unit making reference to [5.1.2 Removing Image Corona, Drum Assembly, Toner Hopper & Developer Unit] on the page 5-6. NOTE Do not put the Cleaning Roller (2) temporarily on the Process Unit, but please remove it completely and put it on the paper.

  • Page 225: Replacing Developer Unit Position Sensor (Ph25)

    5.1.5 Replacing Developer Unit Position Sensor (PH25) 1) Remove each Image Corona (1), Drum Assembly (2), Toner Hopper (3) and Developer Unit (4) from the Process Unit making reference to [5.1.2 Removing Image Corona, Drum Assembly, Toner Hopper & Developer Unit] on the page 5-6. 2) Disconnect the connector (5) in the Process Unit.
  • Page 226 4) Press and release the Stoppers (8), and then remove the Developer Unit Position Sensor (9). Replace the Developer Unit Position Sensor (9). 5-14 K115sm5e2.doc...

  • Page 227: Image Corona

    Image Corona 5.2.1 Replacing each Periodical Replacement Part of the Image Corona (Corona Wire 1 Assembly, Grid Plate & Wire Cleaning Units) NOTE Image Corona has the following Periodical Replacement parts. Corona Wire 1 Assembly (2 pieces) 100,000m Grid Plate (1 piece) 100,000m Wire Cleaning Unit (2 pieces) 100,000m...
  • Page 228 2) Pick the lever of each Wire Cleaning Unit (2) to release, move the unit as the arrow mark and remove from the Image Corona. Replace the Wire Cleaning Units (2) with the new ones. NOTE After installing the new Wire Cleaning Unit, confirm the Corona Wire is caught between pads of Wire Cleaning Unit, and also the Corona Wire is straight.
  • Page 229 3) Loosen 5 pieces of screws (3) to remove each Bracket 220 (4). 4) Remove 2 pieces of bind head screws (5) on the motor side to remove the Electrode Plate (6). 5) Remove the Grid Spring (7) to remove the Hook (8). 5-17 K115sm5e2.doc...
  • Page 230 6) Remove the Grid Plate (9) and replace it with the new one NOTE Grid Plate has flat plate areas at both sides, and one side is wider than the other side. This wider side must be installed on the spring side of the Image Corona. (You do not have to care about front / back.) Wide Narrow...
  • Page 231 8) Remove the Pan Head Screw (12) to remove the Rear Housing Cover (13). 9) Remove Springs (14), and then remove each Corona Wire 1 Assembly (15). Replace the Corona Wire 1 Assemblies (20) with the new ones. NOTE When you stretch the new Corona Wire 1 Assembly, make sure to fit its anti-vibration bead (16) into the necessary space in the Corona Heads, and also make sure to fit the wire into the grooves (17).

  • Page 232: Replacing Wire Cleaning Motor (M9)

    5.2.2 Replacing Wire Cleaning Motor (M9) 1) Remove the Image Corona (1) from the Process Unit making reference to [5.1.2 Removing Image Corona, Drum Assembly, Toner Hopper & Developer Unit] on the page 5-6. 2) Expanding the Hooks (2) outward, remove the Motor Cover (3). 3) Remove the Wire Cleaning Motor (4).

  • Page 233: Drum Assembly

    Drum Assembly 5.3.1 Replacing each Periodical Replacement Part of the Drum Assembly (Photo Conductive Drum & 178T Gear) NOTE Drum Assembly has the following Periodical Replacement parts. Photo Conductive Drum (1 piece) 200,000m 178T Gear (1 piece) 500,000m This section instructs you to replace all of these parts as one sequent work. 1) Remove the Drum Assembly (1) from the Process Unit making reference to [5.1.2 Removing Image Corona, Drum Assembly, Toner Hopper &...
  • Page 234 3) Turn over the Drum Assembly to make the gear side up. 4) Pull out the Stay Assembly (5) from the Photo Conductive Drum (6). Replace the Photo Conductive Drum (6) with the new one. 5) Remove 3 pieces of each hexagon head cap screw (7) and spring washer (8) to remove the 178T Gear (9).

  • Page 235: Toner Hopper

    Toner Hopper 5.4.1 Replacing Hopper Toner Sensor (TLS1) 1) Remove the Toner Hopper (1) from the Process Unit making reference to [5.1.2 Removing Image Corona, Drum Assembly, Toner Hopper & Developer Unit] on the page 5-6. 2) Remove 2 pieces of bind head screw (2) to remove the Hopper Toner Sensor (3).

  • Page 236: Developer Unit

    Developer Unit 5.5.1 Replacing each Periodical Replacement Part of the Developer Unit NOTE (1) The following Periodical Replacement Parts are included in the Developer Unit. Developer Roller 1 piece Bracket 581 Counter Roller Side Seal Side Seal 12 Seal 13 Seal 14 Seal 19 Seal 555...
  • Page 237 2) Remove 4 M4x8 tooth washer screws (2) to remove the Stay 1 (3). NOTE When installing the Stay 1 (3), tighten the screws (2) with pressing Stay 1 in the direction of arrow to contact the cleaning blade surely to the Regulation Roller. 5-25 K115sm5e3.doc...
  • Page 238 3) Remove 7 M4x6 tooth washer screws (4) to remove the Bracket 581 (5) and the Holder Spring (6). Replace the Bracket 581 (7) with the new one. Rubber plate NOTE (1) The rubber plate of the Bracket 581 (5) touches the Regulation Roller and scrapes off the toner.
  • Page 239 4) Remove 7 M4x6 tooth washer screws (7) to remove the Guide Plate 1 (8). 5-27 K115sm5e3.doc...
  • Page 240 5) Remove 3 M4x6 bind screws (9) to remove the Terminal Cover (10). 6) Remove 2 M4x10 bind screws (11), Insulation Collars (12), Insulation Collars 3 (13), and Bracket 500 (14). 7) Remove 3 M3x12 bind screws (15), Bias Terminal 4 (16), Bias Terminal 3 (17), 3 Collars (18) and 3 Collars (19) NOTE Install the Collars (18) and (19) as the right.
  • Page 241 8) Remove the C Ring (20), 56T Gear (21), Parallel Pin (22) and Counter Roller (23). Replace the Counter Roller (23) with the new one. NOTE When reassemble, install Counter Roller in proper direction. The face with 6 bosses should be installed inside of Developer Unit.
  • Page 242 10) Remove the Thrust Washer (28), C Ring (29), 22T Gear (30) and Sliding Key (31). 11) Remove the C Ring (32), 33T Gear (33), Parallel Pin (34) and Collar (35). 12) Remove the Thrust Washer (36), 2 Ball Bearings (37) and Double Gear 39-33 (38). 5-30 K115sm5e3.doc...
  • Page 243 13) Remove the C Ring (39) and Counter Roller (40). Replace the Counter Roller (40) with the new one. NOTE When reassemble, install Counter Roller in proper direction. The face with 6 bosses should be installed inside of Developer Unit. Bosses Bosses 14) Remove 2 M4x6 tooth washer screws (41) and Plate (42).
  • Page 244 15) Remove the Thrust Washer (43), Double Gear 34-18 (44) and 2 Ball Bearings (45) & (46). 16) Remove M5x12 Hexagon Bolt (47), 29T Gear (48) and Thrust Washers (49). 17) Remove the E Ring (50), 30T Gear (51) and Parallel Pin (52). 18) Remove the Spring 2 (53), M4x8 tooth washer screws (54), M3x5 bind screw (55), Stud (56) and 2 M4x6 tooth washer screws (57).
  • Page 245 19) Remove both Blade Arm B (58) and Bracket 9 (59) together. 20) Replace the Seal 555 (60) with the new one, which is on the Bracket 9 (59). 21) Remove the Stud (61) to make the Bias Terminal Lead (62) free. 22) Remove 3 M4x6 bind screws (63) and Bracket 8 (64) together with its inside bearing.
  • Page 246 23) Replace the Seal 555 (65) with the new one, which is on the Bracket 6 (64). 24) Remove the Spring 1 (66), C Ring (67) and Thrust Washer (68). 25) Remove the M4x16 bind screw (69), M4x6 bind screw (70) and Plate 2 (71). 26) Remove the M3x5 bind screw (72), M4x6 bind screw (73), Collar 4 (74) and Blade Arm A (75).
  • Page 247 27) Holding the shafts on both sides, move each Developer Roller (76) and Regulation Roller (77) along the guides, and remove them from the unit. Replace the Developer Roller (76) with the new one. NOTE (1) When installing the Developer Roller (76) and Regulation Roller back to the developer unit, place their longer shaft to the driving side (left side) of unit.
  • Page 248 NOTE If the Development Roller or Regulation Roller is installed incorrectly, the Seal 13 and Seal 14 on the Developer Side Plate may be deformed abnormally, which will cause spilling out of the toner from the unit. To avoid spilling out of toner, place each roller to its own installation position then bring it up and down once to get rid of the deform of seals.
  • Page 249 28) Strip off each seal from the inside of Developer Left Side Plate, clean the surface, and paste new seals. See NOTE on page 5-39 as there are some points you need to take care. Seal 16 (78) Seal 19 (79) Seal 17 (80) Seal 13 (81) Seal 14 (82)
  • Page 250 29) Strip off each seal from the inside of Developer Right Side Plate, clean the surface, and paste new seals. See NOTE on page 5-39 as there are some points you need to take care. Seal 15 (84) Seal 19 (85) Seal 18 (86) Seal 13 (87) Seal 14 (88)
  • Page 251 NOTE (1) There is a projection beside the installation position of Regulation Roller. Align the edge of this projection with the ends of Seal 13 and Seal 14. It is no problem even if another ends of Seal 13 ad Seal 14 are not aligned with each other. Align here.
  • Page 252 NOTE (3) Paste the Seal 13 and Seal 14 first, and paste the Seal 19 with taking care not to have any space between Seal 13 and Seal 19. Have no space Seal 19 Seal 13 Have no space Seal 14 (4) Do not paste the new Side Seals (83 &...
  • Page 253 30) Remove the Ball Bearing (90) and 2 pieces of Side Seal 12 (91) on the left. Replace the Side Seals 12 (91) with the new ones. NOTE (1) 2 pieces of Side Seal 12 are used on the left of unit. (2) Push in the 1st one to the deepest position using something like a stick.
  • Page 254 31) Remove the C Ring (92), Ball Bearing (93) and 1 piece of Side Seal 12 (94) on the right. Replace the Side Seal 12 (94) with the new ones. NOTE (1) 1 piece of Side Seal 12 is used on the right of unit. (2) After fitting the Side Seal 12, move the roller shaft up and down several times.
  • Page 255 5.5.2 Replacing Toner Sensor (Illuminator) 1) Remove the Developer Unit (1) from the Process Unit making reference to [5.1.2 Removing Image Corona, Drum Assembly, Toner Hopper & Developer Unit] on the page 5-6. 2) Remove 3 M4x6 bind screws (2) to remove the Terminal Cover (3). 3) Remove 2 M4x10 bind screws (4), Insulation Collars (5), Insulation Collars 3 (6), and Bracket 500 (7).
  • Page 256 4) Remove 3 M3x12 bind screws (8), Bias Terminal 4 (9), Bias Terminal 3 (10), 3 Collars (11) and 3 Collars (12) NOTE Install the Collars (18) and (19) as the right. 5) Remove the C Ring (13), 56T Gear (14), Parallel Pin (15) and Counter Roller (16). NOTE When reassemble, install Counter Roller in proper direction.
  • Page 257 6) Remove the Stud (17), M4x10 screw (18), M4x12 screw (19) to remove the Guide Bracket (20). 7) Remove 2 M3x5 bind screws (21) and disconnect the connector (22) 8) Remove the M3x8 flush head screw (23), and replace Toner Sensor (24) with the new one.
  • Page 258 5.5.3 Replacing Toner Sensor (Receiver) 1) Remove the Developer Unit (1) from the Process Unit making reference to [5.1.2 Removing Image Corona, Drum Assembly, Toner Hopper & Developer Unit] on the page 5-6. 2) Remove 2 M3x5 bind screws (2) to remove the Sensor Bracket (3). 3) Remove the M3x8 flush head screw (4), and replace the Toner Sensor (5) with the new one.
  • Page 259 Cutter Unit 5.6.1 Removing Cutter Unit 1) Open the Right Side Door. 2) Remove the Bolt (2) which fixes the Cutter Unit from the bottom, and also remove Washer (3), Collar (4) and Spring (5). 5-47 K115sm5e4.doc...
  • Page 260 3) Disconnect the connector (6) of the Solenoid. 4) Catching the Cutter Handle (7), bring up the Cutter Unit (8) a little and pull it out from the machine. 5-48 K115sm5e4.doc...
  • Page 261 5.6.2 Replacing Cutter Oil Supply Solenoid (SL2) 1) Remove the Cutter Unit (1) from the machine making reference to [5.6.1 Removing Cutter Unit] on the page 5-47. 2) Remove 2 pieces of bind head screw (2), release the wire from the Mini Clamp (3), and remove the Stopper (4).
  • Page 262 3) Remove 2 pieces of tooth washer screw (5) to remove the Solenoid Mount Plate (6). 4) Remove 2 pieces of bind head screw (7) to remove the Cutter Oil Supply Solenoid (8). Replace the Cutter Oil Supply Solenoid (8) with the new one. NOTE Fit the boss (9) of the Cutter Oil Supply Solenoid to the hole (10) of the Solenoid Mount Plate.
  • Page 263 5.6.3 Lubrication / Replacement of Stay Assembly NOTE Lubricate the Stay Assembly every 6 months. Use the sewing machine oil for lubrication. 1) Remove the Cutter Unit (1) from the machine making reference to [5.6.1 Removing Cutter Unit] on the page 5-47. 2) Remove 2 pieces of bind head screw (2) to remove the Lower Paper Guide Plate (3).
  • Page 264 3) Remove 1 piece of E Ring (E3) (4) on the handle side. Remove E Ring (E5) (5) and Oilless Metals (6) at both sides to remove the Supporting Shaft 1 (7). As you will find the Stay Assembly, lubricate it at this time. If you will replace the Stay Assembly, go to the next step.
  • Page 265 5.6.4 Adjusting Home Position of Cutter Blade NOTE If you have “Cutter Jam” frequently, please check whether the home position of Cutter Blade is properly adjusted or not. And if necessary, please adjust in the following way. You need the following exclusive tools to check and adjust. HP Adjustment Assembly (3508560021) HP Adjustment tool 2 (3108500020) 1) Remove the Cutter Unit (1) from the machine making reference to [5.6.1 Removing Cutter Unit]...
  • Page 266 3) Remove the Stay Assembly (6) making reference to [5.6.3 Lubrication / Replacement of Stay Assembly] on the page 5-51. 4) Loosen 2 pieces of Set Screw (7) which fix the Joint A (8). 5) Fit the HP Adjustment Assembly (9) firmly to 3 Pins of the Cutter Side Plate. Insert the HP Adjustment tool 2 (10) under the Cutter Blade and place it at the nearest position to the Cutter Side Plate.
  • Page 267 6) Rotate the Cutter Handle until the cutting point (11) of Cutter Blade touches the HP Adjustment tool 2 (10). When the cutting point (11) touches the HP Adjustment tool 2 (10), fix the Joint A (8) tightening Set Screws (7). The gap between cutting point and base of Cutter Unit becomes 16mm by this operation.
  • Page 268 5.6.5 Adjusting angle of Cutter Unit NOTE If you replace the Cutter Unit with the new one, make sure to check whether or not the paper can be cut in a right angle. If not, please adjust in the following way. 1) Print out an A0 paper, and then fold it at the central line.
  • Page 269 3) It is necessary to adjust the angle of Cutter Unit if the difference is longer than 2.5mm. If you loosen 2 pieces of screw (1), you can shift the Cutter Unit left or right. If the right side of print is longer than left side, slide the whole Cutter Unit to the right. If the left side of print is longer than right side, slide the whole Cutter Unit to the left.
  • Page 270 Fuser 5.7.1 Removing Fuser Unit 1) Open both the Rear Upper Cover (1) and Exit Cover (2). 2) Loosen 3 pieces of tooth washer screw (3). 3) Close the Rear Upper Cover (1), and then remove the Cover 7 (4). 5-58 K115sm5e5.doc...
  • Page 271 4) Remove a tooth washer screw (5) to remove each Cover 3 (6) and Cover 4 (7). 5) Disconnect 3 connectors (8). 6) Remove 4 pieces of tooth washer screw (9) to remove the Cover 2 Assembly (10). 5-59 K115sm5e5.doc...
  • Page 272 7) Slide both the Shaft 4 (11) inward to release from the hole, and then remove the Exit Cover Assembly (12) 8) Remove tooth washer screws (13) at both sides to remove the Frame Assembly (14). 5-60 K115sm5e5.doc...
  • Page 273 9) Remove Hexagon Head Bolts (15) at both sides which fix the Fuser Unit. Also, disconnect 4 connectors (16). 10) Remove 7 pieces of tooth washer screw (17) which fix the Fuser Unit from the bottom. 11) Remove the Fuser Unit (18) from the machine. 5-61 K115sm5e5.doc...
  • Page 274 5.7.2 Replacing IR Lamps & Fuser Roller NOTE Fuser Roller is the Periodical Replacement Part, and its life is 200,000m. 1) Open both the Rear Upper Cover (1) and Exit Cover (2). 2) Loosen 3 pieces of tooth washer screw (3). 3) Close the Rear Upper Cover (1), and then remove the Cover 7 (4).
  • Page 275 4) Remove a tooth washer screw (5) to remove each Cover 3 (6) and Cover 4 (7). 5) Disconnect 3 connectors (8). 6) Remove 4 pieces of tooth washer screw (9) to remove the Cover 2 Assembly (10). 5-63 K115sm5e5.doc...
  • Page 276 7) Slide both the Shaft 4 (11) inward to release from the hole, and then remove the Exit Cover Assembly (12) 8) Remove a tooth washer screw (13) to remove each Lamp GP (14) with Lamp Mounts (15) at both sides to make the IR Lamps free.
  • Page 277 9) Pull out the IR Lamps (17) gently. Replace the IR Lamps (17) with the new ones. NOTE (1) There are 2 kinds of IR Lamp. One has a black wire and another has a white one. Make sure to install the black one to the upper Black position.
  • Page 278 10) Remove tooth washer screws (18) at both sides to remove the Frame Assembly (19). 5-66 K115sm5e5.doc...
  • Page 279 11) Pull the Levers L/R (20) at both sides to decompress the Fuser Roller. Then, remove Spring Hooks 3 (21), Spring Hooks 1/2 Assembly (22) and Extension Springs A (23) at both sides. NOTE When you pressurize the Fuser Roller, confirm the Levers L/R are fitted to the inside of Pin. No good (Lever is out of the Pin.) Good (Lever is inside of the Pin.) 5-67...
  • Page 280 12) Remove 2 pieces of Pan Head Screw (24) to remove 50T Spur Gear (25), 3 pieces of Spacer (26), 2 pieces of Wave Washer (27) and 2 pieces of Collar (28). 13) Remove 2 pieces of Pan Head Screw (29) to remove 50T Spur Gear (30) and Collar 1 (31). 14) Remove 4 pieces (2 pieces on each side) of tooth washer screw (32) to remove Collars (33), Ball Bearings (34) and Isolate Bushings (35) at both sides 5-68...
  • Page 281 15) Remove the Fuser Roller (36) pulling out to your side. Remove both the Collar E (37) and Collar 4 (38) from one side (driving side of machine) of the Fuser Roller. Replace both the Fuser Roller (36) and the Collar E (37) with the new ones. NOTE (1) You do not have to be care about the direction (left or right) of the Fuser Roller when you install the new one.
  • Page 282 5.7.3 Replacing Pressure Roller NOTE Pressure Roller is the Periodical Replacement Part, and its life is 200,000m. 1) Open both the Rear Upper Cover (1) and Exit Cover (2). 2) Loosen 3 pieces of tooth washer screw (3). 3) Close the Rear Upper Cover (1), and then remove the Cover 7 (4). 5-70 K115sm5e5.doc...
  • Page 283 4) Remove a tooth washer screw (5) to remove each Cover 3 (6) and Cover 4 (7). 5) Disconnect 3 connectors (8). 6) Remove 4 pieces of tooth washer screw (9) to remove the Cover 2 Assembly (10). 5-71 K115sm5e5.doc...
  • Page 284 7) Slide both the Shaft 4 (11) inward to release from the hole, and then remove the Exit Cover Assembly (12) 8) Remove tooth washer screws (13) at both sides to remove the Frame Assembly (14). 5-72 K115sm5e5.doc...
  • Page 285 9) Pull the Levers L/R (15) at both sides to decompress the Fuser Roller. NOTE When you pressurize the Fuser Roller, confirm the Levers L/R are fitted to the inside of Pin. No good (Lever is out of the Pin.) Good (Lever is inside of the Pin.) 5-73 K115sm5e5.doc...
  • Page 286 10) Remove the Pressure Roller (16) pulling out to your side. Remove C rings (17), Ball Bearings (18) and Isolate Bushing (19) from both sides of the Pressure Roller. Replace the Pressure Roller (16) with the new one. NOTE (1) You do not have to be care about the direction (left or right) of the Pressure Roller when you install the new one.
  • Page 287 5.7.4 Replacing Exhaust Blowers (BL2 & BL3) 1) Open both the Rear Upper Cover (1) and Exit Cover (2). 2) Loosen 3 pieces of tooth washer screw (3). 3) Close the Rear Upper Cover (1), and then remove the Cover 7 (4). 5-75 K115sm5e6.doc...
  • Page 288 4) Remove a tooth washer screw (5) to remove each Cover 3 (6) and Cover 4 (7). 5) Disconnect 3 connectors (8). 6) Remove 4 pieces of tooth washer screw (9) to remove the Cover 2 Assembly (10). 5-76 K115sm5e6.doc...
  • Page 289 7) Open the Licking Wire Saddle (11) to release the wire, and then remove 3 pieces of tooth washer screws (12) to remove each Exhaust Blower (13). Replace the Exhaust Blower (13) with the new one. 5-77 K115sm5e6.doc...
  • Page 290 5.7.5 Replacing Thermistor 1) Remove the Fuser Unit from the machine making reference to [5.7.1 Removing Fuser Unit] on the page 5-58. 2) Loosen 4 tooth washer screws (2), and then remove the Cover 5 (3). 5-78 K115sm5e6.doc...
  • Page 291 3) Remove 5 pieces of bind head screws to remove Nylon Clamps (4) which fix the wire of Thermistor. Pull out the connector (5) from the installation hole of plate, and then pull out the wire (6) from the hole (7). 4) Remove the tooth washer screw (8) to remove the Fitting Plate 1 (9) with the Thermistor.
  • Page 292 5) Remove the tooth washer screw (10) to remove the Thermistor (11). Replace the Thermistor (11) with the new one. 5-80 K115sm5e6.doc...
  • Page 293 5.7.6 Replacing Thermostat 1) Open both the Rear Upper Cover (1) and Exit Cover (2). 2) Loosen 3 pieces of tooth washer screw (3). 3) Close the Rear Upper Cover (1), and then remove the Cover 7 (4). 5-81 K115sm5e6.doc...
  • Page 294 4) Remove a tooth washer screw (5) to remove each Cover 3 (6) and Cover 4 (7). 5) Disconnect 3 connectors (8). 6) Remove 4 pieces of tooth washer screw (9) to remove the Cover 2 Assembly (10). 5-82 K115sm5e6.doc...
  • Page 295 7) Remove the tooth washer screw (11), and then pull out the Fitting Plate 2 (12). 8) Remove 2 pieces of tooth washer screws (13) to remove the Thermostat (14). Replace the Thermostat (14) with the new one. 5-83 K115sm5e6.doc...
  • Page 296 5.7.7 Replacing Stripper Finger Assemblies 1) Open both the Rear Upper Cover (1) and Exit Cover (2). 2) Loosen 3 pieces of tooth washer screw (3). 3) Close the Rear Upper Cover (1), and then remove the Cover 7 (4). 5-84 K115sm5e6.doc...
  • Page 297 4) Remove a tooth washer screw (5) to remove each Cover 3 (6) and Cover 4 (7). 5) Slide both the Shaft 4 (8) inward to release from the hole, and then remove the Exit Cover Assembly (9) 6) Remove the screw (10) to remove each Stripper Finger Assembly (11).
  • Page 298 5.7.8 Replacing Separation Fingers 1) Open both the Rear Upper Cover (1) and Exit Cover (2). 2) Loosen 3 pieces of tooth washer screw (3). 3) Close the Rear Upper Cover (1), and then remove the Cover 7 (4). 5-86 K115sm5e6.doc...
  • Page 299 4) Remove a tooth washer screw (5) to remove each Cover 3 (6) and Cover 4 (7). 5) Slide both the Shaft 4 (8) inward to release from the hole, and then remove the Exit Cover Assembly (9) 5-87 K115sm5e6.doc...
  • Page 300 6) Remove tooth washer screws (10) at both sides to remove the Frame Assembly (11). 5-88 K115sm5e6.doc...
  • Page 301 7) Remove 8 pieces of tooth washer screws (12) to remove the Frame (13). 9) Remove the Extension Spring (14) to remove each Separation Finger (15). Replace the Separation Finger (15) with the new one. 5-89 K115sm5e6.doc...
  • Page 302 5.7.9 Replacing Exit Sensor (LS2) 1) Open both the Rear Upper Cover (1) and Exit Cover (2). 2) Loosen 3 pieces of tooth washer screw (3). 3) Close the Rear Upper Cover (1), and then remove the Cover 7 (4). 5-90 K115sm5e6.doc...
  • Page 303 4) Remove a tooth washer screw (5) to remove the Cover 3 (6). 5) Remove 2 pieces of screw (7), disconnect the connector (8) and remove the Exit Sensor (9). Replace the Exit Sensor with the new one. 5-91 K115sm5e6.doc...
  • Page 304 5.7.10 Replacing Pressure Blowers (BL4 to BL7) 1) Open the Rear Upper Cover (1). 2) Remove 4 pieces of tooth washer screws (2) to remove the Cover 2 Assembly (3). 5-92 K115sm5e6.doc...
  • Page 305 3) Remove 9 pieces of tooth washer screws (4) to remove the Cover 2 (5). 4) Disconnect each connector (6). 5-93 K115sm5e6.doc...
  • Page 306 5) Remove 4 pieces of screw (7) to remove each Pressure Blower (8). Replace the Pressure Blower with the new one. 5-94 K115sm5e6.doc...
  • Page 307 Roll Decks 5.8.1 Removing each Roll Deck NOTE You can remove all Roll Decks in the same way. 1) Draw out the necessary Roll Deck (1). 2) Remove 4 pieces of tooth washer screws (2) which fix the Roll Deck to the Rails. 3) Remove the Roll Deck (3).
  • Page 308 5.8.2 Replacing Bypass Feed Clutch (MC7) & Roll Deck 1 Feed Clutch (MC8) (1st Roll Deck) 1) Draw out the Top Roll Deck (1). 2) Disconnect each connector (2). 3) Expanding the stopper lever (3) outward, pull out each Roll Deck 1 Feed Clutch (4) and Bypass Feed Clutch (5) from the shaft.
  • Page 309 5.8.3 Replacing Roll Set Sensor 1 (PH1), Paper Size Sensors (PH5A to PH11A) & Bypass Start Sensor (PH20) (1st deck) 1) Remove the Top Roll Deck (1) from the machine making reference to [5.8.1 Removing each Roll Deck] on the page 5-95. 2) Remove 2 pieces of tooth washer screw (2) to remove the Harness Cover (3).
  • Page 310 4) Loose 2 pieces of tooth washer screws (7) to remove the Cover 370 (8). 5) Remove 3 pieces of tooth washer screws (9), and then turn over the Stay 344 (10). 5-98 K115sm5e7.doc...
  • Page 311 6) Remove the bind head screw (11), disconnect the connector (12), and remove each Roll Set Sensor 1 Paper Size Sensors (13). Replace each Roll Set Sensor 1 and Paper Size Sensors (13) with the new one. 5-99 K115sm5e7.doc...
  • Page 312 5.8.4 Replacing Roll Set Sensor 2 (PH2) & Paper Size Sensors (PH5B to PH11B) (2nd deck) 1) Draw out the Middle Roll Deck (1). 2) Remove 2 pieces of tooth washer screw (2) to remove the Sensor Cover (3). 5-100 K115sm5e7.doc...
  • Page 313 3) Remove 4 pieces of tooth washer screw (4). 4) Turn over the Bracket (5), and you will find the sensors. 5-101 K115sm5e7.doc...
  • Page 314 5) Remove the bind head screw (6), disconnect the connector (7), and remove each Roll Set Sensor 2 Paper Size Sensors (8). Replace each Roll Set Sensor 2 and Paper Size Sensors (8) with the new one. 5-102 K115sm5e7.doc...
  • Page 315 5.8.5 Replacing Roll Set Sensor 3 (PH3) & Paper Size Sensors (PH5C to PH11C) (3rd deck) 1) Draw out the Bottom Roll Deck (1). 2) Remove 4 pieces of tooth washer screws (2) to remove the Lower Cover (3). 5-103 K115sm5e7.doc...
  • Page 316 3) Remove 2 pieces of tooth washer screw (4). 5-104 K115sm5e7.doc...
  • Page 317 4) Turn over the Stay 346 (5), and you will find the sensors. 5-105 K115sm5e7.doc...
  • Page 318 5) Remove the bind head screw (6), disconnect the connector (7), and remove each Roll Set Sensor 3 Paper Size Sensors (8). Replace each Roll Set Sensor 3 and Paper Size Sensors (8) with the new one. 5-106 K115sm5e7.doc...
  • Page 319 5.8.6 Replacing Roll Set Sensor 4 (PH4) & Paper Size Sensors (PH5D to PH11D) (4th deck) 1) Remove the Bottom Roll Deck (1) from the machine making reference to [5.8.1 Removing each Roll Deck] on the page 5-95. 2) Remove 2 pieces of tooth washer screw (2) to remove the Lower Harness Cover (3). 5-107 K115sm5e7.doc...
  • Page 320 3) Remove 2 pieces of tooth washer screw (4) and 2 pieces of Hexagon Head Bolt (5). 5-108 K115sm5e7.doc...
  • Page 321 4) Remove 3 pieces of tooth washer screw (6) to remove the Rear Cover (7). 5-109 K115sm5e7.doc...
  • Page 322 5) Remove 2 pieces of tooth washer screw (8), and then turn over the Stay 346 (9). 5-110 K115sm5e7.doc...
  • Page 323 6) Remove the bind head screw (10), disconnect the connector (11), and remove each Roll Set Sensor 4 Paper Size Sensors (12). Replace each Roll Set Sensor 4 and Paper Size Sensors (12) with the new one 5-111 K115sm5e7.doc...
  • Page 324 5.8.7 Replacing Paper Feed Clock Sensors (PH13 to PH16) (Common for all decks) NOTE You can remove the Paper Feed Clock Sensor in each Roll Deck in almost same way. This section shows you how to remove the Paper Feed Clock Sensor 1 in the Top Roll Deck as an example.
  • Page 325 3) Remove 2 pieces of tooth washer screw (4) to remove the Cover 1 (5). 6) Remove 3 pieces of tooth washer screw (6) to remove the Upper Sensor Mount (7). 5-113 K115sm5e7.doc...
  • Page 326 7) Disconnect the connector (8), and then press the stopper hooks (9) inward to remove the Paper Feed Clock Sensor 1 (10) from the Mount. Replace the Paper Feed Clock Sensor 1 (10) with the new one. 5-114 K115sm5e7.doc...
  • Page 327 5.8.8 Replacing 501-3M Belt (Common for all decks) NOTE You can remove the 501-3M Belt in each Roll Deck in almost same way. This section shows you how to remove the 501-3M Belt in the Top Roll Deck as an example. 1) Draw out the Top Roll Deck 1 (1).
  • Page 328 3) Remove 2 pieces of tooth washer screw (4) to remove the Pulley (5) with its plate. Then, remove the 501-3M Belt (6). Replace the 501-3M Belt (6) with the new one. NOTE Tighten the tooth washer screws (4) pressing down the Pulley (5) to give a tension to the 501-3M Belt (6).
  • Page 329 5.8.9 Replacing Dehumidify Heaters (1st & 2nd decks) NOTE You can remove both the Dehumidify Heaters (H8 : Roll 1 & H7 : Roll 2) in the same way. This section shows you how to remove the Dehumidify Heater (H8) for the Top Roll Deck as an example.
  • Page 330 3) Disconnect the connector (4), remove 2 pieces of screw (5), and then remove the Dehumidify Heater (6). Replace the Dehumidify Heater (6) with the new one. 5-118 K115sm5e7.doc...
  • Page 331 5.8.10 Replacing Dehumidify Heaters (3rd & 4th decks) 1) Remove both the Middle Roll Deck and the Bottom Roll Deck making reference to [5.8.1 Removing each Roll Deck] on the page 5-95. 2) Remove 2 pieces of tooth washer screw (1) to remove each Cover 341 (2). 5-119 K115sm5e7.doc...
  • Page 332 3) Disconnect the connector (3), remove 2 pieces of screw (4), and then remove each Dehumidify Heater (5). Replace the Dehumidify Heater (5) with the new one. 5-120 K115sm5e7.doc...
  • Page 333 5.8.11 Replacing Spool Brake 1) Remove the Roll Spool (1) from each Roll Deck. 2) Remove E Ring (2), Gear 454 (3), Thrust Washer (4) and Oil-less Bearing (5). 3) Remove E Ring (6) and Spool Brake (7). Replace the Spool Brake (7) with the new one. 5-121 K115sm5e7.doc...
  • Page 334 Bypass Feeder 5.9.1 Removing Bypass Feeder Unit 1) Draw out the Bypass Feeder Unit (1). 2) Remove 4 pieces of tooth washer screw (2) which fix the Bypass Feeder Unit from the bottom. 3) Slide the Bypass Feeder (1) along the Rails and remove it. 5-122 K115sm5e8.doc...
  • Page 335 5.9.2 Replacing Bypass Reversal Roller Down Solenoid (SL4) 1) Remove the Bypass Feeder Unit (1) from the machine making reference to [5.9.1 Removing Bypass Feeder Unit] on the page 5-122. 2) Loosen 5 pieces of tooth washer screws (2), and then slide and remove the Cover 2 (3). 5-123 K115sm5e8.doc...
  • Page 336 3) Disconnect the connector (4). 4) Remove 2 pieces of screw (5) to remove the Bypass Reversal Roller Down Solenoid (6). Replace the Bypass Reversal Roller Down Solenoid (6) with the new one. NOTE Tighten the screws (5) at the center of oval holes. 5-124 K115sm5e8.doc...
  • Page 337 5.9.3 Replacing Cut Sheet Set Sensor (PH31) & Cut Sheet Size Sensors (PH32 to PH37) 1) Remove the Bypass Feeder Unit (1) from the machine making reference to [5.9.1 Removing Bypass Feeder Unit] on the page 5-122. 2) Loosen 5 pieces of tooth washer screws (2), and then slide and remove the Cover 2 (3). 5-125 K115sm5e8.doc...
  • Page 338 3) Remove the screw (4) to remove the Bracket 239 (5), and also remove 2 pieces of screw (6) to remove the Bracket 232 (7). 5-126 K115sm5e8.doc...
  • Page 339 4) Remove the screw (8) and disconnect the connector (9) to remove each Cut Sheet Set Sensor Cut Sheet Size Sensors (10). Replace each Cut Sheet Set Sensor and Cut Sheet Size Sensors (10) with the new one. 5-127 K115sm5e8.doc...
  • Page 340 5.9.4 Replacing Bypass Feeding Roller Down Solenoid (SL3) 1) Open both the Top Roll Deck (1) and the Bypass Feeder Unit (2). (They are removed in the later procedure.) 2) Loosen the tooth washer screw (3) on the bottom, and remove 3 pieces of tooth washer screw (4) to remove the Cover (5).
  • Page 341 3) Remove the Tension Spring (6). As the Spring (7) easily drops off, remove it for the safety. 5-129 K115sm5e8.doc...
  • Page 342 4) Disconnect the connector (8), remove 2 pieces of screw (9), and remove the Bracket 557 (10) with the solenoid. 5-130 K115sm5e8.doc...
  • Page 343 5) Remove the E Ring (E5) (11) and 2 pieces of screw (12) to remove the Bypass Feeding Roller Down Solenoid (13) from the Bracket. Replace the Bypass Feeding Roller Down Solenoid (13) with the new one. 5-131 K115sm5e8.doc...
  • Page 344 5.10 Internal Transportation Unit 5.10.1 Replacing Belt 2 1) Draw out the Process Unit making reference to [5.1.1 Drawing out the Process Unit] on the page 5-3. Remove the Drum Assembly and keep it in the box to avoid the light. 2) Remove the Fuser Unit from the machine making reference to [5.7.1 Removing Fuser Unit] on the page 5-58.
  • Page 345 4) Remove 4 pieces of tooth washer screw (3) to remove the Cover 305 Assembly (4). 5) Unlock the Internal Transportation Unit (5) rotating the Internal Transportation Unit Lever (6) counter-clockwise, bring down the unit and then lock the shaft of lever with the Hook (7). 5-133 K115sm5e9.doc...
  • Page 346 6) Remove 6 pieces of tooth washer screw (8) which fix the Belt Unit. 7) Slide the Belt Unit (9) from the driving side to the driven side to pull out both the roller shaft (10) and Duct (11), and then remove the Belt Unit (9) from the machine. 5-134 K115sm5e9.doc...
  • Page 347 8) Remove 2 pieces of each E Ring (E10) (12) and Ball Bearing (13), and then remove 2 pieces of tooth washer screw (14) to remove the Bracket 1 (15). 9) Remove 2 pieces of each E Ring (E7) (16), Washer (17) and Ball Bearing (18), and then remove 4 pieces of tooth washer screw (19) to remove the Bracket 2 (20).
  • Page 348 5.10.2 Replacing Separation Sensor (PH18) 1) Draw out the Process Unit making reference to [5.1.1 Drawing out the Process Unit] on the page 5-3. Remove the Drum Assembly and keep it in the box to avoid the light. 2) Remove the Fuser Unit from the machine making reference to [5.7.1 Removing Fuser Unit] on the page 5-58.
  • Page 349 4) Remove 4 pieces of tooth washer screw (3) to remove the Cover 305 Assembly (4). 5) Unlock the Internal Transportation Unit (5) rotating the Internal Transportation Unit Lever (6) counter-clockwise, bring down the unit and then lock the shaft of lever with the Hook (7). 5-137 K115sm5e9.doc...
  • Page 350 6) Disconnect the connector (8), and then remove the wire from Wire Saddle (9) and Edge Saddle (10). 7) Loosen the screw (11), and the remove the Bracket 228 (12) with the sensor. 5-138 K115sm5e9.doc...
  • Page 351 8) Pressing the Stopper Hooks (13) inward, remove the Separation Sensor (14) from the bracket. Replace the Separation Sensor (14) with the new one. 5-139 K115sm5e9.doc...
  • Page 352 5.10.3 Removing Internal Transportation Unit 1) Remove the Drum Assembly (1) from the Process Unit making reference to [5.1.2 Removing Image Corona, Drum Assembly, Toner Hopper & Developer Unit] on the page 5-6. 2) Remove the Transfer / Separation Corona (1) from the machine making reference to [5.11.1 Removing Transfer / Separation Corona] on the page 5-151.
  • Page 353 4) Remove the Duct (5) removing 8 pieces of tooth washer screw. 5) Remove 2 pieces of tooth washer screw (6). 6) Open the Right Side Door (7). 5-141 K115sm5eA.doc...
  • Page 354 7) Remove 2 pieces of tooth washer screw (8), and then remove the Cover (9). 8) Remove 2 pieces of tooth washer screw (10). Remove 3 pieces of tooth screws (11) to remove the Gear Assembly (12). 9) Open the Top Rear Cover (13), and then loosen 3 pieces of tooth washer screw (14). 5-142 K115sm5eA.doc...
  • Page 355 10) Close the Top Rear, and then remove the Fuser Cover (15). 11) Remove a tooth washer screw (16) from each Cover, and then remove Cover 3 (17) and Cover 4 (18). 12) Disconnect 3 connectors (19). 5-143 K115sm5eA.doc...
  • Page 356 13) Remove 4 pieces of tooth washer screw (20), open the Exit Cover (21), and then remove the Cooling Fan Unit (22). 14) Remove 5 pieces of tooth washer screw (23) which fix the Fuser Unit from the bottom. 5-144 K115sm5eA.doc...
  • Page 357 15) Remove Hexagon Head Bolts (24) at both sides which fix the Fuser Unit. Also, disconnect 4 connectors (25). 16) Remove the Fuser Unit (26) from the machine. 17) Remove 2 pieces of bind head screw (27) and 7 pieces of tooth washer screw (28) to remove the Rear Cover (29).
  • Page 358 18) Loosen 4 pieces of tooth washer screw inserting a screwdriver from the holes (30), and remove each Base 2 (31) and Base 3 (32). 19) Remove Transmission PCB (33) and Reception PCB (34). (Put them aside as the following right photo, otherwise you will break them when you remove the Inner Transport Assembly.) 20) Disconnect 4 connectors (35) on the Left Side Plate.
  • Page 359 21) Remove Retaining Ring K and Flat Washers (37) at both sides. 22) Prepare the Gas Spring Jigs (38). Gas Spring Jigs : 7708560070 23) Fit the notch (39) of each Gas Spring Jig to the shaft of Inner Transport Lock Lever. 5-147 K115sm5eA.doc...
  • Page 360 24) Bring down the Inner Transport Assembly to shorten the Gas Spring Hinges (40), and then bring up the Gas Spring Jigs (38) to cover the Gas Spring Hinges. NOTE Gas Spring Hinges will not extend more than required because the Gas Spring Jigs restrict their extension, so it will be easy to set the hinges when you reassemble.
  • Page 361 26) Remove the Retaining Ring E and Ball Bearing (42) on the Left Side Plate. 27) Remove the Retaining Ring E (43). 28) Remove Retaining Ring E (44). 5-149 K115sm5eA.doc...
  • Page 362 29) Shift the Shafts (45) inward until they are pulled out from the Side Plates. 30) Remove the Inner Transport Assembly (46) from the machine. 5-150 K115sm5eA.doc...
  • Page 363 5.11 Transfer / Separation Corona 5.11.1 Removing Transfer / Separation Corona 1) Open the Right Side Door (1). 2) Unlock the Internal Transportation Unit (2) rotating the Internal Transportation Unit Lever (3) counter-clockwise, bring down the unit and then lock the shaft of lever with the Hook (4). 5-151 K115sm5eB.doc...
  • Page 364 3) Rotate the Knob (5) counter-clockwise to unlock, and then pull out the Transfer / Separation Corona (6) from the machine. 5-152 K115sm5eB.doc...
  • Page 365 5.11.2 Replacing Corona Wire 2 Assemblies NOTE Corona Wire 2 Assembly is the Periodical Replacement Part, and its life is 100,000m. 1) Remove the Transfer / Separation Corona (1) from the machine making reference to [5.11.1 Removing Transfer / Separation Corona] on the page 5-151. 2) If you press down the Stopper Hooks (2), you can remove each Corona Guards A/B (3).
  • Page 366 3) Remove 2 pieces of screw (4) at both sides, and remove the Corona Housing 5 (5) and several sheets of Spacers 1 (6) from both sides. NOTE As the Spacers 1 (6) adjust the height of Corona Housing 5 (5), the number of them used is different among unit.
  • Page 367 5) Removing the Extension Springs (10) on each Corona Block, remove each Corona Wire 2 Assembly (11). Replace the Corona Wire 2 Assembly (11) with the new one. NOTE When you stretch the new Corona Wire 2 Assembly, make sure to fit its anti-vibration bead (12) into the necessary space in the Corona Heads, and also make sure to fit the wire into the grooves (13) of the Height Adjuster.
  • Page 368 7) Put back both Spacers 1 (6) and Corona Housing 5 (5). NOTE It is necessary to put back both Spacers 1 (6) and Corona Housing 5 (5) before adjusting the height of Transfer Corona Wire. 5-156 K115sm5eB.doc...
  • Page 369 8) Measure the height of each Corona Wire 2 Assembly, and compare with the values written in the 15.0mm label which is pasted inside the Right Side Door. 14.0mm (10.2mm) (The values in the right figure are simply the standards.) 9) If the height is not proper, adjust it rotating the screws (14) on the back of the Corona.
  • Page 370 5.11.3 Replacing Mylar 1) Remove the Transfer / Separation Corona (1) from the machine making reference to [5.11.1 Removing Transfer / Separation Corona] on the page 5-151. 2) Strip off the Mylar (2) from the Corona Housing 5. Replace the new Mylar (2) with the new one NOTE Align the edges of Mylar with the front face and side faces of TR Guides B (3).
  • Page 371 5.11.4 Adjustment of gap between Drum & Corona Housing 5 NOTE In case you have replaced the Transfer / Separation Corona Unit with the new one, make sure to check the gap between Drum and Corona Housing 5 using an exclusive Jig. And adjust the gap properly if necessary.
  • Page 372 2) Remove each Image Corona (2), Drum Assembly (3), Toner Hopper (4) and Developer Unit (5) from the Process Unit making reference to [5.1.2 Removing Image Corona, Drum Assembly, Toner Hopper & Developer Unit] on the page 5-6. NOTE If you take checking or adjustment of gap without removing the Developer Unit, you may damage the surface of Development Roller with the tip of Pin of the Drum Gauge 3) Open the Rear Upper Cover (6).
  • Page 373 4) Disconnect the connector (7), remove 4 pieces of tooth washer screw (8), and then remove the Cover 305 Assembly (9). 5) Fit the “Drum Gauge for Transfer Corona” (10) into the Drum Shaft (11). 5-161 K115sm5eB.doc...
  • Page 374 6) Close the Process Unit, and then fix it with 4 pieces of screw (12). 7) Bring up the Internal Transportation Unit (13) and lock it at the operation position. NOTE Make sure to close and lock both the Process Unit and the Internal Transportation Unit before measurement.
  • Page 375 8) Swing the “Drum Gauge for Transfer Corona” forward and backward to check whether or not its pins touch the Mylar (14) on the Corona Housing 5. One of 2 pins marked with 0.4mm (15) should not touch the Mylar (14). Another pin marked with 1.0mm (16) should touch the Mylar (14) slightly.
  • Page 376 9) If the gap is out of the correct range, adjust the height of Corona Housing 5 by adding or removing Spacer 1 (17). If you add 1 sheet of Spacer 1, the height of Corona Housing 5 gets 0.2mm higher. Spacer 1 (7705104090) 5-164 K115sm5eB.doc...
  • Page 377 5.12 LED Head 5.12.1 Removing LED Head 1) Open the Rear Upper Cover (1). 2) Disconnect the connector (2), remove 4 pieces of tooth washer screw (3), and then remove the Cover 305 Assembly (4). 5-165 K115sm5eC.doc...
  • Page 378 3) Draw out the Process Unit (5) from the machine making reference to [5.1.1 Drawing out the Process Unit] on the page 5-3. Remove the Drum Assembly and keep it in the box to avoid the light. 4) Disconnect 4 connectors (6). 5) Remove 2 pieces of M4x10 black screws (7).
  • Page 379 6) Catch both sides of the LED Head, and then move the driven side of it as the arrow marks in the photo show in order to make the Pin (8) comes out from the Slit (9) of the Side Plate. 7) Pull out the Positioning Pins on the driving side from the Positioning Slits (10), and then remove the LED Head (11) from the machine.
  • Page 380 NOTE Make sure to close the Process Unit without tightening the M4x10 screws (7). The Positioning Bars of the LED Head are fitted into the slits of the Process Unit. Slits Positioning Bars These Positioning Bars are curved upward, and the LED Head is smoothly moved up when the bars are fitted into the slits.
  • Page 381 NOTE After installing the LED Head, please check the Ground Plates (13) are not deformed. Because they easily hook somewhere on the LED Head and are deformed. No Good (Ground Plate is bent.) Good 5-169 K115sm5eC.doc...
  • Page 382 5.12.2 Replacing Pad Assembly 2 NOTE Pad Assembly 2 is the Periodical Replacement Part, and its life is 100,000m. 1) Remove the LED Head (1) from the machine making reference to [5.12.1 Removing LED Head] on the page 5-165. 2) Loosen the screw (2) and remove the Pad Assembly 2 (3).
  • Page 383 5.12.3 Replacing LED Cleaning Motor (M8) 1) Remove the LED Head (1) from the machine making reference to [5.12.1 Removing LED Head] on the page 5-165. 2) Remove the screw (2) and remove the Bracket 222 (3) with the motor. 3) Remove 2 pieces of screw (4) to remove the LED Cleaning Motor (5).
  • Page 384 5.13 Main Frame 5.13.1 Replacing Drum Motor (M1) & Timing Belt 565-5GT-40 1) Remove 4 pieces of tooth washer screw (1) to remove the Side Cover L (2). 2) Remove 2 pieces of tooth washer screw (3) to make the Bracket 316 (4) with PCB free. As the Bracket 316 (4) is preventative for the later works, tape it as the photo shows.
  • Page 385 3) Remove 2 pieces of Nuts (5), remove 2 pieces of Hexagon Head Bolt (6), and remove 2 pieces of Flat Washer (7), Tension Spring (8), Shaft 207 (9) and Bracket 217 (10). NOTE You can adjust the tension of Timing Belt 565-5GT-40 by measuring the distance between both Flat Washers (7).
  • Page 386 4) Remove the tooth washer screw (11) to remove the Contact Plate (12). 5) Remove the C Ring (13), and then remove 4 pieces of Hexagon Head Bolt (14) to remove both Ball Bearing (30x55x13) (15) and Holder (16). Remove the E Ring (E9) (17) to remove the Ball Bearing (12x28x8) (18). 5-174 K115sm5eD.doc...
  • Page 387 6) Open 2 pieces of Locking Wire Saddle (19) to make the harness free, and then remove 7 pieces of tooth washer screw (20) to remove the Bracket (21). 5-175 K115sm5eD.doc...
  • Page 388 7) Remove the E Ring (E8) (22), and remove the Idler Assembly (23). 5-176 K115sm5eD.doc...
  • Page 389 8) Remove 2 pieces of Hexagon Head Cap Screw (24), and then remove both 72T Pulley (25) and Timing Belt 565-5GT-40 (26). Replace the Timing Belt 565-5GT-40 (26) with the new one. 5-177 K115sm5eD.doc...
  • Page 390 9) Remove 2 pieces of Hexagon Head Cap Screw (27), and then remove the 24T Pulley (28). Disconnect the connector (29). NOTE There may be the case that some abnormal sound is generated during operation if the Drum Shaft or Shaft 204 is short of grease.
  • Page 391 10) Remove 8 pieces of tooth washer screw (30) to remove the Motor Bracket (31) with motor. 5-179 K115sm5eD.doc...
  • Page 392 11) Remove 3 pieces of Hexagon Head Bolt (32) and 1 piece of Flush Head Screw (33) to remove the Motor Assembly. 12) Loosen 2 pieces of Set Screw (34), and then pull out the 50T Gear (35) from the shaft of Drum Motor (36).
  • Page 393 5.13.2 Replacing Paper Feed Motor (M2) 1) Remove 4 pieces of tooth washer screw (1) to remove the Side Cover L (2). 2) Disconnect the connector (3), and open the Wire Saddles (4) to make the wires free. 5-181 K115sm5eD.doc...
  • Page 394 3) Remove 4 pieces of tooth washer screw (5) to remove the Motor Base (6) with motor. 4) Loosen 2 pieces of Set Screw (7), and then pull out the 40T Gear (8). 5) Remove 3 pieces of Hexagon Head Bolt (9) to remove the Paper Feed Motor (10).
  • Page 395 5.13.3 Replacing Fuser Motor (M5) 1) Remove 4 pieces of tooth washer screw (1) to remove the Side Cover L (2). 2) Remove 2 pieces of tooth washer screw (3) to make the Bracket 316 (4) with PCB free. As the Bracket 316 (4) is preventative for the later works, tape it as the photo shows. Tape the Bracket 316.
  • Page 396 3) Open 3 pieces of Wire Saddle (5) to make the wires free. 4) Disconnect the connector (6), and then remove 4 pieces of tooth washer screw (7) to remove the Side Plate Assembly (8) with motor. 5-184 K115sm5eD.doc...
  • Page 397 5) Remove the E Ring (E7) (9) to remove the Ball Bearing (10). Remove 4 pieces of Hexagon Head Bolt (11) to divide the Side Plate Assembly into Side Plate 1 (13) and Side Plate 2 (14). 5-185 K115sm5eD.doc...
  • Page 398 6) Loosen 2 pieces of Set Screw (14), and remove the 26T Spur Gear (15). Remove 3 pieces of tooth washer screw (16) to remove the Fuser Motor (17). Replace the Fuser Motor (17) with the new one. 5-186 K115sm5eD.doc...
  • Page 399 5.13.4 Replacing Developer Positioning Motor (M4) 1) Remove 4 pieces of tooth washer screw (1) to remove the Side Cover L (2). 2) Disconnect the connector (3), and then remove 3 pieces of Pan Head Screw (4) to remove the Developer Positioning Motor (5).
  • Page 400 5.13.5 Replacing Cutter Motor (M3), Cutter Home Position Sensor (PH22) & Internal Transportation Unit Set Sensor (PH24) 1) Remove 4 pieces of tooth washer screw (1) to remove the Side Cover L (2). 2) Disconnect the connector (3), and then remove 2 pieces of tooth washer screw (4) to remove the Cooling Fan 4 (5) with its bracket.
  • Page 401 3) Loosen 2 pieces of screw (6), and put the Bracket (7) with PCB aside as it is preventative for later works. 4) Remove the Spring 211 (8), and then remove 2 pieces of Hexagon Head Bolt (9) to remove the 15T Sprocket Assembly (10).
  • Page 402 NOTE When reassembly, put back the 15T Sprocket Assembly (10) with the Hexagon Head Bolts (9) loosed, hook the Spring 211 (8) as it was, then tighten the Hexagon Head Bolts (9). You do not have to give any tension to the Roller Chain especially but only the tension of Spring 211 (8) is enough.
  • Page 403 6) Remove 5 pieces of tooth washer screw (15) and 2 pieces of Hexagon Head Bolt (16) to remove the Motor Bracket (17) with motor. 5-191 K115sm5eE.doc...
  • Page 404 7) Remove the tooth washer screw (18), disconnect the connector (19), and remove the Bracket 14 (20) with sensor. 8) Pressing the Stopper Hooks (21) inward, remove the Internal Transportation Unit Set Sensor (22) from the bracket. Replace the Internal Transportation Unit Set Sensor (22) with the new one. 5-192 K115sm5eE.doc...
  • Page 405 9) Remove the tooth washer screw (23) to remove the Mount (24). 10) Disconnect the connector (25), and then remove 2 pieces of bind head screw (26) to remove the Cutter Home Position Sensor (27). Replace the Cutter Home Position Sensor (27) with the new one. 11) Loosen 2 pieces of Set Screw (27) to remove the Joint B (28).
  • Page 406 12) Remove 4 pieces of Hexagon Head Bolt (29) to remove the Cutter Motor (30). Replace the Cutter Motor (30) with the new one. 5-194 K115sm5eE.doc...
  • Page 407 5.13.6 Replacing Bypass Feeding Motor (M10) 1) Remove both the Top Roll Deck (1) and the Bypass Feeder Unit (2) making reference to [5.8.1 Removing each Roll Deck] on the page 5-95 and [5.9.1 Removing Bypass Feeder Unit] on the page 5-122. 2) Remove 4 pieces of tooth washer screw (3) to remove the Side Cover L (4).
  • Page 408 3) Disconnect 3 connectors (7). 4) Remove 3 pieces of tooth washer screw (8) to remove the Drum Motor Controller PCB (9). 5-196 K115sm5eE.doc...
  • Page 409 5) Loosen the tooth washer screw (10) on the bottom, and remove 3 pieces of tooth washer screw (11) to remove the Cover (12). 5-197 K115sm5eE.doc...
  • Page 410 6) Remove 2 pieces of tooth washer screw (13) to remove the Cover 308 (14). 5-198 K115sm5eE.doc...
  • Page 411 7) Disconnect 2 connectors (15), remove 4 pieces of screw (16), and then pull out the Bypass Feeding Motor (17) to the inside of machine. Replace the Bypass Feeding Motor (17) with the new one. 5-199 K115sm5eE.doc...
  • Page 412 NOTE (1) When reinstalling the Bypass Feeding Motor, tighten the screws while pressing the motor so that there exists no space between Counter Rollers of motor side and that of machine side. Counter Roller of machine side Counter Roller of motor side (2) A red circular seal is pasted on the Bypass Feeding Motor.
  • Page 413 5.13.7 Replacing Toner Supply Motor 2 (M6) 1) Draw out the Process Unit (1) making reference to [5.1.1 Drawing out the Process Unit] on the page 5-3. Remove the Drum Assembly and keep it in the box to avoid the light. 2) Remove the LED Head (2) from the machine making reference to [5.12.1 Removing LED Head] on the page 5-165.
  • Page 414 4) Remove 3 pieces of tooth washer screw (5), disconnect the connector (6), and then take out the Motor Bracket (7) with motor from the machine. 5) Remove 3 pieces of Pan Head Screw (8) to remove the Toner Supply Motor 2 (9).
  • Page 415 5.13.8 Replacing Paper Gate Clutch (MC5) & Paper Gate Brake (MC10) 1) Remove 4 pieces of tooth washer screw (1) to remove the Side Cover L (2). 2) Loosen 2 pieces of Set Screw (3), and remove the rotary side of Paper Gate Brake (4).
  • Page 416 3) Remove the connector (5), and then remove 3 pieces of screw (6) to remove the fixed side of Paper Gate Brake (7). Replace the Paper Gate Brake (both rotary side and fixed side) (4 &7) with the new one. NOTE When you install the new Paper Gate Brake, keep 0.2mm of space between rotary side and fixed side.
  • Page 417 4) Remove 4 pieces of tooth washer (8), disconnect the connector (9), and then remove the Clutch Plate (10). Pull out both the Thrust Washer (11) and Spacer (12) from the shaft. 5) Expanding the stopper lever (13) outward, pull out the Paper Gate Clutch (14) from the shaft.
  • Page 418 5.13.9 Replacing Paper Feed Clutch (MC6) & Paper Feed Brake (MC9) 1) Remove 4 pieces of tooth washer screw (1) to remove the Side Cover L (2). Draw out the Middle Roll Deck (3). 2) Loosen 2 pieces of Set Screw (4), and remove the rotary side of Paper Feed Brake (5).
  • Page 419 3) Disconnect the connector (5), and then remove 3 pieces of screw (6) to remove the fixed side of Paper Feed Brake (7). Replace the Paper Feed Brake (both rotary side and fixed side) (4 &7) with the new one. NOTE When you install the new Paper Feed Brake, keep 0.2mm of space between rotary side and fixed side.
  • Page 420 4) Remove 3 pieces of screw (8), disconnect the connector (9), and then remove the Mount 1 (10). 5) Pull out the Collar (11), and then pull out the Paper Feed Clutch Assembly (12) from the shaft and remove the Sliding Key (13). 5-208 K115sm5eF.doc...
  • Page 421 6) Remove 3 pieces of screw (14) to remove the 50T Spur Gear (15) from the Paper Feed Clutch (16). Replace the Paper Feed Clutch (16) with the new one. NOTE Please check whether or not the Paper Feed Clutch is properly installed or not in the following ways.
  • Page 422 5.13.10 Replacing Roll Paper Feed Clutches (MC1 to MC4) 1) Remove 4 pieces of tooth washer screw (1) to remove the Side Cover L (2). 2) If you will replace either Roll Paper Feed Clutch 3 or Roll paper Feed Clutch 4, loosen 2 pieces of screw (3), and put the Bracket (4) with PCB aside as it is preventative for later works.
  • Page 423 3) Disconnect the connector (5), remove 4 pieces of tooth washer screw (6), and then remove each Clutch Mount (7) with clutch. 4) Pull out the connector (8) from the Clutch Mount. Expanding the stopper lever (9) outward, pull out the Roll Paper Feed Clutch (9) from the shaft.
  • Page 424 5.13.11 Replacing SSR1 and SSR2 1) Remove 4 pieces of tooth washer screw (1) to remove the Side Cover L (2). 2) Remove 8 pieces of tooth washer screw (3) to remove the Duct Assembly (4). 5-212 K115sm5eF.doc...
  • Page 425 3) Disconnect 4 connectors (5), remove 2 pieces of screw (6), and then remove each (7). Replace the with the new one,. 5-213 K115sm5eF.doc...
  • Page 426 NOTE Each connector of SSR is labelled independently. Connect them to the correct position making reference to the following photo. 5-214 K115sm5eF.doc...
  • Page 427 5.13.12 Replacing LED Cooling Fans (BL8 to BL11) 1) Remove both the Top Roll Deck (1) and the Bypass Feeder Unit (2) making reference to [5.8.1 Removing each Roll Deck] on the page 5-95 and [5.9.1 Removing Bypass Feeder Unit] on the page 5-122.
  • Page 428 3) Remove the connector (6), remove 4 pieces of screw (7), and then remove each LED Cooling (8). Replace the LED Cooling Fan (8) with the new one. 5-216 K115sm5eF.doc...
  • Page 429 5.13.13 Replacing Leading Edge Sensor (PH12) 1) Open the Rear Upper Cover (1). 2) Disconnect the connector (2), remove 4 pieces of tooth washer screw (3), and then remove the Cover 305 Assembly (4). 5-217 K115sm5eF.doc...
  • Page 430 3) Draw out the Process Unit (5) from the machine making reference to [5.1.1 Drawing out the Process Unit] on the page 5-3. Remove the Drum Assembly and keep it in the box to avoid the light. 4) Loosen the screw (6) to make the Bracket 207 (7) free. 5-218 K115sm5eF.doc...
  • Page 431 5) Disconnect the connector (8), and remove the bracket with sensor. 6) Remove the screw (9) top remove the Slit Plate (10). Remove the screw (11) to remove the Leading Edge Sensor (12). Replace the Leading Edge Sensor (12) with the new one. 5-219 K115sm5eF.doc...
  • Page 432 5.13.14 Replacing Pre-transfer LED 1) Open the Right Side Door (1). 2) Unlock the Internal Transportation Unit (2) rotating the Internal Transportation Unit Lever (3) counter-clockwise, bring down the unit and then lock the shaft of lever with the Hook (4). 5-220 K115sm5eG.doc...
  • Page 433 3) Rotate the Knob (5) counter-clockwise to unlock, and then pull out the Bracket (6) with Pre-transfer LED. 4) Remove the Cover 6 (7), and then remove both screw (8) and nut (9) to make the wire (10) free. 5-221 K115sm5eG.doc...
  • Page 434 5) Remove both screw (11) and nut (12) to make one more wire (13) free. 6) Remove 6 pieces of each bind head screw (14) and Collar (15), and then divide the lamp into 2 pieces of Pre-Transfer LED PCB (16) disconnecting the connector (17).
  • Page 435 5.13.15 Adjustment of gap between Drum & Transfer Guide Plate NOTE In case you have replaced or removed the Transfer Guide Plate for some reason, make sure to check the gap between Drum and Transfer Guide Plate using an exclusive Jig. And adjust the gap properly if necessary.
  • Page 436 2) Remove each Image Corona (2), Drum Assembly (3), Toner Hopper (4) and Developer Unit (5) from the Process Unit making reference to [5.1.2 Removing Image Corona, Drum Assembly, Toner Hopper & Developer Unit] on the page 5-6. NOTE If you take checking or adjustment of gap without removing the Developer Unit, you may damage the surface of Development Roller with the tip of Pin of the Drum Gauge 3) Open the Rear Upper Cover (6).
  • Page 437 4) Disconnect the connector (7), remove 4 pieces of tooth washer screw (8), and then remove the Cover 305 Assembly (9). 5) Remove the Transfer / Separation Corona (10) from the machine making reference to [5.11.1 Removing Transfer / Separation Corona] on the page 5-151. 5-225 K115sm5eG.doc...
  • Page 438 6) Fit the “Drum Gauge for Transfer Guide” (11) into the Drum Shaft (12). 7) Close the Process Unit, and then fix it with 4 pieces of screw (13). 8) Bring up the Internal Transportation Unit (14) and lock it at the operation position. NOTE Make sure to close and lock both the Process Unit and the Internal Transportation Unit before measurement.
  • Page 439 9) Swing the “Drum Gauge for Transfer Guide” forward and backward to check whether or not its pins touch the Transfer Guide Plate (15). One of 2 pins marked with 0.75mm (16) should not touch the Transfer Guide Plate (15). Another pin marked with 1.25mm (17) should touch the Transfer Guide Plate (15) slightly.
  • Page 440 10) If the gap is out of the correct range, loosen 5 pieces of screw (18) one by one and move the Transfer Guide Plate up or down. 5-228 K115sm5eG.doc...
  • Page 441 5.13.16 Replacing Ozone Filters NOTE Ozone Filters are Periodical Replacement Parts, and their life are 200,000m or 1 year. 1) Remove 14 pieces of tooth washer screw (1) and 2 pieces of bind head screw (2) to remove the Cover 1 (3). 5-229 K115sm5eG.doc...
  • Page 442 2) Remove 2 pieces of screw (4) to remove the Cover 2 (5). 3) Remove 4 pieces of Ozone Filter (6). Replace the Ozone Filters (6) with the new ones. 4) Remove 3 pieces of Ozone Filter (7). Replace the Ozone Filters (7) with the new ones. 5-230 K115sm5eG.doc...
  • Page 443 5.13.17 Replacing Separation Fan (BL1) 1) Remove 14 pieces of tooth washer screw (1) and 2 pieces of bind head screw (2) to remove the Cover 1 (3). 5-231 K115sm5eG.doc...
  • Page 444 2) Remove 2 pieces of each screw (4) and Flat Washer (5) to remove the Cover 1 (6). 5-232 K115sm5eG.doc...
  • Page 445 3) Disconnect the connector (7), and then remove 3 pieces of screw (8) to remove the Separation Fan (9). Replace the Separation Fan (9) with the new one. 5-233 K115sm5eG.doc...
  • Page 446 5.14 Toner Cartridge Driving Part 5.14.1 Replacing Transmission PCB (PW7750) & Receiver PCB (PW7751) 1) Open the Toner Cover (1) and the Toner Cartridge Cover (2). 2) Rotate the Toner Cartridge (3) half revolution to move the opening (4) to the top position. Then, remove the Toner Cartridge (3).
  • Page 447 4) Remove 4 pieces of screw (6) to remove the Cover (7). 5) Disconnect the connector (8), and then remove 4 pieces of Hexagon Screw (9) to remove the Transmission PCB (10). Replace the Transmission PCB (10) with the new one. 6) Remove 3 pieces of tooth washer screw (11) to remove the Toner Cover (1).
  • Page 448 7) Remove 4 pieces of tooth washer screw (12) to remove the Bracket 562 (13). 8) Remove 2 pieces of tooth washer screw (14) to make the Switch (15) free. 5-236 K115sm5eH.doc...
  • Page 449 9) Remove 4 pieces of tooth washer screws (16), disconnect the connector (17), and remove the Bracket (18). 10) Remove 4 pieces of screw (19) and 2 pieces of self-tapping screw (20) to remove the Receiver PCB (21). Replace the Receiver PCB (20) with the new one. 5-237 K115sm5eH.doc...
  • Page 450 5.14.2 Replacing Toner Supply Motor 1 (M7) & Toner Supply Clutch (MC11) 1) Open the Toner Cover (1) and the Toner Cartridge Cover (2). 2) Rotate the Toner Cartridge (3) half revolution to move the opening (4) to the top position. Then, remove the Toner Cartridge (3).
  • Page 451 4) Disconnect the connector (6), and then remove 3 pieces of tooth washer screw (7) to remove the Toner Cover (1). 5) Remove 4 pieces of tooth washer screw (8) to remove the Bracket 562 (9). 5-239 K115sm5eH.doc...
  • Page 452 6) Remove the screw (10) to remove the Cover (11). Disconnect 2 connectors (12). 5-240 K115sm5eH.doc...
  • Page 453 7) Remove 2 pieces of tooth washer screw (13) to remove the Cartridge Driving Unit (14). 5-241 K115sm5eH.doc...
  • Page 454 8) Remove 2 pieces of Set Screw (15). NOTE When reassemble, keep a 0.5mm of space between plastic part (16) of clutch and Pin (17), and then tighten the Set Screw (15). Keep 0.5mm of space. 5-242 K115sm5eH.doc...
  • Page 455 9) Remove the E Ring (E7) (18) to remove the Oilless Metal (19). Remove the E Ring (E8) (20). 5-243 K115sm5eH.doc...
  • Page 456 10) Remove 2 pieces of each screw (21) and Stud (22), and remove the Toner Supply Motor 1 (23). Replace the Toner Supply Motor 1 (23) with the new one. 5-244 K115sm5eH.doc...
  • Page 457 11) Remove the Bracket 511 (24) and the Oilless Metal (25). 12) Remove the E Ring (E10) (26). 13) Pull the Shaft (27) toward the arrow mark to pull out from the Pin (17). 5-245 K115sm5eH.doc...
  • Page 458 14) Expanding the stopper lever (28) outward, pull out the shaft from the Toner Supply Clutch (29). Replace the Toner Supply Clutch (29) with the new one. 5-246 K115sm5eH.doc...
  • Page 459 5.15 Web (Option) 5.15. 1 Replacement of Web Roll 2. Open the Top Rear Cover (1) 3. Loosen 3 screws (2) then close the Top Rear Cover (1). 4. Remove the Cover 5 (3). 5-247 K115sm5eJ.doc...
  • Page 460 5. Remove the screw (4), and remove the Cover 4 (5) on the right. 6. Remove the screw (6), and remove the Cover 3 (7) on the right. 7. Remove 4 screws (8). 8. Remove the Web Unit (9). 5-248 K115sm5eJ.doc...
  • Page 461 9. Pulling out the Pins (10), remove both rolls of old Web from the unit. 10. Install the large web roll (11) to its setting position. (See the following photo) NOTE Install the large web roll pulling out the Pin (12). 5-249 K115sm5eJ.doc...
  • Page 462 11. Install the small web roll (13) of Web Roll to its setting position similarly. NOTE Install the small web roll pulling out the Pin (14). 5-250 K115sm5eJ.doc...
  • Page 463 12. Retrieve the small web roll until the printed number (15) is hidden. 5-251 K115sm5eJ.doc...
  • Page 464 13. Return the Web Unit (9) with new Web to the KIP9000 with 4 screws (8). NOTE Confirm there is no space between Web Unit and Cover 2 Assy. The driving gears are not engaged Is there is space. 5-252 K115sm5eJ.doc...
  • Page 465 14. Return both Cover 3 (7) and Cover 4 (5). 15. Return the Cover 5 (3) finally. 16. Turn on the KIP9000, and set the Web Operation Time to “0 hour 0 minute 0 second” in the following Service Mode items. •...
  • Page 466 5.15. 2 Installation of Web Kit 1. Confirm the following parts are included in the kit. Item name Picture Item name Picture Web Unit Cover 2 Assy Web Motor Assy 56/22 Gear Assy 16T Gear Assy Ball Bearing 22T Gear E Ring Oil Pan 5-254...
  • Page 467 Item name Picture Item name Picture M4x6 tooth M4x8 tooth washer screw washer screw 2 : for Oil Pan 4: for Web Unit 1 : for 56/22 4: for Cover 2 Gear Assy Assy M3x6 bind screw 2. Open the Top Rear Cover (1) 3.
  • Page 468 4. Remove the Cover 5 (3). 5. Remove the screw (4), and remove the Cover 4 (5) on the right. 6. Remove the screw (6), and remove the Cover 3 (7) on the right. 5-256 K115sm5eJ.doc...
  • Page 469 7. Open the Exit Cover (8). Disconnect 2 connectors (9) on the right and 1 connector (10) on the left. 8. Remove 4 tooth washer screws (11). 9. Remove the Cover 2 Assy (12). (This Cover 2 Assy is no longer reused as it is to be replaced with the one included in the kit.) 5-257 K115sm5eJ.doc...
  • Page 470 10. Remove the Brackets (13) on both sides removing 2 screws (14) for each one. 11. Remove 4 screws (15). 12. Remove the Reinforcement Plate (16). (Reinforcement Plate is no longer reused.) 5-258 K115sm5eJ.doc...
  • Page 471 13. Install the 56/22T Gear Assy (17) on the left with 1 piece of M4x6 tooth washer screw (18) 5-259 K115sm5eJ.doc...
  • Page 472 14. Prepare 16T Gear Assy (19), 2 Ball Bearings (20), 22T Gear (21) and E Ring (22). Fit 1 Ball Bearing (20) to the shaft of 16T Gear Assy (19), insert the shaft from inside to outside fitting the 22T Gear (21) as the photo, and fix the end of shaft with another Ball Bearing (20) and E Ring (22).
  • Page 473 15. Fix the 22T Gear (21) with the set screw (23). NOTE Fix the 22T Gear where the set screw (23) contacts on the inside step part (24) on the shaft. Contact them 5-261 K115sm5eJ.doc...
  • Page 474 16. Install the Web Motor Assy (25) with 2 M3x6 bind screws (26). 5-262 K115sm5eJ.doc...
  • Page 475 17. Install the Oil Pan (27) with 2 M4x6 tooth washer screw (28). (Tighten the screws with pressing the Oil Pan in the direction of arrow.) Press to this side Press to this side 5-263 K115sm5eJ.doc...
  • Page 476 18. Return the Brackets (13) on both sides and fix them with screws (14). NOTE 2 Brackets (13) are the same parts. 5-264 K115sm5eJ.doc...
  • Page 477 19. Install the Cover 2 Assy (29) with 4 M4x8 tooth washer screws (30). 5-265 K115sm5eJ.doc...
  • Page 478 20. Connect the connector (10) on the left. 21. Connect 2 connectors (9) which were disconnected at the former procedure 7. And connect 1 “added” connector (31). 5-266 K115sm5eJ.doc...
  • Page 479 22. Prepare the Web Unit (32) and Web Roll (33). 23. Install the large web roll (34) to its setting position. (See the following photo) NOTE Install the large web roll pulling out the Pin (35). 5-267 K115sm5eJ.doc...
  • Page 480 24. Install the small web roll (36) of Web Roll to its setting position similarly. NOTE Install the small web roll pulling out the Pin (37). 5-268 K115sm5eJ.doc...
  • Page 481 25. Retrieve the small web roll until the printed number (38) is hidden. 5-269 K115sm5eJ.doc...
  • Page 482 26. Install the Web Unit (32) with new Web to the KIP9000 with 4 M4x8 screws (39). NOTE Confirm there is no space between Web Unit and Cover 2 Assy. The driving gears are not engaged Is there is space. 5-270 K115sm5eJ.doc...
  • Page 483 27. Return both Cover 3 (7) and Cover 4 (5). 28. Return the Cover 5 (3) finally. 5-271 K115sm5eJ.doc...
  • Page 484 Chapter 6 Maintenance / Checking K115sm6e1.doc...
  • Page 485 Ask user about printer performance / image quality. Print internal test prints 1 & 3. Review Quality. Locate the “KIP 9000 PM Schedule” Form and check off each item completed. Replace noted items as this procedure progresses. Remove drum and place into supplied box.
  • Page 486 KIP 9000 - Maintenance Schedule - Please keep this document with the printer Serial Number - Denote when the maintenance / replacement is performed. Description / Item Part # Code Linear Feet X 1000 Corona Wire Kit (wires & pads)
  • Page 487 KIP 9000 - Maintenance Schedule - Please keep this document with the printer - Denote when the maintenance / replacement is performed. Description / Item Part # Code Linear Feet X 1000 1040 1120 1200 1280 1360 1440 1520 1600 Corona Wire Kit (wires &...
  • Page 488 Chapter 7 Troubleshooting Page 7. 1 Error Codes 7- 3 7. 1. 1 Door Open Errors 7- 3 7. 1. 2 Operator Call Errors 7- 4 7. 1. 3 Service Call Errors 7- 6 7. 2 Measures against Errors 7- 8 7.
  • Page 489 7. 3 Measures against Image Defects 7-25 7. 3. 1 Standard settings of image process items 7-25 7. 3. 2 Measures against each image defect 7-26 7. 3. 2. 1 Halftone is too light 7-26 7. 3. 2. 2 Halftone and solid black are too light 7-27 7.

  • Page 490: Error Codes

    7. 1 Error Codes 7. 1. 1 Door Open Errors KIP9000 will show the following Door Open Error when any door or unit is open or unlocked. The user can fix them. Error Error name Error condition Codes U-01 Top Roll Deck Open Top Roll Deck is open.

  • Page 491: Operator Call Errors

    7. 1. 2 Operator Call Errors KIP9000 will show the following Operator Call Error when it has any error that can be fixed by the user. Error Error name Error condition Codes J-01 Roll 1 Jam 1. Roll Set Sensor 1 Signal (RP_SET1) does not change from H to L within a decided time since the KIP9000 has started transporting the Roll 1 from the wait position.

  • Page 492: J-12" Separation Area Jam

    Error Error name Error condition Codes J-12 Separation Area Jam 1. Separation Sensor Signal (P_SEPR) is L when KIP9000 is turned on. 2. Separation Sensor Signal (P_SEPR) does not change from H to L within a decided time since the KIP9000 has started transporting the media from any of wait positions.

  • Page 493: E-06" Counter A/B Error

    7. 1. 3 Service Call Errors KIP9000 will show the following Service Call Error when it has any significant error which the service personnel only can fix. (User can not fit these errors.) Error Error name Error condition Codes E-01 Fuser Temperature 1.

  • Page 494: E-F0 Folder Error

    Error Error name Error condition Codes E-F0 Folder Error 1. Communication between KIP9000 and Folder is abnormal. 2. Folder has any error other than jam. E-Fb Flash ROM Error Writing to the Flash ROM is failed. K115sm7e1.doc...
  • Page 495 7. 2 Measures against Errors 7. 2. 1 Measures against Door Open Errors 7. 2. 1. 1 “U-01” Top Roll Deck Open Cause Order Checking matter Result Treatment Setting condition of Is the Top Roll Deck closed Close it firmly. Top Roll Deck firmly? Top Roll Deck...
  • Page 496 7. 2. 1. 5 “U-06” Toner Cover Open Cause Order Checking matter Result Treatment Setting condition of Is the Toner Cover closed firmly? Close it firmly. Toner Cover Toner Cover Switch Check the voltage at J202-3 on 1. Check if the harnesses between (DS5 &...
  • Page 497 7. 2. 2 Measures against Operator Call Errors 7. 2. 2. 1 “J-01” Roll 1 Jam Cause Order Checking matter Result Treatment Roll Set Sensor 1 Check the input signal from the 1. Check if the sensor harness has (PH1) Roll Set Sensor 1 (signal code 04) any abnormality.
  • Page 498 7. 2. 2. 3 “J-03” Roll 3 Jam Cause Order Checking matter Result Treatment Roll Set Sensor 3 Check the input signal from the 1. Check if the sensor harness has (PH3) Roll Set Sensor 3 (signal code 06) any abnormality. in the Input/Output Checking 2.
  • Page 499 7. 2. 2. 5 “J-05” Bypass Feeder Jam Cause Order Checking matter Result Treatment Bypass Feed Clutch Can the Bypass Feed Clutch 1. Check if the harness of clutch (MC7) (signal code : 98) be operated has any abnormality. properly in the Function Checking 2.
  • Page 500 7. 2. 2. 7 “J-12” Separation Area Jam Cause Order Checking matter Result Treatment Separation Sensor Check the input signal from the 1. Check if the sensor harness has (PH18) Separation Sensor (signal code any abnormality. 2E) in the Input/Output Checking 2.
  • Page 501 7. 2. 2. 8 “J-13” Fuser Entrance Jam Cause Order Checking matter Result Treatment Exit Sensor Check the input signal from the 1. Check if the sensor harness has (LS2) Exit Sensor (signal code 2F) in any abnormality. the Input/Output Checking Mode 2.
  • Page 502 7. 2. 2.10 Toner Empty Cause Order Checking matter Result Treatment Setting condition of Is the opening of Toner Cartridge Direct it downward. Toner Cartridge directed downward? Toner Supply Motor 1 Can the Toner Supply Motor 1 1. Check if the harness of motor (M7) (signal code : A7) be operated has any abnormality.
  • Page 503 7. 2. 3 Measures against Service Call Errors 7. 2. 3. 1 “E-01” Fuser Temperature Rising Error When “E-01” must not be detected when diagnosing the KIP9000, mask it in the Error Mask Mode. Its Mask Code is “00”. See [8.1.8 Error Mask Mode (Sub Mode 7)] on page 8-114 for the detail. Cause Order Checking matter...
  • Page 504 7. 2. 3. 2 “E-02” Fuser Over-heating Error When “E-02” must not be detected when diagnosing the KIP9000, mask it in the Error Mask Mode. Its Mask Code is “01”. See [8.1.8 Error Mask Mode (Sub Mode 7)] on page 8-114 for the detail. Cause Order Checking matter...
  • Page 505 7. 2. 3. 3 “E-05” Drum Motor Error When “E-05” must not be detected when diagnosing the KIP9000, mask it in the Error Mask Mode. Its Mask Code is “04”. See [8.1.8 Error Mask Mode (Sub Mode 7)] on page 8-114 for the detail. Cause Order Checking matter...
  • Page 506 7. 2. 3. 5 “E-07” Cutter Motor Error When “E-07” must not be detected when diagnosing the KIP9000, mask it in the Error Mask Mode. Its Mask Code is “07”. See [8.1.8 Error Mask Mode (Sub Mode 7)] on page 8-114 for the detail. Cause Order Checking matter...
  • Page 507 7. 2. 3. 6 “E-09” Web End Error Cause Order Checking matter Result Treatment Web Cleaner Clear the Web End Error in any of Measure the thickness of Web roll, Service Modes 5-9E to A0 at first. and input that value in the Service (See NOTE on the page 8-110 for Mode 5-A1.
  • Page 508 7. 2. 3. 8 “E-14” Fuser Motor Error When “E-14” must not be detected when diagnosing the KIP9000, mask it in the Error Mask Mode. Its Mask Code is “05”. See [8.1.8 Error Mask Mode (Sub Mode 7)] on page 8-114 for the detail. Cause Order Checking matter...
  • Page 509 7. 2. 3.11 “E-23” LED Head Cleaning Error When “E-23” must not be detected when diagnosing the KIP9000, mask it in the Error Mask Mode. Its Mask Code is “0b”. See [8.1.8 Error Mask Mode (Sub Mode 7)] on page 8-114 for the detail. Cause Order Checking matter...
  • Page 510 7. 2. 3.15 “E-30” Developer Disconnection Error Cause Order Checking matter Result Treatment Harness Is the connector J84 connected? Connect it. (Is another end of this cable connected to Main Control PCB?)) Main Control PCB Can the error be fixed by (PW11520) replacing the Main Control PCB? 7.
  • Page 511 Checking matter Result Treatment Toner Cartridge Is the KIP Toner Cartridge Install the new KIP Toner Cartridge. installed to KIP 9000, which has already been emptied? Main Control PCB Can the error be fixed by (PW11520) replacing the Main Control PCB? 7-24 K115sm7e1.doc...
  • Page 512 7. 3 Measures against Image Defects 7. 3. 1 Standard settings of image process items The following list shows standard values of voltage and current supplied to each unit that is related with image creation. When any image defect occurs, check if the following standard values are satisfied on each unit.
  • Page 513 7. 3. 2 Measures against each image defect 7. 3. 2. 1 Halftone is too light Cause Order Checking matter Result Treatment Dirt on LED Head Is the LED Head dirty? 1. Take cleaning for the LED Head pressing [EXP CLEAN] Key. 2.
  • Page 514 7. 3. 2. 2 Halftone and solid black are too light Cause Order Checking matter Result Treatment Turn off the KIP9000 in the Transfer defect seems to be middle of printing, draw out the the cause of this issue. Go Process Unit, and check the to the following 2.
  • Page 515 Cause Order Checking matter Result Treatment Development Bias Power Are the following voltages Adjust each output properly defect Supply supplied to the rollers in seeing the following pages. Developer? Developer Roller Developer Roller : Page 4-84 : -250 +/-3V Toner Sup. Roller Toner Sup.
  • Page 516 7. 3. 2. 3 Every image is too light Cause Order Checking matter Result Treatment Turn off the KIP9000 in the Transfer defect seems to be middle of printing, draw out the the cause of this issue. Go Process Unit, and check the to the following 2.
  • Page 517 Cause Order Checking matter Result Treatment Development Bias Power Are the following voltages Adjust each output properly defect Supply supplied to the rollers in seeing the following pages. Developer? Developer Roller Developer Roller : Page 4-84 : -250 +/-3V Toner Sup. Roller Toner Sup.
  • Page 518 7. 3. 2. 4 Uneven density between left and right Cause Order Checking matter Result Treatment Image Corona Is the Image Corona dirty? Clean each Corona Wire, Housing and Grid Plate. Replace the Corona Wire and Grid Plate if too dirty. Is the Corona Wire fitted into the Correct the height of Corona Wire as V shape groove of Corona...
  • Page 519 7. 3. 2. 6 Foggy thick black lines (from LE to TE) Cause Order Checking matter Result Treatment Image Corona Is the Image Corona dirty? Clean each Corona Wire, Housing and Grid Plate. Replace the Corona Wire and Grid Plate if too dirty. Is the Cleaning Pad correctly 1.
  • Page 520 7. 3. 2. 8 White lines (from LE to TE) Cause Order Checking matter Result Treatment Image Corona Is any foreign substance like Remove it. filament jointing the Grid Plate to Drum? Dirt of LED Head Is the LED Head dirty? 1.
  • Page 521 7. 3. 2.10 Dirt on the backside Cause Order Checking matter Result Treatment Toner Receiver under Is the Toner Receiver under the Remove the toner from the Toner Developer Roller Developer Roller fully filled with Receiver. Check if the inside of the toner? machine is dirty with the spilt toner as well.
  • Page 522 7. 3. 2.11 Weak fusing Cause Order Checking matter Result Treatment Printing media Is the Media Selector set correctly Set it correctly. according to the actual media type? Can the issue be fixed if a newly Advise the user to keep the media unpacked media is used? avoiding the humidity.
  • Page 523 7. 3. 2.12 Leading margin defect (No leading margin) Cause Order Checking matter Result Treatment Setting value of Check the setting values on the Change the setting value properly. leading margin following setting items of Adjustment Modes 0 and 1. 4-bb : Image placement (For 2nd and later...
  • Page 524 7. 3. 2.14 Unsharpened image (Focus defect) Cause Order Checking matter Result Treatment Dirt of LED Head Is the LED Head dirty? 1. Take cleaning for the LED Head pressing [EXP CLEAN] Key. 2. Check if the Pad Ass’y 2 of LED Head is dirty or its life is ended.
  • Page 525 7. 3. 2.16 Completely white Cause Order Checking matter Result Treatment Position of Developer Is the Cam of pressurizing Check if the Developer Positioning Unit against Drum mechanism placed at the correct Motor or the pressurizing position for pressing the mechanism has any abnormality.
  • Page 526 Chapter 8 Service Mode Page 8. 1 Service Mode 8- 5 8. 1. 1 General operation of Service Mode 8- 5 8. 1. 1. 1 Entering Service Mode 8- 5 8. 1. 1. 2 Selecting each Sub Mode 8- 8 8.
  • Page 527 (13) Fusing temperature (No.10 to 12) 8-58 (14) LED strobe time (No.13) 8-58 (15) Pre-Transfer LED / Separation Corona OFF timing (PPC) (No.15) 8-59 (16) Pre-Transfer LED ON / OFF (No.16) 8-60 (17) Separation Lamp ON / OFF (PPC) (No.17) 8-60 (18) Separation Lamp ON / OFF (Tracing) (No.18) 8-61...
  • Page 528 (12) Length of image for Roll 3 (No.84 to 8F) 8-107 (13) Length of image for Roll 4 (No.90 to 9b) 8-108 (14) TE margin for cut sheet media (Large) (No.9C) 8-109 (15) Web operation mode (No.9d) 8-110 (16) Web operation time (No.9E to A0) 8-110 (17) Web thickness (No.A1) 8-110...
  • Page 529 8-202 8. 2.15 User Mode F0 to Fb (Fold settings for Bay Folder) 8-205 8. 3 KIP Diagnostics (Program used on field service) 8-212 8. 3. 1 Having a communication between KIP Diagnostics on service laptop (PC) and KIP9000 8-212 8.

  • Page 530: Service Mode

    8. 1 Service Mode 8. 1. 1 General operation of Service Mode 8. 1. 1. 1 Entering Service Mode 1. Press and hold the [ * ] key on the Operation Panel, and press switches in the order as [ ], [ ] and [ ] to enter the Service Mode.
  • Page 531 3. Press the [MENU] key once to move to “LED all lighting mode”. PAPER DECK EXIT 1 2 3 4 SELECT COPY DENSITY MENU ENTER ONLINE WIRE CLEAN EXP- CLEAN When in “LED all lighting mode”; • All LED and segments on the Operation Panel light. PAPER DECK EXIT 1 2 3 4...
  • Page 532 4. Press the [MENU] key once again to finish “LED all lighting mode”, and it becomes possible to select each Sub Mode. (The Input / Output Checking Mode (Sub Mode No.1) is selected firstly at this time.) PAPER DECK EXIT 1 2 3 4 SELECT COPY DENSITY...

  • Page 533: Selecting Each Sub Mode

    8. 1. 1. 2 Selecting each Sub Mode Service Mode consists of 10 Sub Modes, and each of them has its own Sub Mode Number. It is possible to access the necessary Sub Mode by indicating the concerning Sub Mode Number on the Status Display.

  • Page 534: Cancelling The Service Mode

    8. 1. 1. 3 Cancelling the Service Mode Press the [ ONLINE ] Key to cancel the Service Mode. The LED of [ MENU ] Key is put out when cancelled. MENU ENTER ONLINE MENU ENTER ONLINE NOTE Make sure to turn on/off the KIP9000 whenever the Service Mode is cancelled. K115sm8e1.doc...

  • Page 535: Input Output Checking Mode (Sub Mode 1)

    8. 1. 2 Input Output Checking Mode (Sub Mode 1) 8. 1. 2. 1 Function The status of input/output signals can be observed while operating the machine as usual Refer to [8.1.2.4 Signal Code List] on and after the page 8-12 for the Signal Codes, the Signal Names and the Description of each Signal.

  • Page 536: Operation

    8. 1. 2. 3 Operation 1. Enter the Service Mode, and indicate the Sub Mode Number “1” on the 1st digit from the left pressing the [ MENU ] Key. Sub Mode Number of Input / Output Checking Mode MENU ENTER ONLINE 2.

  • Page 537: Signal Code List

    8. 1. 2. 4 Signal code list Code Signal name IC Port Connector Signal Condition I / O F.C. UPPER_SW U015 P30 J202-1 Top Rear Cover Signal Top Rear Cover Switch (DS6) detects door open when “H”. RIGHT_SW1 U015 P31 J202-2 Right Side Door Signal Right Side Door Switch (DS7)
  • Page 538 Code Signal name IC Port Connector Signal Condition I / O F.C. PFMTR_LD U015 P70 J204-9 Paper Feed Motor Paper Feed Motor (M2) is Synchronous Signal rotating when “L”. TNR_BTL U015 P71 J204-10 Toner Remaining Level Toner Remaining Level Detection Signal Sensor detects “No toner”...
  • Page 539 Code Signal name IC Port Connector Signal Condition I / O F.C. DEV_ST U015 P54 J205-9 Developer Setting Status Connector of Developer is Signal disconnected. ------- U015 P55 J205-10 WEB_END U015 P56 J205-11 Web Sensor Signal Web Sensor detects “Web End”...
  • Page 540 Code Signal name IC Port Connector Signal Condition I / O F.C. DISP_DT10 U016 P62 J214-11 Indication Data Signal 10 DISP_DT11 U016 P63 J214-12 Indication Data Signal 11 DISP_DT12 U016 P64 J214-13 Indication Data Signal 12 DISP_DT13 U016 P65 J214-14 Indication Data Signal 13 DISP_DT14 U016 P66...
  • Page 541 Code Signal name IC Port Connector Signal Condition I / O F.C. DRMTR_DIR U017 P32 J208-A34 Drum Motor Reverse Control Drum Motor (M1) rotates Signal oppositely when “H”. EXBLW3 U017 P33 J208-B34 Exhaust Fan 3 Control Exhaust Fan 3 (BL17, 18 & Signal 19) rotate when “H”.
  • Page 542 Code Signal name IC Port Connector Signal Condition I / O F.C. RP_FEED U017 P61 J208-B2 Paper Feed Clutch Control Paper Feed Clutch (MC6) is Signal ON when “H”. RP_CL U017 P62 J208-A3 Roll Paper Feed Clutch 1 Roll Paper Feed Clutch 1 Control Signal (MC1) is ON when “H”.
  • Page 543 Code Signal name IC Port Connector Signal Condition I / O F.C. DISP_DT0 U016 P30 J207-17 Indication Data Signal 0 DISP_DT1 U016 P31 J207-18 Indication Data Signal 1 DISP_DT2 U016 P32 J207-19 Indication Data Signal 2 DISP_DT3 U016 P33 J207-20 Indication Data Signal 3 DISP_DT4 U016 P34...
  • Page 544 Code Signal name IC Port Connector Signal Condition I / O F.C. (KCNT_ST) U015 P J216-8 Kay Card Status Signal “L” when the card is set. ------- U015 P J216-7 ------- U015 P J216-6 ------- U015 P J216-5 ------- U015 P J216-4 ------- U015 P...
  • Page 545 8. 1. 3 Data Monitoring Mode (Sub Mode 2) 8. 1. 3. 1 Function It is possible to monitor several data as the input voltage to the DC Controller PCB or the temperature of Fuser. 8. 1. 3. 2 Indication on the Operation panel The 1st digit from the left indicates “2”...

  • Page 546: Operation

    8. 1. 3. 2 Operation 1. Enter the Service Mode, and indicate the Sub Mode Number “2” on the 1st digit from the left pressing the [ MENU ] Key. Sub Mode Number of Data Monitoring Mode MENU ENTER ONLINE 2.

  • Page 547: Description Of Each Data

    8. 1. 3. 4 Description of each Data (1) Fuser Temperature (00) Actual temperature of Fuser is indicated on 4th, 5th and 6th digits. The unit is “ C”. Dot of the 6th digit lights when the Fuser Lamp 1 is ON, and that of 5th one lights when the Fuser Lamp 2 is ON.

  • Page 548: Input From Paper Size Sensors (01 To 04)

    (2) Input from Paper Size Sensors (01 to 04) Input from Paper Size Sensors (for roll media) is shown by the hexadecimal data. MENU ENTER ONLINE Hexadecimal data To check the input situation, convert the hexadecimal into binary. Each of 8 digits of binary data is related with size sensors as follows.
  • Page 549 (1) Roll 2, 3 & 4 PH5 is arranged at the most inside to detect B3 and 15” paper. PH11 Center of the paper (36") PH10 (A0 & 34") RP_SET2, 3 and 4 (B1 & 30") (A3, 11" & 12") (B3 &...
  • Page 550 (2) Roll 1 PH5 is arranged between PH10 and PH11 to detect 900mm, 891mm and 880mm paper. PH41 is arranged between RP_SET1 and PH6 to detect B3 and 15” paper. (36") Center of the paper PH10 (A0 & 34") RP_SET1 (B1 &...

  • Page 551: Input From Cut Sheet Size Sensors (05)

    (3) Input from Cut Sheet Size Sensors (05) Input from Cut Sheet Size Sensors is shown by the hexadecimal data. MENU ENTER ONLINE Hexadecimal data To check the input situation, convert the hexadecimal into binary. Each of 8 digits of binary data is related with size sensors as follows.
  • Page 552 Center of PH34 PH36 the paper (18") (A2S & 24") PH31 (11") PH32 PH33 PH35 PH37 (A4S & 12") (A3S & 17") (22") (A1S, 30", 34 & 36") Paper width Cut Sheet Size Sensors Hexadecimal PH37 PH36 PH35 PH34 PH33 PH32 PH31 36”/841mm...

  • Page 553: Roll Remaining Level (06 To 09)

    (4) Roll remaining level (06 to 09) The volume of roll media remaining in each Roll Deck is shown by 8 levels. 4th, 5th and 6th digits show the remaining level “X/8”. (8/8 means the maximum level, and 1/8 means the minimum.) MENU ENTER ONLINE Remaining level (Example : 1/8)

  • Page 554: Drum Surface Potential (0C)

    (7) Drum Surface Potential (0C) The Potential of Drum surface detected by the Surface Potential Sensor (SPS) is indicated. The unit is “V”. MENU ENTER ONLINE Drum Surface Potential (Example : 840V) (8) Input Voltage from SPS (0d) The input voltage from the Surface Potential Sensor (SPS) is indicated. The unit is “V”. MENU ENTER ONLINE Input voltage (Example : 4.10V)

  • Page 555: Toner Remaining Level Data (10 To 12)

    (10) Toner remaining level Data (10 to 12) The Toner Remaining Level in the Toner Cartridge is shown by 8 levels. The 4th digit shows the remaining level “X/8”. (Only “X” is indicated.) And the input from Toner Remaining Level Sensors (8 pieces) is shown by hexadecimal data on 5th and 6th digits, which can be used to check if the Toner Remaining Level Sensors are functioning correctly.
  • Page 556 NOTE KIP9000 checks the Toner Remaining Level in the following 3 situations. 1. Right after turning on. 2. After opening/closing the Toner Cover. 3. Every 30m print Checking is performed 3 times keeping an interval between checks. (Toner Cartridge continues to rotate during the interval.) Motor ON 1st checking Interval...

  • Page 557: Function Checking Mode (Sub Mode 3)

    8. 1. 4 Function Checking Mode (Sub Mode 3) 8. 1. 4. 1 Function An individual electric component can be operated singularly to check its operation in the Function Checking Mode. Refer to [8.1.2.4 Signal code list] on and after the page 8-12 for the Signal Code and its target component.

  • Page 558: Operation

    8. 1. 4. 3 Operation 1. Enter the Service Mode, and indicate the Sub Mode Number “3” on the 1st digit from the left pressing the [ MENU ] Key. Sub Mode Number of Function Checking Mode MENU ENTER ONLINE 2.
  • Page 559 3. Press the [ ENTER ] Key to operate the selected component. Hyphens on 5th and 6th digits flash when the component is operating. MENU ENTER ONLINE MENU ENTER ONLINE Hyphens flash when the Separation Lamp is lighting. 4. Press the [ ENTER ] Key again to stop the operation. Hyphens on 5th and 6th digits stop flashing.

  • Page 560: Adjustment Mode 0 (Sub Mode 4)

    8. 1. 5 Adjustment Mode 0 (Sub Mode 4) 8. 1. 5. 1 Function Several fundamental printer settings/parameters can be changed. Refer to [8.1.5.4 Setting item list] on and after the page 8-39 for the brief information of the setting items.

  • Page 561: Operation

    8. 1. 5. 3 Operation 1. Enter the Service Mode, and indicate the Sub Mode Number “4” on the 1st digit from the left pressing the [ MENU ] Key. Sub Mode Number of Adjustment Mode 0 MENU ENTER ONLINE 2.
  • Page 562 3. Press the [ENTER] Key after selecting the necessary Item Number. The setting value on 4th, 5th and 6th digits flashes and becomes changeable. MENU ENTER ONLINE MENU ENTER ONLINE The setting value flashes and becomes changeable. 4. Change the setting value pressing [ ] Key (increment) and [ ] Key (decrement).
  • Page 563 5. Press the [ ENTER ] Key to decide the new setting value. The setting value stops flashing when decided. MENU ENTER ONLINE MENU ENTER ONLINE NOTE If you press the [ ONLINE ] Key before deciding the new value, the former setting value is recovered.

  • Page 564: Setting Item List

    8. 1. 5. 4 Setting item list Item Setting target Default Special Adjustable Unit of Refer value setting Range setting value page; Metric or inch A0 or 36 8-46 Operation of Interface 0 to 2 8-46 Maximum cut length 6 or 24 8-47 Trailing margin of long print On or OFF...
  • Page 565 Item Setting target Default Special Adjustable Unit of Refer value setting Range setting value page; Fuser Motor speed -1.0% to 1.0% 0.05% 8-65 (Bypass feed / Tracing / Large size) Fuser Motor speed -1.0% to 1.0% 0.05% 8-65 (Bypass feed / Tracing / Medium size) Fuser Motor speed -1.0% to 1.0% 0.05%...
  • Page 566 Item Setting target Default Special Adjustable Unit of Refer value setting Range setting value page; Fuser Motor speed -1.0% to 1.0% 0.05% 8-66 (Roll 1 / PPC / Medium size) Fuser Motor speed -1.0% to 1.0% 0.05% 8-66 (Roll 1 / PPC / Small size) Fuser Motor speed -1.0% to 1.0% 0.05%...
  • Page 567 Item Setting target Default Special Adjustable Unit of Refer value setting Range setting value page; Fuser Motor speed -1.0% to 1.0% 0.05% 8-67 (Roll 2 / PPC / Large size / 21 to 22m) Fuser Motor speed -1.0% to 1.0% 0.05% 8-67 (Roll 2 / PPC / Large size / 22 to 23m)
  • Page 568 Item Setting target Default Special Adjustable Unit of Refer value setting Range setting value page; Fuser Motor speed -1.0% to 1.0% 0.05% 8-68 (Roll 3 / PPC / Large size / 19 to 20m) Fuser Motor speed -1.0% to 1.0% 0.05% 8-68 (Roll 3 / PPC / Large size / 20 to 21m)
  • Page 569 Item Setting target Default Special Adjustable Unit of Refer value setting Range setting value page; Fuser Motor speed -1.0% to 1.0% 0.05% 8-69 (Roll 4 / PPC / Large size / 18 to 19m) Fuser Motor speed -1.0% to 1.0% 0.05% 8-69 (Roll 4 / PPC / Large size / 19 to 20m)
  • Page 570 Item Setting target Default Special Adjustable Unit of Refer value setting Range setting value page; Image Enhancement Level (applied when IE 0 to 7 8-80 Mode is OFF, or IE Category is “A1” in any IE Mode ) Image Enhancement Level (applied to IE 0 to 7 8-82 Category A2 when IE Mode is “low”)

  • Page 571: Description Of Each Setting Item

    8. 1. 5. 5 Description of each setting item (1) Metric or Inch (No.00) Either metric (ISO) or inch (ANSI) can be selected as the print format. Selectable setting values are “A0” and “36”. Setting value Description Metric (ISO) Inch (ANSI) (2) Operation of Interface (No.01) It is possible to specify how the Interface operates.

  • Page 572: Maximum Cut Length (No.02)

    (3) Maximum cut length (No.02) Maximum cut length can be set to either 6m or 24m. Setting value Description 6m is the maximum cut length. 24m is the maximum cut length. (4) Trailing margin of long print (No.03) If necessary, a trailing margin of 260mm long can be added to 3m or longer print. Setting value Description If print is 3m or longer, a trailing margin of 260mm long is added.

  • Page 573: Special Paper Size (No.04)

    (5) Special paper size (No.04) The size sensor of Roll Deck 1 located 2nd from the outside is available to detect special paper sizes (widths) 900mm, 891mm and 880mm. When a special size is detected, KIP9000 recognizes its size as any of 900mm, 891mm or 880mm according to the selection in this No.04. (If No.04 is set to “880”, special size roll is recognized as 880mm wide even if it is 891mm or 900mm.) Setting value...

  • Page 574: Counting Unit Of Counter A (No.05)

    (6) Counting unit of Counter A (No.05) Counting unit of the Counter A (Upper Counter) can be specified. Selectable setting values rely on “metric / inch setting (Item No.00)”. • Selectable setting values in No. 05 are 0, 1, 2 and 3 if No.00 is set to “metric”. •...

  • Page 575: Operation Of Dehumidify Heater (No.07)

    (8) Operation of Dehumidify Heater (No.07) It is possible to decide when the Dehumidify Heater should operate. Setting value Description Dehumidify Heater operates only when the Power Switch is OFF. Dehumidify Heater operates always. (9) Cut length of user Test Print (No.08) Cut length of test print that is performed from the User Mode can be specified.
  • Page 576 (10) Standard / Special Setting Value Changing Modes (No.09 to 0b) Some setting items of Adjustment Modes 0/1 are available to have dual setting values as “Standard Setting Value” and “Special Setting Value”. (Such items are called “dual value items”) The modes No.
  • Page 577 getting a proper print result. So he needs to have 2 different fuser temperature settings for getting satisfactory result in both cases, one for recommended paper (Standard Setting Value) and another for special paper (Special Setting Value). NOTE (1) It is not recommended to change the “Standard Setting Value” as it is the best factory setting, but it is possible to do it if necessary.
  • Page 578 [Operation] The “Special Setting Value” of Fuser Temperature for PPC (item No.10) is to be change in this example. 1. As the dual value item concerned with “plain paper” is to be changed, select the item No.09 in the Adjustment Mode 0.. MENU ENTER ONLINE NOTE...
  • Page 579 3. As the “Special Setting Value” is to be changed, select the setting value “1” pressing [ ] Key and [ ] Key. Setting value Description Select this when “Standard Setting Value” is to be changed. Select this when “Special Setting Value” is to be changed. MENU ENTER ONLINE MENU...
  • Page 580 5. Pressing [ ] Key and [ ] Key, indicate your required Item Number of any dual value item. Example : As the “Special Setting Value” of [Fuser temperature (PPC)] is to be changed, indicate its Item Number “10”. MENU ENTER ONLINE MENU ENTER ONLINE...
  • Page 581 7. Change the “Special Setting Value” pressing [ ] Key and [ ] Key. MENU ENTER ONLINE MENU ENTER ONLINE 8. Press the [ ENTER ] Key to decide the “Special Setting Value”. The setting value stops flashing when decided. MENU ENTER ONLINE MENU...

  • Page 582: Cold Sleep On/Off (No.0C)

    (11) Cold Sleep ON/OFF (No.0C) Cold Sleep mode can be set to ON or OFF. (This selection can be done only in the Service Mode.) Setting value Description Cold Sleep works. Cold Sleep does not work. NOTE Cold Sleep timer can be specified in the User Mode 4. See [8.2.4 User Mode 4 (Cold Sleep Mode timer setting)] on page 8-168.

  • Page 583: Fusing Temperature (No.10 To 12)

    (13) Fusing temperature (No.10 to 12) Fusing temperature for each media type can be changed. The setting unit is “degree centigrade”, and the adjustment range is from 150 to 190. Item No. Description Fusing temperature applied when you print with a plain paper. Fusing temperature applied when you print with a tracing paper.
  • Page 584 (15) Pre-Transfer LED / Separation Corona OFF timing (PPC) (No.15) The OFF timing of Separation Corona and Pre-Transfer LED can be decided. This setting is applied when printed with a plain paper. There are 2 selectable settings. Setting value Description Both Separation Corona and Pre-Transfer LED turn OFF normally.

  • Page 585: Pre-Transfer Led On / Off (No.16)

    (16) Pre-Transfer LED ON / OFF (No.16) It is possible to decide whether or not the Pre-Transfer LED turns ON. There are 2 selectable settings. Setting value Description Pre-Transfer LED does not turn ON during the print cycle. Pre-Transfer LED turns ON during the print cycle. Pre-Transfer LED (17) Separation Lamp ON / OFF (PPC) (No.17) It is possible to decide whether or not the Separation Lamp lights.

  • Page 586: Separation Lamp On / Off (Tracing) (No.18)

    (18) Separation Lamp ON / OFF (Tracing) (No.18) It is possible to decide whether or not the Separation Lamp lights. This setting is applied when a tracing paper is used. There are 2 selectable settings. Setting value Description Separation Lamp does not light during the print cycle. Separation Lamp lights during the print cycle.

  • Page 587: Current Setting For The Image Corona Wire (No.1A)

    (19) Developer Bias (applied when Auto Density Control is set to OFF) (No.19) It is possible to adjust the Developer Bias supplied to the Developer Roller. The Bias specified here is directly applied when the Auto Density Control is set to OFF. The setting unit is hexadecimal, and the setting range is from 000 to 0FF.

  • Page 588: Current Setting For The Grid Plate (Applied When Auto Sp Control Is Set To Off) (No.1B)

    (21) Current setting for the Grid Plate (applied when Auto SP Control is set to OFF) (No.1b) Intensity of current that flows on the Grid Plate can be adjusted. The current specified here is directly applied when the Auto SP Control is set to OFF. The setting unit is hexadecimal, and the setting range is from 000 to 500.

  • Page 589: Separation Corona Dc Component (No.1F To 21)

    (23) Separation Corona DC component (No.1F to 21) DC component supplied to the Separation Corona can be adjusted. The setting unit is hexadecimal, and the setting range is from 000 to 500. If the value is increased, more negative electric charges will be provided from the Separation Corona.

  • Page 590: Fuser Motor Speed (Bypass Feed) (No.27 To 32)

    (25) Fuser Motor Speed (Bypass feed) (No.27 to 32) The speed of Fuser Motor can be adjusted. This setting is applied when the print media is fed from the Bypass Feeder. The adjustment unit is “0.05%”, and the adjustment range is from -1.0% to +1.0%.

  • Page 591: Fuser Motor Speed (Roll 1) (No.33 To 54)

    (26) Fuser Motor Speed (Roll 1) (No.33 to 54) The speed of Fuser Motor can be adjusted. This setting is applied when the print media is fed from the Roll Deck 1. The adjustment unit is “0.05%”, and the adjustment range is from -1.0% to +1.0%.

  • Page 592: Fuser Motor Speed (Roll 2) (No.55 To 76)

    (27) Fuser Motor Speed (Roll 2) (No.55 to 76) The speed of Fuser Motor can be adjusted. This setting is applied when the print media is fed from the Roll Deck 2. The adjustment unit is “0.05%”, and the adjustment range is from -1.0% to +1.0%.

  • Page 593: Fuser Motor Speed (Roll 3) (No.77 To 98)

    (28) Fuser Motor Speed (Roll 3) (No.77 to 98) The speed of Fuser Motor can be adjusted. This setting is applied when the print media is fed from the Roll Deck 3. The adjustment unit is “0.05%”, and the adjustment range is from -1.0% to +1.0%.

  • Page 594: Fuser Motor Speed (Roll 4) (No.99 To Ba)

    (29) Fuser Motor Speed (Roll 4) (No.99 to bA) The speed of Fuser Motor can be adjusted. This setting is applied when the print media is fed from the Roll Deck 4. The adjustment unit is “0.05%”, and the adjustment range is from -1.0% to +1.0%.

  • Page 595: Image Placement (For 2Nd And Later Prints) (No.bb)

    (30) Image placement (For 2nd and later prints) (No.bb) The vertical position of print image on the media can be adjusted. This setting is applied to the 2nd and later prints in multiple printing. The setting unit is 0.1mm, and the setting range is from 0 to 100 (0 to 10.0mm).
  • Page 596 (32) Roll Paper Feed Clutches (MC1 to MC4) and Bypass Feed Clutch (MC7) ON timing (No.bd) It is possible to adjust when the Roll Paper Feed Clutches 1, 2, 3 and 4 (MC1 to MC4) and the Bypass Feed Clutch (MC7) should operate. The setting unit is 1 millisecond, and the setting range is from 1 to 20 milliseconds.

  • Page 597: Paper Gate Brake (Mc10) On Timing (No.be)

    (33) Paper Gate Brake (MC10) ON timing (No.bE) It is possible to adjust when the Paper Gate Brake (MC10) should operate. The setting unit is 1 millisecond, and the setting range is from 1 to 20 milliseconds. The ON timing of Paper Gate Brake (MC10) can be decided taking the OFF timing of Paper Gate Clutch (MC5) as the standard.

  • Page 598: Sub Separation Blower On / Off (No. Bf To C1)

    (34) Sub Separation Blower ON / OFF (No. BF to C1) Whether or not the Sub Separation Blower operates can be decided. Setting value Description Sub Separation Blower does not operate during the print cycle. Sub Separation Blower operates during the print cycle. Each Item No.

  • Page 599: Te Margin Compensation (No. C2 To C5)

    (35) TE Margin Compensation (No. C2 to C5) It is possible to select any compensation level which avoids the variation of TE margin caused by the variation of roll thickness. Selectable setting values are 0, 1, 2 and 3. Setting value (Compensation level Description (length of added TE margin) of TE margin) Unit : mm...
  • Page 600 The thickness of roll media is divided into 8 roll thickness levels as “8/8” to “1/8” (level is detected by the Paper Feed Clock Sensor.). 8/8 is the thickest (new roll media) and 1/8 is the narrowest (near to empty). •...

  • Page 601: Separation Lamp On / Off (Film) (No.c6)

    (36) Separation Lamp ON / OFF (Film) (No.C6) It is possible to decide whether or not the Separation Lamp lights. This setting is applied when a film is used. There are 2 selectable settings. Setting value Description Separation Lamp does not light during the print cycle. Separation Lamp lights during the print cycle.

  • Page 602: Image Enhancement Mode Selection (No.c7)

    (37) Image Enhancement Mode Selection (No.C7) The level of Image Enhancement can be selected. The printed image is more enhanced (become darker) when selecting a larger level. Setting value Description (Image Enhancement Mode) Image is not enhanced (Image Enhancement is OFF) Image is enhanced with “low”...
  • Page 603 (39) Pre-Transfer LED / Separation Corona OFF timing (Film) (No.C9) The OFF timing of Separation Corona and Pre-Transfer LED can be decided. This setting is applied when printed with a film. There are 2 selectable settings. Setting value Description Both Separation Corona and Pre-Transfer LED turn OFF normally. When plain paper is used, both Separation Corona and Pre-Transfer LED turn OFF 0.12 seconds earlier than the normal timing.

  • Page 604: Image Enhancement Level For Single Pixel (No.cd)

    (40) Image Enhancement Level for single pixel (No.CD) An isolated single pixel can be enhanced by Image Enhancement Levels (IE Levels). Selectable IE Levels are 0 to 7. Specifying a larger IE Level makes the single pixel darker. Setting value Description (IE Level) Isolated single pixel is not enhanced.

  • Page 605: Image Enhancement Level (No. Ce) (Applied When Ie Mode Is Off, Or Ie Category Is "A1" In Any Ie Mode)

    (41) Image Enhancement Level (No. CE) (applied when IE Mode is OFF, or IE Category is “A1” in any IE Mode) It is possible to select an Image Enhancement Level (IE Level) that makes enhancement commonly to all the images (pixels) belonging to the following conditions. •...
  • Page 606 Reference When the Image Enhancement is activated on the item No. 8044, the KIP9000 categorizes every single pixel of print data into any of 10 IE Categories depending on its “visual appeal power”. 2 factors concern for the categorization, such as “isolate level” and “existence of nearby dot”. •...
  • Page 607 (42) Image Enhancement Level (No. CF to d7) (applied when IE Mode is “low”) Items from CF to d7 specify any of 8 IE Level to each 9 IE Categories (A2 to A5, and B1 to B5) respectively. These settings are applies when the IE Mode is set to “low” in the Item No.C7. All the images (pixels) belonging to a certain Image Enhancement Category is equally enhanced by the Image Enhancement Level specified to this category.
  • Page 608 (43) Image Enhancement Level (No. d8 to E0) (applied when IE Mode is “medium”) Items from d8 to E0 specify any of 8 IE Level to each 9 IE Categories (A2 to A5, and B1 to B5) respectively. These settings are applies when the IE Mode is set to “medium” in the Item No.C7. All the images (pixels) belonging to a certain Image Enhancement Category is equally enhanced by the Image Enhancement Level specified to this category.
  • Page 609 (44) Image Enhancement Level (No. E1 to E9) (applied when IE Mode is “high”) Items from E1 to E9 specify any of 8 IE Level to each 9 IE Categories (A2 to A5, and B1 to B5) respectively. These settings are applies when the IE Mode is set to “high” in the Item No.C7. All the images (pixels) belonging to a certain Image Enhancement Category is equally enhanced by the Image Enhancement Level specified to this category.

  • Page 610: Adjustment Mode 1 (Sub Mode 5)

    8. 1. 6 Adjustment Mode 1 (Sub Mode 5) 8. 1. 6. 1 Function Several fundamental printer settings/parameters can be changed. Refer to [8.1.6.4 Setting item list] on and after the page 8-89 for the brief information of the setting items.

  • Page 611: Operation

    8. 1. 5. 3 Operation 1. Enter the Service Mode, and indicate the Sub Mode Number “5” on the 1st digit from the left pressing the [ MENU ] Key. Sub Mode Number of Adjustment Mode 1 MENU ENTER ONLINE 2.
  • Page 612 3. Press the [ENTER] Key after selecting the necessary Item Number. The setting value on 4th, 5th and 6th digits flashes and becomes changeable. MENU ENTER ONLINE MENU ENTER ONLINE The setting value flashes. 4. Change the setting value pressing [ ] Key (increment) and [ ] Key (decrement).
  • Page 613 5. Press the [ ENTER ] Key to decide the new setting value. The setting value stops flashing when decided. MENU ENTER ONLINE MENU ENTER ONLINE NOTE If you press the [ ONLINE ] Key before deciding the new value, the former setting value is recovered.
  • Page 614 8. 1. 5. 4 Setting item list Item Setting target Default Special Adjustable Unit of Refer value setting Range setting value page; Image placement for cut sheet media 0 to 200 0.1mm 8-96 (PPC / Large size) Image placement for cut sheet media 0 to 200 0.1mm 8-96...
  • Page 615 Item Setting target Default Special Adjustable Unit of Refer value setting Range setting value page; Image placement for Roll 2 0 to 200 0.1mm 8-98 (PPC / Large size) Image placement for Roll 2 0 to 200 0.1mm 8-98 (PPC / Medium size) Image placement for Roll 2 0 to 200 0.1mm...
  • Page 616 Item Setting target Default Special Adjustable Unit of Refer value setting Range setting value page; Image placement for Roll 4 0 to 200 0.1mm 8-100 (PPC / Large size) Image placement for Roll 4 0 to 200 0.1mm 8-100 (PPC / Medium size) Image placement for Roll 4 0 to 200 0.1mm...
  • Page 617 Item Setting target Default Special Adjustable Unit of Refer value setting Range setting value page; TE margin for Roll 2 0 to 200 0.1mm 8-102 (PPC / Large size) TE margin for Roll 2 0 to 200 0.1mm 8-102 (PPC / Medium size) TE margin for Roll 2 0 to 200 0.1mm...
  • Page 618 Item Setting target Default Special Adjustable Unit of Refer value setting Range setting value page; TE margin for Roll 4 0 to 200 0.1mm 8-104 (PPC / Large size) TE margin for Roll 4 0 to 200 0.1mm 8-104 (PPC / Medium size) TE margin for Roll 4 0 to 200 0.1mm...
  • Page 619 Item Setting target Default Special Adjustable Unit of Refer value setting Range setting value page; Length of image for Roll 2 0.00 -1.00 to 1.00 0.01% 8-106 (PPC / Large size) Length of image for Roll 2 0.00 -1.00 to 1.00 0.01% 8-106 (PPC / Medium size)
  • Page 620 Item Setting target Default Special Adjustable Unit of Refer value setting Range setting value page; Length of image for Roll 4 0.00 -1.00 to 1.00 0.01% 8-108 (PPC / Large size) Length of image for Roll 4 0.00 -1.00 to 1.00 0.01% 8-108 (PPC / Medium size)

  • Page 621: Image Placement For Cut Sheet Media (No.00 To 0B)

    8. 1. 6. 5 Description of each setting item (1) Image placement for cut sheet media (No.00 to 0b) It is possible to adjust the vertical placement of print image on the media. These settings are applied when printed with a cut sheet media. The setting unit is 0.1mm, and the setting range is from 0 to 200 (0mm to 20.0mm).

  • Page 622: Image Placement For Roll 1 (No.0C To 17)

    (2) Image placement for Roll 1 (No.0C to 17) It is possible to adjust the vertical placement of print image on the media. These settings are applied when printed with Roll 1. The setting unit is 0.1mm, and the setting range is from 0 to 200 (0mm to 20.0mm).

  • Page 623: Image Placement For Roll 2 (No.18 To 23)

    (3) Image placement for Roll 2 (No.18 to 23) It is possible to adjust the vertical placement of print image on the media. These settings are applied when printed with Roll 2. The setting unit is 0.1mm, and the setting range is from 0 to 200 (0mm to 20.0mm).

  • Page 624: Image Placement For Roll 3 (No.24 To 2F)

    (4) Image placement for Roll 3 (No.24 to 2F) It is possible to adjust the vertical placement of print image on the media. These settings are applied when printed with Roll 3. The setting unit is 0.1mm, and the setting range is from 0 to 200 (0mm to 20.0mm).

  • Page 625: Image Placement For Roll 4 (No.30 To 3B)

    (5) Image placement for Roll 4 (No.30 to 3b) It is possible to adjust the vertical placement of print image on the media. These settings are applied when printed with Roll 4. The setting unit is 0.1mm, and the setting range is from 0 to 200 (0mm to 20.0mm).

  • Page 626: Te Margin For Roll 1 (No.3C To 47)

    (6) TE margin for Roll 1 (No.3C to 47) It is possible to adjust the length of TE margin. These settings are applied when printed with Roll 1. The setting unit is 0.1mm, and the setting range is from 0 to 200 (0mm to 20.0mm). Increment of the value provides more TE margin.

  • Page 627: Te Margin For Roll 2 (No.48 To 53)

    (7) TE margin for Roll 2 (No.48 to 53) It is possible to adjust the length of TE margin. These settings are applied when printed with Roll 2. The setting unit is 0.1mm, and the setting range is from 0 to 200 (0mm to 20.0mm). Increment of the value provides more TE margin.

  • Page 628: Te Margin For Roll 3 (No.54 To 5F)

    (8) TE margin for Roll 3 (No.54 to 5F) It is possible to adjust the length of TE margin. These settings are applied when printed with Roll 3. The setting unit is 0.1mm, and the setting range is from 0 to 200 (0mm to 20.0mm). Increment of the value provides more TE margin.

  • Page 629: Te Margin For Roll 4 (No.60 To 6B)

    (9) TE margin for Roll 4 (No.60 to 6b) It is possible to adjust the length of TE margin. These settings are applied when printed with Roll 4. The setting unit is 0.1mm, and the setting range is from 0 to 200 (0mm to 20.0mm). Increment of the value provides more TE margin.

  • Page 630: Length Of Image For Roll 1 (No.6C To 77)

    (10) Length of image for Roll 1 (No.6C to 77) It is possible to adjust the length of print image. These settings are applied when printed with Roll 1. The setting unit is 0.01%, and the setting range is from -1.00% to +1.00%. Increment makes the image longer to vertical direction.

  • Page 631: Length Of Image For Roll 2 (No.78 To 83)

    (11) Length of image for Roll 2 (No.78 to 83) It is possible to adjust the length of print image. These settings are applied when printed with Roll 2. The setting unit is 0.01%, and the setting range is from -1.00% to +1.00%. Increment makes the image longer to vertical direction.

  • Page 632: Length Of Image For Roll 3 (No.84 To 8F)

    (12) Length of image for Roll 3 (No.84 to 8F) It is possible to adjust the length of print image. These settings are applied when printed with Roll 3. The setting unit is 0.01%, and the setting range is from -1.00% to +1.00%. Increment makes the image longer to vertical direction.

  • Page 633: Length Of Image For Roll 4 (No.90 To 9B)

    (13) Length of image for Roll 4 (No.90 to 9b) It is possible to adjust the length of print image. These settings are applied when printed with Roll 4. The setting unit is 0.01%, and the setting range is from -1.00% to +1.00%. Increment makes the image longer to vertical direction.

  • Page 634: Te Margin For Cut Sheet Media (Large) (No.9C)

    (14) TE margin for cut sheet media (Large) (No.9C) It is possible to adjust the length of TE margin. This setting is applied when printed with a “large” cut sheet media. The setting unit is 0.1mm, and the setting range is from 0 to 200 (0mm to 20.0mm).

  • Page 635: Web Operation Mode (No.9D)

    (15) Web operation mode (No.9d) Set No.9d to “1” if the optional Web Unit is installed to KIP9000. Setting value Description Web Unit does not operate. Web Unit operates. NOTE When No.9d is set to “0”, the Web Unit is inactive even if it is installed. (16) Web operation time (No.9E to A0) It is possible to change the total operation time of Web Unit counted by the KIP9000 firmware.

  • Page 636: Auto Sp Control On/Off (No.a2)

    (18) Auto SP Control ON/OFF (No.A2) Auto SP Control can be set to ON or OFF. Setting value Description Auto SP Control is not performed. Auto SP Control is performed. NOTE Service Mode 5-A2 is the same setting with User Mode D. When the Auto SP Control is set to OFF, it may be possible to avoid machine down caused by the service call error E-26.

  • Page 637: Auto Density Control On/Off (Error Check Level) (No.aa)

    (21) Auto Density Control ON/OFF (error check level) (No.AA) Auto Density Control can be set to any of OFF, ON1 and ON2. Setting value Description Auto Density Control is not performed. Auto Density Control is performed with normal error check level. Auto Density Control is performed with strict error check level.
  • Page 638 8. 1. 7 Running Mode (Sub Mode 6 : Do not use) 8. 1. 7. 1 Function Running Mode (mode No.6) is used only when the manufacturer makes an evaluation test by operating the machine endlessly. Do not make any operation in the Running Mode as this is not required in the field.

  • Page 639: Function

    8. 1. 8 Error Mask Mode (Sub Mode 7) 8. 1. 8. 1 Function It is possible to ignore (mask) the Service Call Errors purposely in the Error Mask Mode. The errors that can be ignored are listed in below. Mask Code Name of error Error Code...
  • Page 640 8. 1. 8. 2 Indication on the Operation panel The 1st digit from the left indicates “7” which is the Sub Mode number of “Error Mask Mode”. The 2nd and 3rd digits from the left indicate the present selection of Mask Code. The 5th and 6th digits indicate the status (“-L”...
  • Page 641 3. The 5th and 6th digits indicates “-L” at first. It means the target item of selected Mask Code is not masked presently. Press the [ ENTER ] Key to mask the target item. “-H” is indicated when masked. Even if this error is detected in the later printing, it will be ignored and the printer will continue to print.

  • Page 642: Function

    8. 1. 9 Test Print Mode (Sub Mode 8) 8. 1. 8. 1 Function Internal test pattern can be printed out for diagnostic purpose, with changing several settings according to the necessity. Test Print Mode has 9 sub modes. Sub Mode No. Setting Print Start Mode Print Number Setting Mode...
  • Page 643 8. 1. 8. 3 Operation 1. Enter the Service Mode, and indicate the Sub Mode Number “8” on the 1st digit from the left pressing the [ MENU ] Key. Sub Mode Number of Test Print Mode MENU ENTER ONLINE 2.
  • Page 644 3. Press the [ ENTER ] Key. The setting value on the 4th, 5th and 6th digits starts flashing and becomes changeable. MENU ENTER ONLINE MENU ENTER ONLINE 4. Change the setting value pressing [ ] Key (increment) and [ ] Key (decrement).
  • Page 645 5. Press the [ ENTER] Key to decide the setting value. The setting value on the 4th, 5th and 6th digits stops flashing when decided. MENU ENTER ONLINE MENU ENTER ONLINE NOTE (1) Unless the setting is decided, it is impossible to select other Sub Mode Numbers or other Setting Mode Numbers.
  • Page 646 6. Change other setting items in the same way if necessary. When all necessary settings are changed, select the Print Start Mode by indicating the Setting Mode Number “0”. MENU ENTER ONLINE MENU ENTER ONLINE Setting Mode Number of “Print Mode” 7.
  • Page 647 8. 1. 8.4 Description of each Setting Mode (1) Print Start Mode (Setting Mode No.0) This mode starts and stops a Test Print. To start printing, press the [ ENTER ] Key when “rdy” is indicated. To stop (cancel) printing in the middle, press the [ ENTER ] Key again. Print Start Mode informs the status of KIP9000 indicating a Status Code on 4th, 5th and 6th digits.
  • Page 648 (2) Print Number Setting Mode (Setting Mode No.1) Number of print can be set. The setting range is from 1 to 99. MENU ENTER ONLINE Number of print (Example : 99 sheets) NOTE Do not select “SP” although it is selectable in Print Number Setting Mode. This is a special mode to print 30,000 prints continuously, which is useful only on testing in manufacturer.
  • Page 649 (3) Test Pattern Selection Mode (Setting Mode No.2) Printed test pattern can be selected. KIP9000 has the following 8 test patterns. Select the necessary patter by indicating its own “pattern number”. MENU ENTER ONLINE Pattern number (Example : Pattern No.3) Pattern No.1 Pattern No.4 Pattern No.7...
  • Page 650 (4) Media Source Selection Mode (Setting Mode No.3) One of 5 media source (roll 1-4 & bypass) can be selected and used for test printing. Select the necessary source indicating its own “media source number”. MENU ENTER ONLINE Media source number (Example : Roll 2) Media source No.
  • Page 651 (5) Cut Length Selection Mode (Setting Mode No.4) It is possible to specify the cut length which is applied when printed with a roll media. MENU ENTER ONLINE Cut length (Example : A0) Selectable setting values are as follows. Metric format Inch format Setting value Cut length...
  • Page 652 (6) Media Type Selection Mode : Bypass Feed only (Setting Mode No.5) When printed with a cut sheet media, the media type can be specified. MENU ENTER ONLINE Media type No. (Example : Plain paper) Media type No. Media type Plain paper Tracing paper Film...
  • Page 653 (8) Negative Mode (Setting Mode No.7) Selected test pattern is printed by negative image. MENU ENTER ONLINE Setting value (Example : Negative image is selected.) Setting value Media source Normal image Negative image (9) Mirror Mode (Setting Mode No.8) Selected test pattern is printed by mirror image. MENU ENTER ONLINE Setting value (Example : Mirror image is selected.)
  • Page 654 8. 1.10 Special Operation Mode (Sub Mode 9) 8. 1.10. 1 Function Special Operation Mode offers the following items; Refer to [8.1.10.3 Operation/description of each item] on and after the page 8-131. Item Setting item Permission for Refer to the operation page ;...
  • Page 655 8. 1.10. 2 Indication of the Operation Panel The 1st digit from the left indicates “9” which is the Sub Mode number of “Special Operation Mode”. The 2nd and 3rd digit indicates any Item Number presently selected. The 4th, 5th and 6th digits indicate either status or setting value. MENU ENTER ONLINE Sub Mode Number of Special Operation Mode...
  • Page 656 8. 1.10. 3 Operation and explanation for each item (1) How to select each item 1. Enter the Service Mode, and indicate the Sub Mode Number “9” on the 1st digit from the left pressing the [ MENU ] Key. Sub Mode Number of Special Operation Mode MENU ENTER ONLINE...
  • Page 657 (2) Image Corona Wire Cleaning Mode (Item No.0) Cleaning for the Image Corona Wire can be performed by operating its cleaning mechanism. 1. Indicate the Item Number “00” on the 2nd digit. After confirming that “- -” on 5th and 6th digits is lighting, press the [ ENTER ] Key to start cleaning.
  • Page 658 (3) Cutter Cleaning Mode (Item No.1) Cleaning for the Cutter Blade can be performed by operating its cleaning mechanism. 1. Indicate the Item Number “01” on the 2nd digit. After confirming that “- -” on 5th and 6th digits is lighting, press the [ ENTER ] Key to start cleaning.
  • Page 659 (4) LED Head Cleaning Mode (Item No.2) Cleaning for the LED Head can be performed by operating its cleaning mechanism. 1. Indicate the Item Number “02” on the 2nd digit. After confirming that “- -” on 5th and 6th digits is lighting, press the [ ENTER ] Key to start cleaning.
  • Page 660 (5) Image Corona Adjustment Mode (Item No.3) When this mode is executed; • Drum rotates in a 330 degrees arc. • Image Corona takes discharging when Drum is rotating. 1. Indicate the Item Number “03” on the 2nd digit. After confirming that “- -” on 5th and 6th digits is lighting, press the [ ENTER ] Key to start the operation.
  • Page 661 (6) Pre-Transfer LED Adjustment Mode (Item No.4) When this mode is executed; • Drum rotates in a 330 degrees arc. • Pre-transfer LED lights when Drum is rotating. 1. Indicate the Item Number “04” on the 2nd digit. After confirming that “- -” on 5th and 6th digits is lighting, press the [ ENTER ] Key to start the operation.
  • Page 662 (7) Transfer Corona Adjustment Mode (Item No.5) When this mode is executed; • Drum rotates in a 330 degrees arc. • Transfer Corona takes discharging when Drum is rotating. 1. Indicate the Item Number “05” on the 2nd digit. After confirming that “- -” on 5th and 6th digits is lighting, press the [ ENTER ] Key to start the operation.
  • Page 663 (8) Separation Corona Adjustment Mode (Item No.6) When this mode is executed; • Drum rotates in a 330 degrees arc. • Separation Corona takes discharging when Drum is rotating. 1. Indicate the Item Number “06” on the 2nd digit. After confirming that “- -” on 5th and 6th digits is lighting, press the [ ENTER ] Key to start the operation.
  • Page 664 (9) Developer Bias (Positive) Adjustment Mode (Toner Collection Process) (Item No.7) Positive Developer Bias is supplied to the Developer Roller. 1. Indicate the Item Number “07” on the 2nd digit. After confirming that “- -” on 5th and 6th digits is lighting, press the [ ENTER ] Key to start outputting the positive Bias.
  • Page 665 (10) Developer Bias (Negative) Adjustment Mode (Print Process) (Item No.8) Negative Developer Bias is supplied to the Developer Roller. 1. Indicate the Item Number “08” on the 2nd digit. After confirming that “- -” on 5th and 6th digits is lighting, press the [ ENTER ] Key to start outputting the negative Bias.
  • Page 666 (11) Toner Supplying Mode (Item No.9) Toner Supplying Mode is a kind of setup mode used during machine installation or developer maintenance. When it is executed, necessary amount of toner can be supplied from Hopper to Developer automatically. 1. Indicate the Item Number “09” on the 2nd digit. After confirming that “- -” on 5th and 6th digits is lighting, press the [ ENTER ] Key to start supplying the toner.
  • Page 667 (12) Surface Potential Control Mode : Manual execution of control (Sub Mode A) It is possible to execute Surface Potential Control manually. 1. Indicate the Item Number “0A” on the 2nd digit. After confirming that “- -” on 5th and 6th digits is lighting, press the [ ENTER ] Key to start Surface Potential Control.
  • Page 668 (13) Density Lock Mode : Setting of Target Density (0b) It is possible to set new Target Density and make the KIP9000 memorize it. NOTE Normally it is unnecessary to set new Target Density as it has been already adjusted properly in the factory.
  • Page 669 (14) Density Control Mode : Manual execution of control (0C) It is possible to execute Density Control manually. 1. Indicate the Item Number “0C” on the 2nd digit. After confirming that “- -” on 5th and 6th digits is lighting, press the [ ENTER ] Key to start Density Control. The 5th and 6th digits indicate “8 8”...
  • Page 670 8. 1.11 Special Setting Mode (Sub Mode A) 8. 1.11. 1 Function Special Operation Mode offers the following items; Refer to [8.1.11.3 Operation/description of each item] on and after the page 8-146. Item Setting item Permission for Refer to the operation page ;...
  • Page 671 8. 1.11. 3 Operation and explanation for each item (1) Backup Data Clearing Mode (Item No.A) All Backup Data values are cleared and go back to the factory defaults. CAUTION Do not make any operation in the Backup Data Clearing Mode (Item No.A)! Careless operation in this mode may result in losing all fundamental setting values individually set on each machine! 1.
  • Page 672 2. Keep your hand from all keys when “CL” is flashing. (“CL” keeps on flashing.) 3. Press the [ ENTER ] key. All backup Data are initialized and the printer is turned off automatically. MENU ENTER ONLI NE 8-147 K115sm8e4.doc...
  • Page 673 (2) Software Counter Setting Modes (Item No. from 1 to4E) The counted values on 2 software counters A and B can be changed on items b to E. The counted value of each counter consists of 7 digits, and it is divided into 2 groups as upper 3 digits and lower 4 digits.
  • Page 674 2. Change the setting value pressing [ ] Key (increment) and [ ] Key (decrement). MENU ENTER ONLINE MENU ENTER ONLINE 3. Decide the setting value pressing the [ ENTER ] Key. The setting value stops flashing when decided. MENU ENTER ONLINE MENU ENTER ONLINE...
  • Page 675 (3) Print interval for continuous long printing (Item No.5) It is possible to keep a longer interval time between prints in continuous multiple number of long printing (longer then 2 meters). The interval time between prints will become about 10 seconds longer than usual when set to “1”.
  • Page 676 3. Decide the setting value pressing the [ ENTER ] Key. The setting value stops flashing when decided. MENU ENTER ONLINE MENU ENTER ONLINE 8-151 K115sm8e4.doc...
  • Page 677 (4) Key Card Setting Mode (Item No.6) If a Key Card is connected to KIP9000, it is possible to make the printer recognize its existence, and it is also possible to decide the counting unit. Setting value Contents Key Card is not connected. Key Card is connected, and it counts the print length by every 1m for each paper width separately.
  • Page 678 3. Decide the setting value pressing the [ ENTER ] Key. The setting value stops flashing when decided. MENU ENTER ONLINE MENU ENTER ONLINE 8-153 K115sm8e4.doc...
  • Page 679 (5) Folder Selection Mode (Item No.7) (USE IPS ONLY) If any folder is connected to KIP9000, it is possible to make the printer recognize what kind of Folder is connected. Setting value Contents Folder is not connected. Bay folder is connected. ESTE folder is connected.
  • Page 680 2. Change the setting value pressing [ ] Key (increment) and [ ] Key (decrement). MENU ENTER ONLINE MENU ENTER ONLINE 3. Decide the setting value pressing the [ ENTER ] Key. The setting value stops flashing when decided. MENU ENTER ONLINE MENU ENTER ONLINE...
  • Page 681 8. 2 User Modes KIP 9000 provides 14 User Modes. Name of Description User Mode Code User Mode User Mode 1 Test print User Mode 2 Calendar setting User Mode 3 Warm Sleep Mode ON / OFF & timer setting...
  • Page 682 ENTER ONLINE Press [ MENU ] once. MENU ENTER ONLINE 2. The 4th, 5th and 6th digits indicates the status of KIP 9000. - - - (flashing) : Test print is not available. ooo (lighting) : Test print is available.
  • Page 683 3. Press the [ ENTER ] Key when “ooo” is lighting. Test print is started and “ooo” flashes. MENU ENTER ONLINE MENU ENTER ONLINE 4. When test print is finished, “ooo” stops flashing and lights. Press the [ ONLINE ] Key to cancel the User Mode 1.
  • Page 684 8. 2. 2 User Mode 2 (Calendar setting) [Function] Calender setting can be corrected if wrong. (KIP9000 memorizes calendar information on its circuit.) NOTE (1) KIP9000 can operate without problem even if the calendar setting is wrong. (2) The calendar setting is used for diagnostics purpose. If some error or mis-feed occurs, KIP9000 records it with the information “when”...
  • Page 685 3. Select the “Confirmation Mode – Date” first pressing the [ ] Key, and confirm the current setting for year, month and date. MENU ENTER ONLINE Example : May 31, 2002 MENU ENTER ONLINE Year Month 4. Select the “Confirmation Mode – Time” next pressing the [ ] Key, and confirm the current setting for hour, minute and second.
  • Page 686 5. If some item needs to be corrected, select its correction mode pressing [ ] and [ ] Keys. 6 Correction Modes are shown by Correction Mode Code as C1, C2, C3, C4, C5 and C6, and necessary correction mode can be selected by indicating its code. Correction Mode Codes Description Correction Mode –...
  • Page 687 7. Change the setting value pressing [ ] Key (increment) and [ ] Key (decrement). Example : Minute is to be corrected from 00 to 05. MENU ENTER ONLINE MENU ENTER ONLINE 8. Decide the new setting value pressing the [ ENTER ] Key. The setting value stops flashing when decided.
  • Page 688 10. When all necessary items are corrected, press the [ ONLINE ] Key to cancel the User Mode 2. MENU ENTER ONLINE MENU ENTER ONLINE 8-163 K115sm8e5.doc...
  • Page 689 It is possible to select whether or not the Warm Sleep Mode works. The timer for Warm Sleep can be specified as well. If the KIP 9000 does not receive any print/copy for the time set as timer in User Mode 3, it will go into the Warm Sleep Mode to save the power consumption.
  • Page 690 2. The Status Display indicates either “OFF” or “On” according to the current setting. Press the [ MENU ] Key. The setting value (OFF/On) flashes and becomes changeable. MENU ENTER ONLINE MENU ENTER ONLINE “OFF” (or “On”) flashes. 3. Select either “OFF” or “On” pressing [ ] Key and [ ] Key..
  • Page 691 4. Press the [ ENTER ] Key to decide the setting. • If “On“ is decided, the Status Display indicates the setting value of Warm Sleep timer in flashing. Go to the following procedure 5 for setting the timer. • If “OFF”...
  • Page 692 6. Press the [ ENTER ] Key to decide the timer value. The setting value stops flashing when decided. MENU ENTER ONLINE MENU ENTER ONLINE Setting value (timer) stops flashing. 7. Press the [ ONLINE ] Key to cancel the User Mode 3. MENU ENTER ONLINE MENU...
  • Page 693 [Function] It is possible to set the Cold Sleep timer. If the KIP 9000 does not receive any print/copy for the time set as timer in User Mode 4, it will go into the Cold Sleep Mode to save the power consumption.
  • Page 694 2. Press the [ MENU ] Key. The timer value for Cold Sleep flashes and becomes changeable. MENU ENTER ONLINE MENU ENTER ONLINE Setting value (timer) flashes. 3. Indicate the necessary Cold Sleep timer value pressing [ ] Key (increment) and [ ] Key (decrement).
  • Page 695 4. Press the [ ENTER ] Key to decide the timer value. The setting value stops flashing when decided. MENU ENTER ONLINE MENU ENTER ONLINE Setting value (timer) stops flashing. 5. Press the [ ONLINE ] Key to cancel the User Mode 4. MENU ENTER ONLINE MENU...
  • Page 696 8. 2. 5 User Mode 5 (Automatic paper cut at power ON) [Function] It is possible to make Initial Cut for all of 4 roll media whenever KIP9000 is turned on. Reference Initial Cut is a function to cut off the leading part of roll media in 240mm long. [Operation] 1.
  • Page 697 3. Change the setting value pressing [ ] Key (increment) and [ ] Key (decrement). Setting value Description KIP 9000 takes Initial Cut for all roll media at turning ON. KIP 9000 does not take Initial Cut at turning ON. MENU ENTER ONLINE MENU...
  • Page 698 5. Press the [ ONLINE ] Key to cancel the User Mode 5. MENU ENTER ONLINE MENU ENTER ONLINE 8-173 K115sm8e5.doc...
  • Page 699 8. 2. 6 User Mode 6 (Transfer Support LED ON/OFF [Film]) [Function] It is possible to turn on the Transfer Support LED for getting a clearer and darker image when printed with a unsupported printing media. (Transfer Support LED is also called “Separation Lamp” that is below the Separation Corona.) NOTE (1) The printed image may look not clear or not enough dark when printed with some king of unsupported type of printing media.
  • Page 700 2. Press the [ MENU ] Key. The setting value flashes and becomes changeable. MENU ENTER ONLINE MENU ENTER ONLINE Setting value flashes. 3. Change the setting value pressing [ ] Key (increment) and [ ] Key (decrement). Setting value Description Transfer Support LED does not work.
  • Page 701 4. Press the [ ENTER ] Key to decide the setting value. The setting value stops flashing when decided. MENU ENTER ONLINE MENU ENTER ONLINE Setting value stops flashing. 5. Press the [ ONLINE ] Key to cancel the User Mode 6. MENU ENTER ONLINE MENU...
  • Page 702 8. 2. 7 User Mode 7 (Alarm ON / OFF) [Function] When alarm is set to ON, the following status can be noticed by the sound of alarm. (1) Toner empty (2) Toner near empty (3) Roll empty Reference Alarm will continue to sound if unless either of the following operations is done. 1.
  • Page 703 2. Press the [ MENU ] Key. The setting value flashes and becomes changeable. MENU ENTER ONLINE MENU ENTER ONLINE Setting value flashes. 3. Change the setting value pressing [ ] Key (increment) and [ ] Key (decrement). Setting value Description Alarm does not sound.
  • Page 704 4. Press the [ ENTER ] Key to decide the setting value. The setting value stops flashing when decided. MENU ENTER ONLINE MENU ENTER ONLINE Setting value stops flashing. 5. Press the [ ONLINE ] Key to cancel the User Mode 7. MENU ENTER ONLINE MENU...
  • Page 705 8. 2. 8 User Mode 8 (Choice of Standard / Special Print Mode [Plain paper]) [Function] The operation mode of KIP9000 can be set to either [Standard Print Mode] or [Special Print Mode] according to the situation. This setting become effective when printed with a plain paper. •...
  • Page 706 [Operation] 1. Press the [ MENU ] Key 8 times to select the User Mode 8. [ MENU ] Key lights green and the Status Display indicates “U8.”. MENU ENTER ONLINE Press [ MENU ] 8 times. MENU ENTER ONLINE 2.
  • Page 707 3. Change the setting value pressing [ ] Key (increment) and [ ] Key (decrement). Setting value Description Standard Print Mode is applied in printing. (When plain paper is used.) Special Print Mode is applied in printing. (When plain paper is used.) MENU ENTER ONLINE MENU...
  • Page 708 5. Press the [ ONLINE ] Key to cancel the User Mode 8. MENU ENTER ONLINE MENU ENTER ONLINE 8-183 K115sm8e6.doc...
  • Page 709 8. 2. 9 User Mode 9 (Choice of Standard / Special Print Mode [Tracing paper]) [Function] The operation mode of KIP9000 can be set to either [Standard Print Mode] or [Special Print Mode] according to the situation. This setting become effective when printed with a tracing paper. •...
  • Page 710 [Operation] 1. Press the [ MENU ] Key 9 times to select the User Mode 9. [ MENU ] Key lights green and the Status Display indicates “U9.”. MENU ENTER ONLINE Press [ MENU ] 9 times. MENU ENTER ONLINE 2.
  • Page 711 3. Change the setting value pressing [ ] Key (increment) and [ ] Key (decrement). Setting value Description Standard Print Mode is applied in printing. (When tracing paper is used.) Special Print Mode is applied in printing. (When tracing paper is used.) MENU ENTER ONLINE MENU...
  • Page 712 5. Press the [ ONLINE ] Key to cancel the User Mode 9. MENU ENTER ONLINE MENU ENTER ONLINE 8-187 K115sm8e6.doc...
  • Page 713 8. 2.10 User Mode A (Choice of Standard / Special Print Mode [Film]) [Function] The operation mode of KIP9000 can be set to either [Standard Print Mode] or [Special Print Mode] according to the situation. This setting become effective when printed with a film. •...
  • Page 714 [Operation] 1. Press the [ MENU ] Key 10 times to select the User Mode A. [ MENU ] Key lights green and the Status Display indicates “UA.”. MENU ENTER ONLINE Press [ MENU ] 10 times. MENU ENTER ONLINE 2.
  • Page 715 3. Change the setting value pressing [ ] Key (increment) and [ ] Key (decrement). Setting value Description Standard Print Mode is applied in printing. (When film is used.) Special Print Mode is applied in printing. (When film is used.) MENU ENTER ONLINE MENU...
  • Page 716 5. Press the [ ONLINE ] Key to cancel the User Mode A. MENU ENTER ONLINE MENU ENTER ONLINE 8-191 K115sm8e6.doc...
  • Page 717 8. 2.11 User Mode B (Selection of Image Enhancement Mode) [Function] The printed image can be enhanced most appropriately by selecting proper Image Enhancement Mode. KIP9000 has 4 Image Enhancement Modes. Printed image is more enhanced (become darker) when selecting a larger level. Try to select a larger level if the image looks weak. Setting Image Enhancement Description...
  • Page 718 2. Press the [ MENU ] Key. The setting value flashes and becomes changeable. MENU ENTER ONLINE MENU ENTER ONLINE Setting value flashes. 3. Change the setting value pressing [ ] Key (increment) and [ ] Key (decrement). Setting Image Enhancement Description value Mode...
  • Page 719 4. Press the [ ENTER ] Key to decide the setting value. The setting value stops flashing when decided. MENU ENTER ONLINE MENU ENTER ONLINE Setting value stops flashing. 5. Press the [ ONLINE ] Key to cancel the User Mode B. MENU ENTER ONLINE MENU...
  • Page 720 8. 2.12 User Mode C (Print on TE margin area) [Function] User Mode C allows to print the image in the TE margin area (no TE margin is provided). Normal Image area is enlarged (TE margin is provided.) (No TE margin is provided.) The following 3 settings are selectable.
  • Page 721 [Operation] 1. Press the [ MENU ] Key 12 times to select the User Mode C. [ MENU ] Key lights green and the Status Display indicates “UC.”. MENU ENTER ONLINE Press [ MENU ] 12 times. MENU ENTER ONLINE 2.
  • Page 722 3. Change the setting value pressing [ ] Key (increment) and [ ] Key (decrement). Setting Selected setting Description value Normal setting Does not allow for printing on TE margin area. (Default) TE Margin Print Mode 1 Allows for printing on TE margin area. A longer interval is kept between prints for cleaning.
  • Page 723 5. Press the [ ONLINE ] Key to cancel the User Mode C. MENU ENTER ONLINE MENU ENTER ONLINE 8-198 K115sm8e6.doc...
  • Page 724 8. 2.13 User Mode D (Auto SP Control ON/OFF : Temporary clearance of E-26 error) [Function] Auto SP Control can be set to ON or OFF. When it is set to OFF, service call errors E-26 might be temporarily cleared for avoiding the breakdown of KIP9000. Reference The image quality varies according to the variation of temperature of surrounding environment.
  • Page 725 2. Press the [ MENU ] Key. The setting value flashes and becomes changeable. MENU ENTER ONLINE MENU ENTER ONLINE Setting value flashes. 3. Change the setting value pressing [ ] Key (increment) and [ ] Key (decrement). Setting value Description KIP9000 does not make error checking for E-26.
  • Page 726 4. Press the [ ENTER ] Key to decide the setting value. The setting value stops flashing when decided. MENU ENTER ONLINE MENU ENTER ONLINE Setting value stops flashing. 5. Press the [ ONLINE ] Key to cancel the User Mode D. MENU ENTER ONLINE MENU...
  • Page 727 8. 2.14 User Mode E (Auto Density Control ON/OFF : Temporary clearance of E-26 error) Auto Density Control can be set to ON or OFF. When it is set to OFF, service call errors E-28 might be temporarily cleared for avoiding the breakdown of KIP9000. Reference The image quality varies according to the variation of temperature of surrounding environment.
  • Page 728 2. Press the [ MENU ] Key. The setting value flashes and becomes changeable. MENU ENTER ONLINE MENU ENTER ONLINE Setting value flashes. 3. Change the setting value pressing [ ] Key (increment) and [ ] Key (decrement). Setting value Description KIP9000 does not make error checking for E-28.
  • Page 729 4. Press the [ ENTER ] Key to decide the setting value. The setting value stops flashing when decided. MENU ENTER ONLINE MENU ENTER ONLINE Setting value stops flashing. 5. Press the [ ONLINE ] Key to cancel the User Mode D. MENU ENTER ONLINE MENU...
  • Page 730 8. 2.15 User Mode F0 to Fb (Fold settings for Bay Folder) [Function] KIP9000 provides 4 kinds of folding method when it is works together with Bay Folder. The User Modes F0 to Fb are available to make customization on each of these folding methods by specifying “fold type”, “width of fan fold”...
  • Page 731 (3) Margin Additional margin can be provided to the “last” fan fold, and its length can be increased or decreased ranging from 0 to 30mm (from 0.0” to 1.2”) in 1mm (0.1”) increment. 12 User Modes from F0 to Fb have their own target setting as follows. User Mode Target setting Target folding method...
  • Page 732 [Operation] 1. Indicate the code of necessary User Modes (F0 to Fb) pressing the [ MENU ] Key when the KIP9000 is in normal condition. User Mode Code Target setting Target folding method Fold type Folding method 1 Width of fan fold Margin Fold type Folding method 2...
  • Page 733 2. The Status Display indicates any setting value on its right half according to the selected User Mode. Press the [ MENU ] Key, and the setting value flashes and becomes changeable. MENU ENTER ONLINE MENU ENTER ONLINE Setting value flashes. 8-208 K115sm8e6.doc...
  • Page 734 3. Change the setting value pressing [ ] Key (increment) and [ ] Key (decrement). Selectable setting values depend on the selected User Mode. (a) Fold type : Select any of “00”, “01” and “02”. Setting Fold type value Not folded Fan fold Fan fold &...
  • Page 735 (b) Width of fan fold : Change the value within the following adjustable range. Unit Adjustable range Setting unit Metric 180 to 210mm Inch 7.1” to 9.0” 0.1” MENU ENTER ONLINE MENU ENTER ONLINE (c) Margin : Change the value within the following adjustable range. Unit Adjustable range Setting unit...
  • Page 736 4. Press the [ ENTER ] Key to decide the selected setting value. It stops flashing when decided. MENU ENTER ONLINE MENU ENTER ONLINE Setting value stops flashing. 5. Press the [ ONLINE ] Key to cancel the User Mode. MENU ENTER ONLINE MENU...
  • Page 737 8. 3 KIP Diagnostics (Program used on field service) KIP Diagnostics is an exclusive program used on the field service of KIP models including KIP9000. 8. 3. 1 Having a communication between KIP Diagnostics on service laptop (PC) and KIP9000 1.
  • Page 738 2. Confirm both service laptop (PC) and KIP9000 are turned off. Connect the COM1 port of laptop and the DIAG. Port of KIP9000 with the RS232C cross cable. Diag Port NOTE Use the following type of RS232C cable. Printer (D-Sub 9 pins female type) (D-Sub 9 pins female type) 2 RxD 2 RxD...
  • Page 739 3. Turn on both laptop and KIP9000. 4. Run [KIPDiag.exe]. The main screen of KIP Diagnostics is indicated without indicating any information. 8-214 K115sm8e7.doc...
  • Page 740 5. Select [Serial Port] under [Setting]. 6. Set the setting items in [Serial Port Dialog] to the values shown in the right picture, and click on [OK]. Set to these values 8-215 K115sm8e7.doc...
  • Page 741 5. KIP Diagnostics starts a communication with the printer. The information sent from the printer is indicated. NOTE If the communication is shut off for some reason, recover it by [Initialize] under [Setting]. 8-216 K115sm8e7.doc...
  • Page 742 8. 3. 2 Outline of Tabs on KIP Diagnostics KIP Diagnostics has 6 Tabs that cover almost all main functions of KIP Diagnostics. Basic Screen Tab Indicates the basic information of KIP9000 such as ROM version, counter value and etc.
  • Page 743 8. 3. 3 Description of each Tab 8. 3. 3. 1 Basic Information Tab Basic Screen Tab indicates the basic information of KIP9000 such as ROM version, counter value and etc. Machine ROM Version Version of current KIP9000 firmware Information I/F Version Version of the Interface 8 Max Length...
  • Page 744 8. 3. 3. 2 Display Tab Display Tab Indicates kinds of signal status (input/output) and input data. (Display Tab covers the functions of “Input/Output Checking Mode” and “Data Monitoring Mode” of Service Mode.) (1) [Number] column indicates the 4 digits codes. The left 2 of each 4 digits code are either “10xx” or “20xx”.
  • Page 745 NOTE Display Tab covers the functions of Input/Output Checking Mode and Data Monitoring Mode of Service Mode. See the following pages for the descriptions of those modes.. [8.1.2 Input / Output Checking Mode (Sub Mode 1)] on and after the page 8-10 [8.1.3 Data Monitoring Mode (Sub Mode 2)] on and after the page 8-20 8-220 K115sm8e7.doc...
  • Page 746 8. 3. 3. 3 Setting Tab It is possible to change many kinds of printer parameters, and also possible to upload and download the backup RAM file. (Setting Tab covers the functions of Adjustment Mode 0/1 of Service Mode.) (1) [Number] column indicates the 4 digits codes. The left 2 of each 4 digits code are either “40xx” or “50xx”.
  • Page 747 (1) Changing the setting value of each Item Number NOTE It is recommended to save all the present setting values in Backup RAM file for safety before changing the setting value. Refer to [(2) Saving all present settings in Backup RAM file (Download)] on the page 8-224.
  • Page 748 2. Change the setting value in the Edit Diagram, and click on [OK]. Example) Setting value is to be changed from “900” to “880”. Reference There are 2 ways to change the setting value. • Select any existent setting value from the pull-down menu. •...
  • Page 749 (2) Saving all present settings in Backup RAM file (Download) All present settings specified on Setting Tab (All Adjustment Mode 0/1 settings of Service Mode) can be downloaded and saved in the Backup RAM file. Reference KIP9000 will recover the previous setting values as specified on Setting Tab at the time of “Download”...
  • Page 750 2. Select a save folder and give a filename for the Backup RAM file, and click on [Save]. All the present setting values specified on Setting Tab are downloaded from KIP9000 and saved in the Backup RAM file. 8-225 K115sm8e7.doc...
  • Page 751 (3) Uploading the Backup RAM file to KIP9000 A Backup RAM file can be uploaded to KIP9000 to recover all the previous setting values specified on Setting Tab at the time of “download”. Upload will be useful in the following situations. •...
  • Page 752 3. KIP Diagnostics reads all the setting values saved in the Backup RAM file, and automatically changes the setting values on the Setting Tab according to the read values. [Complete!] is indicated when all setting values are changed according to the Backup RAM file.
  • Page 753 4. Click on [Upload] icon on the KIP Diagnostics, and click on [Yes] on the confirmation window. All the settings on Setting Tab are uploaded to KIP9000. 5. [Complete!] is indicated when all the settings are uploaded and become effective on KIP9000. Click on [OK] to finally.
  • Page 754 8. 3. 3. 4 History Tab History Tab indicates recent errors (Service Call Error) and jams with such information as error/jam code, date/time, and counter value. Clearance of the error/jam histories is also available. Error history Jam history (1) [Number] column indicates the order that the recent error/jam occurred. (Smaller value means more recently occurred error/jam) (2) [Code] column indicates either Error Code (E-00XX) or Jam Code (J-00XX).
  • Page 755 (1) Clearance of error / jam histories 1. There are 2 [Clear] icons on the History Tab. The upper button in [Error History Information] section clears the error history, and another one in [Jam History Information] clears the jam history. Click on your requested [Clear] icons. Clear icons 2.
  • Page 756 8. 3. 3. 5 Upload ROM Data Tab It is possible to update the firmware by uploading the ROM file (*.rom) to the KIP9000. (ROM file is supplied from the manufacturer.) NOTE All the current printer parameters (specified in Setting Tab of KIPDlPRO or Adjustment Mode 0/1 of Service Mode) will be maintained surely even after firmware updating.
  • Page 757 3. Confirm that the filename of ROM file as well as its file path are indicated in [Filename], and then click on [Upload] icon. Click on [Yes] when a confirmation message is indicated. KIP Diagnostics starts uploading the ROM file to KIP9000. Normally uploading will take some minutes.
  • Page 758 4. Printer is restarted automatically when uploading of ROM file is finished, and [Complete!] is indicated on the application side. Click on [OK] finally. 8-233 K115sm8e7.doc...
  • Page 759 8. 3. 3. 6 Test Print Tab Internal test pattern can be printed out from KIP9000 with specifying several settings as cut length, number of print, media type and etc. (Test Print Tab covers the function of Test Print Mode of Service Mode.) (1) Select any of 8 test patterns.
  • Page 760 Exit Finished KIP Diagnostics. 8. 3. 4. 2 Setting Initialize Recovers the communication between KIP Diagnostics and KIP9000 when it is shut off. Serial Port Specifies the communication settings between KIP Diagnostics and KIP9000. Tool Bar Tool Bar is indicated when checked.
  • Page 761 This command is always not accessible as it is not used in the field. 8. 3. 4. 4 Help Index Can search the necessary functional explanations of KIP Diagnostics by [Contents] or [Index]. About Version of KIP Diagnostics or some other information is indicated.

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